SEN05221-05

SEN05221-05
HYDRAULIC PC200 -8
EXCAVATOR
PC200LC -8
PC200- 1001
SERIAL NUMBERS and up
PC200LC- 1001
SEN05223-05
PC200, 200LC-8E0 (Hybrid)
SEN05223-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)
PC200LC-8E0 (Hybrid)
Machine model Serial number

PC200-8E0 (Hybrid) 1001 and up
PC200LC-8E0 (Hybrid) 1001 and up
00 Index and Foreword

100 Index
Composition of shop manual ...................................................................................................................... 2

Table of contents ........................................................................................................................................ 4
PC200, 200LC-8E0 (Hybrid) 00-100 1

100 Index
SEN05223-05 Composition of shop manual
Composition of shop manual

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

q File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN05221-05
00 Index and foreword SEN05222-05

Index SEN05223-05 q
Foreword and general information SEN05224-02 q
01 Specification SEN05225-02
Specification and technical data SEN05226-02 q
10 Structure, function and maintenance standard SEN05227-03

100 Engine and cooling system SEN05228-00
200 Hybrid Relation SEN05229-02 q
300 Power train SEN05230-00
400 Undercarriage and frame SEN05231-01
501 Hydraulic system, Part 1 SEN05232-01
600 Work equipment SEN05235-00
700 Cab and its attachments SEN05236-00
800 Electrical system SEN05237-01
20 Standard value table SEN05238-00

100 Standard service value table SEN05239-00
30 Testing and adjusting SEN05240-02

101 Testing and adjusting, Part 1 SEN05241-01
102 Testing and adjusting, Part 2 SEN05242-02 q
103 Testing and adjusting, Part 3 SEN05243-01
40 Troubleshooting SEN05244-04
100 Failure code table and fuse location SEN05245-02
200 General information on troubleshooting SEN05246-01
301 Troubleshooting by failure code, Part 1 SEN05247-00
400 Troubleshooting of electrical system (E-mode) SEN05252-00
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN05253-00
00-100 2 PC200, 200LC-8E0 (Hybrid)

100 Index
Composition of shop manual SEN05223-05
600 Troubleshooting of engine (S-mode) SEN05254-01

700 Troubleshooting of Hybrid system (Y-mode) SEN05270-03 q
50 Disassembly and assembly SEN05255-03

100 General information on disassembly and assembly SEN05256-01
200 Engine and cooling system SEN05257-00
300 Hyblid Relation SEN05258-02 q
400 Power train SEN05259-01
500 Undercarriage and frame SEN05260-01
600 Hydraulic system SEN05261-01
700 Work equipment Body SEN05262-00
800 Cab and its attachments SEN05263-00
900 Electric system SEN05264-01
90 Diagrams and drawings SEN05265-01

100 Hydraulic diagrams and drawings SEN05266-01
200 Electrical diagrams and drawings SEN05267-01
PC200, 200LC-8E0 (Hybrid) 00-100 3

100 Index
SEN05223-05 Table of contents
Table of contents
Shop Manual, contents binder, binder label and tabs

Index SEN05223-05
Composition of shop manual ............................................................................................................. 2
Table of contents ............................................................................................................................... 4
Foreword and general information SEN05224-02
Safety notice ...................................................................................................................................... 2
How to read the shop manual ............................................................................................................ 7
Explanation of terms for maintenance standard ................................................................................ 9
Handling of hydraulic components..................................................................................................... 11
Method of disassembling and connecting push-pull type coupler...................................................... 13
Handing of electric equpment ............................................................................................................ 16
How to read electric wire code........................................................................................................... 26
Precautions when carrying out work .................................................................................................. 31
Handling of hybrid devices and high-voltage wirings ......................................................................... 34
Standard tightening torque table........................................................................................................ 42
Conversion table ................................................................................................................................ 46
01 Specification
Specification and technical data SEN05226-02
Outline of hybrid system .................................................................................................................... 2
Specification dimension drawings...................................................................................................... 3
Working range diagram...................................................................................................................... 4
Specifications..................................................................................................................................... 5
Weight table ....................................................................................................................................... 8
Table of fuel, coolant and lubricants .................................................................................................. 10
10 Structure,function and maintenance standard

Engine and cooling system SEN05228-00
Engine related parts........................................................................................................................... 2
Radiator, oil cooler, aftercooler and fuel cooler ................................................................................. 3
Hyblid Relation SEN05229-02
Configuration and safety functions of hybrid system ......................................................................... 2
Cooling system of hybrid component................................................................................................. 6
Motor generator ................................................................................................................................. 8
Swing electric motor........................................................................................................................... 9
Electric control unit............................................................................................................................. 10
High-voltage wiring (power cable)...................................................................................................... 11
Power train SEN05230-00
Power train......................................................................................................................................... 2
Final drive .......................................................................................................................................... 4
Swing machinery................................................................................................................................ 6
Swing circle........................................................................................................................................ 8
Undercarriage and frame SEN05231-01
Track frame and recoil spring ............................................................................................................ 2
Idler .................................................................................................................................................... 4
Carrier roller ....................................................................................................................................... 6
Track roller ......................................................................................................................................... 7
Track shoe ......................................................................................................................................... 8
Hydraulic system, Part 1 SEN05232-01
Hydraulic components layout drawing ............................................................................................... 2
00-100 4 PC200, 200LC-8E0 (Hybrid)

100 Index
Table of contents SEN05223-05
Hydraulic tank and filter ..................................................................................................................... 4

Hydraulic pump.................................................................................................................................. 6
Control valve...................................................................................................................................... 2
CLSS ................................................................................................................................................. 13
Functions and operation by valve ...................................................................................................... 18
Center swivel joint.............................................................................................................................. 2
Travel motor....................................................................................................................................... 4
PPC valve .......................................................................................................................................... 15
Valve control ...................................................................................................................................... 30
Solenoid valve ................................................................................................................................... 32
Accumulator....................................................................................................................................... 34
Hydraulic cylinder .............................................................................................................................. 36
Work equipment SEN05235-00
Dimensions of components ............................................................................................................... 2
Cab and its attachments SEN05236-00
Air conditioner piping ......................................................................................................................... 2
Electrical system SEN05237-01
Engine control.................................................................................................................................... 2
Electrical control system .................................................................................................................... 10
Monitor system .................................................................................................................................. 35
Sensors.............................................................................................................................................. 60
KOMTRAX system............................................................................................................................. 63
20 Standard value table

Standard service value table SEN05239-00
Standard value table for engine related parts.................................................................................... 2
Standard value table for chassis related parts................................................................................... 3
30 Testing and adjusting

Testing and adjusting, Part 1 SEN05241-01
Tools for testing, adjusting and troubleshooting ................................................................................ 3
Testing engine speed ........................................................................................................................ 7
Testing boost pressure ...................................................................................................................... 9
Checking exhaust gas color............................................................................................................... 10
Adjusting valve clearance .................................................................................................................. 11
Testing compression pressure........................................................................................................... 13
Testing blowby pressure.................................................................................................................... 16
Testing engine oil pressure................................................................................................................ 17
Handling fuel system parts ................................................................................................................ 18
Releasing remaining pressure from fuel system................................................................................ 18
Testing fuel system pressure............................................................................................................. 19
Cylinder cut-out test mode operation................................................................................................. 21
No injection cranking operation ......................................................................................................... 21
Testing fuel return rate and leakage .................................................................................................. 22
Bleeding air from fuel circuit .............................................................................................................. 26
Testing fuel circuit for leakage ........................................................................................................... 27
Handling of controller high-voltage circuit.......................................................................................... 28
Testing and adjusting air conditioner compressor belt tension.......................................................... 29
Replacement of fan belt..................................................................................................................... 30
Testing swing circle bearing clearance.............................................................................................. 31
Testing and adjusting track tension ................................................................................................... 32
PC200, 200LC-8E0 (Hybrid) 00-100 5

100 Index
Testing and adjusting hydraulic oil pressure in work equipment and travel circuits........................... 34
Testing source pressure of control circuit .......................................................................................... 37
Testing and adjusting oil pressure in pump PC control circuit ........................................................... 38
Testing and adjusting oil pressure in pump LS control circuit............................................................ 41
Testing solenoid valve output pressure ............................................................................................. 45
Testing PPC valve output pressure ................................................................................................... 48
Adjusting play of work equipment and swing PPC valves ................................................................. 50
Checking parts which cause hydraulic drift of work equipment ......................................................... 51
Releasing remaining pressure from hydraulic circuit ......................................................................... 53
Testing oil leakage ............................................................................................................................. 54
Bleeding air from each part................................................................................................................ 56
Checking cab tipping stopper............................................................................................................. 58
Adjusting mirrors ................................................................................................................................ 59
Angle adjustment of rear view camera............................................................................................... 61
Testing swing brake ........................................................................................................................... 62
Cleaning and replacement of oil filter of electric swing motor............................................................ 64
Operation check of swing emergency stop switch ............................................................................. 65
Special functions of machine monitor ................................................................................................ 2
Handling voltage circuit of engine controller ...................................................................................... 2
Precautions related to hybrid machines............................................................................................. 3
Preparation work for troubleshooting of electrical system ................................................................. 4
Procedure for testing diodes .............................................................................................................. 10
Pm Clinic service ............................................................................................................................... 11
40 Troubleshooting
Failure code table and fuse locations SEN05245-02
Failure code table .............................................................................................................................. 2
Fuse locations.................................................................................................................................... 8
General Information on troubleshooting SEN05246-01
Points to remember when troubleshooting ........................................................................................ 2
Sequence of events in troubleshooting.............................................................................................. 3
Check before troubleshooting ............................................................................................................ 4
Classification and procedures for troubleshooting ............................................................................. 5
Probable problems and troubleshooting No....................................................................................... 7
Information in troubleshooting table................................................................................................... 9
Connection table for connector pin numbers ..................................................................................... 11
T-adapter and box table..................................................................................................................... 47
Troubleshooting by failure code, Part 1 SEN05247-00
Failure code [989L00] Engine Controller Lock Caution 1 .................................................................. 3
Failure code [989M00] Engine Controller Lock Caution 2 ................................................................. 3
Failure code [989N00] Engine Controller Lock Caution 3.................................................................. 4
Failure code [AA10NX] Air Cleaner Clogging .................................................................................... 5
Failure code [AB00KE] Charge Voltage Low ..................................................................................... 6
Failure code [B@BAZG] Eng Oil Press Low...................................................................................... 8
Failure code [B@BAZK] Eng oil level low .......................................................................................... 8
Failure code [B@BCNS] Eng Water Overheat .................................................................................. 9
Failure code [B@BCZK] Eng Water Level Low ................................................................................. 9
Failure code [B@HANS] Hydr oil overheat ........................................................................................ 10
Failure code [CA111] EMC Critical Internal Failure ........................................................................... 11
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .............................................................. 11
Failure code [CA122] Chg Air Press Sensor High Error .................................................................... 12
00-100 6 PC200, 200LC-8E0 (Hybrid)

100 Index
Failure code [CA123] Chg Air Press Sensor Low Error ..................................................................... 16
Failure code [CA132] Throttle Sensor Low Error............................................................................... 18
Failure code [CA144] Coolant temp. sensor high error ..................................................................... 20
Failure code [CA145] Coolant temp. sensor low error....................................................................... 22
Failure code [CA153] Chg Air Temp Sensor High Error .................................................................... 24
Failure code [CA154] Chg Air Temp Sensor Low Error ..................................................................... 26
Failure code [CA155] Chg Air Temp High Speed Derate .................................................................. 28
Failure code [CA187] Sens Supply 2 Volt Low Error ......................................................................... 30
Failure code [CA221] Ambient Press Sens High Error ...................................................................... 32
Failure code [CA222] Ambient Press Sens Low Error....................................................................... 34
Failure code [CA227] Sens Supply 2 Volt High Error ........................................................................ 36
Failure code [CA234] Eng Overspeed ............................................................................................... 37
Failure code [CA238] Ne Speed Sens Supply Volt Error................................................................... 38
Failure code [CA271] IMV/PCV1 Short Error..................................................................................... 39
Failure code [CA272] IMV/PCV1 Open Error .................................................................................... 40
Failure code [CA322] Inj #1 (L#1) Open/Short Error ......................................................................... 42
Failure code [CA331] Inj #2(L#2) Open/Short Error .......................................................................... 46
Failure code [CA342] Calibration Code Incompatibility ..................................................................... 3
Failure code [CA351] Injectors Drive Circuit Error............................................................................. 3
Failure code [CA352] Sens Supply 1 Volt Low Error ......................................................................... 4
Failure code [CA386] Sens Supply 1 Volt High Error ........................................................................ 6
Failure code [CA428] Water in Fuel Sensor High Error ..................................................................... 8
Failure code [CA429] Water in Fuel Sensor Low Error...................................................................... 10
Failure code [CA435] Eng Oil Press Sw Error ................................................................................... 12
Failure code [CA441] Battery Voltage Low Error............................................................................... 14
Failure code [CA442] Battery Voltage High Error .............................................................................. 16
Failure code [CA449] Rail Press Very High Error.............................................................................. 18
Failure code [CA451] Rail Press Sensor High Error.......................................................................... 20
Failure code [CA452] Rail Press Sensor Low Error........................................................................... 22
Failure code [CA488] Chg Air Temp High Torque Derate ................................................................. 24
Failure code [CA553] Rail Press High Error ...................................................................................... 24
Failure code [CA559] Rail Press Low Error ....................................................................................... 25
Failure code [CA689] Eng Ne Speed Sensor Error ........................................................................... 26
Failure code [CA731] Eng Bkup Speed Sens Phase Error................................................................ 28
Failure code [CA757] All Continuous Data Lost Error ....................................................................... 30
Failure code [CA778] Eng Bkup Speed Sensor Error...........................................................................32
Failure code [CA1633] KOMNET Datalink Timeout Error.................................................................. 34
Failure code [CA2185] Throt Sens Sup Volt High Error .................................................................... 35
Failure code [CA2186] Throt Sens Sup Volt Low Error ..................................................................... 36
Failure code [CA2249] Rail Press Very Low Error............................................................................. 37
Failure code [CA2311] IMV Solenoid Error........................................................................................ 37
Failure code [CA2555] Grid Htr Relay Volt High Error....................................................................... 38
Failure code [CA2556] Grid Htr Relay Volt Low Error ....................................................................... 40
Failure code [D19JKZ] Personal Code Relay Abnormality ................................................................ 42
Failure code [D862KA] GPS Antenna Discon.................................................................................... 44
Failure code [DA22KK] Pump Solenoid Power Low Error ................................................................. 46
Failure code [DA25KP] 5V Sensor 1 Power Abnormality .................................................................. 48
Failure code [DA26KP] 5V Sensor 2 Power Abnormality .................................................................. 52
Failure code [DA29KQ] Model Selection Abnormality ....................................................................... 54
PC200, 200LC-8E0 (Hybrid) 00-100 7

100 Index

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 [DHS5KK] Travel Speed PPC Sensor Abnormality....................................................... 22
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality.............................................. 24
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality................................................. 26
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ................................................. 28
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ........................................... 30
Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Shrt Cir .................................................... 32
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir ........................................... 33
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir ................................................. 34
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir .................................................. 35
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir .............................................. 36
Failure code [DW43KA] Travel Speed Sol Discon............................................................................. 38
Failure code [DW43KB] Travel Speed Sol Short ............................................................................... 40
Failure code [DW45KA] Swing Brake Sol. Valve Open Cir................................................................ 42
Failure code [DW45KB] Swing Brake Sol. Valve Short Cir................................................................ 43
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir.......................................................... 44
Failure code [DW91KA] Travel Junction Sol Discon.......................................................................... 46
Failure code [DW91KB] Travel Junction Sol Short ............................................................................ 48
Failure code [DWK0KA] 2-stage Relief Sol Discon............................................................................ 50
Failure code [DWK0KB] 2-stage Relief Sol Short .............................................................................. 52
Failure code [DXA8KA] PC-EPC (F) Sol Discon................................................................................ 2
Failure code [DXA8KB] PC-EPC (F) Sol Short .................................................................................. 4
Failure code [DXA9KA] PC-EPC (R) Sol Discon ............................................................................... 6
Failure code [DXA9KB] PC-EPC (R) Sol Short.................................................................................. 8
Failure code [DXE0KA] LS-EPC Sol Discon...................................................................................... 10
Failure code [DXE0KB] LS-EPC Sol Short ........................................................................................ 12
Failure code [DXE5KA] Merge-divider Main Sol Discon .................................................................... 14
Failure code [DXE5KB] Merge-divider Main Sol Short ...................................................................... 16
Failure code [DXE6KA] Merge-divider LS Sol Discon ....................................................................... 18
Failure code [DXE6KB] Merge-divider LS Sol Short.......................................................................... 20
Failure code [DY20KA] Wiper Working Abnormality.......................................................................... 22
Failure code [DY20MA] Wiper Parking Abnormality .......................................................................... 24
Failure code [DY2CKA] Washer Drive Discon ................................................................................... 26
Failure code [DY2CKB] Washer Drive Short ..................................................................................... 28
Failure code [DY2DKB] Wiper Drive (For) Short................................................................................ 30
Failure code [DY2EKB] Wiper Drive (Rev) Short............................................................................... 32
Precautions related to hybrid machines............................................................................................. 4
Common troubleshooting of hybrid components and high voltage wiring (high voltage section) ...... 9
Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Short Cir .................................................. 24
Failure code [DHV9KZ] HYB boom Lower PPC Pr. Sen. Opn/Shrt Cir ............................................ 26
Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt. ............................................... 28
Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen Opn/Short Cir.................................................... 31
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/Short Cir. ............................................ 34
00-100 8 PC200, 200LC-8E0 (Hybrid)

100 Index
Failure code [DW45KA] Swing Brake Sol. Valve Open Cir ............................................................... 36
Failure code [DW45KB] Swing Brake Sol. Valve Short Cir................................................................ 40
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir. ........................................................ 42
Failure code [GA01KA] Power Cable Interlock Open Circuit ............................................................ 44
Failure code [GA02KZ] DC Line Open/Short Circuit.......................................................................... 46
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster....................................................... 47
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster ....................................................... 48
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster......................................................... 49
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster..................................................... 50
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster. ........................................................ 51
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster ......................................................... 52
Failure code [GA09KP] Low DC SW Output Volt. After Booster ....................................................... 53
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster ....................................................... 54
Failure code [GA0BKZ] AC Line Open/Short Circuit ........................................................................ 55
Failure code [GA11KK] HYB Cont. Low Supply Voltage ................................................................... 56
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure ................................................................... 59
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON ......................................................... 60
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF........................................................ 61
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure ....................................................... 62
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure ....................................................... 64
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir................................................... 67
Failure code [GA16KK] Low HYB Cont. VDD Suppl. Volt. ................................................................ 68
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure ....................................................... 69
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit......................................................... 70
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit .......................................................... 71
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded ............................................................. 72
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure ...................................................... 73
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt ...................................................... 74
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure ............................................... 75
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. ................................................ 76
Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction ......................................................... 76
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation ............................................... 78
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled...................................................... 79
Failure code [GA1AKZ] Gen. Mot. Dr. Temp. Sens. Opn/Short Cir. .................................................. 80
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction .................................................... 81
Failure code [GA1DMA] Gen. Motro Driver IPM1 Abnormality.......................................................... 82
Failure code [GA1EMA] Gen. Motor Driver IPM 2 Abnormality ......................................................... 83
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure ..................................................... 84
Failure code [GA1FMA] Abnormal Swing Motor Driver .................................................................... 85
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU ............................................... 86
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure. .............................................. 87
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal................................................. 88
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfuuction ................................................... 89
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded ............................................. 90
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op......................................................... 91
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled ................................................... 92
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. ............................................. 93
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir. ............................................... 94
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir............................................... 95
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir..................................................... 96
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir....................................................... 97
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat ............................................................ 98
Failure code [GA1PNV] Swg Mot. Driver IPM Ph-U Not Warm up .................................................... 99
Failure code [GA1QNV] Swg Mot. Driver IPM Ph-V Not Warm Up ................................................... 100
PC200, 200LC-8E0 (Hybrid) 00-100 9

100 Index
Failure code [GA1RNV] Swng Mot. Driver IPM Ph-W Not Warm Up ................................................ 101
Failure code [GA1SFS] Contactor Locked......................................................................................... 102
Failure code [GA1SMC] Contactor Failure ........................................................................................ 103
Failure code [GA1TKG] Capacitor HVPS Abnormal Voltage............................................................. 104
Failure code [GA1TKP] Capacitor Low Output Voltage ..................................................................... 105
Failure code [GA1TNS] Capacitor Overheat...................................................................................... 106
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir....................................................... 108
Failure code [GA1VFS] Capacitor Contactor Locked ........................................................................ 110
Failure code [GA1VMC] Capacitor Contactor Failure ........................................................................ 112
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ..................................................... 113
Failure code [GA1YNS] Booster Inductor Overheat .......................................................................... 114
Failure code [GA1YNV] Booster Inductor Not Warming Up............................................................... 115
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ. ................................................. 116
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat.......................................................... 117
Failure code [GA1ZNV] Booster IGBT Temp. Sens. Not Warm Up................................................... 118
Failure code [GA21KB] Booster IGBT Short Circuit........................................................................... 119
Failure code [GA22NS] Booster IGBT Junction Overheat ................................................................. 120
Failure code [GA60MC] Generator Motor Failure .............................................................................. 121
Failure code [GA60MD] Gen. Mot. Defective Movement................................................................... 122
Failure code [GA60N1] Generator Motor Overrun ............................................................................. 123
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir. .................................................... 124
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat ................................................... 126
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir.................................................. 127
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir ................................................... 128
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction .................................................. 129
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir.................................................. 130
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir ................................................... 131
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction ................................................... 132
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir.................................................. 133
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir. .................................................. 134
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction................................................... 135
Failure code [GA70KB] HYB Swing Motor Short Circuit .................................................................... 136
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion.................................................... 137
Failure code [GA70NS] HYB Swing Motor Overheat......................................................................... 138
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir................................................. 139
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction...................................................... 141
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op........................................................ 143
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. .................................................... 145
Troubleshooting of electrical system (E-mode) SEN05252-00
Before performing troubleshooting of electrical system ..................................................................... 3
E-1 When starting switch is turned to ON position, machine monitor displays nothing ..................... 6
E-2 When starting switch turned ON (before starting engine), basic check monitor lights up ........... 8
E-3 Engine does not start (Engine does not crank) ........................................................................... 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 Caution monitor lights up while engine is running ....................................................................... 20
E-8 Emergency monitor lights up while engine is running ................................................................. 25
E-9 Engine coolant temperature gauge does not indicate normally .................................................. 26
E-10 Hydraulic oil temperature gauge does not indicate normally..................................................... 27
E-11 Fuel level gauge does not indicate normally ............................................................................. 29
E-12 Contents of display by machine monitor are different from applicable machine ....................... 31
E-13 Some areas of the machine monitor screen are not displayed ................................................. 32
00-100 10 PC200, 200LC-8E0 (Hybrid)

100 Index
E-14 Function switch does not work .................................................................................................. 33

E-15 Auto-deceleration does not operate normally ........................................................................... 34
E-16 Working mode does not change ............................................................................................... 35
E-17 Travel speed does not change.................................................................................................. 36
E-18 Alarm buzzer cannot be stopped .............................................................................................. 37
E-19 Windshield wiper and window washer do not operate .............................................................. 38
E-20 One-touch power maximizing function does not operate normally ........................................... 40
E-21 Swing brake does not operate normally.................................................................................... 43
E-22 Travel alarm does not sound or does not stop sounding .......................................................... 46
E-23 Air conditioner does not operate normally (including air conditioner abnormality record)......... 48
E-24 While starting switch is in OFF position, service meter is not displayed ................................... 59
E-25 Machine monitor cannot be set in service mode....................................................................... 60
E-26 Monitoring function does not display lever control signal normally ........................................... 61
E-27 KOMTRAX system does not operate normally ......................................................................... 67
Troubleshooting of hydraulic and mechanical system (H-mode) SEN05253-00
System diagram of hydraulic and mechanical system....................................................................... 4
H-1 Speed or power of all work equipment and travel is low............................................................. 7
H-2 Engine speed lowers significantly or engine stalls...................................................................... 8
H-3 All work equipment and travel systems do not work ................................................................... 9
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 .............................................................................. 12
H-7 Speed or power of boom is low................................................................................................... 13
H-8 Speed or power of arm is low ..................................................................................................... 14
H-9 Speed or power of bucket is low ................................................................................................. 15
H-10 Work equipment does not move in its single operation ............................................................ 16
H-11 Hydraulic drift of work equipment is large ................................................................................. 17
H-12 Time lag of work equipment is large ......................................................................................... 18
H-13 When part of work equipment is relieved singly, other parts of work equipment move ............ 19
H-14 Power maximizing function does not work................................................................................ 20
H-15 In compound operation of work equipment, speed of part loaded more is low......................... 21
H-16 When machine swings and travels simultaneously, travel speed is low ................................... 22
H-17 Machine deviates during travel ................................................................................................. 23
H-18 Travel speed is low ................................................................................................................... 24
H-19 Machine is not steered well or steering power is low................................................................ 25
H-20 Travel speed does not shift or travel speed is low or high ........................................................ 26
H-21 Travel system does not work (only one side)............................................................................ 27
H-22 Upper structure does not swing ................................................................................................ 28
H-23 Swing acceleration or swing speed of upper structure is low ................................................... 29
H-24 Upper structure overruns remarkably when it stops swinging .................................................. 30
H-25 Large shock is made when upper structure stops swinging ..................................................... 31
H-26 Large sound is made when upper structure stops swinging ..................................................... 32
H-27 Upper structure lowers largely by its own weight...................................................................... 33
Troubleshooting of engine (S-mode) SEN05254-01
Method of using troubleshooting chart............................................................................................... 2
S-1 Starting performance is poor....................................................................................................... 6
S-2 Engine does not start .................................................................................................................. 7
S-3 Engine does not pick up smoothly .............................................................................................. 10
S-4 Engine stops during operations................................................................................................... 11
S-5 Engine does not run smoothly..................................................................................................... 12
S-6 Engine lacks output power .......................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) ...................................................................... 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 15
PC200, 200LC-8E0 (Hybrid) 00-100 11

100 Index
S-9 Oil becomes contaminated early ................................................................................................. 16

S-10 Fuel consumption is excessive.................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) ................................................ 18
S-12 Oil pressure drops ..................................................................................................................... 19
S-13 Oil level rises (Entry of coolant/fuel).......................................................................................... 20
S-14 Coolant temperature becomes too high (overheating) .............................................................. 21
S-15 Abnormal noise is made............................................................................................................ 22
S-16 Vibration is excessive................................................................................................................ 23
Troubleshooting of Hybrid system (Y-mode) SEN05270-03
Precautions related to hybrid machine............................................................................................... 2
Y-1 Hybrid monitor does not go off ................................................................................................... 4
Y-2 Upper structure does not swing................................................................................................... 6
Y-3 Swing acceleration or swing speed is low ................................................................................... 8
Y-4 Upper structure overruns largely after swinging.......................................................................... 9
Y-5 Large shock is made when upper structure stops swinging........................................................ 10
Y-6 Large abnormal sound is made when upper structure stops swinging ....................................... 11
Y-7 Upper structure lowers largely by its own weight ........................................................................ 12
Y-8 Swing electric motor temperature increases abnormally............................................................. 13
Y-9 Motor-generator temperature increases abnormally ................................................................... 15
Y-10 Inverter temperature increases abnormally............................................................................... 16
Y-11 Capacitor temperature increases abnormally............................................................................ 17
50 Disassembly and assembly

General information on disassembly and assembly SEN05256-01
How to read this manual .................................................................................................................... 2
Precautions related to hybrid machine............................................................................................... 4
Coating materials list.......................................................................................................................... 5
Special tools list ................................................................................................................................. 8
Sketches of special tools ................................................................................................................... 12
Engine and cooling system SEN05257-00
Removal and installation of fuel supply pump assembly ................................................................... 2
Removal and installation of fuel injector assembly ............................................................................ 6
Removal and installation of engine front seal .................................................................................... 13
Removal and installation of engine rear seal ..................................................................................... 15
Removal and installation of cylinder head assembly ......................................................................... 18
Removal and installation of radiator assembly .................................................................................. 35
Removal and installation of hydraulic oil cooler assembly................................................................. 37
Removal and installation of aftercooler assembly.............................................................................. 40
Removal and installation of fuel cooler assembly .............................................................................. 43
Removal and installation of engine/motor-generator/hydraulic pump assembly................................ 45
Removal and installation of fuel tank assembly ................................................................................. 60
Hyblid Relation SEN05258-02
Draining and adding coolant and bleeding air for hybrid system ....................................................... 2
Removal and installation of hybrid radiator assembly........................................................................ 7
Removal and installation of water pump assembly for hybrid system ............................................... 10
Removal and installation of inverter assembly................................................................................... 13
Removal and installation of inverter and capacitor assembly ............................................................ 17
Draining and adding generator lubricating oil .................................................................................... 23
Removal and installation of tandem pump assembly......................................................................... 25
Removal and installation of motor-generator and housing assembly ................................................ 28
Removal and installation of swing electric motor assembly............................................................... 37
Removal and installation of final drive assembly ............................................................................... 2
Disassembly and assembly of final drive assembly........................................................................... 3
00-100 12 PC200, 200LC-8E0 (Hybrid)

100 Index
Removal and installation of "swing electric motor and swing machinery assembly" ......................... 11
Disassembly and assembly of swing machinery assembly ............................................................... 15
Removal and installation of swing circle assembly ............................................................................ 29
Undercarriage and frame SEN05260-01
Disassembly and assembly of carrier roller assembly....................................................................... 2
Disassembly and assembly of track roller assembly ......................................................................... 5
Disassembly and assembly of idler assembly ................................................................................... 7
Disassembly and assembly of recoil spring assembly....................................................................... 10
Removal and installation of sprocket ................................................................................................. 12
Expansion and installation of track shoe assembly ........................................................................... 13
Removal and installation of revolving frame assembly...................................................................... 16
Removal and installation of counterweight assembly ........................................................................ 18
Hydraulic system SEN05261-01
Removal and installation of center swivel joint assembly .................................................................. 2
Disassembly and assembly of center swivel joint assembly.............................................................. 4
Removal and installation of hydraulic tank assembly ........................................................................ 5
Removal and installation of control valve assembly .......................................................................... 10
Disassembly and assembly of control valve assembly...................................................................... 14
Removal and installation of hydraulic pump assembly ...................................................................... 18
Removal and installation of oil seal in hydraulic pump input shaft..................................................... 22
Disassembly and assembly of work equipment PPC valve assembly............................................... 23
Disassembly and assembly of travel PPC valve assembly ............................................................... 25
Disassembly and assembly of hydraulic cylinder assembly .............................................................. 28
Work equipment Body SEN05262-00
Removal and installation of work equipment assembly ..................................................................... 2
Cab and its attachments SEN05263-00
Removal and installation of operator's cab assembly........................................................................ 2
Removal and installation of operator cab glass (stuck glass)............................................................ 6
Removal and installation of front window assembly .......................................................................... 15
Removal and installation of floor frame assembly ............................................................................. 22
Removal and installation of air conditioner unit assembly ................................................................. 27
Electric system SEN05264-01
Removal and installation of KOMTRAX terminal ............................................................................... 2
Removal and installation of monitor assembly .................................................................................. 3
Removal and installation of pump controller assembly...................................................................... 5
Removal and installation of engine controller assembly.................................................................... 8
90 Diagrams and Drawings

Hydraulic diagrams and drawings SEN05266-01
Hydraulic circuit diagram ................................................................................................................... 3
Electrical diagrams and drawings SEN05267-01
Electrical circuit diagram.................................................................................................................... 3
Connector list and sterogram............................................................................................................. 17
PC200, 200LC-8E0 (Hybrid) 00-100 13

SEN05223-05
PC200, 200LC-8E0 (Hybrid) Hydraulic excavator
Form No. SEN05223-05
©2012 KOMATSU
All Rights Reserved
Printed in Japan 10-12 (01)
00-100 14
SEN05224-02
SEN05224-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


200 Foreword and general information
Safety notice ............................................................................................................................................... 2

How to read the shop manual ..................................................................................................................... 7
Explanation of terms for maintenance standard ......................................................................................... 9
Handling of hydraulic components.............................................................................................................. 11
Method of disconnecting and connecting push-pull type coupler ............................................................... 13
Handling of electric equipment.................................................................................................................... 16
How to read electric wire code.................................................................................................................... 26
Precautions when performing work............................................................................................................. 31
Handling of hybrid devices and high-voltage wirings .................................................................................. 34
Standard tightening torque table................................................................................................................. 42
Conversion table ......................................................................................................................................... 46
PC200, 200LC-8E0 (Hybrid) 00-200 1

SEN05224-02 Safety notice
Safety notice
(Rev. 2012/07)
Hybrid
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific pur-
pose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the
situation.
1. Precautions peculiar to hybrid machine 00-200).

1) Hybrid mark k 6. When handling hybrid devices or
k 1. This machine is equipped with the high voltage wirings, there is a proce-
hybrid system consisting of an electric dure to look into the charge level in-
motor and a diesel engine. The above spection window at the contactor box
Hybrid mark is attached to each expla- above the capacitor and to check that
nation peculiar to the hybrid system the LED display for capacitor charge
(contents different from those for the state indicates "UNCHARGED". Before
common diesel engine machine).Be discharging capacitor, check display
sure to read the Operation and Mainte- function of this LED according to the
nance Manual, "Introduction", "Out- following procedure.
line of hybrid system" (Section 1), 1] Both of two LEDs are lit 1 minute after
"Safety", "Safety Precautions on Safe- engine is started.
ty Indicators" (Section 2) and this 2] One LED is lit after turning the key to
Shop Manual, "Handling of hybrid de- the OFF position. (One LED goes out
vices and high-voltage wiring" (Sec- by turning the key to the OFF posi-
tion 00-200) and "Items related to tion.)
hybrid system" (Section 10-200) to un- LED display function to show capaci-
derstand the hybrid system. tor charge state may be defective if the
k 2. The persons who engage in the in- above cannot be confirmed even when
stalling or removing work of the hybrid any failure is not occurring in hybrid
devices (motor-generator, capacitor, system. In this case, replace the ca-
inverter, swing electric motor) must pacitor according to the following
follow the local Industrial Safety and "General precautions".
Health Law concerning electricity.
k 3. Never disassemble the hybrid devic- 2. General precautions
es mentioned above. The hybrid devic- k Mistakes in operation are extremely dan-
es and high-voltage wiring (orange gerous. Read the Operation and Mainte-
color) must be replaced by the unit. nance Manual carefully before operating
k 4. When handling hybrid devices, be the machine. In addition, read this manu-
sure to discharge the capacitor com- al and understand its contents before
pletely first. For details, see this man- starting the work.
ual, "Handling of hybrid devices and 1) Before carrying out any greasing or repairs,
high-voltage wirings", "Discharge pro- read all the safety labels stuck to the
cedure for capacitor" (Section 00-200) machine. For the locations of the safety
or Testing and adjusting (Part 2), "Dis- labels and detailed explanation of precau-
charge" of capacitor" (Section 30-102). tions, see the Operation and Maintenance
k 5. When handling the hybrid devices Manual.
or high-voltage wirings, be sure to fol- 2) Decide a place in the repair workshop to
low "Handling of hybrid devices and keep tools and removed parts. Always keep
high-voltage wirings" (Section the tools and parts in their correct places.
00-200 2 PC200, 200LC-8E0 (Hybrid)

Safety notice SEN05224-02
Always keep the work area clean and make 3. Preparations for work
sure that there is no dirt, water, or oil on the 1) Before adding oil or making any repairs, park
floor. Smoke only in the areas provided for the machine on a hard and level ground, and
smoking. Never smoke while working. apply the parking brake and block the wheels
3) When carrying out any operation, always or tracks to prevent the machine from
wear safety shoes and helmet. Do not wear moving.
loose work clothes, or clothes with buttons 2) Before starting work, lower the work equip-
missing. ment (blade, ripper, bucket, etc.) to the
q Always wear safety glasses when hitting ground. If this is not possible, insert the lock
parts with a hammer. pin or use blocks to prevent the work equip-
q Always wear safety glasses when grind- ment from falling. In addition, be sure to lock
ing parts with a grinder, etc. all the control levers and hang warning tag on
4) When carrying out any operation with 2 or them.
more workers, always agree on the operating 3) When disassembling or assembling, support
procedure before starting. Always inform the machine with blocks, jacks, or stands
your fellow workers before starting any step before starting work.
of the operation. Before starting work, hang 4) Remove all mud and oil from the steps or
UNDER REPAIR warning signs in the oper- other places used to get on and off the
ator's compartment. machine. Always use the handrails, ladders
5) Only qualified workers must carry out work or steps when getting on or off the machine.
and operation which require license or quali- Never jump on or off the machine. If it is
fication. impossible to use the handrails, ladders or
6) Keep all tools in good condition, learn the steps, use a stand to provide safe footing.
correct way to use them, and use the proper
ones. Before starting work, thoroughly check 4. Precautions during work
the tools, machine, forklift, service car, etc. 1) Before disconnecting or removing compo-
7) If welding repairs are needed, always have a nents of the oil, water, or air circuits, first
trained and experienced welder carry out the release the pressure completely from the
work. When carrying out welding work, circuit. When removing the oil filler cap, a
always wear welding gloves, apron, shielding drain plug, or an oil pressure pickup plug,
goggles, cap and other clothes suited for loosen it slowly to prevent the oil from
welding work. spurting out.
8) Before starting work, warm up your body 2) The coolant and oil in the circuits are hot
thoroughly to start work under good condi- when the engine is stopped, so be careful not
tion. to get scalded. Wait for the oil and coolant to
9) Avoid continuing work for long hours and cool before carrying out any work on the oil or
take rests at proper intervals to keep your water circuits.
body in good condition. Take rests in speci- 3) Before starting work, stop the engine. When
fied safe places. working on or around a rotating part, in partic-
ular, stop the engine. When checking the
Safety points machine without stopping the engine
1 Good arrangement (measuring oil pressure, revolving speed,
2 Correct work clothes
temperature, etc.), take extreme care not to
3 Following work standard
4 Making and checking signals get caught in rotating parts or moving parts.
5 Prohibition of operation and handling by unli- 4) Before starting work, remove the leads from
censed workers the battery. Always remove the lead from the
6 Safety check before starting work negative (–) terminal first.
7 Wearing protective goggles (for cleaning or grind- 5) When raising a heavy component (heavier
ing work)
than 25kg), use a hoist or crane. Before
8 Wearing shielding goggles and protectors (for
welding work) starting work, check that the slings (wire
9 Good physical condition and preparation ropes, chains, and hooks) are free from
10 Precautions against work which you are not used damage. Always use slings which have
to or you are used to too much ample capacity and install them to proper
places. Operate the hoist or crane slowly to
prevent the component from hitting any other
part. Do not work with any part still raised by
the hoist or crane.
PC200, 200LC-8E0 (Hybrid) 00-200 3

6) When removing a cover which is under 5. Precautions for sling work and making
internal pressure or under pressure from a signals
spring, always leave 2 bolts in diagonal posi- 1) Only one appointed worker must make
tions. Loosen those bolts gradually and alter- signals and co-workers must communicate
nately to release the pressure, and then with each other frequently. The appointed
remove the cover. signaler must make specified signals clearly
7) When removing components, be careful not at a place where he is well seen from the
to break or damage the electrical wiring. operator's seat and where he can see the
Damaged wiring may cause electrical fires. working condition easily. The signaler must
8) When removing piping, stop the fuel or oil always stand in front of the load and guide
from spilling out. If any fuel or oil drips onto the operator safely.
the floor, wipe it up immediately. Fuel or oil q Do not stand under the load.
on the floor can cause you to slip and can q Do not step on the load.
even start fires. 2) Check the slings before starting sling work.
9) As a general rule, do not use gasoline to 3) Keep putting on gloves during sling work.
wash parts. Do not use it to clean electrical (Put on leather gloves, if available.)
parts, in particular. 4) Measure the weight of the load by the eye
10)Be sure to assemble all parts again in their and check its center of gravity.
original places. Replace any damaged parts 5) Use proper sling according to the weight of
and parts which must not be reused with new the load and method of slinging. If too thick
parts. When installing hoses and wires, be wire ropes are used to sling a light load, the
sure that they will not be damaged by contact load may slip and fall.
with other parts when the machine is oper- 6) Do not sling a load with 1 wire rope alone. It
ated. may rotate and may slip out of the rope.
11)When installing high pressure hoses and Install 2 or more wire ropes symmetrically.
tubes, make sure that they are not twisted. k Slinging with 1 rope may cause turn-
Damaged hoses and tubes are dangerous, ing of the load during hoisting, un-
so be extremely careful when installing twisting of the rope, or slipping of the
hoses and tubes for high pressure circuits. In rope from its original winding position
addition, check that connections of them are on the load, which can result in a dan-
correct. gerous accident.
12)When assembling or installing parts, always 7) Limit the hanging angle to 60 °, as a rule.
tighten them to the specified torques. When Do not sling a heavy load (heavier than 25
installing protective parts such as guards, or kg) with ropes forming a wide hanging angle
parts which vibrate violently or rotate at high from the hook.
speeds, be particularly careful to check that When hoisting a load with 2 or more ropes,
they are installed correctly. the force subjected to each rope will increase
13)When aligning 2 holes, never insert your with the hanging angle. The table below
fingers or hand. Be careful not to get your shows the variation of allowable load in kN
fingers caught in a hole. {kg} when hoisting is made with 2 ropes,
14)When measuring hydraulic pressure, check each of which is allowed to sling up to 9.8kN
that the measuring tools are correctly {1,000kg} vertically, at various hanging
installed. angles. When the 2 ropes sling a load verti-
15)Take care when removing or installing the cally, up to 19.6kN {2,000kg} of total weight
tracks of track-type machines. When can be suspended. This weight is reduced to
removing the track, the track separates 9.8kN {1,000kg} when the 2 ropes make a
suddenly, so never let anyone stand at either hanging angle of 120 °. If the 2 ropes sling a
end of the track. 19.6kN {2,000kg} load at a lifting angle of
16)If the engine is operated for a long time in a 150 ° , each of them is subjected to a force as
place which is not ventilated well, you may large as 39.2kN {4,000kg}.
suffer from gas poisoning. Accordingly, open
the windows and doors to ventilate well.
00-200 4 PC200, 200LC-8E0 (Hybrid)

Safety notice SEN05224-02
q When lowering a load, stop it temporarily

at 30cm above the floor, and then lower it
slowly.
q Check that the load is stable, and then re-
move the sling.
q Remove kinks and dirt from the wire
ropes and chains used for the sling work,
and put them in the specified place.
6. Precautions for using mobile crane

a Read the Operation and Maintenance Manu-
al of the crane carefully in advance and oper-
ate the crane safely.
8) When installing wire ropes to an angular
7. Precautions for using overhead hoist crane
k When raising a heavy part (heavier than
load, apply pads to protect the wire ropes. If
the load is slippery, apply proper material to
25kg), use a hoist, etc. In Disassembly
prevent the wire rope from slipping.
and assembly, the weight of a part heavier
9) Use the specified eyebolts and fix wire ropes, than 25kg is indicated after the mark of
4.
chains, etc. to them with shackles, etc.
10)Apply wire ropes to the middle portion of the 1) Before starting work, inspect the wire ropes,
hook. brake, clutch, controller, rails, over wind stop
q Slinging near the tip of the hook may
device, ground fault circuit interrupter, crane
cause the rope to slip off the hook during collision prevention device, and power appli-
hoisting. The hook has the maximum cation warning lamp, and check safety.
strength at the middle portion.
2) Observe the signals for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions of
the control buttons without fail.
5) Do not sling a load at an angle. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the crane
is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting a load, stop it just after it leaves
the ground and check safety, and then lift it
up.
9) Consider the travel route in advance and lift
11)Do not use twisted or kinked wire ropes. up a load to a safe height.
12)When lifting a load, observe the following. 10)Place the control switch on a position where
q Wind in the crane slowly until wire ropes
it will not be an obstacle to work and
are stretched. When settling the wire passage.
ropes with the hand, do not grasp them 11)After operating the hoist, do not swing the
but press them from above. If you grasp control switch.
them, your fingers may be caught. 12)Remember the position of the main switch so
q After the wire ropes are stretched, stop that you can turn off the power immediately in
the crane and check the condition of the an emergency.
slung load, wire ropes, and pads. 13)If the hoist stops because of a power failure,
q If the load is unstable or the wire rope or turn the power switch OFF. When turning on
chains are twisted, lower the load and lift a switch which was turned OFF by the
it up again. ground fault circuit interrupter check that the
q Do not lift up the load slantingly. devices related to that switch are not in oper-
13)When lifting down a load, observe the ation state.
following. 14)If you find an obstacle around the hoist, stop
the operation.
PC200, 200LC-8E0 (Hybrid) 00-200 5

15)After finishing the work, stop the hoist at the

specified position and raise the hook to at 2) Connection
least 2m above the floor. Do not leave the 1] When installing the air conditioner circuit
sling installed to the hook. hoses and tubes, take care that dirt, dust,
water, etc. will not enter them.
8. Selecting wire ropes 2] When connecting the air conditioner
1) Select adequate ropes depending on the hoses and tubes, check that O-rings (1)
weight of parts to be hoisted, referring to the are fitted to their joints.
table below. 3] Check that each O-ring is not damaged or
Wire ropes deteriorated.
(Standard "Z" twist ropes without galvanizing) 4] When connecting the refrigerant piping,
(JIS G3525, No. 6, Type 6X37-A) apply compressor oil for refrigerant
Nominal diameter Allowable load
(R134a) (DENSO: ND-OIL8, VALEO
of rope
mm kN ton THERMAL SYSTEMS: ZXL100PG
10 8.8 0.9 (equivalent to PAG46)) to its O-rings.
12 12.7 1.3 a Example of O-ring (Fitted to every joint of hoses
14 17.3 1.7 and tubes)
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
a The allowable load is one-sixth of the

breaking strength of the rope used (Safe-
ty coefficient: 6).
9. Precautions for disconnecting and

connecting hoses and tubes in air condi-
tioner circuit a For tightening torque, see the precautions for in-
1) Disconnection stallation in each section of "Disassembly and
k For the environment, the air condition- assembly".
er of this machine uses the refrigerant
(air conditioner gas: R134a) which has
fewer factors of the depletion of the
ozone layer. However, it does not
mean that you may discharge the re-
frigerant into the atmosphere as it is.
Be sure to recover the refrigerant
when disconnecting the refrigerant
gas circuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight and your skin may be fro-
zen. Accordingly, put on safety glass-
es, safety gloves and safety clothes
when recovering or adding the refrig-
erant.
Refrigerant gas must be recovered
and added by a qualified person.
00-200 6 PC200, 200LC-8E0 (Hybrid)

How to read the shop manual SEN05224-02
How to read the shop manual

(Rev. 2010/10)
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is
required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine vol-
ume of the engine model mounted on the machine.
1. Composition of shop manual

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

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

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

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

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

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

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
PC200, 200LC-8E0 (Hybrid) 00-200 7

SEN05224-02 How to read the shop manual
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition table.
q Revised edition mark

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

a Caution
necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when selecting hoisting
Weight
wire, or when working posture is important, etc.
3 Tightening torque Places that require special attention for tightening torque during assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5 Oil, coolant Places where oil, etc. must be added, and capacity.
6 Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conven-
tionally used Gravitational System of units is indicated in parentheses { }.
00-200 8 PC200, 200LC-8E0 (Hybrid)

Explanation of terms for maintenance standard SEN05224-02
Explanation of terms for maintenance standard

(Rev. 2010/03)
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the ma-
chine maintenance work. The following terms are used to explain the criteria.
1. Standard dimension and tolerance

q To be accurate, the finished dimension of
parts is slightly different from one to another.
q To specify the finished dimension of a part, a
certain dimension is set for the part and an al-
lowable difference from that dimension is in-
dicated.
q The above dimension set is called the "stan-
dard dimension" and the range of difference
from the standard dimension is called the
"tolerance".
q The tolerance with the symbols of + or – is in-
dicated on the right side of the standard di-
mension.
Example:
Standard dimension Tolerance
-0.022
120
-0.126
a The tolerance may be indicated in the text

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

mension of the shaft to be inserted into that
hole are indicated by the same standard di-
mension and different tolerances of the hole
and shaft. The tightness of fit is decided by
the tolerance. 3. Standard interference
q Indication of dimension of rotating shaft and q When the diameter of a hole of a part shown
hole and their related drawing. in the given standard dimension and toler-
ance table is smaller than that of the shaft to
Example: be inserted, the difference between those di-
Standard dimen- Tolerance
ameters is called the "interference".
sion Shaft Hole
q The range (between A and B) from the differ-
-0.030 +0.046
60 ence (A) between the minimum dimension of
-0.076 0
the shaft and the maximum dimension of the
2. Standard clearance and standard value hole to the difference (B) between the maxi-
q The clearance made when new parts are as-
mum dimension of the shaft and the mini-
sembled is called the "standard clearance", mum dimension of the hole is the “standard
which is indicated by the range from the min- interference”.
imum clearance to the maximum clearance. q After repairing or replacing some parts, mea-
q When some parts are repaired, the clearance sure the dimension of their hole and shaft
is generally adjusted to the standard clear- and check that the interference is in the stan-
ance. dard range.
q The values indicating performance and func-
tion of new products or equivalent are called
the "standard value", which is indicated by a
range or a target value.
q When some parts are repaired, the value of
performance/function is set to the standard
value.
PC200, 200LC-8E0 (Hybrid) 00-200 9

SEN05224-02 Explanation of terms for maintenance standard
4. Repair limit and allowable value or allowable

dimension
q The dimension of a part changes because of
wear and deformation while it is used. The
limit of changed dimension is called the "re-
pair limit".
q If a part is worn to the repair limit, it must be
replaced or repaired.
q The performance and function of a product
lowers while it is used. A value with which the
product can be used without causing a prob-
lem is called the "allowable value" or "allow-
able dimension".
q If a product deviates from the allowable val-
ue, it must be checked or repaired. However,
since most of the allowable values are esti-
mated from various tests or experiences in
most cases, it must be judged after consider-
ing the operating condition and customer's
requirement.
5. Allowable clearance
q Parts can be used until the clearance be-
tween them is increased to a certain limit.
The limit at which those parts cannot be used
is called the "allowable clearance".
q If the clearance between the parts exceeds
the allowable clearance, they must be re-
placed or repaired.
6. Allowable interference
q The allowable maximum interference be-
tween the hole of a part and the shaft of an-
other part to be assembled is called the
"allowable interference".
q The allowable interference shows the repair
limit of the part of smaller tolerance.
q If the interference between the parts exceeds
the allowable interference, they must be re-
placed or repaired.
00-200 10 PC200, 200LC-8E0 (Hybrid)

Handling of hydraulic components SEN05224-02
Handling of hydraulic components

(Rev. 2010/03)
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding hydraulic oil,
or when disassembling or assembling hydraulic components.
1. Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is
performed on hydraulic components in the field,
there is danger of dust entering the components.
It is also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
components should be performed in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.
4. Preventing intrusion of foreign materials

during refilling operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has been collected during storage, so this is
an even more effective method.
PC200, 200LC-8E0 (Hybrid) 00-200 11

SEN05224-02 Handling of hydraulic components
5. Replacing hydraulic oil while its temperature is high

When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
hole in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
performed twice. Primary flushing is performed
by use of flushing oil and secondary flushing is
performed by use of the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
perform oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment can remove the ultra fine
(about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.
00-200 12 PC200, 200LC-8E0 (Hybrid)

Method of disconnecting and connecting push-pull type coupler SEN05224-02
Method of disconnecting and connecting push-pull type coupler

(Rev. 2010/03)
k Before performing the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the remaining pressure in the hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
a The adapter can be pushed in about 3.5
mm.
a Do not hold rubber cap portion (4).
2) With hose joint (2) pushed into adapter (3),
press rubber cap portion (4) against adapter
(3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull it
out. (Fig. 3)
a Since some hydraulic oil flows out, pre-
pare an oil container.
2. Connection
1) Hold hose adapter (1) or hose (5) and insert
it in mating adapter (3), aligning them with
each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose fitting in the adapter
on the other side perfectly, pull it back to
check the connecting condition (Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormal-
ity, however.
PC200, 200LC-8E0 (Hybrid) 00-200 13

SEN05224-02 Method of disconnecting and connecting push-pull type coupler
Type 2
1. Disconnection
1) Hold the tightening portion and push body (7)
straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1) and
2), pull out whole body (7) to disconnect it.
(Fig. 8)
2. Connection
q Hold the tightening portion and push body (7)
straight until sliding prevention ring (6) con-
tacts contact surface (a) of the hexagonal
00-200 14 PC200, 200LC-8E0 (Hybrid)

Method of disconnecting and connecting push-pull type coupler SEN05224-02
Type 3
1. Disconnection
1) Hold the tightening portion and push body (9)
straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
2) While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the
male end. (Fig. 11)
3) While holding the condition of Steps 1) and
2), pull out whole body (9) to disconnect it.
(Fig. 12)
2. Connection
q Hold the tightening portion and push body (9)
straight until sliding prevention ring (8) con-
tacts contact surface (b) of the hexagonal
PC200, 200LC-8E0 (Hybrid) 00-200 15

SEN05224-02 Handling of electric equipment
Handling of electric equipment

(Rev. 2010/03)
To maintain the performance of the machine over a long period, and to prevent failures or other troubles be-
fore they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics and is aimed at im-
proving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment".
Points to remember when handling electric equipment

1. Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wires.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harnesses
1) Defective contact of connectors (defective
contact between male and female connec-
tors)
Problems with defective contact are likely to
occur because the male connector is not
properly fitted into the female connector, or
because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces. The
corroded or oxidized contact surfaces may
become shiny again (and contact may
become normal) by connecting and discon-
necting the connector about ten times.
2) Defective crimping or soldering of connectors
The pins of the male and female connectors
are attached to wires by crimping or
soldering. If excessive force is applied to the
wire, the joint is separated and causes a
defective contact or the wire is broken.
00-200 16 PC200, 200LC-8E0 (Hybrid)

Handling of electric equipment SEN05224-02
3) Disconnections in wiring
If the harness is pulled to disconnect the
connector, or components are lifted with a
crane with the harness still connected, or a
heavy object hits the harness, the crimping of
the connector may separate, or the soldering
may be damaged, or the harness may be
broken.
4) High-pressure water entering connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the
connector, depending on the direction of the
water jet.
Accordingly, take care not to spray water
over the connector.
The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the
connector, the pins will be short-circuited by
the water, so if any water gets in, immediately
dry the connector or take other appropriate
action before passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector and
an oil film is formed on the mating surface of
the male and female pins, the oil will not let
the electricity pass, so there will be defective
contact. If there is oil or grease stuck to the
connector, wipe it off with a dry cloth or blow
it to dry with compressed air and spray it with
electric contact cleaner.
a When wiping the joint portion of the con-
nector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the com-
pressed air completely before cleaning
with compressed air.
PC200, 200LC-8E0 (Hybrid) 00-200 17

3. Removing, installing, and drying connectors

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

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

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

After removing a connector, cover it with
a vinyl bag to prevent the entry of dust,
dirt, oil, or water to the contact portion.
a If the machine is left disassembled for
a long time, it is particularly easy for
improper contact to occur, so always
cover the connector.
00-200 18 PC200, 200LC-8E0 (Hybrid)

2) Connecting connectors
1] Check the connector visually. a If there is any damage or breakage,
Check that no oil, dirt, or water is stuck to replace the connector.
connector pins (joint portion).
Check that connector pins are free from
deformation, defective contact, corrosion,
or damage.
Check that external surfaces of the
connectors are free from damage or
breakage.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the con-
nector and harness with a dryer, but
be careful not to make them too hot as
this will cause short circuits.
2] Fix the connector securely.
Position the connectors correctly, and
then fit them securely. For connectors
with the lock stopper, push in the
connector until the stopper clicks into
position.
3] Correcting protrusion of the boot and
misalignment of the wiring harness
For connectors fitted with the boot,
correct any extrusion of the boot. In addi-
tion, if the wiring harness is moved in
laying, or the clamp is out of position,
correct it to its right position.
a If the connector cannot be corrected
easily, remove the clamp and adjust
the position.
q If the connector clamp is removed, be
sure to return it to its original position.
Check also that there are no loose
clamps.
PC200, 200LC-8E0 (Hybrid) 00-200 19

3) Deutsch connector (DT 8-pin, 12-pin)

Disconnection (Left of figure) q Disconnection q Connection (Example of
While pressing locks (a) and (b), pull out the incomplete setting of
female connector (2). (a))
Connection (Right of figure)
1] Push in female connector (2) horizontally
until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector (2)
while moving it up and down until the
locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled down
(not set completely) and lock (b) is set
completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
00-200 20 PC200, 200LC-8E0 (Hybrid)

4) Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must
be washed in water, do not use high-pres-
sure water or steam directly on the wiring
harness. If water gets directly on the
connector, do as follows.
1] Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is the risk that
oil in the air may cause defective con-
tact, remove oil and water in the air
before starting air blow.
2] Dry the inside of the connector with a

dryer.
If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is
used in order not to make the connec-
tor or related parts too hot, as this will
cause deformation or damage to the
connector.
3] Perform a continuity test on the

connector.
After drying, leave the wiring harness
disconnected and perform a continuity
test to check for any short circuits
between pins caused by water.
a After completely drying the connector,
blow it with electric contact cleaner
and reassemble.
PC200, 200LC-8E0 (Hybrid) 00-200 21

4. Handling of connectors used on engine

a Mainly, following engines are object for following connectors.
q 95E-5
q 107E-1
q 114E-3
q 125E-5
q 140E-5
q 170E-5
q 12V140E-3
1) Slide, lock type (FRAMATOME-3, FRAM- Examples)

ATOME-2) Intake air temperature sensor in
q 95/107/114/125/140/170/12V140 Series intake manifold: TIM
q Various pressure sensors and NE Fuel temperature sensor: TFUEL
speed sensor Oil temperature sensor: TOIL
Examples) Coolant temperature sensor: TWTR,
Intake air pressure sensor in intake etc.
manifold: PIM (125/170/12V140
series) Disconnection
Oil pressure sensor: POIL Disconnect the connector by pulling lock (B)
(125/170/12V140 series) (on the wiring harness side) of connector (2)
Oil pressure switch (95/107/114 outward.
series)
Ne speed sensor on flywheel housing:
NE (95/107/114/125/140/170/12V140
series)
Ambient pressure sensor: PAMB
(125/170/12V140 series)
Disconnection
1] Slide lock L1 to the right.
2] While pressing lock L2, pull out connector
(1) toward you.
a Even if lock L2 is pressed, connector
(1) cannot be pulled out toward you, if
part (A) does not float. In this case,
float part (A) with a small screwdriver Connection
while pressing lock L2, and then pull Insert the connector straight until it "clicks".
out connector (1) toward you.
Connection
Insert the connector straight until it "clicks".
2) Pull lock type (PACKARD-2)
q 95/107/114/125/140/170/12V140 Series
q Various temperature sensors
00-200 22 PC200, 200LC-8E0 (Hybrid)

3) Push lock type (1) While pressing up lock (C) of the connector
q 95/107/114 series with flat-head screwdriver [1], pull out
Example) Fuel pressure sensor in connector (3) in the direction of the arrow.
common rail (BOSCH-03)
Disconnection
While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 series
Connection
4) Push lock type (2)

q 107/114 series
Example) Intake air pressure/tempera-
ture sensor in intake manifold (SUMI-
q 107 series TOMO-04)
Disconnection
While pressing lock (D), pull out connector
(4) in the direction of the arrow.
a If the lock is located on the underside, use

flat-head screwdriver [1] since you cannot
insert your fingers.
Connection
PC200, 200LC-8E0 (Hybrid) 00-200 23

5) Push lock type (3) Example) Intake air pressure sensor in

q 95/125/140/170/12V140 series intake manifold.
(CANNON-04): PIM, etc.
Disconnection
While pressing lock (E) of the connector, pull
out connector (5) in the direction of the arrow. Disconnection
Example) Fuel pressure sensor in common 1] Turn housing (H1) in the direction of the
rail: PFUEL etc. (AMP-3) arrow.
a When connector is unlocked, housing
(H1) becomes heavy to turn.
2] Pull out housing (H1) in the direction of
the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example) Injection pressure control valve of

fuel supply pump: PCV (SUMITOMO-2)
Connection
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of the
arrow until it "clicks".
Examples) Speed sensor of fuel supply

pump: G (SUMITOMO-3)
a Pull the connector straight up.
Connection
6) Turn-housing type (Round green
connector)
q 140 series
00-200 24 PC200, 200LC-8E0 (Hybrid)

5. Handling controller
1) The controller contains a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the
controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in a place that can be heated to a high
temperature even for a short time. (Place it
on a suitable dry stand.)
6) Precautions when performing arc welding
When performing arc welding on the
machine body, disconnect all of the wiring
harness connectors connected to the
controller. Fit an arc welding ground to the
place close to the welding point.
6. Points to remember when troubleshooting

electric circuits
1) Be sure to turn the power OFF before discon-
necting or connecting connectors.
2) Before performing troubleshooting, check all
the related connectors for loose connection.
a Disconnect and connect the related con-
nectors several times to check.
3) Be sure to connect any disconnected
connectors before going on to the next step.
a If the power is turned ON with the connec-
tors still disconnected, unnecessary
warning will be displayed.
4) When performing troubleshooting of circuits
(measuring the voltage, resistance, conti-
nuity, or current), wag the related wiring
harnesses and connectors several times and
check that there is no change in the reading
of the tester.
a If there is any change, there may be de-
fective contact in the circuit.
PC200, 200LC-8E0 (Hybrid) 00-200 25

SEN05224-02 How to read electric wire code
How to read electric wire code

(Rev. 2010/10)
Hybrid
a The information about the wires unique to Hybrid machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L — Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No.
of 0.85
Indicates color of wire by color code.

Color codes are shown in Table 3.
Indicates size of wire by nominal No.

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

Type, symbol, and material of wire are shown in Table 1.
(Since the use of AV, AVS, AVSS, and CAVS wires depend on size (nominal No.),
their symbols are not indicated on the diagram.)
1. Type, symbol, and material

AV, AVS and AVSS are different in only thickness and outside diameter of the cover. AEX is similar to AV
in thickness and outside diameter of AEX and different from AV, AVS and AVSS in material of the cover.
CAVS is circular compressed conductor in conductor and different appearence from AV and AVS.
(Table 1)
Using tempera-
Type Symbol Material Example of use
ture range (°C)
Annealed copper for electric
Conductor
Low-voltage wire for appliance General wiring (Nominal
AV
automobile No. 5 and above)
Insulator Soft polyvinyl chloride
–30 to +60
Annealed copper for electric AVS: General wiring (Nomi-
Thin-cover low-volt- Conductor
AVS appliance nal No. 3 to 5)
age wire for automo-
AVSS AVSS: General wiring
bile Insulator Soft polyvinyl chloride
(Nominal No. 2)
Annealed copper for electric General wiring in extremely
Heat-resistant Conductor
appliance cold district, wiring at high
low-voltage wire for AEX –50 to +110
Heat-resistant crosslinked ambient temperature place
automobile Insulator
polyethylene
Compressed-conduc- Annealed copper for electric
Conductor
tor thin-cover appliance General wiring (Nominal
CAVS -30 to +60
low-voltage wire for Plasticized type polyvinyl No. 0.5 to 1.25)
Insulator
automobile chloride
00-200 26 PC200, 200LC-8E0 (Hybrid)

How to read electric wire code SEN05224-02
(Table2)
Using tempera-
Type Symbol Material Example of use
ture range (°C)
Conduc- Annealed copper wire for
tor electric appliance
Insulator Soft polyvinyl chloride
Foil shielded
Sn plated annealed copper For general signal wiring
cable for auto- AVSSCS Drain wire -30 to +60
wire strand (nominal size: 0.5, double core)
mobiles
Shield Aluminum foil
Seal Soft polyvinyl chloride

Conduc- Annealed copper wire for
tor electric appliances
Thin low-capacitance cross-
Heat-resistant Insulator For signal wiring in high-tempera-
linked polyethylene
low-voltage wire PEXBS -50 to +120 ture place
Sn plated, annealed, braided
for automobile Shield (nominal size: 0.5, 3 cores)
copper wire
Heat-resistant crosslinked
Seal
polyethylene
PC200, 200LC-8E0 (Hybrid) 00-200 27

2. Dimensions
AVS, AV, AEX, AVSS
(Table 3)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diame- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
ter of strand
Conduc- Sectional area
tor 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 -
Standard - - - - - - - 4.6
Cover D
AV
AEX Standard 2.0 2.2 2.7 3.0 3.1 - 3.8 4.6
AVSS Standard - - - 2.7 2.7 - - -
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diame- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
ter of strand
Conduc- Sectional area
tor 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard - - - - - - - - -
Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Cover D
AV
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AVSS Standard - - - - - - - - -
CAVS
(Table 4)
Nominal No. 0.5 0.85 1.25
16/Circular compres-
Number of strands 7/Circular compression 11/Circular compression
sion
Conductor Cross-sectional area
0.56 0.88 1.29
(mm2)
d (approx.) 0.9 1.1 1.4
Cover D CAVS Standard 1.6 1.8 2.1
00-200 28 PC200, 200LC-8E0 (Hybrid)

How to read electric wire code SEN05224-02
AVSSCS PEXBS
(Table 5) (Table 6)
Nominal No. 0.5f
Nominal No. 0.5f
Number of cores 3
Number of cores 2 Construction
Construction 20/0.18
19/0.19 Core conductor (No./mm)
Core conductor (No./mm) Cross-sectional
Cross-sectional 0.51
0.54 area (mm2)
area (mm2) Outside diameter
Outside diameter 2.0
1.6 (mm)
(mm) Strand diameter
Construction 0.12
20/0.18 (mm)
(No./mm) Braided shield
Drain wire No. of wires/strands 5/16
Cross-sectional Density (%) Min. 70
0.51
area (mm2) Sheath thickness (mm) 0.5
Aluminum foil thickness (mm) 0.03 Finished outside diameter (mm) 5.9
Sheath thickness (mm) 0.5
Number of cores 4.3
“f” of nominal No. denotes flexible”.
PC200, 200LC-8E0 (Hybrid) 00-200 29

3. Color codes table
(Table 7)
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 8)
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 cir-
Br BrW BrR BrY BrB - - -
cuit
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -
00-200 30 PC200, 200LC-8E0 (Hybrid)

Precautions when performing work SEN05224-02
Precautions when performing work

(Rev. 2010-03)
When removing, installing, disassembling or assembling a unit, be sure to follow the general precautions giv-
en below.
1. Precautions for removal work

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

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379 - 00400 07378 - 10400 07371 - 30400
05 07379 - 00500 07378 - 10500 07371 - 30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part No.
number D d L
06 07049 - 00608 5 6 8
08 07049 - 00811 8 6.5 11
10 07049 - 01012 10 8.5 12
12 07049 - 01215 12 10 15
14 07049 - 01418 14 11.5 18
16 07049 - 01620 16 13.5 20
18 07049 - 01822 18 15 22
20 07049 - 02025 20 17 25
22 07049 - 02228 22 18.5 28
24 07049 - 02430 24 20 29
27 07049 - 02734 27 22.5 34
PC200, 200LC-8E0 (Hybrid) 00-200 31

SEN05224-02 Precautions when performing work
2. Precautions for installation work

q Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
q Install the hoses without twisting or interference and fix them with intermediate clamps, if available.
q Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean and degrease the part, and coat the threaded portion with two to
three drops of adhesive.
q When coating with liquid gasket, clean and degrease the surface, and apply it uniformly after making
sure that the surface is free from dirt or damage.
q Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
q Coat the rotating parts and sliding parts with engine oil.
q When press-fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
q After installing the snap rings, check that the snap ring is settled in the ring groove completely.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
them securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When installing split flanges, fasten them uniformly and alternately to prevent excessive tightening on
one side.
a When operating the hydraulic cylinders for the first time after reassembling the cylinders, hydraulic
pumps and other hydraulic component removed for repair, be sure to bleed the air as follows:
1] Start and run the engine at low idle.
2] Operate the work equipment control lever to operate the hydraulic cylinder four to five times, stop-
ping the piston at 100 mm off the end of its stroke.
3] Next, operate the hydraulic cylinder three to four times to the end of its stroke.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions for completing work

1) Refilling of coolant, oil and grease
q If the coolant is drained, close the drain valve, and add coolant to the specified level. Run the engine
to circulate the coolant through the system. Then add the coolant again if necessary.
q If the hydraulic component is removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then add the oil again if necessary.
q If the hydraulic piping or hydraulic equipment are removed, be sure to bleed air from the system
after reassembling the parts, by referring to "Testing and adjusting".
q Supply the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.
2) Checking cylinder head and manifolds mountings for looseness

Check the cylinder head and intake and exhaust manifold mountings for looseness.
If any part is loosened, retighten it.
q For the tightening torques, see the "Disassembly and assembly".
3) Checking engine piping for damage and looseness

Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and
exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leak-
age.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
00-200 32 PC200, 200LC-8E0 (Hybrid)

Precautions when performing work SEN05224-02
4) Checking muffler, exhaust pipe and their mounts for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness.
If any part is loosened, retighten it.
5) Checking muffler function
Check the muffler for unusual sound and sound different from that of a new muffler.
If any unusual sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
PC200, 200LC-8E0 (Hybrid) 00-200 33

SEN05224-02 Handling of hybrid devices and high-voltage wirings
Handling of hybrid devices and high-voltage wirings

(Rev. 2012/07)
Hybrid
k 1. In order to handle (such as install or remove) the hybrid devices (motor-generator, swing electric
motor, capacitor, inverter) and high-voltage wirings, you must follow the local Industrial Safety
and Health Law concerning electricity. If you touch a device or a wiring carelessly, you may get an
electric shock and may be injured seriously since high-voltage may be stored in that device.
Never disassemble the hybrid devices or high-voltage wirings. If the devices are disassembled
carelessly, their quality assurance will be lost and a serious trouble may occur.
1. Generator motor 4. Inverter (control unit)

2. High-voltage wirings (orange) 5. Cooling system
3. Capacitor 6. Swing electric motor
k 2. The hybrid devices and high-voltage wirings (wound with orange conduits) must be replaced by
the assembly.
k 3. When testing, servicing or replacing a hybrid device or a high-voltage wiring, discharge the ca-
pacitor in advance. (For details, see the latter half of this manual)
k 4. The machine is equipped with the capacitor discharge system. If it breaks down, discharge the
capacitor with the capacitor discharger.
k 5. Handling of inverter and capacitor
1) Handling of inverter and capacitor
Handle the inverter and capacitor with extreme care since they have microcomputers and electronic
control circuits in them.
2) Precautions when performing arc welding
When performing arc welding on the body for repair of the machine etc., disconnect all wiring harness
connectors and ground cable connected to the inverter and capacitor. Connect the arc welding ground
cable close to the welding point.
00-200 34 PC200, 200LC-8E0 (Hybrid)

Handling of hybrid devices and high-voltage wirings SEN05224-02
5) Look into the charge level inspection window

at the contactor box above the capacitor.
Check that the LED display for capacitor
Precautions for maintenance of hybrid system
charge state indicates "UNCHARGED", then
Materials for handling hybrid devices and high-volt-
remove one-touch connector of capacitor.
age wirings
If it doesn't indicate "UNCHARGED", leave it
(1) Insulating gloves (rubber gloves, etc.)
until LED goes out. (Leave it for maximum 14
(2) Safety shoes (insulating type)
days.)
(3) Safety glasses
Clearly write "Do not discharge" on sealing
(4) ABC fire extinguisher
tape with a marker and stick it on the capac-
(5) Sealing tape (for insulation)
itor body.
(6) Cloth (rag)
6) Ensure that the each hybrid device case is
Take care of high voltage and high temperature grounded securely to the machine. Check
This machine has a high-voltage system and some the continuity between the machine frame
parts become very hot. Improper handling of it can and the hybrid device with a circuit tester.
cause a serious personal injury such as getting an If the hybrid device case is not grounded, fix
electric shock or a burn. The handle-with-care labels the ground cable securely when performing
are attached to the hybrid devices and orange step 1) of the reinstallation procedure.
high-voltage wirings. Handle correctly according to 7) Remove the terminal mounting bolt of each
the directions in those labels. high-voltage wiring and remove the
Never disassemble the hybrid devices and connector terminal.
high-voltage wirings (orange). 8) Measure the voltage between each terminal
of the hybrid device and its case.
1] If the voltage between each terminal and
the case is 30 V or below (safety voltage),
you can remove the hybrid device.
However, do not touch the terminal and
the case simultaneously even at this time.
2] If the above voltage is not below 30 V,
wait for a while until it decreases below 30
V. (If the inverter is normal, no voltage is
applied.)
9) Stick a sealing tape etc. to the connector
insertion hole on each hybrid device side for
Precautions for ordinary testing and service
insulation.
Never disassemble the hybrid devices (generator
motor, swing electric motor, capacitor, inverter) and 10) Wrap the connector terminal in a vinyl sheet
high-voltage wirings (orange). etc. to protect it from dirt and then wind a
When the hybrid devices need to be tested, re- sealing tape etc. further for insulation.
moved and reinstalled, work according to the follow- 11) Remove the hybrid device.
ing procedure.
1. Procedure for removing hybrid devices and 2. Reinstallation
high-voltage wirings and testing connection 1) Install the hybrid device.
terminals 2) Thoroughly wipe the connector mounting
1) Put the machine indoors so that the face of each hybrid device, thinly apply
high-voltage wiring terminals and hybrid grease to the connector sealing rubber, and
devices etc. to be removed will not be insert the connector terminal fully.
exposed to rain, dust, etc. 3) Fix the connector terminal with the specified
2) Discharge the capacitor according to the M6 bolt to 8.8 - 10.8 Nm (0.9 - 1.1 kgm).
capacitor discharge procedure (00-200) 4) Install the capacitor one-touch connector.
described after.
3) Perform the testing and service with the key
switch OFF.
4) Put on insulating gloves, safety glasses and
safety shoes (insulating type).
PC200, 200LC-8E0 (Hybrid) 00-200 35

Precautions when submerged

If the hybrid devices are submerged, they may mal-
function and can cause a trouble and the machine
Precautions when machine tips over or hybrid
may not be operated safely. If you touch the ma-
device is broken
chine carelessly, you may get an electric shock and
When the machine tips over or any hybrid device or
may be injured seriously. In such a case, observe
high-voltage wiring (orange) is broken in an acci-
the following items and test and service with ex-
dent, if you touch them carelessly, you may be in-
treme care for safety.
jured seriously.
1) Put on insulating gloves (rubber gloves etc.),
In such a case, observe the following items and
safety glasses and safety shoes (insulating
work with extreme care for safety.
type).
1) When servicing, be sure to stop the engine
2) Be sure to stop the engine so that a high
so that a high voltage will not be applied to
voltage will not be applied to the hybrid
the hybrid devices.
devices.
2) If a fire breaks out on the machine, put it out
3) Lift up the machine above the water with
with the "ABC fire extinguisher" (for both oil
another machine.
and electric fires).
It is rather dangerous to try to extinguish a 4) Remove the capacitor one-touch connector.
fire with a small amount of water. When extin- 5) Discharge the capacitor with the capacitor
guishing with water, splash a large quantity discharger.
of water from a hydrant etc. 6) Look into the charge state inspection window
3) Put on insulating gloves (rubber gloves etc.), at the contactor box above the capacitor, and
safety glasses and safety shoes (insulating check that the LED display for capacitor state
type). indicates "UNCHARGED".
4) Raise the machine with another machine and If it doesn't indicate "UNCHARGED", leave it
move it to a safe place. until LED goes out. (Leave it for maximum 14
days.)
5) Do not touch an bare wire which is unknown
Clearly write "Do not discharge" on sealing
if it is a high-voltage wiring. If it is obliged or
tape with a marker and stick it on the capac-
possible for you to touch such a wire, put on
itor body.
insulating gloves, ensure that the voltage
between the wire and the machine body is 7) Perform testing, service, removal, etc. of the
below 30 V (safety voltage), and then insu- hybrid devices according to steps 5) and
late the wire with a sealing tape. after in Precautions for ordinary testing and
service described above.
6) Remove the capacitor one-touch connector.
7) Discharge the capacitor with the capacitor
Precautions in cold weather
discharger.
q In a cold weather the upper structure swings at
8) Look into the charge state inspection window the normal speed but the work equipment speed
at the contactor box above the capacitor, and and travel speed become slower than at the nor-
check that the LED display for capacitor state mal temperature, thus the machine do not move
indicates "UNCHARGED". as the operator expects. Warm up the machine
If it doesn't indicate "UNCHARGED", leave it sufficiently since it may collide with an obstacle.
until LED goes out. (Leave it for maximum 14 q If it is required to move the machine before
days.) warming it up, fully recognize the difference of
Clearly write "Do not discharge" on sealing the movement of the machine and work equip-
tape and stick it on the capacitor body. ment in work equipment operation, travel opera-
9) Perform testing, service, removal, etc. of the tion, and swing operation, then operate the
hybrid devices according to steps 6) and machine carefully.
after in Precautions for ordinary testing and
service described above.
If the capacitor case is broken, take extreme
care not to touch the cells directly.
00-200 36 PC200, 200LC-8E0 (Hybrid)

Procedure for discharging capacitor

If the hybrid system is normal, the capacitor can be
discharged by operating the machine monitor. In
this case, the charge in the capacitor is consumed
by the motor-generator. Accordingly the capacitor
cannot be discharged with the machine monitor
when the hybrid system is stopped by an error, de-
pending on the type of that error (see"Errors that
disable machine monitor from discharging capacitor
"). In this case, the capacitor needs to be discharged
by using the special capacitor discharger.
a Even if an error disables the machine monitor
from discharging the capacitor, the machine
monitor screen can "change to the screen for
discharging and perform the discharge opera-
tion". However, do not perform the discharge
operation.
a You cannot swing the upper structure while the
capacitor is being discharged but you can oper-
ate the work equipment. Take care.
1. Turn the key switch ON, start the engine, and set
the engine speed to low idle.
2. While pressing machine monitor switch "4", input
"1+2+3" to enter the service mode.
3. Select "09 Discharge capacitor" in the service

menu and press "F6".
4. Press "F1" to start discharging.

Since the charge in the capacitor is consumed
through the generator motor by this operation,
the engine speed increases temporarily. This is
normal.
PC200, 200LC-8E0 (Hybrid) 00-200 37

5. Wait for approximately 5 minutes. If the

message "Capacitor charge ratio 0%" is
displayed, discharging is finished.
00-200 38 PC200, 200LC-8E0 (Hybrid)

6. Look into the charge level inspection window at the contactor box above the capacitor and check that the
capacitor charge level indicator LED indicates discharged.
The capacitor is discharged completely now.
a If the capacitor charge ratio does not decrease in 5 minutes, or if the LED does not indicate
"UNCHARGED" when the capacitor charge ratio is "0%", or "Completed" is not indicated and LED
doesn't indicate "UNCHARGED" when 30 minutes passed after starting discharge, the capacitor is not
discharged for some reason. In this case, immediately stop discharging the capacitor with the machine
monitor, and then use the special capacitor discharger.
a If the capacitor is not discharged after discharging by capacitor discharger, leave it until LED lamp goes
out. (Leaving period: maximum 14 days)
Stick a piece of sealing tape to the capacitor body and write down "Discharge is not available" with a
felt-tip pen.
a If LED lamp lights up again after discharging and leaving, perform the discharge from Step 1 again, or
leave it until LED lamp goes out. (Leaving period: maximum 14 days)
7. Turn the key switch to the OFF position to stop the engine completely.
a If key switch operation such as the following is performed, capacitor performs electric charge again.
Do not perform the following operation.
q After turning key switch to the OFF position, turn the key switch to the ON position before the engine
stops completely.
q After turning key switch to the OFF position and the engine stops completely, turn key switch to the
ON position to start the engine.
PC200, 200LC-8E0 (Hybrid) 00-200 39

a Even if the capacitor charge ratio indicates "0", the capacitor voltage can not be completely 0 V. Be-
cause of the characteristics of the capacitor, its voltage tends to increase again a little to 0 - 30 V after
it is discharged. Accordingly, take extreme care when disconnecting the connector or performing other
service work.
00-200 40 PC200, 200LC-8E0 (Hybrid)

Errors that disable machine monitor from discharging capacitor.
Errors shown in the table below disable machine monitor from discharging capacitor.
Even if an error disables the machine monitor from discharging the capacitor, the machine monitor screen can
"change to tne screen for discharging and perform the discharge operation". However, do not perform the dis-
charge operation.
Capacitor discharge with machine monitor cannot be performed when the following errors are indicated.
Error related to high-voltage circuit Error related to motor-geverator circuit
User code Failure code User code Failure code

GA01KA Power Cable Interlock Open Circuit GA17KR Gen. Mot. Drv. Communication Failure
GA04KG Abnormal DC HW Volt. Before Booster GA17KY Gen. Mot Dr. Power Line Short Circuit
GA05KG Abnormal DC SW Volt. Before Booster GA17KZ Gen. Motor Driver Open/Short Circuit
GA05KP Low DC SW Output Volt. Bef. Booster GA17MB Gen. Mot. Drv. Function Degraded
GA06KZ DC Vlt. Sen. Opn./Shrt.Cir. Bef. Booster GA19KK Gen. Mot. Drv. Sub-CPU Low Sup.Volt
GA08KG Abnorm. DC HW Volt. After Booster GA19KR Gen. Motor Driver Sub-CPU Comm.Failure
GA09KG Abnorm. DC SW Volt. After Booster GA19KT Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con.
Gen. Mot. Drv. Sub-CPU Malfunction CPU
GA09KP Low DC SW Output Volt. After Booster GA19MA
Con.
GA0AKZ DC Vlt. Sen. Op./Shrt cir. Aft. Booster GA19MC Gen. Mot. Drv. Sub-CPU Defect. Operation
GA12MC HYB Cont. Pow. Suppl. Failure GA19NA Gen. Mot. Drv. Sub-CPU Start Disabled
GA12NK HYB Cont. Pow. Suppl. Not Turn.ON GA1AKZ Gen. Mot. Dr. Temp. Sens.Open/Short Cir.
GA12NL HYB Cont. Pow. Suppl. Not Turn.OFF GA1BMA Gen. Mot. Dr. DC Vlt. Sens.Malfunction
GA16KK Low HYB Cont. VDD Suppl. Volt. GA1CNS Gen. Motor Driver IPM Overheat
GA18MC Gen. Mo.Dr. Excite. Pow. Sup.Failure GA1CNV Gen. Motor Driver IPM Not Warm Up
GA1SFS Contractor Locked GA1DMA Gen. Motor Driver IPM1 Abnormality
GA1SMC Contractor Failure GA1EMA Gen. Motor Driver IPM2 Abnormality
GA1VFS Capacitor Contractor Locked GA60MD Gen. Bot. Defective Movement
GA1VMC Capacitor Contractor Failure GA60N1 Generator Motor Overrun
GA1XKZ Boost. Ind. Temp. Sens. Open/Shrt. GA61KZ Gen. Motor Temp. Sens.Opn/Short Cir.
GA1YNS Booster Inductor Overheat Circ. GA61NS Generator Motor Temp. Sensor Overheat
GA1YNV Booster Inductor Not Warming Up GA62KY Gen. Mot. Ph-A Cur. Sen. Power Short Cir
Booster IGBT Temp. Sens.Opn/Shrt.
GA1ZKZ GA62KZ Gen. Mot. Ph-A Cur. Sen.Open/Short Cir
Circ.
GA1ZNS Booster IGBT Temp. Sens.Overheat GA62MA Gen. Mot. Ph-A Current Sen.Malfunction
Booster IGBT Temp. Sens. Not Warm Gen. Mot. Ph-B Cur. Sen. Power Short
GA1ZNV GA63KY
Up Cirm
GA21KB Booster IGBT Open Circuit GA63KZ Gen. Mot. Ph-B Cur. Sen.Open/Short Cir.
GA22NS Booster IGBT Junction Overheat GA63MA Gen. Mot. Ph-B Current Sen. Malfunction
GA64KY Gen. Mot. Ph-C Cur. Sen. Power Short Cir
GA64KZ Gen. Mot. Ph-C Cur. Sen.Open/Short Cir
GA64MA Gen. Mot. Ph-C Current Sen. Malfunction
GA70MD HYB Swing Motor Defective Stirr.Motion
PC200, 200LC-8E0 (Hybrid) 00-200 41

SEN05224-02 Standard tightening torque table
Standard tightening torque table

(Rev. 2010/03)
1. Table of tightening torques for bolts and nuts
a Unless otherwise specified, tighten metric nuts and bolts to the torque shown in the following table.
1) The following table applies to the bolts in Fig. A.

Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10(10) 11.8 –14.7 1.2 – 1.5
8 13(12) 27 – 34 2.8 – 3.5
10 17(14) 59 – 74 6.0 – 7.5
12 19(17) 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2) The following table applies to the bolts in Fig. B.

Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
Fig. A Fig. B
a Values with ( ) are applied to (*) marked bolt (flange bolt) as the width across flats.
00-200 42 PC200, 200LC-8E0 (Hybrid)

Standard tightening torque table SEN05224-02
2. Table of tightening torque for split flanged bolts

a Unless otherwise specified, tighten split flanged bolts to the torque shown in the following table.
Tightening torque
eter of bolt flats
mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten O-ring boss piping joints to the torque shown in the following table.
Tightening torque (Nm {kgm})
Nominal No. eter flats
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}
Varies
03, 04 20 84 – 132 {8.5 – 13.5} 103 {10.5}
depending on
05, 06 24 128 – 186 {13.0 – 19.0} 157 {16.0}
type of con-
10, 12 33 363 – 480 {37.0 – 49.0} 422 {43.0}
nector.
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten O-ring boss plugs to the torque shown in the following table.
Tightening torque (Nm {kgm})
Nominal No. eter flats
mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
PC200, 200LC-8E0 (Hybrid) 00-200 43

SEN05224-02 Standard tightening torque table
5. Table of tightening torque for hoses (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a Apply the following torque when the threads are coated with engine oil (wetted).
Tightening torque (Nm {kgm}) Taper seal Face seal
Nominal Width Nominal No.
Thread diame-
number of across Thread size –Number of
Range Target ter (mm) (Ref-
hose flats (mm) (mm) threads, type of
erence)
thread
34 – 54 {3.5 – 5.5} 44 {4.5} – 9/16 – 18UN 14.3
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
22 54 – 93 {5.5 – 9.5} 74 {7.5} – 11/16 – 16UN 17.5
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 13/16 – 16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16 – 12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torque for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be
used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Tightening torque (Nm {kgm}) Face seal
Outer diam- Width across Nominal No.
Thread diameter
eter of pipe flats –Number of
Range Target (mm)
(mm) (mm) threads, type of
(Reference)
thread
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16 – 18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16 – 16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16 – 16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1 – 14UNS 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1 – 3/16 – 12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
00-200 44 PC200, 200LC-8E0 (Hybrid)

Standard tightening torque table SEN05224-02
7. Table of tightening torque for 102, 107 and 114 engine series (bolts and nuts)
a Unless otherwise specified, tighten the metric bolts and nuts used for the 102, 107 and 114 engine se-
ries to the torque shown in the following table.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 – –
8. Table of tightening torque for 102, 107 and 114 engine series (eye joints)
a Unless otherwise specified, tighten the metric eye joints used for the 102, 107 and 114 engine series
to the torque shown in the following table.
Thread size Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torque for 102, 107 and 114 engine series (taper screws)
a Unless otherwise specified, tighten NPT screws used for the 102, 107 and 114 engine series to the
torque shown in the following table.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
PC200, 200LC-8E0 (Hybrid) 00-200 45

SEN05224-02 Conversion table
Conversion table
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the meth-
od of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from milli-
meters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to
the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
4)
Millimeters to inches (B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A) 60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-200 46 PC200, 200LC-8E0 (Hybrid)

Conversion table SEN05224-02
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1l= 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC200, 200LC-8E0 (Hybrid) 00-200 47

Liters to U.K. Gallons

1l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-200 48 PC200, 200LC-8E0 (Hybrid)

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC200, 200LC-8E0 (Hybrid) 00-200 49

Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-200 50 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 00-200 51

SEN05224-02
©2012 KOMATSU
All Rights Reserved
00-200 52
SEN05226-02
SEN05226-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

01 Specification
100 Specification and technical data
Outline of hybrid system ............................................................................................................................. 2

Specification dimension drawings............................................................................................................... 3
Working range diagram............................................................................................................................... 4
Specifications.............................................................................................................................................. 5
Weight table ................................................................................................................................................ 8
Table of fuel, coolant and lubricants ........................................................................................................... 10
PC200, 200LC-8E0 (Hybrid) 01-100 1

SEN05226-02 Outline of hybrid system
Outline of hybrid system
This machine is equipped with the hybrid system consisting of an electric motor and a diesel engine to reduce
fuel consumption.
Configuration of hybrid system

In the hybrid system of this machine, the high-voltage wirings connecting the hybrid devices of about 550 V
(motor generator, swing electric motor, capacitor, inverter) and other devices and the cooling system become
high temperature in the machine operation.
1. Motor generator (*1) 4. Inverter (control unit) (*1)

2. High-voltage wirings (orange) (*1) 5. Cooling system
3. Capacitor (*1) 6. Swing electric motor (*1)
*1: Indicates the high voltage (550 V) portions.
Low fuel consumption by hybrid system

q The upper structure is swung with the swing electric motor and the kinetic energy generated when the
swing brake operates is converted into electric energy and stored in the capacitor.
The stored electric energy is supplied to the swing electric motor when the upper structure is swung next
time.
q When the control lever is in neutral, the engine speed is decreased to the minimum to reduce fuel con-
sumption.
The engine speed is controlled according to the lever operation quantity, operation pattern and load so
that the fuel consumption efficiency will be kept best.
01-100 2 PC200, 200LC-8E0 (Hybrid)

Specification dimension drawings SEN05226-02
Specification dimension drawings
Item Unit PC200-8E0 PC200LC-8E0

A Overall length mm 9,425 9,425
B Overall height mm 2,970 2,970
C Overall width mm 2,800 3,080
D Shoe width mm 600 700
E Cab height mm 3,040 3,040
F Tail swing radius mm 2,750 2,750
G Overall track length mm 4,070 4,450
Length of track on
H mm 3,275 3,655
ground
Max. ground clearance mm 440 440
PC200, 200LC-8E0 (Hybrid) 01-100 3

SEN05226-02 Working range diagram
Working range diagram
Item Unit PC200-8E0 PC200LC-8E0

A Max. digging reach mm 9,875 9,875
B Max. digging depth mm 6,620 6,620
C Max. digging height mm 10,000 10,000
D Max. vertical wall depth mm 5,980 5,980
E Max. dumping height mm 7,110 7,110
F Min. dumping height mm 2,645 2,645
Max. reach at ground
G mm 9,700 9,700
level
01-100 4 PC200, 200LC-8E0 (Hybrid)

Specifications SEN05226-02
Specifications
PC200-8E0, PC200LC-8E0
Machine model PC200-8E0 PC200LC-8E0
Serial number 1001 and up 1001 and up
Bucket capacity m3 0.8 (0.7) 0.8 (0.7)
Machine mass kg 19,800 21200
Max. digging depth mm 6,620 6,620
Working ranges
Max. vertical wall depth mm 5,980 5,980

Max. digging reach mm 9,875 9,875
Max. reach at ground level mm 9,700 9,700
Max. digging height mm 10,000 10,000
Performance
Max. dumping height mm 7,110 7,110

Max. digging force kN {kg} 138.3 {14,100} 138.3 {14,100}
(when power max. function is turned on) (149.1 {15,200}) (149.1 {15,200})
Swing speed rpm 12.4 12.4
Swing operation max. slope angle deg. 25 25
Travel speed km/h Lo: 3.0 Mi: 4.1 Hi: 5.5 Lo: 3.0 Mi: 4.1 Hi: 5.5
Gradeability deg. 35 35
Ground pressure (Standard shoe) kPa {kg/cm2} 45.4 {0.46} 37.6 {0.38}
Overall length mm 9,425 9,425
Overall width mm 2,800 3080
Overall of track width mm 2,800 3080
Overall height (During transportation) mm
3,040 (Cab height) 3040
(*)
Machine body overall height (*) mm 3,040 (Cab height) 3040
Ground clearance of upper structure mm
Dimensions
1,085 1,085
bottom
Max. ground clearance mm 440 440
Tail swing radius mm 2,750 2,750
Min. swing radius of work equipment mm 3,040 3,040
Top height at min. swing radius of mm
8,005 8,005
work equipment
Length of track on ground mm 3,275 3,655
Track gauge mm 2,200 2,380
Machine cab height mm 2,390 2,390
Width of standard shoe mm 600 700
*: Grouser height (26 mm) included.
PC200, 200LC-8E0 (Hybrid) 01-100 5

SEN05226-02 Specifications

Serial number 1001 and up 1001 and up
Model SAA4D107E-1-A
Type 4-cycle, water-cooled in-line, direct injection with turbocharger and

air-cooled aftercooler
Number of cylinders – bore x stroke mm 4 – 107 × 124
Piston displacement l {cc} 4.46 {4.460}
Rated pressure kW/rpm {HP/rpm} 103/2,000 {140/2,000}

Performance
Max. torque Nm/rpm {kgm/rpm} 573/1,700 {58.5/1,700}

Engine
High idle under no load rpm 2,060

Low idle under no load rpm 1,050, 700
Min. fuel consumption g/kWh {g/HPh} 215 {155}
Starting motor 24 V, 5.5 kW
24 V, 35 A
Alternator
12 V, 110 Ah × 2
Battery
Radiator type Corrugated aluminum, 4 array
Carrier roller 2 on one side
Undercarriage
Track roller 7 on one side 9 on one side

Assembly-type triple
Assembly-type triple grosser
Track shoe grosser
45 on one side
49 on one side
Type and numbers HPV95 + 95, Variable displacement piston type: 2

Hydraulic pump
Delivery l/min Piston: 219.5 × 2
Set pressure MPa {kg/cm2} Piston: 37.2 {380}

Hydraulic motor Control valve
Type and numbers 6-spool type: 1
Operating method Hydraulic

Hydraulic system
HMV110ADT-2, piston type: 2

Travel motor
(with brake valve and parking brake)
Arm (*1)
Boom (*1) Bucket
(*2)
Hydraulic cylinder
Double act- Double act-

Type Double acting piston
ing piston ing piston
Cylinder inner diameter mm 120 135 115
Piston rod diameter mm 85 95 80
Stroke mm 1,334.5 1,490 1,120
Max. pin-to-pin distance mm 3,204.5 3,565 2,800
Min. pin-to-pin distance mm 1,870 2,075 1,680
Hydraulic tank Closed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler CF40-1 (Air cooled)
*1: Cushion is provided on the head side
*2: Cushion is provided on the bottom side
01-100 6 PC200, 200LC-8E0 (Hybrid)

Specifications SEN05226-02
Machine model PC200-8E0, PC200LC-8E0

Serial number. 1001 and up
Type and 3-phase motor × 1
quantity
Motor generator Operating 550V (DC)
Electric motor
voltage
Drive method Direct coupling with engine
Type and
Electrical equipment
3-phase motor × 1
quantity
Swing electric motor
Operating
550V (AC)
voltage
Type and
Control unit Inverter × 1
quantity
Type and
Electric storage device Capacitor × 1
quantity
PC200, 200LC-8E0 (Hybrid) 01-100 7

SEN05226-02 Weight table
Weight table
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Serial number 1001 and up
Engine assembly 840 840
q Engine *1 452 452
q Motor generator *1 225 225
q Hydraulic pump 152 152
Radiator and oil cooler assembly 151 151
Inverter *1 45 45
Capacitor *1 112 112
Hydraulic tank and filter assembly (Not including
123 123
hydraulic oil)
Fuel tank assembly (Not including fuel) 134 134
Revolving frame 1,799 1,799
Cab 480 480
Operator's seat 35 35
Counterweight 3,435 3,435
Swing machinery 229 229
Control valve 235 235
Swing electric motor *1 70 70
Travel motor 93 × 2 93 × 2
Center swivel joint 36 36
Track frame assembly (Not including piping) 4,264 4,862
q Track frame 2,260 2,649
q Swing circle 273 273
q Idler 101 × 2 101 × 2
q Idler cushion 118 × 2 129 × 2
q Carrier roller 14 × 4 14 × 4
q Track roller 36 × 14 36 × 18
q Final drive (including travel motor) 322 × 2 322 × 2
Track shoe assembly
1,215 × 2 1,325 × 2
q Standard triple shoe (600 mm)
q Standard triple shoe (700 mm) - 1,530 × 2
q Wide triple shoe (800 mm) - 1,670 × 2
01-100 8 PC200, 200LC-8E0 (Hybrid)

Weight table SEN05226-02
Unit: kg
Machine model PC200-8E0, PC200LC-8E0
Serial number 1001 and up
Boom assembly 1,393
Arm assembly 633
Bucket assembly 633
Boom cylinder assembly 173 × 2
Arm cylinder assembly 223
Bucket cylinder assembly 133
Link (large) assembly 83
Link (small) assembly 22 × 2
Boom pin 42 + 8 × 2 + 28 + 10 + 26
Arm pin 12 + 8
Bucket pin 20 × 2
Link pin 13 × 2
PC200, 200LC-8E0 (Hybrid) 01-100 9

SEN05226-02 Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants

a For details of the notes (Note 1, Note 2... ) in the table, see Operation and Maintenance Manual.
q ASTM: American Society of Testing and Material
01-100 10 PC200, 200LC-8E0 (Hybrid)

Table of fuel, coolant and lubricants SEN05226-02
Unit: l
PC200-8E0, PC200LC-8E0
Refilling points
Specified capacity Refill capacity
Engine oil pan *1 20 18
Motor generator case *1 6.5 6.0
Swing electric motor case *1 2.6 1.7
Swing machinery case *1 7.1 7.1
Final drive case
3.5 3.3
(each sides)
Hydraulic system 232 135
Fuel tank 400 –
Engine cooling system *1 17.3 –
Hybrid device cooling system *1 6.4 3.5
Note 1: The power train oil and engine oil are different from each other. Use oils recommended for them re-
spectively.
Note 2: When environment preservation is important in river works, marine and shore works, forest works,
etc., recommend use of bio hydraulic oil and bio grease.
Note 3: Hyper white grease (G0-T, T2-T) indicates high-performance white grease.
Recommend use of G0-T or G2-T in the following cases.
(1): Lubrication performance of grease is required to prevent the pins and bushings from creaking.
(2): Outside staining with black grease needs to be prevented.
Note 4: Do not use bio grease to the rolling bearings, including the swing bearing.
Features of grease (reference)

Rolling
bearing
Item Heavy load Wear-resistant lubrication Heat-resistant Water-resistant Biodegradable Remarks
(fretting-resist
ant)
Non-black
Hyper White
w w w w w × heavy duty
Grease
grease
Lithium
E Q w Q Q × -
grease
Synthetic
biodegrad-
Bio grease E Q × w Q w
able lithium
grease
w: Excellent Q: Satisfactory E: Average ×: Low
Note 5: Super coolant

(1) Super Coolant has important functions as a corrosion inhibitor for the cooling system in addition to the
function of preventing freezing.
Use Super Coolant even in an area where freeze prevention is not required.
Do not recommend other coolants than Komatsu genuine Super Coolant (AF-NAC) in principle. Using another
coolant can cause critical failure to the cooling system including the engine.
(2) For the mixing proportion of Super Coolant and water, see Disassembly and assembly, "Draining, refilling
and air bleeding procedure for coolant in hybrid system".
When the machine is shipped, Super Coolant AF-NAC is added more than 30% unless otherwise specified.
Accordingly, its concentration does not need to be changed as long as the temperature does not decrease
below -10°C.
If the temperature decreases below -10°C, adjust the mixing proportion of Super Coolant and water accord-
ing to the mixing proportion table in Disassembly and assembly, "Draining, refilling and air bleeding procedure
for coolant in hybrid system".
(3) Be sure to keep the concentration of Super Coolant above 30% to maintain its corrosion inhibition ability.
PC200, 200LC-8E0 (Hybrid) 01-100 11

SEN05226-02
©2012 KOMATSU
All Rights Reserved
01-100 12
SEN05228-00
SEN05228-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

10 Structure, function and

maintenance standard
100 Engine and cooling system
Engine related parts.................................................................................................................................... 2

Radiator, oil cooler, aftercooler and fuel cooler .......................................................................................... 3
PC200, 200LC-8E0 (Hybrid) 10-100 1

SEN05228-00 Engine related parts
Engine related parts
1. Muffler Outline
2. Rear engine mount The motor generator is mounted.
3. Front engine mount
4. Motor generator
10-100 2 PC200, 200LC-8E0 (Hybrid)

Radiator, oil cooler, aftercooler and fuel cooler SEN05228-00
Radiator, oil cooler, aftercooler and fuel cooler
1. Reservoir tank Specifications

2. Fan Radiator: Corrugated aluminum 4 - array
3.Shroud Oil cooler: CF40-1
4. Radiator cap Aftercooler: Corrugated aluminum
5. Radiator inlet hose Fuel cooler: Drawn cup type
6. Net *1 Radiator for hybrid system: Corrugated aluminum
7. Radiator outlet hose
8. Radiator
9. Oil cooler
10. After cooler
11. Fuel cooler
12. Air conditioner condenser
*1
13. Radiator for hybrid system
PC200, 200LC-8E0 (Hybrid) 10-100 3

SEN05228-00
©2009 KOMATSU
All Rights Reserved
Printed in Japan 08-09
10-100 4
SEN05229-02
SEN05229-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


200 Hybrid Relation
Configuration and safety functions of hybrid system .................................................................................. 2

Cooling system of hybrid component.......................................................................................................... 6
Motor generator .......................................................................................................................................... 8
Swing electric motor.................................................................................................................................... 9
Electric control unit...................................................................................................................................... 10
High-voltage wiring (power cable)............................................................................................................... 11
PC200, 200LC-8E0 (Hybrid) 10-200 1

200 Hybrid Relation
SEN05229-02 Configuration and safety functions of hybrid system
Configuration and safety functions of hybrid system
Configuration of hybrid system

The high-voltage system of the hybrid system is not grounded and is insulated from the machine frame inside
the case of each hybrid device and the shield braid of the high-voltage wiring.
Therefore, you will not get an electric shock, unless you break the insulation of the high-voltage system and
touch the positive and negative sides simultaneously.
In addition, the case of each hybrid device and the shield braid are grounded to the machine frame through
flexible cables or other devices.
1. Motor-generator case
2. Engine
3. Motor-generator high-voltage portion
4. Connector
5. High-voltage wiring
6. Capacitor case
7. Inverter case
8. Swing electric motor case
9. Inverter high-voltage portion
10. Swing electric motor high-voltage portion
11. Capacitor high-voltage portion
12. Swing machinery
13. Machine frame
14. Flexible cable
a. Insulation
b. Shield braid
10-200 2 PC200, 200LC-8E0 (Hybrid)

200 Hybrid Relation
Configuration and safety functions of hybrid system SEN05229-02
Protection function of hybrid devices

Each inverter has an electric leakage detector in it to minimize breakage of the hybrid equipment when an
electric leakage occurs. The electric leakage detector stops each device in the inverter (inverter, booster, and
driver) if it detects deterioration of insulation of the high-voltage equipment or a short circuit to the machine
body.
Conditions for stopping whole hybrid system

1. When the temperature of the swing electric motor, motor-generator, inverter, or capacitor exceeds the
following system stop temperature
Example of corresponding failure code: [GA1AKZ] Gen. Mot. Dr. Temp. Sens.Open/Short Cir.
[GA1TNS] Capacitor Overheat
Warning System stop
Component name Portion name Monitoring item name temperature temperature
[°C] [°C]
Swing electric motor Stator coil Swing electric motor coil temperature 140 160
Motor-generator Generator coil Motor-generator temperature — 180
Booster transformer Booster inductor temperature 120 130
Booster IGBT junction* — — 135
Inverter Booster IGBT base Booster IGBT temperature 80 100
IGBT junction for PM* Swing inverter JCT temperature 125 135
IGBT junction for SR* Generator driver temperature — 150
Bus bar #1 Capacitor Temperature #1 63 65
Capacitor
Bus bar #2 Capacitor Temperature #2 63 65
The values of items marked with * are not measured but estimated from calculation.
2. When an overcurrent is detected in the swing electric motor or motor-generator (including breakage of a
fuse)
Or, when an abnormality is detected in the current sensor
Example of corresponding failure code: [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir
[GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction
3. When an overvoltage is detected in the high-voltage wiring

Or, when an abnormality is detected in the voltage sensor
Example of corresponding failure code: [GA08KG] Abnorm. DC HW Volt. After Booster
[GA0AKZ] DC Vlt. Sen. Op./Shrt cir. Aft. booster
4. When an abnormality is detected in the high-voltage wiring connector (open circuit, hot short circuit, or
ground fault in the interlock circuit)
Example of corresponding failure code: [GA01KA] Power Cable Interlock Open Circuit
5. When swing emergency stop switch is pressed

Example of corresponding failure code: [GA08KG] Abnorm. DC HW Volt. After Booster
[GA81KZ] Swing Motor Power Cable Opn/Shrt Circ.
6. When an earth leakage is detected

Example of corresponding failure code: [GA02KZ] DC Line Open & Short Circuit
[GA0BKZ] AC line Open & Short Circuit
7. When an abnormality is detected in the capacitor or in its high-voltage wiring (including wrong connection)
Example of corresponding failure code: [GA02KZ] DC Line Open & Short Circuit
[GA04KG] Abnormal DC HW Volt. Before Booster
PC200, 200LC-8E0 (Hybrid) 10-200 3

200 Hybrid Relation
SEN05229-02 Configuration and safety functions of hybrid system
Protection function of hybrid devices
a Condition for stopping whole hybrid system

1. High temperature
2. Overcurrent
(swing electric motor, motor-generator)
3. Overcurrent (high-voltage line)
4. Defective connector
5. Emergency stop switch
6. Ground leakage detector (built-in inverter)
7. Fuse is broken when capacitor cable has short
circuit
10-200 4 PC200, 200LC-8E0 (Hybrid)

200 Hybrid Relation
Configuration and safety functions of hybrid system SEN05229-02
Safety functions when disassembling hybrid component

1. If the key switch is turned OFF, each hybrid device is disconnected from the high voltage.
The 2 contactors for connecting the inverter and capacitor are opened and no power is supplied to the
capacitor. The charge in the inverter is discharged through the internal discharge resistor in several
minutes.
2. Even if the key switch is ON, when a high-voltage wiring is removed, the interlock switch performs the
above disconnecting operation.
3. The capacitor can be discharged by consuming it in the motor-generator with the discharge function of the
monitor.
Since the electrode of the one-touch connector is protected with the insulator and waterproof seal and
cannot be touched easily, safety is secured even while there is charge left in the capacitor.
PC200, 200LC-8E0 (Hybrid) 10-200 5

200 Hybrid Relation
SEN05229-02 Cooling system of hybrid component
Cooling system of hybrid component
Configuration of cooling system
1. Swing electric motor a. Passages of cooling and lubricating oil

2. Stator coil temperature b. Passage of coolant
3. Stator coil c. Temperature sensor
4. Radiator
5. Hybrid radiator
6. Engine
7. Motor-generator
8. Coil temperature
9. Pump
10. Rotor
11. Coil
12. Cooling and lubricating oil pumps
13. Inverter
14. Water pump
15. Inside of booster
16. Capacitor
17. Capacitor cell
18. Temperature of capacitor cell and bus bar
10-200 6 PC200, 200LC-8E0 (Hybrid)

200 Hybrid Relation
Cooling system of hybrid component SEN05229-02
Interlock function
This function checks for a loose or disconnected connector in the high-voltage wiring (power cable) and out-
puts an error signal to the monitor and stops the hybrid system if it detects an abnormality.
The interlock circuit in the following figure is installed to the high-voltage wiring connectors of the
motor-generator, inverter, and swing electric motor. If the contacts of a connector in the circuit are parted from
each other, this function judges that an abnormality has occurred and stops the hybrid system.
This function also checks the interlock circuit and stops the hybrid system if it detects abnormality in the circuit,
outputting the error signal similarly to the above.
The power cable connectors marked with a and connected to the inverter are also equipped with interlock
circuits, which check for loose or disconnected connectors.
Interlock circuit diagram
1. Swing electric motor 6. Interlock circuit

2. Disconnection of connector 7. Interlock output
3. Motor-generator 8. Interlock input
4. Inverter
5. Capacitor a. High-voltage wiring
PC200, 200LC-8E0 (Hybrid) 10-200 7

200 Hybrid Relation
SEN05229-02 Motor generator
Motor generator
1. Generator 4. Coolant pipe

2. Lubrication pump 5. Oil feed pipe
(for generator motor and swing electric motor) 6. Level gauge
3. Coolant pipe 7. Filter
Function Specifications
q The motor-generator coverts the rotation and Model: ZG030
torque of the engine into electric power and sup- Lubricating oil:
plies it to the swing motor. Specified capacity: 6.5 l
q The motor-generator receives electric power Refill capacity: 6.0 l
from the capacitor and assists the engine output. Oil type: TO10
Weight: 225 kg
10-200 8 PC200, 200LC-8E0 (Hybrid)

200 Hybrid Relation
Swing electric motor SEN05229-02
Swing electric motor
1. Swing electric motor 5. Coolant outlet

2. Oil filler plug 6. Lubricating oil inlet
3. Level gauge 7. Lubricating oil outlet
4. Coolant inlet 8. Lubricating oil drain
q The swing electric motor converts the electric Model: ZM100
power supplied from the generator and capacitor Specified oil capacity: 2.6 l
into rotation and torque of the motor output shaft Refill capacity (TO10): 1.7 l
and transmits it to the swing machinery. Oil type: TO10
q The swing electric motor coverts the kinetic en- Weight: 70kg
ergy of the upper structure into electric power
and supplies it to the capacitor.
PC200, 200LC-8E0 (Hybrid) 10-200 9

200 Hybrid Relation
SEN05229-02 Electric control unit
Electric control unit
1. Inverter 3. Water pump

2. Capacitor 4. Mount rubber
q Motor generator control Inverter model: ZD100
q Swing motor control Fuse rating: 150 A
q Capacitor charge and discharge control Total weight: 157 kg
Inverter weight: 45 kg
10-200 10 PC200, 200LC-8E0 (Hybrid)

200 Hybrid Relation
High-voltage wiring (power cable) SEN05229-02
High-voltage wiring (power cable)
1. High-voltage wiring (motor generator) A: Motor generator

2. High-voltage wiring (motor generator) B: Electric control unit
3. High-voltage wiring (swing electric motor) C: Swing electric motor
4. High-voltage wiring (capacitor)
q The high-voltage wiring supplies high-voltage q Waterproof and shield structure
power.
q The high-voltage wiring connectors are colored
respectively to prevent a wrong connection.
q Each high-voltage wiring connector is equipped
with an interlock switch. If the connector is dis-
connected, the switch is opened and the hybrid
system stops.
PC200, 200LC-8E0 (Hybrid) 10-200 11

SEN05229-02
©2012 KOMATSU
All Rights Reserved
10-200 12
SEN05230-00
SEN05230-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


300 Power train
Power train.................................................................................................................................................. 2
Final drive ................................................................................................................................................... 4
Swing machinery......................................................................................................................................... 6
Swing circle................................................................................................................................................. 8
PC200, 200LC-8E0 (Hybrid) 10-300 1

300 Power train
SEN05230-00 Power train
Power train
1. Idler
2. Center swivel joint
3. Control valve
4. Final drive
5. Travel motor (HMV110ADT-2)
6. Hydraulic pump (HPV95 + 95)
*1 7. Motor generator
8. Engine (SAA6D107E-1)
9. Travel speed solenoid valve
10. Swing brake solenoid valve
*1 11. Swing electric motor (ZM100)
12. Swing machinery
13. Swing circle
10-300 2 PC200, 200LC-8E0 (Hybrid)

300 Power train
PC200, 200LC-8E0 (Hybrid) 10-300 3

300 Power train
SEN05230-00 Final drive
Final drive
10-300 4 PC200, 200LC-8E0 (Hybrid)

300 Power train
Final drive SEN05230-00
1. Level plug
2. No. 1 planetary gear (No. of teeth: 42)
3. Drain plug
4. No. 1 sun gear (No. of teeth: 10)
5. No. 2 sun gear (No. of teeth: 21)
6. No. 1 planetary carrier
7. Cover
8. No. 2 planetary carrier
9. Gear hub (No. of teeth: 95)
10. Sprocket
11. Floating seal
12. Travel motor
13. No. 2 planetary gear (No. of teeth: 36)
Specifications
Reduction ratio: – ((10 + 95)/10) x ((21 + 95)/21) + 1 = –57.000
Unit: mm
No. Item Criteria Remedy
Backlash between No. 2 sun gear Standard clearance Allowable clearance
14
and No.2 planetary gear 0.13 – 0.47 1.00
Backlash between No. 1 planetary
15 0.17 – 0.57 1.10
gear and gear hub
16 0.06 – 0.25 —
carrier and motor
Replace
Backlash between No. 1 sun gear
17 0.14 – 0.46 1.00
and No. 1 planetary gear
18 0.16 – 0.56 1.10
gear and gear hub
19 0.38 – 0.66 1.00
carrier and No. 2 sun gear
20 Amount of wear on sprocket tooth Repair limit: 6
Build-up welding or
Standard dimension Repair limit
21 Width of sprocket tooth replace
71 68
PC200, 200LC-8E0 (Hybrid) 10-300 5

300 Power train
SEN05230-00 Swing machinery
Swing machinery
10-300 6 PC200, 200LC-8E0 (Hybrid)

300 Power train
Swing machinery SEN05230-00
1. Drain plug *1 13. No.1 ring gear

2. Swing pinion (No. of teeth: 13) *1 14. No.1 planetary carrier
3. Cover *1 15. No.1 planetary gear
4. Plate *1 16. No.1 sun gear
5. No. 3 planetary carrier *1 17. Oil level gauge
6. No. 2 ring gear *1 18. Oil feed pipe
7. No. 3 planetary gear *1 19. Swing electric motor
8. No. 3 sun gear *1 20. Spring
9. No. 2 planetary carrier *1 21. Brake piston
10. No. 2 planetary gear *1 22. Brake gear
*1 11. No. 2 sun gear *1 23. Brake plate
*1 12. Case *1 24. Brake disc
Specifications
Reduction ratio: ((17 + 58)/17) x ((18 + 58)/18) x ((16 + 62)/16) = 90.811
Unit: mm
Backlash between swing motor Standard clearance Allowable clearance
*1 25
shaft and No. 1 sun gear 0.07 – 0.18 —
*1 26 0.12 – 0.31 0.80
and No.1 planetary gear
*1 27 0.14 – 0.43 0.90
gear and ring gear
*1 28 0.07 – 0.21 —
carrier and No. 2 sun gear
29 0.16 – 0.50 1.00
and No.2 planetary gear
30 0.18 – 0.59 1.10
gear and ring gear
Backlash between No.2 planetary
31 0.39 – 0.71 1.20 Replace
carrier and No.3 sun gear
32 0.16 – 0.50 0.90
and No. 3 planetary gear
Backlash between No.3 planetary
33 0.18 – 0.59 1.00
gear and No.2 ring gear
Backlash between swing pinion and
34 0.07 – 0.23 —
No. 3 planetary carrier
Backlash between swing pinion
35 0.22 – 1.32 2.00
and swing circle
Clearance between plate and
36 0.66 – 1.14 —
No. 3 planetary carrier
Clearance between No. 3 sun
37 1.66 – 2.94 —
gear and plate
Standard dimension Repair limit Apply hard
Wear of swing pinion surface con-
38 chrome plating or
tacting with oil seal f125 (0/–0.100) —
replace
PC200, 200LC-8E0 (Hybrid) 10-300 7

300 Power train
SEN05230-00 Swing circle
Swing circle
1. Swing circle inner race (No. of teeth: 96) a. Inner race soft zone “S“ position
2. Ball b. Outer race soft zone “S“ position
3. Swing circle outer race
Specifications
Reduction ratio: –96/13 = –7.385
Amount of filled grease: 14.6l (G2-LI)
Unit: mm
Axial clearance of bearing Standard clearance Allowable clearance
4 Replace
(when mounted on chassis) 0.5 – 1.6 3.2
10-300 8 PC200, 200LC-8E0 (Hybrid)

300 Power train
Swing circle SEN05230-00
PC200, 200LC-8E0 (Hybrid) 10-300 9

SEN05230-00
©2009 KOMATSU
All Rights Reserved
10-300 10
SEN05231-01
SEN05231-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


400 Undercarriage and frame
Track frame and recoil spring ..................................................................................................................... 2

Idler ............................................................................................................................................................. 4
Carrier roller ................................................................................................................................................ 6
Track roller .................................................................................................................................................. 7
Track shoe .................................................................................................................................................. 8
PC200, 200LC-8E0 (Hybrid) 10-400 1

SEN05231-01 Track frame and recoil spring
Track frame and recoil spring
1. Idler q Number of track rollers (One side): 7

2. Track frame
3. Carrier roller
4. Final drive
5. Track roller
6. Track shoe
7. Center guard
8. Front guard
10-400 2 PC200, 200LC-8E0 (Hybrid)

Track frame and recoil spring SEN05231-01
Standard shoe
Models
PC200-8E0 PC200LC-8E0
Shoe width (mm) 600 700
Item Link pitch (mm) 190 190
Q'ty (One side) 45 49
Unit: mm
Standard dimen-
Tolerance Repair limit
Vertical width of idler sions
9
guide Track frame 107 — — Build-up welding or
Idler support 105 — — replace
Horizontal width of Track frame 250 — —
10
idler guide Idler support 247.4 — —
Standard dimensions Repair limit
Free length x Installation Installation Installation
Outside diam- Free length
eter length load load
11 Recoil spring 109.3 kN 87.4 kN Replace
PC200-8E0 558 × 238 417 531.4
{11,150 kg} {8,920 kg}
126.5 kN 101 kN
PC200LC-8E0 561.4×237 433 534
{12,900 kg} {10,300 kg}
PC200, 200LC-8E0 (Hybrid) 10-400 3

SEN05231-01 Idler
Idler
10-400 4 PC200, 200LC-8E0 (Hybrid)

Idler SEN05231-01
Unit: mm
1 Outside diameter of protrusion
538 —
2 Outside diameter of tread 500 488
Build-up welding or
3 Thickness of tread 26 20
replace
4 Difference of tread 19 25
5 Total width 159 —
6 Width of tread 37.5 —
Standard Tolerance Standard Allowable
Clearance between shaft and bush- dimension Shaft Hole clearance clearance
7
ing - 0.250 + 0.164
65 0.176 - 0.514 —
- 0.350 - 0.074
Standard Tolerance Standard inter- Allowable
Interference between idler and dimension Shaft Hole ference interference Replace bushing
8
bushing + 0.108 - 0.032
72 0.040 - 0.170 —
+ 0.008 - 0.062
9 Clearance between bushing Standard clearance Allowable clearance
and support
0.5 – 1.0 —
(Total of both sides)
PC200, 200LC-8E0 (Hybrid) 10-400 5

SEN05231-01 Carrier roller
Carrier roller
Unit: mm
1 Outside diameter of flange
145 -
3 Width of tread 43 -
4 Thickness of tread 23 -
5 Width of flange 14 -
6 Replace
ing - 0.170 + 0.301 0.338 –
40 -
- 0.190 + 0.168 0.491
Interference between roller and dimension Shaft Hole ference interference
7
bushing + 0.061 0 0.016 –
47 -
+ 0.016 - 0.040 0.101
8 Standard clearance Allowable clearance
End play of axial direction
0.44–0.76 -
10-400 6 PC200, 200LC-8E0 (Hybrid)

Track roller SEN05231-01
Track roller
Unit: mm
1 Outside diameter of flange
188 -
Build-up welding or
3 Thickness of tread 44.5 38.5
replace
4 Total width 225 16
5 Width of tread 44.5 -
6 Width of flange 25.5 -
7
ing - 0.215 + 0.195 0.215 –
60 -
- 0.315 0 0.510
Replace bushing
Interference between roller and dimension Shaft Hole ference interference
8
bushing + 0.153 + 0.030 0.023 –
67 -
+ 0.053 0 0.153
End play of axial direction Standard clearance Allowable clearance
9
(total of both sides) 0.5–1.0 - Replace
PC200, 200LC-8E0 (Hybrid) 10-400 7

SEN05231-01 Track shoe
Track shoe
a P portion shows the link of bushing press-fitting end.

q Number of shoes
*1. Triple grouser shoe Models Q'ty (each side)
*2. Road liner
PC200-8E0 45
*3. Swamp shoe PC200LC-8E0 49
*4. Flat shoe
10-400 8 PC200, 200LC-8E0 (Hybrid)

Track shoe SEN05231-01
Unit: mm
1 Link pitch
190.3 193.3
Standard dimension Reverse Reverse or replace
2 Outside diameter of bushing
59.3 54.3
3 Thickness of bushing metal 10.4 5.4
4 Link height
105 97
Repair or replace
Thickness of link metal
5 28.5 20.5
(bushing press-fitting portion)
6 160.4
7 Shoe bolt pitch 124.4
8 62
9 Inside width 84.8
10 Link Overall width 45.4
11 Tread width 39.6
Regular 2.5
12 Protrusion of pin Adjust or replace
Master 2.5
Protrusion of Regular 4.85
13
bushing Master 0.0
Overall length of Regular 212
14
pin Master 212
Overall length of Regular 138.5
15
bushing Master 128.7
16 Thickness of spacer —
17 Bushing 88.2 – 245 kN {9 – 25 ton}
18 Regular pin 127.4 – 274.4 kN {13 – 28 ton}
Press-fitting force —
19
Master pin 78.4 – 147 kN {8 – 15 ton}
(*)
Tightening torque Retightening angle
a. Regular link Triple grouser shoe 490±49 120±10

20 Shoe bolt Road liner 549±59 — Retighten
Tightening torque Retightening angle Lower limit torque
b. Master link (Nm {kgm}) (deg.) (Nm {kgm})
— — —
Standard dimen- Tolerance Standard interfer-
Interference between bushing and sions Shaft Hole ence
21
link +0.434 +0.074
59 0.320 – 0.434
22 Interference between regular pin 38 +0.222 -0.138 0.300 – 0.422
Tolerance
Clearance between regular pin and Standard dimension Shaft Hole
Standard clearance
23 Adjust or replace
bushing +0.222 +0.902
38 0.180 – 0.740
24 Interference between master pin Tolerance Standard interfer-
Standard dimension
(*) and link Shaft Hole ence
Tolerance
25 Clearance between master pin and Standard dimension Shaft Hole
Standard clearance
(*) bushing 38 -0.150 +0.902 0.552 – 1.252
* Dry type track link
PC200, 200LC-8E0 (Hybrid) 10-400 9

SEN05231-01 Track shoe
Triple grouser shoe
Swamp shoe
Road liner
10-400 10 PC200, 200LC-8E0 (Hybrid)

Track shoe SEN05231-01
Unit: mm
1 Height
26 16
2 Thickness 8.5
3 Length of base 26
4 Length of base 19
5 Length at tip 20 Build-up welding or
6 Length at tip 14 replace
7 Length at tip 19
8 Thickness
34.5 24.5
9 Height 102.5 90.5
10 Thickness 17 5
11 Height 70 Replace
PC200, 200LC-8E0 (Hybrid) 10-400 11

SEN05231-01
©2010 KOMATSU
All Rights Reserved
10-400 12
SEN05232-01
SEN05232-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


501 Hydraulic system, Part 1
Hydraulic components layout drawing ........................................................................................................ 2

Hydraulic tank and filter .............................................................................................................................. 4
Hydraulic pump ........................................................................................................................................... 6
PC200, 200LC-8E0 (Hybrid) 10-501 1

SEN05232-01 Hydraulic components layout drawing
Hydraulic components layout drawing

1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic oil filter
6. R.H travel motor
7. Hydraulic pump
8. Control valve
9. Oil cooler
10. L.H. travel motor
11. Left PPC valve
12. Lock lever
13. Center swivel joint
14. Right PPC valve
15. Travel PPC valve
16. Accumulator
17. Solenoid valve assembly
17A. PPC lock solenoid valve
17B. 2-stage relief solenoid valve
17C. Swing brake solenoid valve
17D. Travel speed solenoid valve
17E. Travel junction solenoid valve
10-501 2 PC200, 200LC-8E0 (Hybrid)

Hydraulic components layout drawing SEN05232-01
PC200, 200LC-8E0 (Hybrid) 10-501 3

SEN05232-01 Hydraulic tank and filter
Hydraulic tank and filter
1. Hydraulic tank Specifications

2. Oil filler port cap Tank capacity: 190 l
3. Filter element Quantity of oil in tank: 135 l
4. Strainer
5. Bypass valve Pressure valve
6. Suction strainer (this valve is equipped on the oil filler cap)
7. Sight gauge Relief cracking pressure:
16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2}
Suction cracking pressure:
0 – 0.49 kPa {0 – 0.005 kg/cm2}
Bypass valve set pressure:
150 ± 30 kPa {1.5 ± 0.3 kg/cm2}
10-501 4 PC200, 200LC-8E0 (Hybrid)

Hydraulic tank and filter SEN05232-01
PC200, 200LC-8E0 (Hybrid) 10-501 5

SEN05232-01 Hydraulic pump
Hydraulic pump
Type: HPV95+95
10-501 6 PC200, 200LC-8E0 (Hybrid)

Hydraulic pump SEN05232-01
Outline
q This pump consists of two variable capacity
swash plate piston pumps, PC valve, LS valve,
and EPC valve.
IMF: Front PC mode selector current

IMR: Rear PC mode selector current
ISIG: LS set pressure selector current
PAF: Front pump delivery port
PAR: Rear pump delivery port
PBF: Pump pressure input port
PD1F: Case drain port
PD1R: Air bleeder
PD2F: Drain plug
PD2R: Drain plug
PENF: Front control pressure pickup port
PENR: Rear control pressure pickup port
PEPC: EPC source pressure port
PEPCC: EPC source pressure pickup port
PFC: Front pump discharge pressure pickup port
PLSF: Front load pressure input port
PLSFC: Front load pressure pickup port
PLSR: Rear load pressure input port
PLSRC: Rear load pressure pickup port
PMF: Front PC mode selector pressure pickup port
PMR: Rear PC mode selector pressure pickup port
PRC: Rear pump discharge pressure pickup port
PS: Pump suction port
PSIG: LS set selector pressure pickup port
1. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. LS-EPC valve
6. PC-EPC valve
PC200, 200LC-8E0 (Hybrid) 10-501 7

1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. Servo piston
13. PC valve
10-501 8 PC200, 200LC-8E0 (Hybrid)

Function
q The pump converts the engine torgue transmit- q Cylinder block (7) seals the pressurized oil to
ted to its shaft into oil pressure and delivers pres- valve plate (8) and carries out relative rotation.
surized oil corresponding to the load. q This surface is designed so that the oil pressure
q It is possible to change the discharge amount by balance is maintained at a suitable level.
changing the swash plate angle. q The oil inside the respective cylinder chambers
of cylinder block (7) is suctioned and discharged
Structure through valve plate (8).
q Cylinder block (7) is connected with shaft (1) on
spline (14).
q Shaft (1) is supported by front and rear bearings
(15).
q Tip of piston (6) is shaped as a concave sphere
and shoe (5) is caulked to it to form one unit.
q Piston (6) and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe (5)
is always pressed against this surface while slid-
ing in a circular movement.
q Rocker cam (4) conducts high pressure oil to the
cylindrical surface (B) with cradle (2), which is
secured to the case, and forms a static pressure
bearing with oil when it pivots.
q Piston (6) perform the reciprocation inside each
cylinder chamber of cylinder block (7).
PC200, 200LC-8E0 (Hybrid) 10-501 9

Operation of pump
q Cylinder block (7) rotates together with shaft (1), q As center line (X) of rocker cam (4) matches the
and shoe (5) slides on flat surface (A). axis of cylinder block (7) (swash plate angle (a)
q When this happens, rocker cam (4) moves along = 0), the difference between volumes (E) and (F)
cylindrical surface (B), so angle (a) between cen- inside cylinder block (7) becomes 0.
ter line (X) of rocker cam (4) and the axis of cyl- q Suction and discharge of pressurized oil is not
inder block (7) changes. performed in this stage. Namely pumping action
q (a) is named the swash plate angle. is not performed. (Actually, however, the swash
plate angle is not set to 0)
q With center line (X) of rocker cam (4) at a swash

plate angle (a) in relation to the axis of cylinder
block (7), flat surface (A) acts as a cam in rela-
tion to shoe (5).
q In this way, piston (6) slides on the inside of cyl-
inder block (7), so a difference between volumes
(E) and (F) is created inside cylinder block (7).
q Each piston (6) suctions and discharges the oil
by the amount (F) minus (E).
q As cylinder block (7) rotates and the volume of
chamber (E) decreases, the pressurized oil is
discharged.
q On the other hand, the volume of chamber (F) in-
creases and, in this process, the oil is suctioned.
(In the figure, chamber (F) is at the end of the
suction stroke and chamber (E) is at the end of
the discharge stroke.)
10-501 10 PC200, 200LC-8E0 (Hybrid)

Control of delivery
q If the swash plate angle (a) increases, the differ-
ence between volumes (E) and (F) increases
and also pump delivery (Q) increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) perform linear reciprocation
according to the signal pressure from the PC
valve and LS valve.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Rocker cam (4) is supported on the cylindrical
surface of cradle (2) and slides on the cylindrical
surface to change swash plate angle (a).
q The pressure receiving area of servo piston (12)
are not equal on the left side and right side. Main
pump discharge pressure (self pressure) (PP)
always applies to the pressure chamber of the
small diameter piston side.
q Output pressure (PEN) of the LS valve applies to
the chamber receiving the pressure at the large
diameter piston end.
q "The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end" and "the
ratio between the area receiving the pressure of
the small diameter piston and the large diameter
piston" control the movement of servo piston
(12).
PC200, 200LC-8E0 (Hybrid) 10-501 11

1. LS valve
PA: Pump port 1. Sleeve

PDP: Drain port 2. Piston
PLP: LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Sheet
PPL: Control pressure input port 6. Sleeve
PSIG: LS mode selector pilot port 7. Plug
8. Locknut
Function
q The LS (load sensing) valve detects the load of
the actuator and controls the discharge amount.
q This valve controls main pump delivery (Q) ac-
cording to differential pressure (dPLS) [=(PP) -
(PLS)] (called the LS differential pressure) (be-
tween main pump discharge pressure (PP) and
control valve outlet port pressure (PLS).
q Main pump pressure (PP) and pressure (PLS)
(called the LS pressure) coming from the control
valve output, and pressure (PSIG) (called the LS
selector pressure) from the proportional solenoid
valve enter this valve.
q The relationship between the "LS differential
pressure between the main pump pressure (PP)
and LS pressure (PLS) (dPLS) [=(PP) - (PLS)]"
and " the pump delivery (Q) " changes as shown
in the diagram according to LS selector current
(ISIG) of the LS-EPC valve.
q If (ISIG) changes from 0A to 1A, setting force the
spring changes, too. As the result, the specified
median of the pump delivery volume switching
point changes as shown in the diagram. It will
change in the range of 0.27 to 1.7 MPa{2.78 to
17.75 kg/cm2}.
10-501 12 PC200, 200LC-8E0 (Hybrid)

Operation
1) When the control valve is situated at neutral
q The LS valve is a 3-way selector valve, and pres- q Pump pressure (PP) is conducted to the large di-
sure (PLS) (LS pressure) from the inlet port of ameter end from the port (K).
the control valve applies to spring chamber (B) q The same pump pressure (PP) is conducted to
and main pump discharge pressure (PP) applies the small diameter end from the port (J).
to port (H) of sleeve (8). q According to the difference in the areas on servo
q The relation between the force resulting from piston (12), the pressure moves in such that the
this LS pressure (PLS), force of spring (4) and swash plate angle may be minimized.
the pump delivery pressure (self pressure) (PP)
determine the position of spool (6).
q However, magnitude of the output pressure
(PSIG) (called the LS selector pressure) of the
EPC valve for the LS valve entering port (G) also
changes the position of spool (6). (Setting force
of the spring is changed)
q Before the engine is started, servo piston (12) is
pushed to the left by the spring. (See the figure)
q If the control lever is in the neutral position when
the engine is started, LS pressure (PLS) will be
set to 0 MPa {0 kg/cm2} (It is interconnected to
the drain circuit through the control valve spool)
q Spool (6) is pushed to the right, and port (C) and
port (D) will be connected.
PC200, 200LC-8E0 (Hybrid) 10-501 13

2) Action for the direction of maxinizing the pump delivery
q When the difference between the main pump q If the output pressure of the EPC valve for the LS
pressure (PP) and LS pressure (PLS), in other valve enters port (G), rightward force is generat-
words, LS differential pressure (dPLS) becomes ed on piston (7).
smaller (for example, when the area of opening q If piston (7) is pushed to the right, setting force of
of the control valve becomes larger and pump spring (4) is weakened, changing the LS differ-
pressure (PP) drops), spool (6) is pushed to the ential pressure (dPLS) [Difference between oil
left by the combined force of LS pressure (PLS) pressures (PLS) and (PP) ] when ports (D) and
and the force of spring (4). (E) of spool (6) are connected.
q When spool (6) moves, port (D) and port (E) are
interconnected and connected with the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K) be-
comes drain pressure (PT). (The operation of
the PC valve is explained later.)
q The pressure at the large diameter end of servo
piston (12) becomes drain pressure (PT), and
pump pressure (PP) enters port (J) at the small
diameter end, so servo piston (12) is pushed to
the left side. Therefore, the swash plate is
moved in the direction to make the discharge
amount larger.
10-501 14 PC200, 200LC-8E0 (Hybrid)

3) Action for the direction of minimizing the pump delivery
q When LS differential pressure (dPLS) increases

(for example, when the area of opening of the
control valve decreases and pump pressure
(PP) rises) because of the rightward move (it re-
duces pump delivery) of servo piston (12), pump
pressure (PP) pushes spool (6) to the right.
q When spool (6) moves, pump pressure (PP)
flows from port (C) to port (D) and from port (K),
it enters the large diameter end of the piston.
q Main pump pressure (PP) also enters port (J) of
the small diameter end of the piston, but be-
cause of the difference in area between the large
diameter end and the small diameter end on ser-
vo piston (12), it is pushed to the right. As the re-
sult, the servo piston (12) moves into the
direction of reducing the swash plate angle.
q As LS selector pressure (PSIG) is input to port
(G), setting force of spring (4) is reduced.
PC200, 200LC-8E0 (Hybrid) 10-501 15

4) When servo piston is balanced
q Let us take the area receiving the pressure at the q Force of spring (4) is adjusted in such that the
large diameter end of the piston as (A1), the area position of the balanced stop of this spool (6)
receiving the pressure at the small diameter end may be determined when (PP) — (PLS) = 1.7
as (A0), and the pressure flowing into the large MPa {17.75 kg/cm2} at the median of the speci-
diameter end of the piston as (PEN). fied value.
q If the main pump pressure (PP) of the LS valve q If (PSIG) [Output pressure of LS-EPC valve, 0 to
and the "combined force of spring (4) and LS
2.9 MPa {0 to 30 kg/cm2}] is input to port (G), the
pressure (PLS) " are balanced, and the relation-
position of the balanced stop is changed in the
ship is (A0) x (PP) = (A1) x (PEN), servo piston
range of (PP) — (PLS) = 1.7 to 0.27 MPa {17.75
(12) will stop in that position.
q The swash plate of the pump will be held at the to 2.78 kg/cm2} in proportion to (PSIG) pres-
intermediate position. [Spool (6) will be stopped sure.
at a position where the distance of the opening
from port (D) to port (E) and the distance from
port (C) to port (D) is almost the same.]
q At this point, the relationship between the both
pressure receiving areas of servo piston (12) is
(A0):(A1)=3:5, so the pressure applied to the
both piston ends when it is balanced becomes
(PP):(PEN)C5:3.
10-501 16 PC200, 200LC-8E0 (Hybrid)

2. PC valve
PA : Pump port 1. Plug

PA2: Pump pressure pilot port 2. Servo piston assembly
PDP: Drain port 3. Pin
PM : Mode selector pressure pilot port 4. Spool
PPL: Control pressure output port (to LS valve) 5. Retainer
6. Seat
7. Cover
8. Wiring
Function
q When the pump discharge pressure (PP1) q If the engine speed goes beblow the specified
(self-pressure) and (PP2) (other pump pressure) value because of increased load ,the controller
are high, the PC valve controls the pump so that sends a command current to PC-EPC valve so-
the volume of oil beyond the discharge pres- lenoid in order to reduce the swash plate angle
sure-based specific flow rate may not be con- in proportion to reduction in the engine speed.
ducted however you may increase the control
valve stroke. Namely it is intended at controlling
the horsepower for the pumps so that it may not
exceed the engine hosepower.
q If the pump discharge pressure (PP) increases
due to increased load during operation, this
valve decreases the pump delivery.
q And if the pump delivery pressure goes low, it in-
creases the pump delivery.
q In this case, relation between the mean dis-
charge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and the pump delivery (Q) will
becomes as shown in the diagram if the relation
is represented as the parameter the current val-
ue (X) to be given to PC-EPC valve solenoid.
q The controller continues counting the actual en-
gine speed.
q If the engine speed is slowed down due to in-
creased load, the controller reduces the pump
delivery to recover the speed.
PC200, 200LC-8E0 (Hybrid) 10-501 17

Operation
1) When pump controller is normal
(1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1)

q Command current (X) is being sent to PC-EPC For the front pump pressure, the other pump's
valve solenoid (1) from the pump controller. pressure is that of the rear pump.
q This command current (X) acts on PC-EPC And for the rear pump pressure, the other
valve to output the signal pressure in order to pump's pressure is that of the front pump.
modify the force pushing piston (2).
q Spool (3) stops at a position where the combined
spool-pushing force is balanced by the setting
force of springs (4) and (6) as well as the pump
pressures (PP1) (self-pressure) and (PP2) (an-
other pump's pressure).
q The pressure [port (C) pressure] output from PC
valve is changed depending on the above posi-
tion.
q The size of command current (X) is determined
by the working item (lever operation), the select-
ed working mode, and the set value and actual
value of the engine speed.
a Other pump’s pressure denotes the pressure of
the pump situated on the opposite side.
10-501 18 PC200, 200LC-8E0 (Hybrid)

Action of spring
q Load of springs (4) and (6) on the PC valve is de- q Ports (C) and (D) are connected, and the pres-
termined by the swash plate position. sure entering the LS valve becomes drain pres-
q As servo piston (9) moves to right, spring (6) is sure (PT).
compressed. q If port (E) and port (G) of the LS valve are con-
q If the servo piston moves further to be right , it nected, the pressure entering the large diameter
will be contacted against seat (5) and spring (6) end of the piston from port (J) becomes drain
will be fixed (solid). pressure (PT), and servo piston (9) moves to the
q After that, spring (4) alone will operate. left side.
q The spring load is changed by servo piston (9) q The pump delivery will be set to the increasing
as it extends or compresses springs (4) and (6). trend.
q If the command current (X) to PC-EPC valve so- q According to the move of servo piston (9),
lenoid (1) changes, so does the force pushing springs (4) and (6) will be expanded and the
piston (2). spring force decreases.
q Spring force of springs (4) and (6) is also affect- q As the spring force decreases, spool (3) moves
ed by the command current (X) to PC-EPC valve to the right, the connecting between port (C) and
solenoid. port (D) is shut off and the pump discharge pres-
q Port (C) of the PC valve is connected to port (E) sure ports (B) and (C) are connected.
of the LS valve. q As a result, the pressure on port (C) increases
q Self pressure (PP1) enters port (B) and the small and the pressure on the large diameter end of
diameter end of servo piston (9), and other pump the piston also increases. Thus, the leftward
pressure (PP2) enters port (A). move of servo piston (9) is stopped.
q When pump pressures (PP1) and (PP2) are
small,spool (3) will be positioned in the left side.
PC200, 200LC-8E0 (Hybrid) 10-501 19

q Servo piston (9) stop position (= Pump delivery)

is decided by the position where the pushing
force generated from the pressures (PP1) and
(PP2) applied to spool (3) , the pushing force of
the solenoid in PC-EPC valve generates and the
pushing force of springs (4) and (6) are bal-
anced.
10-501 20 PC200, 200LC-8E0 (Hybrid)

(2) When load on actuator is large and pump discharge pressure is high
Outline
q When the load is large and pump discharge q When spool (3) moves to the left, the openings
pressures (PP1) and (PP2) are high, the force of port (C) and port (D) increases.
pushing spool (3) to the right becomes larger q As a result, the pressure on port (C) (= J) is de-
and spool (3) will be moved to the position creased and the rightward move of servo piston
shown in above figure. (9) is stopped.
q Part of the pressure to be conducted from port q The position in which servo piston (9) stops at
(C) to LS valve flows from port (B) to port (C) and this time is further to the right than the position
(D) via LS valve. At the end this flow, level of this when pump pressures (PP1) and (PP2) are low.
pressure becomes approximately half of pump
pressure (PP2).
Operation
q When port (E) and port (G) of the LS valve are
connected, this pressure from port (J) enters the
large diameter end of servo piston (9), and servo
piston (9) is stopped.
q If pump pressure (PP2) increases further and
spool (3) moves further to the right, pump pres-
sure (PP1) flows to port (C) and acts to make the
pump delivery the minimum.
q When servo piston (9) moves to the right,
springs (4) and (6) are compressed and push
back spool (3).
PC200, 200LC-8E0 (Hybrid) 10-501 21

q The relationship between the average pump

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

solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/2,
and pump delivery (Q) is proportional to the force
of the PC-EPC valve solenoid and moves in par-
allel.
q Namely, the force of PC-EPC valve solenoid (1)
is added to the pushing force to the right be-
cause of the pump pressure applied to the spool
(3) , so the relationship between the average
pump pressure (PP1 + PP2)/2 and the pump de-
livery (Q) moves from (A) to (B) as the command
current (X) is increased.
10-501 22 PC200, 200LC-8E0 (Hybrid)

2) As the emergency pump drive switch is turned "ON" due to failure of the pump controller
(1) When the main pump is under light load
q If there is a failure in the pump controller, the

emergency pump drive switch is turned "ON" to
switch over the control to the resistor side.
q In this case, the power is directly supplied from
the battery. The current, however, is too large as
is, so the resistor is set in between to control the
current flowing to PC-EPC valve solenoid (1).
q The current becomes constant, so the force
pushing piston (2) is also constant.
q If the main pump pressures (PP1) and (PP2) are
low, the combined force of the pump pressure
and the PC-EPC valve solenoid (1) is weaker
than the spring set force, so spool (3) is bal-
anced at a position to the left.
q The port (C) is connected to the drain pressure
of the port (D), and the large diameter end of the
servo piston (9) also becomes the drain pres-
sure (PT) through the LS valve.
q Since the pressure on the small diameter end of
the piston high, servo piston (9) moves in the di-
rection to increase the delivery.
PC200, 200LC-8E0 (Hybrid) 10-501 23

(2) When the main pump is under heavy load
q If the emergency pump drive switch is in "ON" q The curve resulting when the emergency pump
position as in above, the command current (X) drive switch is ON is situated further to the left
sent to PC-EPC valve solenoid (1) becomes (B) than when the pump controller is normal (A).
constant.
q For this reason, the force of piston (2) pushing
spool (3) is constant.
q If main pump pressures (PP1) and (PP2) in-
crease, spool (3) moves further to the right than
when the main pump load is light, and is bal-
anced at the position in the figure above.
q In this case, the pressure from port (B) flows to
port (C), so servo piston (9) moves to the right
(smaller pump delivery) and stops at a position
to the further to the right then when the load on
the pump is light.
q When the emergency pump drive switch is
turned on, too, the pump pressure (PP) and
pump delivery (Q) have a relationship as shown
with the curve in the figure corresponding to the
current sent to the PC-EPC valve solenoid
through the resistor.
10-501 24 PC200, 200LC-8E0 (Hybrid)

3. LS (PC)-EPC valve
C: To LS (PC) valve
P: From self-pressure reducing valve
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
PC200, 200LC-8E0 (Hybrid) 10-501 25

Function Operation
q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion. 1) When signal current is 0 (coil is de-energized)
q When it receives signal current (i) from the con- q When there is no signal current flowing from the
troller, it generates the EPC output pressure in controller to coil (2), coil (2) is de-energized.
proportion to the size of the signal, and outputs it q Spool (5) is pushed to the left by spring (4).
to the LS (PC) valve. q Port (P) closes and the pressurized oil from the
self-pressure reducing valve does not flow to the
LS (PC) valve.
q The pressurized oil from the LS (PC) valve is
drained to the tank through port (C) and port (T).
10-501 26 PC200, 200LC-8E0 (Hybrid)

2) When signal current is minute (coil is ener- 3) When signal current is maximum (coil is ener-
gized) gized)
q When a minute signal current flows to coil (2) , q As the signal current flows to coil (2), coil (2) is
coil (2) is energized, and a thrust toward the right energized.
is generated on plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the thrust of plunger (7) is also at
surized oil flows from port (P) to port (C). its maximum.
q Pressure on port (C) increases and the force to q Spool (5) is pushed toward right by rod (6).
act on spool (5) surface and the force of spring q The maximum volume of pressurized oil flows
(4) become larger than the thrust of plunger (7). from port (P) to port (C), increasing the circuit
q Spool (5) is pushed to the left, and port (P) is pressure across EPC valve and LS (PC) valve to
shut off from port (C). the maximum level.
q Port (C) and port (T) are connected. q Since port (T) is closed, the pressurized oil does
q Spool (5) moves so that the thrust of plunger (7) not flow to the tank.
may be balanced with pressure of port (C) + the
force of spring (4).
q The circuit pressure between the EPC valve and
the LS (PC) valve is controlled in proportion to
the size of the signal current.
PC200, 200LC-8E0 (Hybrid) 10-501 27

SEN05232-01
©2010 KOMATSU
All Rights Reserved
10-501 28
SEN05233-01
SEN05233-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


Control valve ............................................................................................................................................... 2

CLSS........................................................................................................................................................... 13
Functions and operation by valve ............................................................................................................... 18
PC200, 200LC-8E0 (Hybrid) 10-502 1

SEN05233-01 Control valve
Control valve
Outline
q This control valve consists of a 6-spool valve q Since all the valves are assembled together with
(unit type) , pump merge-divider valve, back connecting bolts and their passes are connected
pressure valve and boom hydraulic drift preven- to each other inside the assembly, the assembly
tion valve.(No service valve is set) is compact and easy to maintain.
q The ports which are used on PC200-8 but not q With one spool provided for one work equip-
used on PC200-8 (Hybrid) are indicated as "not ment, this control valve is simple in construction.
used."
A1: To bucket cylinder head P7: Not used

A2: To L.H. travel motor P8: Not used
A3: To boom cylinder bottom P9: From R.H. Travel PPC valve
A4: Not used P10: From R.H. Travel PPC valve
A5: To R.H. travel motor P11: From arm PPC and EPC valves
A6: To arm cylinder head P12: From arm PPC and EPC valves
A-1: Not used P-1: Not used
ATT: From attachment P-4: Not used
B1: To bucket cylinder bottom P-5: Not used
B2: To L.H. travel motor P-6: Not used
B3: To boom cylinder head PLS1: To rear pump control
B4: Not used PLS2: To front pump control
B5: To R.H. travel motor PLSC: LS pressure pickup port
B6: To arm cylinder bottom PP1: From front pump
B-1: Not used PP2: From rear pump
B-2: Not used PP2S: Pressure sensor mounting port
B-3: Not used PPC: Pilot source pressure pickup port
BP1: From LS select solenoid valve PPS1: Pressure sensor mounting port
BP5: Not used PPS2: To front pump control
C: To tank PR: To solenoid valve, PPC valve, and EPC valve
IS1: From controller PST: From travel junction valve solenoid valve
IS2: From controller PX1: From 2-stage relief solenoid valve
P1: From bucket PPC and EPC valves PX2: From 2-stage relief solenoid valve
P2: From bucket PPC and EPC valves T: To tank
P3: From L.H. Travel PPC valve T1: To tank
P4: From L.H. Travel PPC valve TS: To tank
P5: From boom PPC and EPC valves TSW: Not used
P6: From boom PPC and EPC valves
1. 6-spool valve
2. Cover A
3. Cover B
4. Not used
5. Not used
6. Not used
7. Merge-divider valve
8. Boom drift prevention valve
9. Not used
10. Arm quick return valve
10-502 2 PC200, 200LC-8E0 (Hybrid)

Control valve SEN05233-01
General view
PC200, 200LC-8E0 (Hybrid) 10-502 3

Sectional view
(1/5)
10-502 4 PC200, 200LC-8E0 (Hybrid)

1. Pressure compensation valve (Arm IN)

2. Pressure compensation valve (R.H. travel FORWARD)
3. Not used
4. Pressure compensation valve (Boom LOWER)
5. Pressure compensation valve (L.H. travel FORWARD)
6. Pressure compensation valve (Bucket CURL)
7. Not used
8. Not used
9. Not used
10. Pressure compensation valve (Bucket DUMP)
11. Pressure compensation valve (L.H. travel REVERSE)
12. Pressure compensation valve (Boom RAISE)
13. Not used
14. Pressure compensation valve (R.H. travel REVERSE)
15. Pressure compensation valve (Arm OUT)
16. Main relief valve
17. Not used
19. Not used
20. Not used
21. Not used
22. Spool (Bucket)
23. Spool (L.H. travel)
24. Spool (Boom)
25. Not used
26. Spool (R.H. travel)
27. Spool (Arm)
Unit: mm
Criteria Remedy
No. Item
Free length x
Installed Installation Installation
length load load
28 Spool return spring eter
407 N 326 N
55.2×34.4 51.2 —
{41.5 kg} {33.2 kg} If damaged or
393 N 315 N deformed, replace
29 Spool return spring 54.5×34.8 51.2
{40.1 kg}
—
{32.1 kg} spring
375 N 300 N
{38.2 kg}
—
{30.6 kg}
421 N 336 N
{42.9 kg}
—
{34.3 kg}
PC200, 200LC-8E0 (Hybrid) 10-502 5

(2/5)
10-502 6 PC200, 200LC-8E0 (Hybrid)

1. Suction valve (Arm IN)

2. Suction valve (R.H. travel FORWARD)
3. Suction valve (Boom LOWER)
4. Suction valve (L.H. travel FORWARD)
5. Safety-suction valve (Bucket CURL)
6. Not used
7. Not used
8. Not used
9. Not used
10. Suction - safety valve (Bucket DUMP)
11. Suction valve (L.H. travel REVERSE)
12. Suction - safety valve (Boom RAISE)
13. Suction - safety (R.H. travel REVERSE)
14. Suction - safety valve (Arm OUT)
15. LS shuttle valve (Arm)
16. LS shuttle valve (R.H. travel)
17.LS select valve
18. LS shuttle valve (Boom)
19.LS shuttle valve (L.H. travel)
20. LS shuttle valve (Bucket)
21. Not used
22. Not used
23. Not used
24. LS check valve
25. Pressure relief plug
Unit: mm
Criteria Remedy
No. Item
Free length x
length load load
26 Suction valve spring eter If damaged or
5.5 N 4.4 N deformed, replace
46.8×7.5 40.6 —
{0.56 kg} {0.45 kg} spring
1.5 N 1.2 N
27 Check valve spring 11.5×4.6 8.5
{0.15 kg}
—
{0.12 kg}
PC200, 200LC-8E0 (Hybrid) 10-502 7

(3/5)
10-502 8 PC200, 200LC-8E0 (Hybrid)

1. Unload valve
2. Safety valve (Boom RAISE)
4. Lift check valve
Arm valve
5. Arm check valve
6.LS shuttle valve
7. Quick return valve
8. Pressure compensation valve (OUT)
9. Spool
10. Suction - safety valve (OUT)
11. Back pressure valve
12. Regeneration circuit check valve
13. Suction valve (IN)
13A. Suction - safety valve (IN)
14. Pressure compensation valve (IN)
R.H. travel valve

15. LS shuttle valve
16. Pressure compensation valve (REVERSE)
17. Spool
18. Suction valve (REVERSE)
19. Suction valve (FORWARD)
20. Pressure compensation valve (FORWARD)
Unit: mm
Criteria Remedy
No. Item
Free length x
length load load
25 Check valve return spring eter
14.7 N 11.8 N
59.3×14.4 43 —
{1.5 kg} {1.2 kg}
13.7 N 11 N
26 Check valve spring 33.8×6 29
{1.4 kg}
—
{1.12 kg} If damaged or
170 N 135 N deformed, replace
27 Piston return spring 60.2×20 36
{17.3 kg}
—
{13.8 kg} spring
5.9 N 4.71 N
{0.6 kg}
—
{0.48 kg}
157 N 126 N
29 Piston return spring 88.2×28.4 65
{16 kg}
—
{12.8 kg}
36.1 N 28.8 N
30 Piston return spring 18.0×9.3 13.4
{3.68 kg}
—
{2.94 kg}
PC200, 200LC-8E0 (Hybrid) 10-502 9

(4/5)
10-502 10 PC200, 200LC-8E0 (Hybrid)

1. Return spring L.H. travel valve

2. Merge-divider valve (for LS) 15. Merge-divider valve (travel junction valve)
3. Valve (Sequence valve) 16. Return spring
4. Spring (Sequence valve) 17. LS shuttle valve
5. Merge-divider valve (Main) 18. Pressure compensation valve (REVERSE)
6. Return spring 19. Spool
20. Suction valve (REVERSE)
Boom valve 21. Suction valve (FORWARD)
7. Drift prevention valve 22. Pressure compensation valve (FORWARD)
8.LS shuttle valve
9. Pressure compensation valve (RAISE) Bucket valve
10. Spool 23. LS shuttle valve
11. Suction - safety valve (RAISE) 24. Pressure compensation valve (DUMP)
12. Regeneration circuit check valve 25. Spool
13. Suction valve (LOWER) 26. Suction - safety valve (DUMP)
14. Pressure compensation valve (LOWER) 27. Suction - safety valve (CURL)
28. Pressure compensation valve (CURL)
Unit: mm
Criteria Remedy
No. Item
Free length x
length load load
29 Spool return spring eter
121 N 96.5 N
36.4×21.8 33.0 —
{12.3 kg} {9.84 kg}
250 N 200 N
{25.5 kg}
—
{20.4 kg}
178 N 142 N If damaged or
{18.1 kg}
—
{14.5 kg} deformed, replace
35.3 N 28.2 N spring
{3.6 kg}
—
{2.88 kg}
13.7 N 11.0 N
{1.4 kg}
—
{1.12 kg}
5.9 N 4.71 N
34 Piston return spring 31.5×10.3 19.5
{0.6 kg}
—
{0.48 kg}
50.0 N 40.0 N
35 Piston return spring 30.7×20.5 23
{5.1 kg}
—
{4.08 kg}
PC200, 200LC-8E0 (Hybrid) 10-502 11

(5/5)
1. Unload valve
3. LS bypass plug
10-502 12 PC200, 200LC-8E0 (Hybrid)

CLSS SEN05233-01
CLSS
Outline of CLSS
Features Configuration
CLSS stands for "Closed center Load Sensing Sys- q CLSS is configured with variable capacity piston
tem", which has the following characteristics: pumps, control valves, and respective actuators.
q The hydraulic pump is configured with pump
q Fine control not influenced by load body, PC valve and LS valve.
q Controllability enabling digging even with fine
control
q Ease of compound operation ensured by flow di-
vider function using area of opening of spool dur-
ing compound operations
q Energy saving using variable pump control
PC200, 200LC-8E0 (Hybrid) 10-502 13

SEN05233-01 CLSS
Basic principle
1. Pump swash plate angle control

q The pump swash plate angle (pump delivery) is q The pump swash plate angle shifts toward the
controlled so that LS differential pressure (dPLS) maximum position if LS differential pressure
which is the difference between pump pressure (dPLS) is lower than the set pressure of the LS
(PP) and control valve outlet port LS pressure valve (when the actuator load pressure is high).
(PLS) (load pressure of actuator) is constant. q If it becomes higher than the set pressure (when
q [LS differential pressure (dPLS)= Pump dis- the actuator load pressure is low), the pump
charge pressure (PP) - LS pressure (PLS)] swash plate angle shifts toward the minimum po-
sition.
LS differential pressure (dPLS) and pump swash

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

“ paragraph.
10-502 14 PC200, 200LC-8E0 (Hybrid)

CLSS SEN05233-01
2. Pressure compensation control
q A pressure compensation valve is installed to

the outlet port side of the control valve to balance
the load.
q During the combined operations of actuators,
the pressure difference (dP) between the up-
stream (inlet port) and downstream (outlet port)
of the spool of each valve becomes the same re-
gardless the size of the load (pressure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of openings
(S1) and (S2) of each valve.
PC200, 200LC-8E0 (Hybrid) 10-502 15

SEN05233-01 CLSS
3. System diagram
a The illustration shows the actuator (6) in the

merge mode with stroke end at the relief.
1. Front pump 9. LS circuit

2. Rear pump 10. Tank circuit
3. Main relief valve 11. Valve
4. Unload valve 12. Spring
5. Merge-divider valve 13. LS bypass valve
6. Control valve 14. LS valve
7. Actuator 15. PC valve
8. Pump circuit
10-502 16 PC200, 200LC-8E0 (Hybrid)

CLSS SEN05233-01
PC200, 200LC-8E0 (Hybrid) 10-502 17

SEN05233-01 Functions and operation by valve
Functions and operation by valve

Hydraulic circuit diagram and the name of valves
10-502 18 PC200, 200LC-8E0 (Hybrid)

Functions and operation by valve SEN05233-01
1. Arm valve 28. Arm quick return valve

2. R.H. travel valve 29. Arm check valve (for central safety valve circuit)
3. Not used 30. Self-pressure reducing valve
4. Boom valve 31. Travel junction valve
5. L.H. travel valve 32. Back pressure valve
6. Bucket valve 33. Cooler check valve
7. Not used 34. Boom drift prevention valve
8. Not used 35. Main relief valve (bucket side)
9. Not used Set pressure: 34.9±0.5 MPa {355.5±5 kg/cm2}
10. Arm spool When digging force increased:
11. R.H. travel spool 37.5±0.5 MPa {382±5 kg/cm2}
12. Not used 36. Main relief valve (arm side)
13. Boom spool Set pressure: 34.9±0.5 MPa {355.5±5 kg/cm2}
14. L.H. travel spool When digging force increased:
15. Bucket spool 37.5±0.5 MPa {382±5 kg/cm2}
16. Not used 37. Unload valve (bucket side)
17. Not used Cracking pressure: 2.5±0.5 MPa {26±5 kg/cm2}
18. Not used 38. Unload valve (arm side)
19. Pressure compensation valve Cracking pressure: 2.5±0.5 MPa {26±5 kg/cm2}
20. Suction valve 39. Not used
21. Check valve(for boom regeneration circuit) 40. Suction-safety valve
22. Check valve(for arm regeneration circuit) Set pressure: 31.4±0.5 MPa {320±5 kg/cm2}
23. EPC valve(for switching main spool of merge-di 41. Suction-safety valve
vider valve) Set pressure: 38.2±0.5 MPa {390±5 kg/cm2}
24. EPC valve(for switching LS spool of merge-di 42. Not used
vider valve)
25. LS shuttle valve
26. LS select valve
27. Merge-divider valve
PC200, 200LC-8E0 (Hybrid) 10-502 19

Unload valve
1. When the unload valve is actuating
1. LS circuit 4. Tank circuit

2. Valve 5. Spring
3. Pump circuit
Function Operation
q Drains an oil discharge for the portion of the min- q Pressure of pump circuit (3) is received by the
imum pump swash plate angle while all control end of valve (2).
valves are in the holding position. q Since the control valve is in neutral position,
q The pump pressure will correspond to a set load pressure of LS circuit (1) is 0 MPa {0kg/cm2}.
of spring (5) inside the valve (this pressure will q Pressurized oil of pump circuit (3) stops at valve
be P1). (2), and the pressure rises as no relief is avail-
q Since LS pressure is drained from the LS bypass able.
valve, LS pressure C tank pressureC0 MPa{0 q When this pressure becomes larger than the
kg/cm2}. force of spring (5), valve (2) moves to the left.
q Ports (b) and (c) are interconnected and the
pump pressure flows to tank circuit (4).
q The pressurized oil of LS circuit (1) passes from
orifice (a) through port (c) and is drained to the
tank circuit (4).
q When actuated, LS pressure C tank pressure.
q Since the pump discharge pressure - LS circuit
pressure during unloading is larger than the
pump LS control pressure, the signal is output to
minimize the pump swash plate angle.
q During operation (a work within a scope of dis-
charge by a minimum swash plate angle), the
discharge pressure for the portion of minimum
pump swash plate angle is set to LS pressure +
P1 pressure.
10-502 20 PC200, 200LC-8E0 (Hybrid)

q LS control differential pressure (dPLS) of dis- 2. Operation of relief valve

charge for the portion of minimum swash plate q When the cylinder reaches the stroke end, the
angle will be equal to P1 pressure. main relief valve opens.
q The pump delivery (Q) is relieved to the tank.
(See the system diagram)
q The pump discharge pressure (PP) and LS pres-
sure (PLS) become approximately the same as
each has not flow at the upstream and down-
stream of the spool, and LS differential pres-
sure(dPLS) becomes 0 MPa {0 kg/cm2}.
q As LS differential pressure (dPLS) is lower than
the LS set pressure of LS valve, LS valve is ac-
tuated to maximize the pump swash plate angle.
q Mechanically, operation of PC valve has priority
over that of LS valve.
q The pump is held at a minimum swash plate an-
gle by the cut-off function of PC valve.
PC200, 200LC-8E0 (Hybrid) 10-502 21

Introduction of LS pressure
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function
q Introduces the upstream pressure (downstream
pressure of the spool meter-in) of pressure com-
pensation valve (3) and leads to LS shuttle valve
(7) as the LS pressure.
q Connected to actuator port (B) through valve (4),
and makes LS pressure C actuator load pres-
sure.
q Inlet port (a) inside main spool (2) has a small di-
ameter concurrently serving as a throttle.
Operation
q When main spool (2) is operated, the pump pres-
sure enters port (c) through inlet port (a) and is
led to the LS circuit.
q When the pump pressure rises to reach the load
pressure of port (B), check valve (5) opens.
10-502 22 PC200, 200LC-8E0 (Hybrid)

LS bypass valve
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass valve
6.LS circuit
Function
q Releases the residual pressure in LS pressure
circuit (6) from orifices (a) and (b).
q Slows down the rising rate of LS pressure to pre-
vent a sudden change of hydraulic pressure.
q Bypass flow from LS bypass valve (5) causes a
pressure loss to be generated due to the circuit
resistance between throttle (c) of main spool (2)
and LS shuttle valve (4).
q Effective LS differential pressure drops to im-
prove a dynamic stability of the actuator.
PC200, 200LC-8E0 (Hybrid) 10-502 23

Pressure compensation valve

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

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve
Function
q Pressure compensation valve works as the load q If high peak pressure is generated at port (C),
check valve. valve (7) does not collide with the valve cham-
q If the pump pressure (LS pressure) is lower than ber.
the load at port (c), shuttle valve (3) in pressure q With a bucket valve, etc., port (C) and spring
compensation valve piston (4) interconnects chamber (E) are designed to interconnect before
spring chamber (E) and port (C). valve (7) is in the closed position.
q The force of spring (5) operates piston (4) and
valve (2) to the closing direction.
Integrated pressure compensation valve

q High stress may occur when valve (2) collides
with valve chamber seat portion (C) if a high
peak pressure is generated in the actuator circuit
or repetitive peak pressure occurs continuously
(example: when using the breaker).
q To prevent this, a pressure compensation valve
with integrated valve (2) and piston (4) is used.
q With the present machine, this device is adopted
for the bucket valve (cylinder bottom) and the
service valve.
q As principle, port (C) and spring chamber (E) are
not interconnected in an integrated pressure
compensation valve.
10-502 24 PC200, 200LC-8E0 (Hybrid)

2. When compensated
(If the load pressure is lower than other work equipment during a combined operation)
Function
q The pressure compensation valve closes under
LS pressure of port (D), and the spool meter-in
downstream pressure of port (B) becomes
equivalent to the maximum pressure of other
work equipments.
q Since the spool meter-in upstream pressure of
port (A) is the pump pressure, the spool meter-in
differential pressure [upstream pressure port (A)
pressure] – downstream pressure [port (B) pres-
sure] becomes equivalent to all the spools in op-
eration.
q Pump flow is divided according to the ratio of the
meter-in opening area.
Operation
q Spring chamber (E) is interconnected to port (D).
q Piston (4) and valve (2) operate in the closing di-
rection (to the right) under the LS circuit pressure
from other work equipment of port (F).
q Valve upstream pressure (= spool meter-in
downstream pressure) of port (B) is controlled
with LS pressure.
PC200, 200LC-8E0 (Hybrid) 10-502 25

3. Pressure compensation valve area ratio
Function
q The dividing condition changes according to the
area ratio of pressure compensation portion (A1)
and (A2). Area ratio = (A2)/(A1)
q If area ratio = 1: The spool meter-in downstream
pressure will be equal to the maximum load
pressure, and the pressure will be divided ac-
cording to the opening area ratio.
q If area ratio = 1 or over: The spool meter-in
downstream pressure will be greater than the
maximum load pressure, and the pressure will
be divided smaller than the opening area ratio.
q If area ratio = 1 or under: The spool meter-in
downstream pressure will be smaller than the
maximum load pressure, and the pressure will
be divided greater than the opening area ratio.
10-502 26 PC200, 200LC-8E0 (Hybrid)

Pressure compensation valve inner shuttle valve

1. If holding pressure at port (A) is larger than LS pressure in the spring chamber (B)
1. Hydraulic pump
2. Valve
3. Pressure compensation valve inner shuttle valve
4. Piston
Function
q Shuttle valve (3) is pushed to the right by port (A)
pressure and cuts off interconnection between
ports (A) and (C).
q Holding pressure at port (A) is led to the spring
chamber (B) to push piston (4) to the left so that
piston (4) and valve (2) will not be separated.
PC200, 200LC-8E0 (Hybrid) 10-502 27

2. In the case of travel
Outline
q Since no holding pressure is generated at port
(A) of the travel circuit, a pressure compensation
valve without shuttle valve (3) is adopted.
10-502 28 PC200, 200LC-8E0 (Hybrid)

Boom regeneration circuit

1. If the cylinder head pressure is lower than the bottom pressure (free fall, etc.)
1. Hydraulic pump 5. Suction valve

2. Boom spool 6. Check valve
3. Pressure compensation valve 7. LS shuttle valve
4. Suction-safety valve
Function Operation
q Provides the regeneration circuit from the cylin- q If the cylinder head pressure is lower than the
der bottom to the cylinder head when the boom bottom pressure, pressurized oil (A) from the cyl-
is lowered and increases flow to the cylinder inder bottom flows to drain circuit (B) from the
head. notch of boom spool (2).
q On the other hand, remaining oil flows to regen-
eration circuit (C), opens check valve (6) and
flows to the cylinder head through circuit (D).
q Flow from regeneration circuit (C) and pump (1)
merges in circuit (E).
PC200, 200LC-8E0 (Hybrid) 10-502 29

2. If the cylinder head pressure is higher than the bottom pressure (digging work, etc.)
Function
q Check valve (6) provided to regeneration circuit
(C) closes to shut off the flow from the cylinder
bottom to the head.
10-502 30 PC200, 200LC-8E0 (Hybrid)

Arm regeneration circuit

1. If the cylinder head pressure is higher than the bottom pressure
1. Hydraulic pump 5. Suction valve

2. Arm spool 6. Check valve
3. Pressure compensation valve 7. LS shuttle valve
4. Suction-safety valve
Function Operation
q During arm IN, regeneration circuit provided q If the cylinder head pressure is higher than the
from the cylinder head to the bottom increases bottom pressure, pressurized oil (A) from the cyl-
the cylinder speed as the cylinder flow involves inder head flows to drain circuit (B) from the
the pump delivery plus regenerated flow. notch of arm spool (2).
q On the other hand, remaining oil flows to regen-
eration circuit (C), opens check valve (6) and
flows to the cylinder bottom through circuit (D).
q Flow from regeneration circuit (C) and pump (1)
merges in circuit (E).
PC200, 200LC-8E0 (Hybrid) 10-502 31

2. If the cylinder head pressure is lower than the bottom pressure
Function
q Check valve (6) provided to regeneration circuit
(C) closes to shut off the flow from the cylinder
head to the bottom.
10-502 32 PC200, 200LC-8E0 (Hybrid)

Merge-divider valve
1. When flows from the pumps merge [if merge-divider selector signals (IS1) and (IS2) are OFF]
1. Main spool 6. LS circuit (bucket side)

2. Spring 7. LS circuit (arm side)
3. LS spool 8. LS circuit (arm side)
4. Spring 9. EPC valve (for main spool)
5. LS circuit (bucket side) 10. EPC valve (for LS spool)
Function
q Merges pressurized oil (P1) and (P2) discharged q Since selector signal (IS2) is not applied for LS
from the two pumps or divides (to respective spool (3), it is pressed to the right by spring (4),
control valve group). and ports (A) – (D) and ports (B) – (C) are inter-
q Merges and divides LS circuit pressure. connected.
q Transmits LS pressure led from respective con-
Operation trol valve spools to LS circuits (5), (6), (7) and (8)
q Since selector signal (IS1) is not applied, output to all the pressure compensation valves.
pressure from EPC valve is 0 MPa{0 kg/cm2} .
q Main spool (1) is pressed to the right by spring
(2) and ports (E) and (F) are interconnected.
q Merges pressurized oil (P1) and (P2) discharged
from the two pumps at ports (E) and (F) and
sends to necessary control valve.
PC200, 200LC-8E0 (Hybrid) 10-502 33

2. When flows from the pumps divide [if merge-divider selector signals (IS1) and (IS2) are ON]
Operation
q Selector signal (IS1) turns ON, and output pres-
sure from the EPC valve shifts main spool (1) to
the left, and ports (E) and (F)are divided.
q Pressurized oil discharged from the two pumps
are sent to respective control valves.
P1 pressure: To bucket, L.H. travel, and boom
P2 pressure: To swing, R.H. travel, and arm
q When selector signal (IS2) is turned ON, LS
spool (3) too shifts to the left under the output
pressure from the EPC valve, interconnects
ports (A) and (C) and divides other ports.
q Transmits LS pressure led from each control
valve spool to LS circuits (5), (6), (7) and (8) to
respective control valves.
10-502 34 PC200, 200LC-8E0 (Hybrid)

LS select valve
The circuit is left but not used. (As the swing circuit is eliminated)
PC200, 200LC-8E0 (Hybrid) 10-502 35

Self-pressure reducing valve
Function
q Reduces the discharge pressure of the main
pump and supplies it as control pressure for the
solenoid valves, EPC valves, etc.
Operation
1. While engine is stopped
q Poppet (11) is pressed by spring (12) against the
seat and port (PR) is not connected to (TS).
q Valve (14) is pressed by spring (13) against the
left side and port (P2) is connected to (TS).
q Valve (7) is pressed by spring (8) against the left
side and port (P2) is closed to (A2).
10-502 36 PC200, 200LC-8E0 (Hybrid)

2. During neutral and when load pressure (P2) is 3. When load pressure (P2) is high
low q Load pressure (A2) increases with the operation
a When load pressure (A2) is lower than self-pres- of digging, etc., and the pump discharge increas-
sure reducing valve output pressure (PR) es accordingly.
q Valve (7) is pressed to the closing direction of q Pressure (P2) increases to [(fd area × P2 pres-
circuit between ports (P2) and (A2) by spring (8) sure) > force of spring (8) + (fd area × PR pres-
and under pressure (PR) (which is 0 MPa sure)], and valve (7) moves to the right to the
{0 kg/cm2}). stroke end.
q When pressurized oil flows in from port (P2), a q As a result, opening between ports (P2) and (A2)
balance is reached due to [(fd area × P2 pres- increases, and the pass resistance reduces, re-
sure)= force of spring(8) + (fd area × PR pres- ducing the engine horsepower loss.
sure)]. q When pressure (PR) rises above the set pres-
q Adjusts valve (7) opening to keep pressure (P2) sure, poppet (11) opens.
at a constant level over pressure (PR). q Pressurized oil flows from port (PR) to orifice (a)
q When pressure (PR) rises above the set pres- in spool (14), then flows to seal drain port (TS)
sure, poppet (11) opens. from poppet (11) opening.
q Pressurized oil flows from port (PR) to orifice (a) q Differential pressure is generated before and af-
in spool (14), then flows to seal drain port (TS) ter orifice (a) in spool (14) and then spool (14)
from poppet (11) opening. moves to close the pass between ports (P2) and
q Differential pressure is generated before and af- (PR).
ter orifice (a) in spool (14) and then spool (14) q Pressure (P2) is reduced by the opening at this
moves to close the pass between ports (P2) and time and adjusted to a constant pressure (the set
(PR). pressure) and supplied as pressure (PR).
q Pressure (P2) is reduced by the opening at this
time and adjusted to a constant pressure (the set
pressure) and supplied as pressure (PR).
PC200, 200LC-8E0 (Hybrid) 10-502 37

4. When abnormally high pressure is generated

q If pressure (PR) of self-pressure reducing valve
becomes abnormally high, ball (16) contracts
spring (15) and becomes separated from the
seat.
q Allows the pressurized oil to (TS) from port (PR)
and lowers pressure (PR).
q Protects PPC valve, solenoid valve and other
devices from abnormal pressure.
10-502 38 PC200, 200LC-8E0 (Hybrid)

Travel junction valve

1. When pilot pressure is applied
Function Operation
q This valve connects the L.H. and R.H. travel cir- q Pilot pressure (PST) from the travel junction so-
cuits through travel junction valve so that the hy- lenoid valve compresses spring (1), and travel
draulic oil will be supplied evenly to both travel junction spool (2) shifts to the left to the stroke
motors to ensure machine's straight travel per- end.
formance. q Junction circuit between port (PTL) (L.H. travel
q When the machine is steered, outside pilot pres- circuit) and port (PTR) (R.H. travel circuit) is
sure (PST) closes the travel junction valve to enclosed.
sure steering performance.
PC200, 200LC-8E0 (Hybrid) 10-502 39

2. When pilot pressure is not applied
Operation
q If pilot pressure (PST) from the solenoid valve is q If the oil flow rates to the L.H. and R.H. travel mo-
0 MPa {0 kg/cm2}, travel junction spool (2) is tors become different from each other, the oil
pressed by the force of spring (1) against the flows through the route between port (PTL), trav-
right side and the pass between ports (PTL) and el junction spool (2), and port (PTR) so that the
(PTR) is open. oil flow rates to both motors will be equalized
again.
10-502 40 PC200, 200LC-8E0 (Hybrid)

Travel PPC shuttle valve

1. When travel lever is in neutral
Function Operation
q Regulates flow to each cylinder by controlling q The oil in stroke regulation signal chamber (a) is
the stroke of each spool of the boom, arm, and drained through orifices (5) and (6) of pistons (3)
bucket using the pilot pressure of travel PPC and (4) in the travel spring case and the travel
valve while climbing a steep grade, and operat- PPC valve.
ing boom RAISE, arm IN or OUT, bucket CURL q When operated for boom RAISE (or arm IN or
or DUMP. OUT, bucket CURL or DUMP), spool (1) shift to
q When controlling the stroke of the boom, arm the left until it makes contact with the end face of
and/or bucket, pilot pressure of travel PPC valve spring casing (2)(st0).
passes through the circuit inside the control
valves to actuate the system.
PC200, 200LC-8E0 (Hybrid) 10-502 41

2. When traveling
Operation
q If the right travel lever is set in the reverse (or for-
ward) direction, pilot pressure from the PPC
valve presses spool (7) to the left (or right).
q Spool (7) pushes piston (3) to close orifice (5)
and shut off stroke regulation signal chamber (a)
and the drain circuit of the travel PPC valve.
q At this time, the right travel reverse (or forward)
lever is set, pilot pressure from the PPC valve is
applied through orifice (6) of piston (4) to the left
end of piston (8) to push piston (8) to the right.
q When operated for boom RAISE (or arm IN,
OUT, bucket CURL, DUMP), spool (1) shifts to
the left.
q Maximum stroke of the spool is limited to (st1) for
the amount of movement (st2) of piston (8) to the
right.
10-502 42 PC200, 200LC-8E0 (Hybrid)

Boom hydraulic drift prevention valve

1. At boom RAISE
Function
q This valve prevents the oil in the boom cylinder
bottom from leaking through spool (1) and the
boom from lowering under its weight while the
boom lever is not operated.
Operation
q When the boom RAISE is operated, pressurized
oil from the control valve works on the
ring-shaped area (S)[= Ø(d1) area – Ø(d2) area]
caused by the difference between outside diam-
eter (d1) of poppet (5) and seat diameter (d2) to
move it to the left.
q Contracts spring (4) and poppet (5) moves to the
left.
q As a result, pressurized oil from the control valve
passes through the opening of poppet (5) and
flows to the bottom end of the boom cylinder.
PC200, 200LC-8E0 (Hybrid) 10-502 43

2. At boom in NEUTRAL
Operation
q Moves the lever to neutral at the boom RAISE
position.
q Pressurized oil flown inside poppet (5) from ori-
fice (a) of poppet (5) is closed by pilot piston (2).
q The holding pressure of boom cylinder bottom
works on the ring-shaped area (S) caused by the
difference between outside diameter (d1) of pop-
pet (5) and seat diameter (d2) to move it to the
right.
q The sum of this force and the force of spring (4)
closes poppet (5).
q Pressurized oil from the control valve and the
holding pressure of the boom cylinder bottom
are shut off.
10-502 44 PC200, 200LC-8E0 (Hybrid)

3. At boom LOWER
Operation
q When the boom LOWER is operated, pilot pres-
sure from the PPC valve presses pilot piston (2).
q Pressurized oil in chamber (b) inside the poppet
is drained through orifice (c).
q Pressurized oil of the boom bottom flows to ori-
fice (a) o chamber (b) o orifice (c) o drain (T),
and the pressurized oil in chamber (b) lowers.
q As the pressure of chamber (b) lowers under the
pressure of port (B), poppet (5) opens.
q Pressurized oil from port (B) is led to port (A) and
then flows to the control valve.
PC200, 200LC-8E0 (Hybrid) 10-502 45

Quick return valve

1. At arm OUT
Function
q At arm OUT, large volume of oil returns from the q If the pressure of chamber (b) drops lower than
cylinder bottom. that of port (A), the pressure force of portion [fd2
q Reduces this pressure loss. area (S2) (seat diameter area)] on the port (A)
becomes greater than the combined force of the
Operation pressure force of portion [fd1 area (S1)] on the
q When arm OUT is operated, pilot piston (1) is chamber (b) of valve (2) and the spring force.
pushed by the pilot pressure from the PPC valve. q (fd2 pressure force > fd1 pressure force +
q Pressurized oil in chamber (b) inside the valve is spring force)
drained through orifice (c). q Valve (2) is pressed to the right and pressurized
q Pressurized oil of the arm bottom side flows to oil is led from port (A) to (B).
orifice (a) o chamber (b) o orifice (c) o drain (T), q From port (B), pressurized oil is drained directly
and the pressure in chamber (b) lowers. to the tank.
10-502 46 PC200, 200LC-8E0 (Hybrid)

2. At arm in neutral
Operation
q Returning the lever to neutral reduces the pilot
pressure from the PPC valve to 0 MPa {0
kg/cm2}.
q The pressurized oil that has flowed and been
drained through orifice (a) in valve (2) is closed
by pilot piston (1).
q The holding pressure on the arm bottom side
works on the difference between areas (S2) and
(S1) of valve (2) to the left.
q Valve (2) is closed by the total of this force and
the force of spring (3), so ports (A) and (B) are
shut off.
PC200, 200LC-8E0 (Hybrid) 10-502 47

Lift check valve
Function 2. While engine is running

q This valve applies back pressure to the drain cir- q Output pressure (PR) of the self pressure reduc-
cuit to prevent generation of negative pressure ing valve is applied through the control valve to
on each actuator (motors, cylinders, etc.). spring chamber (c) of lift check valve (3).
q Output pressure (c) led to spring chamber (C) is
Operation applied to the left end of valve (1) (area of fd) to
1. While engine is stopped push valve (1) to the right.
q Pressurized oil is not fed to the self pressure re- q At this time, pressure (PA) of drain circuit (a) of
ducing valve from the pump, and valve (1) is the control valve is applied to the right end of
pressed to the right by the force of spring (2). valve (1) (area of fd1) to push valve (1) to the left.
q Drain circuit (a) of the control valve is connected q Valve (1) strikes balance to make the back pres-
with port (T) through orifice (b) of valve (1) . sure equal to (PA) in the equation below.
(Area of fd) × PR + force of spring (2)

PA=
Area of fd1
10-502 48 PC200, 200LC-8E0 (Hybrid)

Main relief valve
1. Spring
2. Poppet
Function
q Set pressure of the relief valve is in two stages.
q When power is needed, pilot pressure (P) is ap-
plied and the set pressure becomes higher.
Operation
q The set pressure of relief valve is determined by
spring (1) installed load. (1st stage)
q Respective setting is not required for both the 1st
and 2nd stages. Setting the 1st stage completes
the setting of the 2nd stage.
1. If pilot pressure (P) is not applied: Low-pres-

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

setting
Spring (1) installed load is added with pilot pressure
(P) applied to the area of poppet diameter (d1), rais-
ing the set pressure to higher level.
PC200, 200LC-8E0 (Hybrid) 10-502 49

SEN05233-01
©2010 KOMATSU
All Rights Reserved
10-502 50
SEN05234-02
SEN05234-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


Center swivel joint....................................................................................................................................... 2

Travel motor................................................................................................................................................ 4
PPC valve ................................................................................................................................................... 15
Valve control ............................................................................................................................................... 30
Solenoid valve............................................................................................................................................. 32
Accumulator ................................................................................................................................................ 34
Hydraulic cylinder........................................................................................................................................ 36
PC200, 200LC-8E0 (Hybrid) 10-503 1

SEN05234-02 Center swivel joint
Center swivel joint
10-503 2 PC200, 200LC-8E0 (Hybrid)

Center swivel joint SEN05234-02
1. Cover
2. Slipper seal
3. Body
4. O-ring
5. Shaft
A1: From control valve port (A2)

A2: To L.H.travel motor REVERSE port (PB)
B1: From control valve port (B2)
B2: To L.H.travel motor FORWARD port (PA)
C1: From control valve port (A5)
C2: To R.H.travel motor REVERSE port (PA)
D1: From control valve port (B5)
D2: To R.H.travel motor FORWARD port (PB)
E: To L.H.and R.H. travel motors port (P)
T1: From L.H.and R.H. travel motors port (T)
T2: To tank
Unit: mm
No Item Criteria Remedy
Standard dimension Standard clearance Allowable clearance
6 Clearance between rotor and shaft Replace
80 - -
PC200, 200LC-8E0 (Hybrid) 10-503 3

SEN05234-02 Travel motor
Travel motor
Type: HMV110ADT-3
B : Brake release pressure port Specifications

MA: MA pressure pickup port Models PC200, 200LC-8, PC220-8,
MB: MB pressure pickup port Item PC210, 210LC-8 PC240LC-8
P : From travel speed solenoid valve Type HMV110ADT-3
PA: From control valve Theoretical dis- Min. 78.6 cm3/rev 74 cm3/rev
placement Max. 106.2 cm3/rev 110.7 cm3/rev
PB: From control valve Rated pressure 37.3 MPa {380 kg/cm2}
T : To tank Capacity
min.
2,805 rpm 3,046 rpm
Rated speed
Capacity
max.
1,842 rpm 1,588 rpm
Brake release pressure 1.18 MPa {12 kg/cm2}
Travel speed Differen-
selector pres- tial pres- 0.78 MPa {8 kg/cm2}
sure sure
10-503 4 PC200, 200LC-8E0 (Hybrid)

Travel motor SEN05234-02
PC200, 200LC-8E0 (Hybrid) 10-503 5

10-503 6 PC200, 200LC-8E0 (Hybrid)

1. Regulator piston
2. Spring
3. Regulator valve
4. Motor case
5. Suction-safety valve spring
6. Check valve
7. Output shaft
8. Rocker cam
9. Retainer guide
10. Pin
11. Retainer
12. Piston
13. Cylinder block
14. Valve plate
15. Counterbalance valve
16. Ring
17. Brake piston
18. Plate
19. Disc
20. Ball
Unit: mm
Criteria Remedy
No Item
Free length x
length load load
21 Check valve spring eter
7.16 N 5.69 N
32.5×6.5 24.2 -
{0.73 kg} {0.58 kg} If damaged or
1.96 N 1.57 N deformed, replace
{0.2 kg}
-
{0.16 kg} spring
427 N 341 N
23 Spool return spring 58.4×30 42
{43.5 kg}
-
{34.8 kg}
54.9 N 43.9 N
24 Regulator valve spring 21.5×11.1 17.1
{5.6 kg}
-
{4.48 kg}
PC200, 200LC-8E0 (Hybrid) 10-503 7

Operation of motor
1) At slow speed (motor swash plate angle at maximum)
q As the solenoid valve is de-energized, the pilot q The combined force of the piston propulsion
pressurized oil from the self-pressure reducing forces works as the moment to incline rocker
valve does not flow to port (P). cam (4) toward the maximum swash plate angle.
q Regulator valve (9) is pushed to the right by q The pressurized oil at regulator piston (15) pass-
spring (10). es through orifice (c) of regulator valve (9) and is
q Pressurized oil being transmitted from the con- drained in the motor case.
trol valve to end cover (8) by pressing check q Rocker cam (4) is inclined in the maximum
valve (22) is shut off by regulator valve (9). swash plate angle direction. The motor capacity
q Fulcrum (a) of rocker cam (4) is eccentric to the becomes maximum, turning on the low speed
working point (b) of the combined force of the travel.
propulsion force of cylinder (6)
10-503 8 PC200, 200LC-8E0 (Hybrid)

2) At high speed (motor swash plate angle at minimum)
q As the solenoid valve is energized, the pilot pres-

surized oil from the self pressure reducing valve
flows to port (P).
q Regulator valve (9) is pushed to the left.
q The pressurized oil from the control valve pass-
es through passage (d) in regulator valve (9) and
enters regulator piston (15).
q Regulator piston(15) is pushed to the right.
q Rocker cam (4) is inclined in the minimum swash
plate angle direction. The motor capacity be-
comes minimum, turning on the high speed trav-
el.
PC200, 200LC-8E0 (Hybrid) 10-503 9

Operation of parking brake

1) When machine starts to travel
q As the travel lever is operated, pressurized oil

from the pump acts on counterbalance valve
spool (19), to open the parking brake circuit.
q The pressurized oil is transmitted to chamber (e)
of brake piston (12) and compresses spring (11),
pushing piston (12) toward the left.
q Since the pushing force does not act on plate
(13) and disc (14), plate (13) is separated from
disc (14) and the parking brake is released.
10-503 10 PC200, 200LC-8E0 (Hybrid)

2) When machine stops
q As the travel lever is returned to the neutral po-

sition, counterbalance valve spool (19) returns to
the neutral position and closing the parking
brake circuit.
q The pressurized oil in chamber (e) of brake pis-
ton (12) passes through orifice (f) of brake piston
(12) and is drained in the motor case.
q Brake piston (12) is pushed to the right by spring
(11).
q Plate (13) and disc (14) are pushed together,
and the parking brake engages.
q As brake piston (12) returns, slow return valve
(22) restricts the return flow of pressurized oil.
q The restriction of the return flow of pressurized
oil delays the application of the parking brake.
The parking brake is applied after the machine
has stopped.
PC200, 200LC-8E0 (Hybrid) 10-503 11

Brake valve Operation when pressurized oil is supplied

q The brake valve consists of suction safety valve q When the travel lever is operated, the pressur-
(18A) and counterbalance valve (18). ized oil from the control valve flows to port (PA).
q Functions and operations of respective compo- q The pressurized oil opens suction safety valve
nents are as follows. (18A) and then flows to motor outlet port (MB)
through motor inlet port (MA).
1) Counterbalance valve and check valve q The motor outlet side is closed by suction safety
valve (18B) and spool (19), so the pressure at
Function the supply side rises.
q When the machine travels down a slope, its trav-
el speed tends to get faster than the motor (en-
gine) speed because of the downward force
generated from its own weight.
q If the machine travels with the engine at low
speed, the motor may run idle, and the machine
runs out of control ; it is in a very dangerous sit-
uation.
q These valves are used to prevent above by con-
trolling the machine to travel according to the en-
gine speed (pump delivery).
10-503 12 PC200, 200LC-8E0 (Hybrid)

q The pressurized oil on the supply side flows to Operation of brake during travelling downhill
chamber (S1) through orifice (E1) and orifice q If the machine runaway is sensed while its trav-
(E2) of the spool (19). els down a slop, the motor will be caused to run
q As the pressure in chamber (S1) goes above the idle and the inlet side oil pressure will be de-
spool selector pressure, spool (19) is pushed to- crease.
ward the right. q Pressure in chamber (S1) is released through or-
q Port (MB) and port (PB) are connected, opening ifices (E1) and (E2).
the motor outlet port side and starting the motor q As the pressure in chamber (S1) become lower
rotating. than the spool selector pressure, spool (19) is re-
turned to the left by spring (20) and outlet port
(MB) is throttled.
q The pressure at the outlet port side rises, gener-
ating rotation resistance on the motor to prevent
the machine from a runaway.
q The spool moves to a position where the pres-
sure on outlet port (MB) can be balanced against
the machine's own weight and the inlet port pres-
sure.
q Oil flow from the outlet circuit is restricted to en-
sure the travel speed corresponded to the pump
delivery.
PC200, 200LC-8E0 (Hybrid) 10-503 13

2) Safety valve q When the pressure rises above the set pressure
of the suction safety valve, poppet (1) opens.
Function q The pressurized oil passes through notch (A1) of
q As long as the machine travel is stopped (or it is spool (19) into chamber (MA) of the circuit at the
travels down a slope), the counterbalance valve opposite side.
closes the inlet and outlet circuits of the motor. q At the time of left turn, it makes reverse opera-
q Since the motor is rotated by inertial force, pres- tion for right turn.
sure in the motor outlet port side is abnormally
increased, potentially resulting in damages on
the motor and piping.
q The safety valve releases this abnormal pres-
sure to the inlet port side of the motor in order to
prevent damages to the equipment.
Operation
(1) During machine stops (or when travelling
downhill) (Right turn)
q Reduction of the pressure at motor inlet (PA) de-
creases the pressure in chamber (S1).
q When it drops beyond the spool selector pres-
sure, spool (19) is returned to the left by spring
(2) When starting travel (or when traveling at a
(20), reducing the pressure at outlet passage
constant speed)
(B1).
q As the travel lever is operated, the pressurized
q The motor tries to continue rotation with to iner-
oil from the pump moves spool (19) toward the
tial force, thus pressure on the outlet port (MB) is
right.
increased.
q The passage to the suction safety valve func-
tions as a circuit which passes through notch
(B2) of spool (19), producing large differential
pressure.
q The pump pressure rises, providing a large trac-
tional force to the valve.
10-503 14 PC200, 200LC-8E0 (Hybrid)

PPC valve SEN05234-02
PPC valve
Work equipment and swing PPC valve
P: From self-pressure reducing valve

P1: L.H. PPC valve: Arm OUT port/R.H. PPC valve: Boom LOWER port
P2: L.H. PPC valve: Arm IN port/R.H. PPC valve: Boom RAISE port
P3: L.H. PPC valve: Swing LEFT port/R.H. PPC valve: Bucket CURL port
P4: L.H. PPC valve: Swing RIGHT port/R.H. PPC valve: Bucket DUMP port
T: To tank
PC200, 200LC-8E0 (Hybrid) 10-503 15

SEN05234-02 PPC valve
10-503 16 PC200, 200LC-8E0 (Hybrid)

1. Spool 6. Plate
2. Piston 7. Retainer
3. Disc 8. Body
4. Nut (for lever connection) 9. Filter
5. Joint
Unit: mm
Free length x
Centering spring Outside diam- Free length
10 (for ports P3and P4) eter
length load load
If damaged or
17.7 N 14.1 N
42.5×15.5 34.0 - deformed, replace
{1.80 kg} {1.44 kg}
spring
Centering spring 29.4 N 23.5 N
11 (for ports P1and P2) 44.5×15.5 34.0
{3.0 kg}
-
{2.40 kg}
16.7 N 13.3 N
12 Metering spring 26.5×8.15 24.9
{1.70 kg}
-
{1.36 kg}
PC200, 200LC-8E0 (Hybrid) 10-503 17

Operation
When in neutral q The relationship of the position of spool (1) and
q Ports (A) and (B) of the control valve and ports body (10) [fine control hole (f) is in the middle be-
(P1) and (P2) of the PPC valve are connected to tween drain chamber (D and pump pressure
drain chamber (D) through fine control hole (f) in chamber (PP)] does not change until retainer (9)
spool (1). contacts spool (1).
q Metering spring (2) compresses in proportion to
the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force of
the return spring of the control valve spool are
balanced.
2. During fine control

(Neutral o fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, and metering spring (2) moves
spool (1) downward.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil from the self-pressure re-
ducing valve is led to port (A) from port (P1
through fine control hole (f). Note: The description of the control valve spool is
q When the pressure at port (P1) becomes higher, not applied to the control for the swing electric mo-
spool (1) is pushed back and fine control hole (f) tor.
is shut off from pump pressure chamber (PP). At
almost the same time, it is connected to drain
chamber (D) to release the pressure at port (P1).
q As a result, spool (1) moves upward and down-
ward until the force of metering spool (2) is bal-
anced with the pressure at port (P1).
10-503 18 PC200, 200LC-8E0 (Hybrid)

3. During fine control 4. At full stroke

(When control lever is returned) q Disc (5) pushes down piston (4), and retainer (9)
q When disc (5) starts to be returned, spool (1) is moves spool (1) downward.
pushed up by the force of centering spring (3) q Fine control hole (f) is shut off from drain cham-
and the pressure at port (P1). ber (D), and is interconnected to pump pressure
q Because of this, fine control hole (f) is connected chamber (PP).
to drain chamber (D), and the pressurized oil at q Therefore, the pilot pressure oil from the self
port (P1) is released. pressure reducing valve passes through fine
q If the pressure of port (P1) is lowered excessive- control hole (f) and flows to chamber (A) from
ly, spool (1) is pushed down by metering spring port (P1) to push the control valve spool.
(2). q The oil returning from chamber (B) passes from
q Fine control hole (f) is shut off from drain cham- port (P2) through fine control hole (f') and flows
ber (D), and it is almost simultaneously intercon- to drain chamber (D).
nected to pump pressure chamber (PP).
q Pump pressure is supplied until the pressure at-
port (P1) recovers to the level equivalent to the
control lever position.
q When the spool of the control valve returns, the
oil in drain chamber (D) flows in from fine control
hole (f') in the valve on the side that is not work-
ing. The oil passes through port (P2) and enters
chamber (B) to replenish the chamber with pres-
surized oil.
Note: The description of the control valve spool is

not applied to the control for the swing electric mo-
tor.
PC200, 200LC-8E0 (Hybrid) 10-503 19

10-503 20 PC200, 200LC-8E0 (Hybrid)

Travel PPC valve
P : From self-pressure reducing valve

P1: L.H. travel REVERSE port
P2: L.H. travel FORWARD port
P3: R.H. travel REVERSE port
P4: R.H. travel FORWARD port
P5: Travel signal port
P6: Steering signal port
T : To tank
PC200, 200LC-8E0 (Hybrid) 10-503 21

10-503 22 PC200, 200LC-8E0 (Hybrid)

1. Plate
2. Body
3. Piston
4. Collar
5. Valve
6. Damper
7. Steering signal spool
Unit: mm
Free length x
8 Centering spring length load load
eter
If damaged or
108 N 86.3 N
48.6×15.5 32.5 - deformed, replace
{11.0 kg} {8.8 kg}
spring
16.7 N 13.3 N
9 Metering spring 26.5×8.15 24.9 -
{1.7 kg} {1.36 kg}
8.83 N 7.06 N
10 Steering signal spring 12.8×7.3 8.5 -
{0.9 kg} {0.72 kg}
PC200, 200LC-8E0 (Hybrid) 10-503 23

1. Pressure reducing valve function

Operation q The relationship of the position of spool (1) and
1) When in neutral body (10) [the position of fine control hole (f) is in
q Ports (A) and (B) of the control valve and ports the middle between drain chamber (D) and
(P1) and (P2) of the PPC valve are connected to pump pressure chamber (PP)] does not change
drain chamber (D) through fine control hole (f) in until retainer (9) contacts spool (1).
spool (1). q Metering spring (2) compresses in proportion to
q Pressure at port (P1) also rises in proportion to
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force of
the return spring of the control valve spool are
balanced.
2) During fine control

(Neutal o fine control)
q When piston (4) is pushed by lever (5), retainer
(9) is pushed, metering spring (2) moves spool
(1) downword.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil from the pressure reducing
vale is led to port (A) from port (P1) through fine
control hole (f).
q When the pressure at port (P1) becomes higher,
spool (1) is pushed back and fine control hole (f)
is shut off from pump pressure chamber (PP). At
almost the same time, it is connected to drain
chamber (D) to release the pressure at port (P1).
q As a result, spool (1) moves upword and down-
word until the force of metering spool (2) is bal-
anced with the pressure at port (P1).
10-503 24 PC200, 200LC-8E0 (Hybrid)

3) During fine control q Therefore, the pilot pressure oil from the self
(When control lever is returned) pressure reducing valve passes through fine
q When lever (5) starts to be returned, spool (1) is control hole (f) and flows to chamber (A) from
pushed up by the force of centering spring (3) port (P1) to push the control valve spool.
and pressure at port (P1). q The oil returning from chamber (B) passes from
q Because of this, fine control hole (f) is connected port (P2) through fine control hole (f') and flows
to drain chamber (D), and the pressurized oil at to drain chamber (D).
port (P1) is released.
q If the pressure of port (P1) is lowered excessive-
ly, spool (1) is pushed down by metering spring
(2).
q Fine control hole (f) is shut off from drain cham-
ber (D), and it is almost simultaneously intercon-
nected to pump pressure chamber (PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
control lever position.
q When the spool of the control valve returns, the
oil in drain chamber (D) flows in from fine control
hole (f') in the valve on the side that is not work-
ing. The oil passes through port (P2) and enters
chamber (B) to replenish the chamber with pres-
surized oil.
2. Travel signal/Steering function
Travel signal
q If either of the L.H. or R.H. travel levers is oper-
ated, the higher PPC output pressure of both
sides is output as the travel signal.
q Accordingly, whether the machine is traveling is
judged by the signal of port (P5).
Steering signal
q If the operation quantities of both levers are dif-
ferent from each other as in the steering opera-
tion, the higher one of the PPC output pressures
of both sides is output as the steering signal.
q Any signal is not out put from port (P6) while the
4) At full stroke machine is travelling straight (forward or re-
q Lever (5) pushes down piston (4), and retainer verse) or in the neutral position.
(9) moves spool (1) downward. q Accordingly, whether the machine is being
q Fine control hole (f) is shut off from drain cham- steered is judged by the signal of port (P6).
ber (D), and is interconnected to pump pressure
chamber (PP).
PC200, 200LC-8E0 (Hybrid) 10-503 25

Operation
1) At the neutral position
q Any signal is not output from respective output

ports [from port (P1) to (P4)], travel signal [port
(P5)] and steering signal [port (P6)].
10-503 26 PC200, 200LC-8E0 (Hybrid)

2) During straight travel
a The Illustration shows the circuit for travelling straight forward.

q When operating L.H. motor forward [port (P2)
output] and R.H. motor forward [port (P4) out-
put], pressure of both L.H. spring chamber (k)
and R.H. spring chamber (l) rises high.
q Steering signal spool (j) remains at neutral posi-
tion and does not output a steering signal to port
(P6).
PC200, 200LC-8E0 (Hybrid) 10-503 27

3) At turn or pivot turn
a The Illustration shows the circuit for travelling left forward (slow) and right forward (fast) operation.
q If the operation quantities of both levers are dif- q Port (P4) pressure of the L.H. or R.H. PPC
ferent from each other as in the steering opera- valves, whichever having a higher output pres-
tion (if the difference of the pilot pressure sure, is output to port (P6) as the steering signal.
between both sides is higher than a certain lev-
el), the pilot pressure is output as the steering
signal.
q The pressure in left spring chamber (k) of steer-
ing signal spool (j) is (P2).
q The pressure in right spring chamber (l) is (P4).
q When the pressure reaches [(P4 - P2) x (Spool
cross-sectional area) > Spring set load], the
spool shifts to the direction of the arrow.
10-503 28 PC200, 200LC-8E0 (Hybrid)

4) At counter rotate turn
a The illustration shows the circuit for travelling left reverse and right forward.
q When operating L.H. motor reverse [port (P1)

output] and R.H. motor forward [port (P4) out-
put], pressure of the R.H. spring chamber (l) only
rises high.
q Steering signal spool (j) shifts to the left to output
the steering signal to port (P6).
PC200, 200LC-8E0 (Hybrid) 10-503 29

SEN05234-02 Valve control
Valve control
10-503 30 PC200, 200LC-8E0 (Hybrid)

Valve control SEN05234-02
1. Travel PPC valve

2. L.H. travel lever
3. R.H. travel lever
4. R.H. PPC valve
5. R.H. work equipment control lever
6. Solenoid block
7. Accumulator
8. Control valve
9. Hydraulic pump
10. Junction box (equipped with pressure sensor
and pressure switch)
11. L.H. work equipment control lever
12. Left PPC valve
Lever positions
A. Hold
B. Boom “RAISE”
C. Boom “LOWER”
D. Bucket “DUMP”
E. Bucket “CURL”
F. Hold
G. Arm “IN”
H. Arm “OUT”
J. Swing “RIGHT”
K. Swing “LEFT”
L. Neutral
M. Travel “REVERSE”
N. Travel “FORWARD”
PC200, 200LC-8E0 (Hybrid) 10-503 31

SEN05234-02 Solenoid valve
Solenoid valve
For PPC lock, travel junction, travel speed, swing brake, and 2-stage relief solenoid valves
10-503 32 PC200, 200LC-8E0 (Hybrid)

Solenoid valve SEN05234-02
1. PPC lock solenoid valve When solenoid is energized

2. 2-stage relief solenoid valve q As the signal current flows from the controller to
3. Swing brake solenoid valve solenoid (9), solenoid (9) is energized.
4. Travel speed solenoid valve Accordingly, spool (10) is pushed to the right.
5. Travel junction solenoid valve This operation allows the flow of the pressurized
6. Connector oil from the main pump, through port (P), via
7. Moving core inside spool (10), to port (A), and eventually to
8. Coil the actuator.
9. Spool At the same time, port (T) closes, the oil does not
10. Block flow to the tank.
11. Spring
T: To tank
A1: To PPC valve
A2: To main valve (2-stage relief valve)
A3: To swing motor
A4: To L.H. and R.H. travel motors
A5: To main valve (Travel junction valve)
P1: From main pump
ACC: To accumulator
Operation
When solenoid is de-energized
q Since the signal current does not flow from the
controller, solenoid (9) is de-energized.
For this reason, spool (10) is pushed to the left
by spring (12).
Since the pass from port (P) to port (A) is closed,
pressurized oil from the main pump does not
flow to the actuator.
At this time, the oil from the actuator is drained
through ports (A) and (T) into the tank.
PC200, 200LC-8E0 (Hybrid) 10-503 33

SEN05234-02 Accumulator
Accumulator
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6.Oil port
Specifications
Gas capacity: 300 cc (for PPC)
10-503 34 PC200, 200LC-8E0 (Hybrid)

Hydraulic cylinder SEN05234-02
Hydraulic cylinder
Boom cylinder
Arm cylinder
Bucket cylinder
PC200, 200LC-8E0 (Hybrid) 10-503 35

SEN05234-02 Hydraulic cylinder
Unit: mm
No Check item Criteria Remedy
Cylinder
dimensions Shaft Hole clearance clearance
Boom -0.036 +0.222 0.083 –
85 0.412
Clearance between pis- (PC200-8) -0.090 +0.047 0.312
1 Replace bushing
ton rod and bushing -0.036 +0.222 0.083 –
Arm 95 0.412
-0.090 +0.047 0.312
-0.030 +0.222 0.077 –
Bucket 80 0.398
-0.076 +0.047 0.298
-0.030 +0.190 0.100 –
Boom 80 1.0
-0.060 +0.070 0.250
Clearance between pis-
-0.030 +0.190 0.100 –
2 ton rod support shaft Arm 80 1.0
-0.076 +0.070 0.266
and bushing
-0.030 +0.170 0.100 –
Bucket 70 1.0
-0.076 +0.070 0.246 Replace pin or
-0.030 +0.165 0.075 – bushing
Boom 70 1.0
-0.060 +0.045 0.225
Clearance between cyl-
-0.030 +0.190 0.100 –
3 inder bottom support Arm 80 1.0
-0.076 +0.070 0.266
shaft and bushing
-0.030 +0.165 0.075 –
Bucket 70 1.0
-0.060 +0.045 0.225
10-503 36 PC200, 200LC-8E0 (Hybrid)

Hydraulic cylinder SEN05234-02
PC200, 200LC-8E0 (Hybrid) 10-503 37

SEN05234-02
©2011 KOMATSU
All Rights Reserved
10-503 38
SEN05235-00
SEN05235-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


600 Work equipment
Dimensions of components......................................................................................................................... 2
PC200, 200LC-8E0 (Hybrid) 10-600 1

600 Work equipment
SEN05235-00 Dimensions of components
Dimensions of components
10-600 2 PC200, 200LC-8E0 (Hybrid)

600 Work equipment
Dimensions of components SEN05235-00
Unit: mm
No Item Criteria Remedy
Clearance between pin connecting
dimensions Shaft Hole clearance clearance
1 "boom and revolving frame" and
-0.036 +0.135
bushing 90 0.110 – 0.206 1.0
-0.071 +0.074
Clearance between pin connecting -0.036 +0.137
2 90 0.113 – 0.208 1.0
"boom and arm" and bushing -0.071 +0.077
3 70 0.108 – 0.234 1.0 Replace
"arm and link" and bushing -0.076 +0.078
4 80 0.104 – 0.213 1.0
"arm and bucket" and bushing -0.076 +0.074
5 80 0.116 – 0.242 1.0
"link and bucket" and bushing -0.076 +0.086
6 70 0.104 – 0.230 1.0
links and bushing -0.076 +0.074
PC200, 200LC-8E0 (Hybrid) 10-600 3

600 Work equipment
1. Dimension of arm
10-600 4 PC200, 200LC-8E0 (Hybrid)

600 Work equipment
Unit: mm
PC200-8E0, PC200LC-8E0
No.
Standard dimensions Tolerance
+0.1
1 f80
0
+1.5
2 109.3
0
0
3 305.5
-0.5
+0.054
4 f90
0
5 402.1 ±1
6 187.2 ±0.5
7 829.1 ±1
8 2,919 —
9 2,630.5 ±1
10 410 ±1
11 640 ±0.2
12 600 ±0.5
13 458.1 —
14 1,486 —
+0.1
15 f80
0
16 325 ±0.5
+0.1
17 f80
0
0
Arm boss (without bushing) 311
-0.5
18
When press-fitting bushing
325 —
(with bushing)
Min. 1,680 —
19
Max. 2,800 —
PC200, 200LC-8E0 (Hybrid) 10-600 5

600 Work equipment
2. Dimension of bucket
10-600 6 PC200, 200LC-8E0 (Hybrid)

600 Work equipment
Unit: mm
PC200-8E0, PC200LC-8E0
No.
Standard dimensions Tolerance
1 457.6 ±0.5
2 22 ±0.5
3 92°45' —
4 458.1 —
5 1,477.3 —
6 158.6 —
7 — —
8 15°54' —
+0.1
9 f80
0
10 326.5 ±1
11 56 —
12 106 —
13 470 —
14 f23.5 —
15 f140 —
16 f190 —
17 133.2 —
18 131.6 —
19 107 —
20 85 —
+2
21 348.5
0
22 38 —
PC200, 200LC-8E0 (Hybrid) 10-600 7

SEN05235-00
©2009 KOMATSU
All Rights Reserved
10-600 8
SEN05236-00
SEN05236-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


700 Cab and its attachments
Air conditioner piping .................................................................................................................................. 2
PC200, 200LC-8E0 (Hybrid) 10-700 1

SEN05236-00 Air conditioner piping
Air conditioner piping
1. Air conditioner unit A : Fresh air

2. Hot water supply piping B : Recirculated air
3. Air conditioner compressor C : Hot air/cold air
4. Refrigerant piping
5. Condenser
6. Hot water return piping
7. Duct
10-700 2 PC200, 200LC-8E0 (Hybrid)

Air conditioner piping SEN05236-00
PC200, 200LC-8E0 (Hybrid) 10-700 3

SEN05236-00
©2009 KOMATSU
All Rights Reserved
10-700 4
SEN05237-01
SEN05237-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


800 Electrical system
Engine control ............................................................................................................................................. 2

Electrical control system ............................................................................................................................. 10
Monitor system............................................................................................................................................ 35
Sensors....................................................................................................................................................... 60
KOMTRAX system...................................................................................................................................... 63
PC200, 200LC-8E0 (Hybrid) 10-800 1

SEN05237-01 Engine control
Engine control
Operation of system
Starting engine
q When the starting switch is turned to the START
position, the starting signal flows to the starting
motor. Then, the starting motor turns to start the
engine.
At this time, the engine controller receives the

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

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

the supply pump depending on the signal
voltage to control the fuel injection pump, and
eventually controls the engine speed.
Stopping engine
q When detecting that the starting switch is set to
the “STOP” position, the engine controller stops
the signal of the supply pump drive solenoid to
stop the engine.
10-800 2 PC200, 200LC-8E0 (Hybrid)

Engine control SEN05237-01
Component
Fuel control dial
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
PC200, 200LC-8E0 (Hybrid) 10-800 3

Function
q The fuel control dial is installed on the machine
monitor side.
q Turning knob (1) rotates the shaft of potentiome-
ter(5).
q The rotation of the shaft changes the resistance
of the variable resistor in potentiometer (5),
sending any throttle signal to the engine control-
ler.
q The hatched area in the graph is the abnormality
detection area. When the throttle voltage is with-
in this area, the engine is running at low idle.
10-800 4 PC200, 200LC-8E0 (Hybrid)

Engine controller
Input and output signals

q Meanings of signal category in the terminal table CN-CE01
are as follows. Signal
Pin No. Signal name
category
A: Power supply
11 NC (*) —
B: Input 12 NC (*) —
C: Ground/Shield/Return 13 NC (*) —
D: Output 14 WIF sensor B
15 Coolant temperature sensor B
E: Communication 16 5 V electric power supply for sensor A
CN-CE01 17 Oil pressure switch B
Signal 18 NC (*) —
Pin No. Signal name
category 19 NC (*) —
1 NC (*) — 20 NC (*) —
2 Electric power supply for IMA D 21 NC (*) —
3 Ambient pressure sensor B 22 NC (*) —
4 NC (*) — 23 Boost temperature sensor B
5 NC (*) — 24 NC (*) —
6 CAN (-) E 25 Common rail pressure sensor B
7 NC (*) — 26 Buckup sensor B
8 CAN(+) E 27 NE sensor (+) B
9 NC (*) —
10 NC (*) — *: Never connect to NC or malfunctions or failures
will occur.
*: Never connect to NC or malfunctions or failures
will occur.
PC200, 200LC-8E0 (Hybrid) 10-800 5

CN-CE01 CN-CE02
Signal Signal
Pin No. Signal name Pin No. Signal name
category category
28 NC (*) — 13 NC (*) B
29 NC (*) — 14 NC (*) B
30 NC (*) — 15 NC (*) B
31 NC (*) D 16 NC (*) B
32 IMA return C 17 NC (*) B
33 5 V electric power supply for sensor A 18 NC (*) B
34 NC (*) — 19 NC (*) B
35 NC (*) A 20 NC (*) E
36 NC (*) — 21 NC (*) A
37 5 V electric power supply for sensor A 22 Fuel control dial (+5 V) A
38 (GND) C 23 Fuel control dial (–) C
39 NC (*) — 24 NC (*) B
40 NC (*) — 25 NC (*) B
41 NC (*) — 26 NC (*) B
42 NC (*) C 27 NC (*) B
43 NC (*) — 28 NC (*) B
44 Boost pressure sensor B 29 NC (*) C
45 Injector #1 (+) D 30 NC (*) B
46 Injector #5 (+) D 31 NC (*) B
47 Sensor GND C 32 NC (*) C
48 Ne sensor (–) C 33 (GND) C
49 NC (*) — 34 NC (*) C
50 NC (*) — 35 NC (*) B
51 Injector #2 (–) C 36 NC (*) B
52 Injector #3 (–) C 37 NC (*) C
53 Injector #1 (–) C 38 NC (*) D
54 Injector #2 (+) D 39 Key switch (ACC) B
55 Injector #3 (+) D 40 Electrical intake air heater relay drive D
56 Injector #4 (+) D 41 NC (*) D
57 Injector #6 (+) D 42 Electrical intake air heater relay return C
58 Injector #4 (–) C 43 NC (*) D
59 Injector #6 (–) C 44 NC (*) D
60 Injector #5 (–) C 45 NC (*) —
46 CAN(+) E
*: Never connect to NC or malfunctions or failures 47 CAN (-) E
will occur. 48 NC (*) D
49 PWMOUTPUT D
50 NC (*) D
CN-CE02
Signal *: Never connect to NC or malfunctions or failures
Pin No. Signal name
category will occur.
1 NC (*) B
2 NC (*) B
3 NC (*) B CN-CE02
4 NC (*) B Signal
Pin No. Signal name
5 NC (*) B category
6 NC (*) B 1 (GND) C
7 NC (*) B 2 NC (*) C
8 NC (*) B 3 Electric power supply (+24 V constantly) A
9 Fuel control dial (+) B 4 NC (*) A
10 NC (*) E
11 NC (*) B *: Never connect to NC or malfunctions or failures
12 NC (*) B will occur.
will occur.
10-800 6 PC200, 200LC-8E0 (Hybrid)

Coolant temperature sensor
1. Connector
2. Sensor
3. O-ring
Oil pressure switch
1. Connector
2. Sensor
3. O-ring
PC200, 200LC-8E0 (Hybrid) 10-800 7

Speed sensor
1. Connector
2. Sensor
3. O-ring
Boost pressure and temperature sensor
1. Connector
2. Sensor
3. O-ring
10-800 8 PC200, 200LC-8E0 (Hybrid)

WIF (water-in-fuel) sensor
1. Connector
2. Tube
3. Sensor
4. O-ring
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
PC200, 200LC-8E0 (Hybrid) 10-800 9

SEN05237-01 Electrical control system
Electrical control system
Machine control system diagram
10-800 10 PC200, 200LC-8E0 (Hybrid)

Electrical control system SEN05237-01
PC200, 200LC-8E0 (Hybrid) 10-800 11

1. Engine and pump combined control function
10-800 12 PC200, 200LC-8E0 (Hybrid)

Function
q This function allows the machine to select engine torque (T) and pump absorption torque according to the
work contents. The 2 working modes of P and E are set.
q Select either working mode with the working mode switch of the machine monitor. The inverter controls
the engine speed and pump absorption torque according to the lever operation quantity and operation pat-
tern.
q The inverter controls the pump so that the pump will absorb all the torque at each engine output point ac-
cording to the pump absorption torque set for each mode, speed set with the fuel control dial and actual
engine speed.
1) Control method in each mode
P mode, E mode
q Matching point:
Working mode Max. matching point
109 kW/1800 rpm

p
(148 PS/1800 rpm)
79 kW/1860 rpm
E
(108 PS/1860 rpm)
q In the P and E modes, the engine speed is kept

near the matching point in each mode indicated
by the inverter.
q If the pump load increases and the pressure in-
creases consequently, the engine speed (N) de-
creases. At this time, the pump controller
decreases pump delivery (Q) to increase the en-
gine speed to near the matching point. If the load
decreases reversely and the pressure decreas-
es consequently, the pump controller increases
the pump delivery until the engine speed reach-
es near the matching point.
q The inverter calculates the command value from
the lever operation quantity, operation pattern,
load, pump absorption torque set for each mode,
speed set with the fuel control dial and actual en-
gine speed. The maximum command value is at
the maximum matching point.
q Since the matching point calculated by the in-
verter varies with the load, less fuel is consumed
than in the control where the maximum matching
point is commanded constantly.
PC200, 200LC-8E0 (Hybrid) 10-800 13

2) Pump control function during travel

q During travel in Lo, the inverter gives a command of the matching point in accordance with the load to the
pump controller as in the control method in each mode described above.
q During travel in Mid or Hi, the engine speed (N) increases to the fuel control dial setting, regardless of the
load.
q The engine speed and pump absorption torque in the P mode are different from those in the E mode.
10-800 14 PC200, 200LC-8E0 (Hybrid)

3) Control function when emergency pump drive

switch is turned ON
q Even if the controller or a sensor has a trouble,
the operator can operate the machine with ab-
sorption torque almost equivalent to in the E
mode by turning emergency pump drive switch
(1) ON.
In this case, since a constant current flows from
the battery to the EPC valve for the PC, oil pres-
sure is sensed by only the sensor of the EPC
valve for the PC.
The engine speed is kept at a constant value set
with the fuel control dial, regardless of the load
and lever operation.
PC200, 200LC-8E0 (Hybrid) 10-800 15

2. Pump and valve control function
Function
q The machine is matched to various types of work
properly with the 2-stage relief function to in-
crease the digging force, etc.
10-800 16 PC200, 200LC-8E0 (Hybrid)

1) LScontrol function 3) 2-stage relief function

q Depending on the operation condition of the ac- q The relief pressure in the normal work is 34.8
tuator, this function changes the pressure output MPa {355 kg/cm2} If the 2-stage relief function is
from the LS-EPC valve to LS valve to change the turned on, however, the relief pressure rises to
change point (LS set differential pressure (DLS))
about 37.2 MPa {380 kg/cm2} By this operation,
of the pump discharge in the LS valve.
the hydraulic force is increased further.
q By this operation, the start-up time of the pump
Operating condition for turning on
discharge is optimized and the combined opera- Relief pressure
2-stage relief function
tion and fine control performance is improved. q During travel
q When swing lock switch is turned to 34.8 MPa
the ON position {355 kg/cm2}
q When boom is lowered O
q When one-touch power maximizing 37.2 MPa
function is turned on {380 kg/cm2}
q When L mode is operated
2) Cut-off function
q This function increases PC-EPC current (J) to
reduce the flow rate in the relief state, improving
fuel consumption.
Operating condition for turning on cut-off function
When the average value of the front and rear pressure
sensors is 27.9 MPa {285 kg/cm2} or more with the
one-touch power maximizing function off.
The cut-off function does not work, however, while the
machine is travelling in A mode, swing lock switch is in
the “ON” position.
PC200, 200LC-8E0 (Hybrid) 10-800 17

3. One-touch power maximizing function
Function
q The one-touch power maximizing function al-
lows the operator to increases power for a cer-
tain time by operating the left knob switch.
q This function is used to increase digging force for
a certain period of time (e.g., when digging up a
large rock).
q Pressing the L.H. knob switch in P or E, mode in-
creases a hydraulic force by approximately 7 %
and horsepower by approximately 3 %, increas-
ing a digging force.
At this time, each function is automatically set as
shown below.
q These settings are automatically reset after 8.5
seconds when the switch is pressed.
Function Setting
Engine and pump control Matching at rated output point
34.8 MPa {355 kg/cm2}
2-stage relief function O
37.2 MPa {380 kg/cm2}
Software cut-off function Cancel
10-800 18 PC200, 200LC-8E0 (Hybrid)

4. Auto-deceleration function
Function
q The auto-deceleration function automatically re- q If the capacitor voltage decreases during decel-
duces the engine speed to its medium speed eration, the engine speed increases to 1,050
range when the all control levers are set in the rpm to charge the capacitor. After the capacitor
NEUTRAL position while waiting for a dump is charged, the engine speed decreases to about
truck or work to reduce the fuel consumption and 700 rpm.
noise
q If the control lever is operated, the engine speed
increases immediately in accordance with the le-
ver operation quantity. At this time, the engine
speed upper limit is set with the fuel control dial.
Operation
When control levers are set in the neutral posi-
tion
q If the all control levers are set in the neutral po-
sition while the machine is working/traveling with
the auto-deceleration function is ON, the engine
speed decreases to the waiting speed (1,250
rpm) temporarily. If the machine is kept under
this condition for 4 seconds, the engine speed
decreases further to the deceleration speed
(about 700 rpm) and keeps at that speed until
any lever is operated.
PC200, 200LC-8E0 (Hybrid) 10-800 19

When any control lever is operated

q If any control lever is operated while the engine
speed is kept at the deceleration speed, the en-
gine speed increases immediately in accor-
dance with the lever operation quantity.
10-800 20 PC200, 200LC-8E0 (Hybrid)

5. Auto-warm-up and overheat prevention function
Function
q The engine automatic warm-up function increas-
es the engine speed to warm up the engine if
coolant temperature is too low after engine
starts.
q The overheat prevention function reduces the

pump load when coolant or hydraulic oil temper-
ature is too high during operation to protect the
engine from overheating.
PC200, 200LC-8E0 (Hybrid) 10-800 21

1) Auto-warm-up function
q After the engine is started, if the engine coolant
temperature is low, the engine speed is raised
automatically to warm up the engine
Operating condition (All of following conditions) Operation

Coolant temperature: Below 30 °C
Engine speed: 1,200 rpm
Engine speed: Max. 1,200 rpm
Resetting condition (Any one of following conditions) Free

Coolant temperature: Above 30 °C
Auto
Auto-warm-up operation time: Min. 10 minutes
Fuel control dial: Engine speed: Any level
Manual Kept at 70 % of full level or more for 3 sec. or lon-
ger
2) Overheat prevention function

1] Overheat prevention function for engine and hydraulic components
q If the engine coolant temperature rises too high during work, the pump load and engine speed
are reduced to protect the engine from overheating.
q This function starts when coolant temperature reaches 100 °C or hydraulic oil temperature
reaches 95 °C.
Operating condition Operation/Remedy Resetting condition
Hydraulic oil temperature: Below 95 °C
Working mode:Travel
Hydraulic oil tempera- q Under above condition, controller is set
Engine speed: Keep as is.
ture: Min. 95 °C to condition before operation of function.
Lower travel speed.
(Automatic reset)

Coolant temperature: Hydraulic oil or coolant temperature: Below
Min. 100 °C Working mode: P or E mode 100 °C
or Engine speed: Keep as is. q Under above condition, controller is set
Hydraulic oil tempera- Lower pump discharge. to condition before operation of function.
ture: Min. 100 °C (Automatic reset)

Coolant temperature: Hydraulic oil or coolant temperature: Below
Working mode: P or E mode
Min. 102 °C 102 °C
Engine speed: Keep as is.
or q Under above condition, controller is set
Monitor alarm lamp: Lights up.
Hydraulic oil tempera- to condition before operation of function.
Reduce pump delivery.
ture: Min. 102 °C (Automatic reset)

Hydraulic oil temperature: Below 105 °C
Coolant temperature:
Working mode: Any mode Fuel control dial:Ruturn to low idle position
Min. 105 °C
Engine speed: low idle once.
or
Monitor alarm lamp: Lights up. q Under above condition, controller is set
Hydraulic oil tempera-
Alarm buzzer: Sounds to condition before operation of function.
ture: Min. 105 °C
(Automatic reset)
2] Overheat prevention function for hybrid components
q This function decreases the hybrid system load to protect the hybrid components from an over-
heat when their temperature increases high.
q If this function operates, the alarm buzzer sounds and the hybrid temperature monitor lights up.
q If an overheat cannot be prevented with this function, the alarm buzzer sounds and the monitor
displays an error to indicate the component overheat, and the hybrid system stops.
10-800 22 PC200, 200LC-8E0 (Hybrid)

6. Swing control function
Function
The swing lock and swing brake function are provid-
ed as a swing control function.
PC200, 200LC-8E0 (Hybrid) 10-800 23

1) Swing lock and swing brake function 2) Quick hydraulic oil warm-up function when
q The swing lock function (manual) is used to lock swing lock switch is in the ON position
machine from swinging at any position. The q If swing lock switch (2) is in the ON position, the
swing brake function (automatic) is used to pre- pump cut-off function is cancelled and the relief
vent hydraulic drift after the machine stops pressure rises from 34.8 MPa {355 kg/cm2} to
swinging.
37.2 MPa {380 kg/cm2}.
q Operation of swing lock switch and swing lock/
If the work equipment circuit is relieved under
swing brake
this condition, the hydraulic oil temperature rises
Lock Lock
Function Operation quickly and the warm-up time can be shortened.
switch lamp
If swing lever is moved to
the neutral position, swing
brake operates in about 5
Swing
OFF OFF sec.
Brake
If swing lever is operated,
brake is released and
machine can swing freely
Swing lock operates and
machine is locked from
swinging.
Swing
ON ON Even if swing lever is oper-
lock
ated, swing lock is not reset
and machine does not
swing.
Swing brake release switch
q If the controller, etc. has a problem, the swing
brake is not released normally, and the machine
cannot swing, the swing lock can be released
with the swing brake cancel switch
Swing hold-
ON OFF
ing brake
(When controller has (When the controller is
release
trouble) normal)
switch
Swing lock
ON OFF ON OFF
switch
Swing
Swing Swing lock Swing lock Swing lock
brake
brake works. is canceled. works.
works.
q Even if the swing brake cancel switch is turned

on, while the swing lock switch stays in the ON
position, the swing brake is not released.
q If the swing lock is released, only the hydraulic
brake is applied by the safety valve. Note that if
swinging is stopped on a slope, the upper struc-
ture may swing by its gravity.
k If the swing lock is released while the hy-

brid system is in an abnormal state, the
stop function is lost.
Accordingly, if this operation is performed on
a slope, the upper structure swings down,
and this is dangerous. Never perform this
operation since it can cause a serious acci-
dent.
10-800 24 PC200, 200LC-8E0 (Hybrid)

7. Travel control function
Function
q The machine is provided with a function that en-
sures travel performance best fit to the type of
work and jobsite by controlling pumps during
travel or allowing operator to change travel
speed automatically or manually.
PC200, 200LC-8E0 (Hybrid) 10-800 25

1) Pump control function during travel

q For details, see "Engine and pump combined
control function."
2) Travel speed change function
1] Manual change with travel speed switch
Switching the travel speed selector switch
from Lo to Mi and Hi causes the pump
controller to control the pump capacity
and motor capacity at each gear speed as
shown below, switching the travel speed.
Mi
Travel speed selec- Lo(Low Hi (High
(Medium
tor switch speed) speed)
speed)
Pump capacity (%) 80 90 100
Motor capacity Max. Max. Min.
Travel speed (km/h) 3.0 4.1 5.5
2] Automatic selection corresponding to
engine speed
If you adjust the engine speed to 1,500
rpm or less with the fuel control dial,
q The travel speed does not switch to Hi
when the machine is traveling in Mi.
q The travel speed automatically switch-
es to Mi when the machine is travel-
ling in Hi.
3] Automatic selection corresponding to
pump discharge pressure
If the travel hydraulic pressure is kept to
24.5 MPa {250 kg/cm2} or more at
least0.5 sec. due to increased load during
traveling in Hi on an uphill, the travel
motor capacity automatically switches to
the medium speed (Mi) (the travel speed
switch stays at Hi).
If the machine starts traveling on level
ground or downhill during operation of the
above mentioned function and the travel
hydraulic pressure goes 14.7 MPa
{150 kg/cm2 or less} and continues such
the condition at least 0.5 sec., the travel
motor capacity will automatically change,
switching the travel speed switch back to
Hi.
10-800 26 PC200, 200LC-8E0 (Hybrid)

8. System component parts

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 Two PPC oil pressure switches are installed to
the junction block.
q This sensor senses the operating condition of
each actuator by the PPC pressure and sends it
to the pump controller.
PC200, 200LC-8E0 (Hybrid) 10-800 27

Oil pressure sensor
1. Sensor
2. Connector
Function
q Six PPC oil pressure sensors are installed to the
junction block.
q This sensor detects the operating condition of
each actuator by the PPC pressure and transmit
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 increases output voltage (E) and
q The deformation in the diaphragm causes the re-
transmits it to the pump controller.
sistance of the gauge to change. This causes a
change in the output voltage, which is transmit-
ted to the amplifier (voltage amplifier).
q The relationship between the pressure applied

to sensors (P) and output voltage (E) is shown
in the following figure.
10-800 28 PC200, 200LC-8E0 (Hybrid)

Pump pressure sensor (high pressure)
1. Sensor
2. Connector
Operation
q The relationship between the pressure applied
to sensors (P) and output voltage (E) is shown in
the figure below.
PC200, 200LC-8E0 (Hybrid) 10-800 29

Pump controller
10-800 30 PC200, 200LC-8E0 (Hybrid)


CN-C01 CN-C01
Pin No. Signal name Input/output Pin No. Signal name Input/output
1 Constant power supply Input 50 NC (*) Input
2 Constant power supply GND Input 51 NC (*) Input
3 Window washer Output 52 Service switch Input
4 Constant power supply Input 53 Boom RAISE pressure sensor Input
5 Constant power supply GND Input 54 NC (*) Input
6 NC (*) Input 55 Travel pressure switch Input
7 NC (*) - 56 Wiper limit switch Input
8 Potentiometer power supply (5 V) Output 57 Window limit switch Input
9 Potentiometer power supply (5 V) Output 58 Model Select 4 Input
10 NC (*) Input 59 NC (*) Input
11 NC (*) Input 60 Key SW (C) Input
13 NC (*) Input 62 External drive signal Input
14 Boom lower pressure SW Input 63 NC (*) -
15 Arm Out pressure SW Input 64 CAN_L Input/Output
16 Swing (L) pressure sensor Input 65 NC (*) Input
17 Arm In pressure sensor Input 66 NC (*) Input
18 Analog GND Input 67 NC (*) Input
19 Swing lock Input 68 R pump pressure sensor Input
21 Model Select 2 Input 70 Analog GND Input
23 NC (*) Input 72 Swing (R) pressure sensor Input
24 Key Switch (ACC) Input 73 Bucket digging pressure sensor Input
26 NC (*) - 75 Wiper (P) Input
27 NC (*) Output 76 NC (*) Input
28 NC (*) Output 77 Model Select 3 Input
29 Hydr. Oil Temperature Input 78 NC (*) Input
30 NC (*) Input 79 Key Switch (ACC) Input
33 NC (*) Input
34 Bucket DUMP pressure sensor Input *: Never connect to NC, or malfunctions or failures
35 NC (*) Input will occur.
36 Travel steering pressure SW Input
37 NC (*) Input
38 Swing prolix switch Input
39 Model Select 5 Input
40 Model Select 1 Input
41 Knob SW Input
42 NC (*) Input
43 Key Switch (ACC) Input
44 NC (*) Input
45 CAN_H Input/Output
46 Analog GND Input
47 NC (*) Input
48 NC (*) Input
49 F pump pressure sensor Input
*: Never connect to NC, or malfunctions or failures

will occur.
PC200, 200LC-8E0 (Hybrid) 10-800 31

CN-C02
Pin No. Signal name Input/output
82 NC (*) -
83 NC (*) -
84 NC (*) Output
85 NC (*) Output
86 ATT circuit selector solenoid Output
87 Travel speed solenoid Output
88 LS EPC Output
89 Merge-devider LS EPC Output
90 NC (*) -
91 NC (*) -
92 NC (*) Output
93 NC (*) Output
94 NC (*) Output
95 NC (*) Output
96 PC-EPC (F) Output
97 Service flow adjustment EPC Output
98 NC (*) -
99 NC (*) -
100 NC (*) Output
101 Swing brake solenoid Output
102 NC (*) Output
103 NC (*) Output
104 PC-EPC (R) Output
105 NC (*) Output
106 NC (*) -
107 NC (*) Output
108 Battery relay Output
109 2-stage relief solenoid Output
110 Travel junction SOL Output
111 NC (*) Output
112 Merge-divider (main) EPC Output
113 NC (*) Output
114 Wiper motor (-) Output
115 Solenoid GND Input
116 Solenoid power Input
118 Solenoid power Input
119 Wiper motor(+) Output
121 Solenoid power supply Input
*: Never connect to NC, or malfunctions or failures

will occur.
10-800 32 PC200, 200LC-8E0 (Hybrid)

Inverter
PC200, 200LC-8E0 (Hybrid) 10-800 33


CN-HC01 (DRC) CN-HC02 (DRC )
1 Terminal M+24 V Input 1 CAN line Input/Output
2 NC (*) output 2 Main moniter Input/Output
3 Contactor output 3 Emergency stop Switch Input
4 Caution buzzer output 4 SRM position sensor Input
5 Contactor +24 V Input 5 Resolver R1OUT output
6 ACC Input 6 Resolver S1IN Input
7 Terminal M+24 V Input 7 Sensor power supply Input
8 Swing lock output 8 Coolant Th(spare) Input
9 Contactor GND - 9 Swing lever Input
10 NC (*) output 10 Arm lever Input
11 Contactor +24 V Input 11 CAN line Input/Output
12 ACC Input 12 Main moniter Input/Output
13 Terminal M GND - 13 Work equipment lock lever Input
14 NC (*) output 14 Interlock input Input
15 Unconnected - 15 Resolver R2OUT output
16 NC (*) output 16 Resolver S3IN Input
17 (GND) - 17 (GND) -
18 NC (*) Input 18 PM Input
19 Terminal M GND - 19 Swing lever Input
20 Terminal M GND - 20 Bucket lever Input
21 Unconnected - 21 NC (*) Input/Output
22 NC (*) output 22 NC (*) Input/Output
23 (GND) - 23 NC (*) Input
24 NC (*) Input 24 Interlock output output
25 NC (*) output
*: Never wire NC since this can cause a malfunction 26 Resolver S2IN Input
and a trouble. 27 Capacitor Th1 Input
28 SRM Input
29 Boom lever Input
30 NC (*) Input
31 NC (*) Input/Output
32 NC (*) Input/Output
32 (GND) -
33 (GND) -
34 NC (*) -
35 Resolver S4IN Input
36 Capacitor Th2 Input
37 (GND) -
98 (GND) -
39 NC (*) Input
10-800 34 PC200, 200LC-8E0 (Hybrid)

Monitor system SEN05237-01
Monitor system
q The monitor system notifies the operator of ma-

chine status. It monitors the condition of the ma-
chine with the sensors installed on various parts
of the machine, processes and immediately dis-
plays the obtained information on the panel.
The outline of the information displayed on the
machine monitor is as follows.
1. Alarm when the machine has troubles.
2. Machine condition (Temperature of coolant
and hydraulic oil, fuel level, etc.)
q The monitor panel also has various mode selec-
tor switches and functions to operate the ma-
chine control system.
PC200, 200LC-8E0 (Hybrid) 10-800 35

SEN05237-01 Monitor system
Machine monitor
Outline
q The machine monitor has the functions to dis-
play various items and the functions to select
modes and the functions to turn on/off electrical.
q The machine monitor has a CPU (Central Pro-
cessing Unit) in it to process, display, and output
the information.
q The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
10-800 36 PC200, 200LC-8E0 (Hybrid)

Input/Output signal
CN-CM01 CN-CM03
1 Battery power (+24 V constantly) Input RS232C CD for communication termi-
1 Input/Output
2 Battery power (+24 V constantly) Input nal
3 Battery power GND - RS232C RXD for communication ter-
2 Input
4 Battery power GND - minal
5 Wake-up Input/Output RS232C SG for communication termi-
6 Relay output Output 3 -
nal
7 Chassis signal GND - Signal GND for communication termi-
8 NC (*) - 4 -
nal control
9 Hydraulic oil temperature Input Communication terminal selection sig-
10 NC (*) - 5 Input
nal
11 Battery charge Input RS232C RTS for communication ter-
12 Chassis analog signal GND - 6 Output
minal
13 Light switch Input RS232C TXD for communication ter-
14 Key switch (ACC) Input 7 Output
minal
15 Key switch (C) Input RS232C DTR for communication ter-
16 Preheat Input 8 Output
minal
17 NC (*) -
RS232C DSR for communication ter-
18 NC (*) - 9 Intput
minal
*: Never connect to NC or malfunctions or failures RS232C CTS for communication ter-
10 Input
minal
will occur.
RS232C RI for communication termi-
11 Input
nal
CN-CM02 Power GND for communication termi-
Pin No. Signal name Input/output 12 -
nal
1 NC (*) - Input CH1 for communication terminal
2 Engine oil level sensor Input 13 Input
status
3 Coolant level sensor Input Output for communication terminal
4 Air cleaner clogging sensor Input 14 Output
power control
5 Swing lock Input Output CH1 for communication termi-
6 NC (*) Input 15 Output
nal control
7 Chassis signal GND Input Output CH2 for communication termi-
8 CAN terminating resistance - 16 Output
nal control
9 CAN_H Input/Output Input CH2 for communication terminal
10 CAN_L Input/Output 17 Input
status
11 NC (*) Input/Output Electric power supply for communica-
12 NC (*) Input/Output 18 Output
tion terminal
will occur. CN-CM04
1 NC (*) -
2 NC (*) -
3 NC (*) -
4 NC (*) -
5 NC (*) -
6 NC (*) -
7 NC (*) -
8 NC (*) -
9 NC (*) -
10 NC (*) -
11 NC (*) -
12 NC (*) -

will occur.
CN-CM05
1 Electric power supply for camera Output
2 Camera NTSC signal input 1 Input
5 Electric power supply GND for camera -
6 Camera signal GND1 -
PC200, 200LC-8E0 (Hybrid) 10-800 37

Monitor control, display portion
10-800 38 PC200, 200LC-8E0 (Hybrid)

A: Normal operation screen

1. Engine coolant temperature monitor
2. Engine coolant temperature gauge
*1 3. Fuel consumption monitor(every minute)
4. Hydraulic oil temperature gauge
5. Service meter, clock
6. AUto-deceleration monitor
7. Working mode monitor
8. Travel speed monitor
9. Fuel gauge
10. ECO indicator
11. Fuel level monitor
12. Hydraulic oil temperature monitor
B: Caution all light up screen

*1 13. Hybrid temperature monitor
14. Engine oil pressure monitor
15. Charge level monitor
16. Radiator coolant level monitor
17. KOMTRAX message monitor
18. Air conditioner monitor
19. Wiper monitor
20. Swing lock monitor
21. Engine pre-heating monitor one-touch power maximizing monitor
22. Engine oil level monitor
23. Air cleaner clogging monitor
24. Water separator monitor
*1 25. Hybrid monitor
C: Maintenance warning screen

26. Maintenance time monitor
Precautions on the machine monitor display

q One of the features of liquid crystal display pan-
els is that there may be black spots (spots that
do not light up) or white spots (spots that stay
lighted up) on the screen. If there are fewer than
10 black or white spots, this is not a failure or a
defect.
q When the engine is started, the battery voltage
may suddenly drop depending on the tempera-
ture and the battery condition. If this happens,
the display on the machine monitor may momen-
tarily go out, but this does not indicate any ab-
normality.
q Continuous operation of the machine monitor
may display blue bright spots on the screen hav-
ing a black background; it is quite normal.
The screen normally displayed on the monitor
has a blue or white background. For this reason,
blue spots will not cause any problem (since the
liquid crystal lights up red, blue, and green spots
when displaying white).
PC200, 200LC-8E0 (Hybrid) 10-800 39

Monitor items and display

Symbol Display item Description
Swing holding brake

Swing lock switch Display of symbol
cancel switch
OFF OFF Off
Swing lock
ON OFF ON
OFF ON Blinking
ON ON Blinking
Preheater operates at low temperature andsym-

bol keeps lighting up for up to about 30 seconds
Automatic preheating
and then goes off after engine starts.
Preheat
Time after setting Display of symbol
0 – 30 sec ON
Manual preheating
30 – 40 sec Blinking
After 40 sec Off
One-touch power max.

Display of symbol
switch
One-touch power Keeps lighting up.
max. While pressed Goes off after about nine seconds if switch is
kept pressed.
While released Off
Engine coolant tem-

perature
Hydraulic oil tem- See gauge display on next page.
perature
Fuel level
10-800 40 PC200, 200LC-8E0 (Hybrid)

The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Temperature or
Gauge Range Indicator Buzzer sound
volume
A1 105 Red Q
Engine coolant tem- A2 102 Red
A3 100 Off
perature
A4 85 Off
(°C)
A5 60 Off
A6 30 White
B1 105 Red
B2 102 Red
Hydraulic oil tempera-
B3 100 Off
ture
B4 85 Off
(°C)
B5 40 Off
B6 20 White
C1 289 Off
C2 244.5 Off
Fuel level C3 200 Off
(l) C4 100 Off
C5 60 Off
C6 41 Red
PC200, 200LC-8E0 (Hybrid) 10-800 41

At "Checks before starting (all symbols light up), and when maintenance interval is exceeded."
The cautions (symbols) as the following table are displayed. In addition, if there are the exceeded mainte-
nance interval items or the abnormal items, they are displayed on the part where the hydraulic oil temperature
gauge and the hydraulic oil monitor are displayed. Their light-up and light-out are shown according to the con-
dition on the table.
Check before starting

Symbol Display item While engine is stopped While engine is running
item
Lights up and buzzer

Engineoil pressure q ―
sounds when abnormal.
Lights up when abnor-

Battery charge q ―
mal.
Lights up when abnor- Lights up and buzzer

Radiator coolant level q
mal. sounds when abnormal.

Engine oil level q ―
mal.

Air cleaner clogging q ―
mal.
Lights up when abnor- Lights up when abnor-

Water separator q
mal. mal.
Notice lamp (yellow) / warning lamp (red).

Maintenance Lights up for only thirty seconds after starting
swith is turned ON, then goes out.
*1
Hybrid temperature q ―
mal.
monitor
*1 Lights up when abnor-

q ―
Hybrid monitor mal.
Symbols appear in the order in which they occur

from the upper left. When symbols are displayed, if
the hydraulic oil temperature is high or low, only its
symbol is displayed.
Condition of hydraulic oil Color of symbol
Black on white back-
Low (Below B6 or equivalent)
ground
Normal (B6–B2) No display
White on red back-
High temperature (or more B2)
ground
10-800 42 PC200, 200LC-8E0 (Hybrid)

Display cat-
Symbol Display item Display range Description
egory
Green:
There is unread message. Display state of massage
KOMTRAX message Blue: (for only machine equipped
There is unreturned mes- with KOMTRAX)
sage.
Air conditioner/Heater Operation io Stop Displays operating condition.
INT ON OFF
Wiper Displays current status.
Monitor
Working mode P, E, L, B, ATT Displays set mode.
Lo Mi Hi
Travel speed Displays current status.
Auto-deceleration Operation io Reset Displays operating condition.
Green:
Displays average work load in
Work load is light –
ECO indi- 1 minute on 10 levels. (Does
ECO indicator medium.
cator not display if ECO display is
Orange:
set OFF in service menu.)
Work load is heavy.
Displays the total hours of

Service While service meter is operation
Service meter indicator
meter working (Switches to clock display if
F4 is depressed.)
Displays the time

12-hour displayio24-hour
Clock Clock (Switches to service meter
display
display if F4 is depressed.)
*1 Top of gauge:30 l/h

Fuel con- Right end gauge: Latest Middle of gauge:18 l/h
sumption Average fuel consump- value – Every minute (Graph is erased each time
monitor tion left end gauge: Value 5 When starting Switch is
(every min- minute Before turned from OFF position to
ute) ON Position)
PC200, 200LC-8E0 (Hybrid) 10-800 43

Switches
1. Buzzer cancel switch Auto-deceleration switch

2. Auto-deceleration switch Each time the switch is pressed, the auto-decelera-
3. Guidance icon tion is switched between ON and OFF. When the
4. Function switch working mode is switched, it is automatically set to
5. Working mode selector switch ON. When it is set to ON, the auto-deceleration
6. Travel speed selector switch monitor appears.
7. Window washer switch a The auto-deceleration function does not work in
8. Wiper switch L mode.
9. Air conditioner control switch
Guidance icon and function switch
Buzzer cancel switch The function switches differ depending on the
Pressing this switch when the alarm buzzer is mak- screen display. Each guidance icon shows the func-
ing sound stops the alarm buzzer. tion of the switch below it.
If a new abnormality is detected, the alarm buzzer Switches with no guidance icon are disabled.
sounds. The functions shown by the guidance icons are as
Depending on the alarm buzzer type, it does not shown in the table below.
stop even if you press the buzzer cancel switch.
10-800 44 PC200, 200LC-8E0 (Hybrid)

Switch
Symbol Item Function
power
F6 Enter Enters selected/set item.
F5 Return Returns to previous screen.
*1
F2 Change to fuel consumption monitor screen.
Fuel log screen display
*1
F1 Change to energy monitor screen.
Energy monitor screen display
F3 Select camera screen Selects camera screen.
F4 Select service meter/clock Selects service meter and clock alternatively.
F5 Select maintenance screen Selects maintenance screen.
F6 Select user mode screen Selects use mode screen.

Selects item on left side (Selects right end item after left
F3 Select item
end item).
Selects item on right side (Selects left end item after
F4 Select item
right end item).
Selects item on lower side (Selects top item after bot-
F3 Select item
tom item)/Resets holding of monitoring.
Selects item on upper side (Selects bottom item after
F4 Select item
top item)/Holds monitoring.
Selects page on lower side (Selects top page after bot-
F1 Select item
tom page).
Selects page on upper side (Selects bottom page after
F2 Select item
top page).
F1 Display No. 1 camera screen Selects No. 1 camera screen.
Display No. 1 and No. 2 camera Displays No. 1 and No. 2 camera screens simultane-
F4
screens ously.
Returns selected item to default setting. (Used for
F2 Return to default setting
adjustment of screen.)
Starts operation. (Used to start measurement of split
F1 Start
fuel consumption on fuel consumption display screen.)
Stops operation. (Used to stop measurement of split
F1 Stop
fuel consumption on fuel consumption display screen)
F1/F2 Clear Clears selected/displayed item.
F1 Set Executes setting.
PC200, 200LC-8E0 (Hybrid) 10-800 45

Working mode selector switch Air conditioner control switch

Pressing working mode selector switch (5) switches To operate the air conditioner, use the air condition-
among working modes. er control switches.
Check the working mode on the working mode mon-
itor.
9a: Switch to adjust the air flow

9b: Switch to control temperature inside the cab.
9c: AUTO
Travel speed selector switch 9d: A/C
Each time you press the travel speed selector 9e: Switch to select the vents.
switch, the travel speed setting switches as shown 9f: Switch to select recirculated air and fresh air
below. 9g: OFF
LooMioHioLoo…. 9a to 9c:
The travel speed setting is confirmable on the travel Enables entered information simultaneously with
speed monitor. switching to the air conditioner adjustment screen
The relationship between the speed setting and the below.
monitor display is shown in the table below. 9d to 9f:
Display Setting Switches to the air conditioner adjustment screen
Crawler symbol +Lo Low speed (default) below. Another pressing switches among modes.
Crawler symbol+Mi Medium speed 9g:
Crawler symbol+Hi High speed Turns OFF the air conditioner function. Even if this
switch is pressed, the monitor screen does not
Window washer switch switch to the air conditioner adjustment screen.
While the switch is being pressed, window washer
fluid is sprayed out from the nozzle. The window
wiper will also operate.
Wiper switch
Each time you press the wiper switch, the wiper set-
tings switch as follows.
OFFoINToONoOFFo….
The wiper operation setting is confirmable on the
wiper monitor.
The relationship between the wiper setting and the
monitor display is shown in the table below.
Display Setting Wiper operation status
Stowing stopped or now stow-
None OFF
ing
Wiper symbol +
INT Intermittent operation
+INT
Wiper symbol +
ON Continuous operation
+ON
10-800 46 PC200, 200LC-8E0 (Hybrid)

If you do no operation at least 5 sec. while the air F1: Displays the image of No. 1 camera full-screen.
conditioner adjustment screen is displayed, the win- F2: Displays the image of No. 2 camera full-screen.
dow returns to the standard screen. F3: Displays the image of No. 3 camera full-screen.
a When communication with the air conditioner is F4: Displays the images of No. 1 and No. 2 cameras
disconnected, or “vent damper”, “air-mixed at the same time.
damper”, or “refrigerant pressure” has a prob- F5: Returns to the standard screen.
lem, the following screen appears.
q Making operation of air conditioner button (1)
with the camera screen displayed may switch to
the air conditioner operation screen.
Camera screen display function

q For an optional-camera-equipped machine,
pressing the F3 on the standard screen switches
to the camera image.
q For a machine with no camera equipped, the
guidance icon for switching to the camera
screen does not appear; even if you press the
switch, the screen does not switch to the camera
image.
q Up to three cameras are mountable.
PC200, 200LC-8E0 (Hybrid) 10-800 47

F6 Return to the camera screen: No operation for 5 Service meter/clock selector function
sec., returns to the camera screen. q Pressing F4 on the standard screen when the
service meter is displayed in the top center of the
q Even when the camera screen is displayed, the screen switches the display to the clock, and do-
working mode selector switch, travel speed se- ing so when the clock is displayed switches the
lector switch, auto-deceleration switch, buzzer display to the service meter.
cancel switch, wiper switch, and window washer
switch are enabled.
q Changing the working mode or travel speed re-
turns to the normal screen.
q If an abnormality corresponding to an alarm item
with the camera screen displayed, the alarm
monitor appears on the upper left of the screen.
If it appears, return to the standard screen with
F5 to check the alarm display.
q If an abnormality corresponding to an error item
with the camera screen displayed, the error
monitor appears on the upper left of the screen.
If it appears, you must move the machine to safe
posture immediately and make inspections.
q When the error monitor starts to blink, if no lever
is operated for more than 10 seconds, the
screen automatically returns to the standard
screen.
10-800 48 PC200, 200LC-8E0 (Hybrid)

Maintenance function
If switch F2 is pressed while the normal screen is

displaye, the monitor display screen changes to the
fuel consumption monitor screen (lateat 60 min-
utes).
Fuel consumption monitor screen

On the fuel consunption monitor screen, the follow-
ing operations can be performed with switches F1,
F2 and F5.
F1: Change to energy monitor screen.

F2: Change to next fuel consumption monitor
screen.
F5: Return to nomal screen.
q If any machine abnormality (any of various errors

and warnings,excluding low hydraulic oil temper-
ature) is detected while the fuel consumption
monitor screen is displayed, the screen ruturns
to the normal screen immediately.
q On each fuel consumption monitor screen which
changes each time switch F2 is pressed, the fuel
consumption is calculated and displayed graphi-
cally in each time unit. On any screen the right
end graph is the latest one.
PC200, 200LC-8E0 (Hybrid) 10-800 49

Supplementary explanation
Each time F2 is pressed while the fuel consumption
monitor screen is displayed, the screen changes in
the following order.
No Item Update Unit Remarks

Latest 60 min-
(1) 10 minutes l/h -
utes
(2) Latest 12 hours 1 hours l/h -
Total key-ON time of the of the day is displayed at the top of each
(3) latest 1 week 1 day l
graph
Total key-ON time of the Week is displayed at the top of each
(4) latest 1 month 1 week l
graph
10-800 50 PC200, 200LC-8E0 (Hybrid)

Deletion of fuel consumption monitor record
Fuel consumption log clear

The fuel consumption monitor record can be deleted 3. Select a fuel consumption monitor item to be
with this fuel consumption log clear menu. deleted from the selection menu of "Fuel
1. Press switch F6 while the normal screen is consumption log clear".
displayed. On the fuel consumption log clear selection
screen, the following operations can be
performed with switches F3 - F6.
F3: Move to next item (one line below)

F4: Move to previous item (one line above)
F5: Return to user menu screen.
F6: Go to fuel consumption log clear confirma-
tion screen of selected item
2. Select a fuel consumption monitor item to be

deleted from the selection menu of "Fuel
consumption log clear".
PC200, 200LC-8E0 (Hybrid) 10-800 51

Energy monitor screen
4. If switch F6 is pressed while the fuel consump-

tion log clear confirmation screen, the record of If switch F1 is pressed while the fuel consumption
the selected item is deleted and the following monitor screen is displayed, the monitor display
completion screen is displayed. screen changes to the energy monitor screen.
q To return to the previous screen without de- On the energy monitor screen, the power transmis-
leting the record, press switch F5. The sion condition among the components and the mo-
screen returns to the selection menu of "Fuel mentary fuel consumption are displayed.
consumption log clear". q (A) - (F) indicate the power flow condition among
the components.
(A): Between engine and generator motor
(B): Between generator motor and capacitor
(C): Between generator motor and swing electric
motor
(D): Between capacitor and swing electric motor
(E): Between hydraulic pump and work equip-
ment cylinder
(F): Between generator motor and hydraulic
pump
(G): Indicates the momentary fuel consumption.
If switch F5 is pressed, the screen returns to the
fuel consumption log screen.
5. To return to the fuel consumption log clear

screen from the fuel consumption log clear
completion screen,press switch F5.
10-800 52 PC200, 200LC-8E0 (Hybrid)

Maintenance function
q Pressing F5 on the standard screen switches to
the maintenance list screen.
F5: Cancels the reset to return to the maintenance

list screen.
F6:Resets the remaining time to return to the stan-
dard screen.
No operation at least 30 sec.: Returns to the stan-
dard screen.
F5: Cancels the reset to return to the maintenance

F1: Displays the next page.
table screen.
Displays the top page when the last page is dis-
F6: Resets the remaining time to return to the nor-
played.
mal screen.
F2: Displays the previous page.
No operation at least 30 sec.: Returns to the normal
Displays the last page when the top page is dis-
screen.
played.
F3: Selects (highlights) an item one line down.
q The table below shows the maintenance items
F4: Selects (highlights) an item one line up.
and replacement intervals. The time remaining
F5: Returns to the standard screen.
to maintenance is reduced as the machine is op-
F6: Switches to the maintenance time reset screen.
erated.
No operation at least 30 sec. : Returns to the stan-
dard screen. Replacement inter-
No Item
val (Hours)
01 Engine oil 500
q On the maintenance list screen, if the time re- 02 Engine oil filter 500
maining until maintenance for any item is less 03 Fuel main filter 1000
than 30 hours, the remaining time display is 41 Fuel prefilter 500
highlighted in yellow. If the time remaining until 04 Hydraulic oil filter 1000
maintenance becomes 0 hour, the remaining 05 Hydraulic tank breather 500
time display is highlighted in red. 06 Corrosion resistor 1000
08 Final case oil 2000
q On the maintenance time reset screen, reset the
09 Machinery case oil 1000
remaining time for the selected item to return to 10 Hydraulic oil 5000
the default. *1
45 Gen. Oil Change, Filter Clean 1000
q If switch F6 is not kept pressed for at least 1.5 *146 Swing Motor Oil Change 1000
seconds, the switch operating sound can be
heard, but the screen does not switch to the
screen for resetting the remaining time.
PC200, 200LC-8E0 (Hybrid) 10-800 53

q The content of the caution display differs accord- User mode

ing to the remaining time. The relationship is as q Pressing F6 on the standard screen enters the
shown in the table below. user mode, switching to the user menu screen.
Display Condition q In user mode, you can specify items relating to
Remaining time for mainte- the machine monitor and machine shown below.
None nance for all items is more than
Breaker/Attachment Settings
30 hours.
Notice display There is one or more items with User Message
(black symbol displayed on less than 30-hour remaining Screen Adjustmen
yellow background) time for maintenance. Clock Adjustment
Warning display There is one or more items with Language selection
(white symbol displayed on less than 0-hour remaining time
red background) for maintenance.
Economy mode adjustment
q You can lock the maintenance time by a pass-

word to prevent it from carelessly being reset.

F5: Returns to the standard screen.
F6: Switches to the setting screen for the selected
q The default password is “000000”. item.
a Enabling the password lock on an attach- No operation at least 30 sec.: Returns to the stan-
ment-equipped machine locks the breaker/at- dard screen.
tachment setting screen at the same time. (In user mode, no switch operation at least 30 sec.
a For information on changing the maintenance returns to the previous screen.)
password, see “Maintenance password change
function” in the Testing and adjusting section.
10-800 54 PC200, 200LC-8E0 (Hybrid)

Message display
q For a KOMTRAX-equipped machine, you can
view notification from the sales representative.
When there is a message, the message monitor
appears on the upper left of the standard screen.
q The lighting green monitor icon indicates that
there are unread messages.
q The lighting blue monitor appears when you
have not sent replies yet after opening messag-
es which accept replies.
q Messages will be deleted when their validity ex-

pire or a new message is received.
q When no message has been received, “No
message” is diaplayed on the top portion of the
screen.
q Separately from the message display for users
above, the service menu is provided with mes-
sage display for technician.
Screen adjustment
q Press F6 to enter user mode and select q Selecting the Screen adjustment from the user
“Message display” and you can view (open) the menu and pressing F6 switches to the screen
messages. adjustment screen.
q From this menu, you can adjust the brightness,
contrast, and luminance of the machine monitor
screen.
q When the light switch is in Night mode ON, the
night mode screen is adjustable.
q When the light switch is in Daytime mode ON or
OFF, the daytime mode screen is adjustable.
F6: Returns to the user mode screen.
q Under messages that accept replies, " 10 key in-

put value ": [ ]” appears. If it appears, enter the
selected item number provided in the message
using the switches of the machine monitor, and
press F6.
q When "Sent input?" is displayed under the mes- F2: Returns all adjusted values to the defaults.
sage, press F6 again. The input value is sent. F3: Decreases the value indicated by the indicator
one graduation left.
F4: Increases the value indicated by the indicator
one graduation right.
F5: Cancels changes you made before confirming
them with F6 to return to the menu screen.
F6: Confirms the changes and moves to the next
item.
PC200, 200LC-8E0 (Hybrid) 10-800 55

q For a camera-equipped machine, the bright- Clock adjustment

ness, contrast, and illuminance of the camera q Selecting the Clock adjustment from the user
screen are also adjustable. menu and pressing F6 switches to the clock ad-
q For a camera-equipped machine, selecting justment screen.
Screen adjustment from the user menu switches q On this screen, you can change the setting of the
to the screen for selecting a screen you want to time displayed on the standard screen.
adjust.
1) Clock setting
F3: Selects (highlights) an item one line down. Adjust the clock time. If the time setting item
F4: Selects (highlights) an item one line up. is not highlighted, press F6 to highlight it.
F5: Cancels changes you made before confirming
them with F6 to return to the menu screen. The time display part is highlighted.
F6: Moves to the setup items of the selected (high- F3: Advances the time one hour.
lighted) item. F4: Set the time back one hour.
F5: Cancels changes you made before
q The adjustment methods for the camera screen confirming them with F6 to return to the user
and standard screen are the same. menu.
q The background when adjusting the camera F6: Confirms the changes and moves to
screen is the No. 1 camera image. minute setting.
The minute display part is highlighted.

F3: Advances the time one min.
F4: Set the time back one min.
confirming them with F6 to return to the use
menu.
F6: Confirms the changes and moves to the
12/24 display mode.
2) 12/24 display mode

Specify time display to 12-hour display
(AM/PM) or 24-hour display. If the item of
F3: Selects (highlights) an item one line down. 12/24 display mode is not highlighted, press
F4: Selects (highlights) an item one line up. F6 to highlight it.
F5: Cancels changes you made before confirming F3: Moves to the item one right.
them with F6 to return to the menu screen. F4: Moves to the item one left.
F6: Moves to the setup items of the selected (high- F5: Cancels changes you made before
lighted) item. confirming them with F6 to return to the menu
screen.
F6: Confirms the changes and moves to
summer time.
10-800 56 PC200, 200LC-8E0 (Hybrid)

3) Summer time
Selecting ON for this sets the time forward
one hour. Setting OFF returns to the ordinary
time.
F3: Moves to the item one right.
F4: Moves to the item one left.
confirming them with F6 to return to the user
menu screen.
F6: Confirms the changes and moves to the
time setting.
a Summer time (daylight saving time) is a

system to lead a life according to the This screen switches to the normal screen if one of
one-hour advanced time in order to make the following conditions occurs.
efficient use of daylight time. q When the lever is operated
q When F5 is pressed
Language selection q When an error or caution occurs
q Selecting the Language from the user menu When you switch to the normal screen by pressing
screen and pressing F6 switches to the lan- F5, this screen does not appear even if the engine
guage selection screen. continues to run at idle. If the engine continues to
q From this menu, you can change the language to
run at least five min. after operating the lever, this
be displayed on the monitor. Available languag- screen appears again.
es are as follows.
English, Japanese, Chinese, French, Spanish, Service meter check function
Portuguese, Italian, German, Russian, and q If you continuously pressing auto-deceleration
Turkish switch (1) and buzzer cancel switch (2) at the
same time when turning the starting switch to the
OFF position, the service meter will appear on
the screen in 3 to 5 sec.

F5: Cancels the changes to return to the user menu.
F6: Confirms the changes to return to the user
menu.
Idle stop guidance function

This function displays the guidance to save fuel con-
sumption. It is displayed only when all the following
conditions are met.
q Energy saving guidance display of the service
menu is specified to ON.
q No operation is made at least 5 min. and the en-
gine is running at idle.
q No error or caution (excluding low hydraulic oil
temperature) is occurring.
PC200, 200LC-8E0 (Hybrid) 10-800 57

q When these switches (1) and (2) are released, User code/failure code display function
the LCD goes out. q If there is any problem in machine operation, the
a Long time operation of the machine monitor may user code and failure code are displayed on the
display blue bright spots on this screen; it is quite monitor to advise the operator of the steps to
normal. take.
q These codes appear on the standard screen.
Display LCD check function q On the standard screen, user code (1) and fail-
q Pressing the buzzer cancel switch (1) and F2 at ure code (2) are displayed on the portion for the
the same time on the standard screen causes hydraulic oil temperature gauge.
the full screen of LCD to light in white.Release
F2 and buzzer cancel switch in order.
q One of the features of liquid crystal display pan-
els is that there may be black spots (spots that
do not light up) or white spots (spots that stay
lighted up)on the screen. If there are fewer than
10 black or white spots, this is not a failure or a
defect.
q If multiple user codes or failure codes are issued,

they are displayed alternately every 2 sec. The
figure below shows the case two types of user
codes and failure codes are displayed.
q If the telephone number has been set in the ser-

vice menu, the screen shows the telephone
symbol and telephone number simultaneously
with the user code/failure code. (For information
q Pressing any function switch returns to the pre- on how to input and set the telephone number,
vious screen. see “Special functions of monitor panel” in the
Testing and adjusting section.)
10-800 58 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 10-800 59

SEN05237-01 Sensors
Sensors
q The signals from the sensors are input to the Value in
Type of When
monitor panel directly. Sensor name normal
sensor abnormal
q Either side of a sensor of contact type is always state
connected to the chassis ground. Resis-
Fuel level - -
tance
Value in OFF ON
Type of When Air cleaner clogging Contact
Sensor name normal (Closed) (Open)
sensor abnormal
state ON OFF
Coolant level Contact
ON OFF (Closed) (Open)
Hydraulic oil level Contact
(Closed) (Open)
Hydraulic oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
10-800 60 PC200, 200LC-8E0 (Hybrid)

Sensors SEN05237-01
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor
PC200, 200LC-8E0 (Hybrid) 10-800 61

SEN05237-01 Sensors
Coolant level sensor
1. Reserve tank
2. Float
3. Sensor
4. Connector
10-800 62 PC200, 200LC-8E0 (Hybrid)

KOMTRAX system SEN05237-01
KOMTRAX system
q The KOMTRAX system consists of a KOMTRAX

terminal, communication antenna, machine
monitor, and GPS antenna.
q This system transmits various kinds of machine
information wirelessly. Persons to operate the
KOMTRAX can refer to the information at office
to provide various kinds of services for custom-
ers.
q The information available from the KOMTRAX
system are as follows:
1. Operation map
2. Service meter
3. Position information
4. Failure record
and others.
a To provide the services, you need to make an ar-
rangement for starting the KOMTRAX service
separately.
PC200, 200LC-8E0 (Hybrid) 10-800 63

SEN05237-01 KOMTRAX system
KOMTRAX terminal
Using a satellite wave
1. Communication antenna connection Outline

2. Connector A (14 poles) q The KOMTRAX terminal is a wireless communi-
3. Connector B (10 poles) cation device to transmit various kinds of ma-
chine information or GPS position information
the monitor obtains from network signals or input
signals in the machine. The terminal can trans-
mit information via the communication antenna.
q KOMTRAX terminal cannnot be used in the
countries or territories where it is not authorized
by the communication contract.
q When starting to use the KOMTRAX system ex-
cept the country where it is authorized, you are
required to notify the country where it will be
used in advance.

Connector A Connector B
A-1 Power supply -12 V input B-1 Serial signal DCD output
A-2 NC(*1) - B-2 Serial signal RXD output
A-3 NC(*1) - B-3 Serial signal TXD input
A-4 Electric power supply switching output B-4 Serial signal DTR input
A-5 NC(*1) - B-5 Serial signal SGND -
A-6 NC(*1) - B-6 Serial signal DSR output
A-7 (GND) - B-7 NC(*1) -
A-8 (GND) - B-8 NC(*1) -
A-9 NC(*1) - B-9 NC(*1) -
A-10 NC(*1) - B-10 NC(*1) -
A-11 NC(*1) -
A-12 NC(*1) - *1: Never connect to NC or malfunctions or failures
A-13 NC(*1) - will occur.
A-14 NC(*1) -
*1: Never connect to NC or malfunctions or failures

will occur.
10-800 64 PC200, 200LC-8E0 (Hybrid)

KOMTRAX system SEN05237-01
PC200, 200LC-8E0 (Hybrid) 10-800 65

SEN05237-01
©2010 KOMATSU
All Rights Reserved
10-800 66
SEN05239-00
SEN05239-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

20 Standard value table

100 Standard service value table
Standard value table for engine related parts ............................................................................................. 2

Standard value table for chassis related parts............................................................................................ 3
PC200, 200LC-8E0 (Hybrid) 20-100 1

SEN05239-00 Standard value table for engine related parts
Standard value table for engine related parts

PC200, PC200LC-8E0
Applicable model PC200, PC200LC-8E0

Engine SAA4D107E-1
Cat
Standard value for Judgement crite-
eg Item Measurement condition Unit
new machine ria
ory
High idle rpm 2,060 ± 70 2,060 ± 70
q Coolant temperature: op-
Engine speed *Low idle rpm 700 ± 50 700 ± 50
erating range
Rated speed rpm 2,000 2,000
Intake pressure q Coolant temperature: operating range kPa Min. 133 107
(boost pressure) q Arm IN relief + Power Max. {mmHg} {Min.1,000} {800}
At sudden
q Coolant temperature: op- acceleration % Max.25 35
Exhaust gas color
erating range
At full speed % ― ―
Intake valve mm 0.25 0.152 – 0.381
Valve clearance q Normal temperature Exhaust
mm 0.51 0.381 – 0.762
valve
Compres- MPa Min. 2.41 1.69
sion pres-
Compression pres- q Oil temperature: 40 –
sure {kg/cm2} {Min.24.6} {17.2}
sure 60 °C
Engine
Engine
rpm 250 – 280 250 – 280

speed
q Coolant temperature: operating range MPa Max.0.98 1.96
Blow-by pressure
q Arm IN relief + power max. {mmH2O} {Max.100} {200}
q SAE0W30E0S, Mpa Min. 0.29 0.25
SAE5W40E0S, Full speed
{kg/cm2} {Min.3.0} {2.5}
SAE10W30DH,
Oil pressure SAE15W40DH,
MPa Min. 0.10 0.07
SAE30DH engine oil Low idle 2}
{kg/cm {Min.1.0} {0.7}
q Coolant temperature: op-
erating range
Oil temperature q Whole speed range (inside oil pan) °C 80 – 110 120
q Between fan pulley and alternator pulley
Fan belt tension q Deflection when pressed with finger mm Auto-tensioner Auto-tensioner
force of approx. 98 N {10 kg}
q Between fan pulley and compressor
Air conditioner com- pulley
mm 6.3 – 8.7 6.3 – 8.7
pressor belt tension q Deflection when pressed with finger
force of approx. 98 N {10 kg}
* The low idle speed can be set to 2 levels.

1) When auto-decelerator is OFF: 1,050 rpm (Same with PC200-8 standard model)
2) When auto-decelerator is ON: 700 rpm (Exclusive for hybrid model)
20-100 2 PC200, 200LC-8E0 (Hybrid)

Standard value table for chassis related parts SEN05239-00
Standard value table for chassis related parts

PC200, PC200LC-8E0
Cate Standard value Judgement
Item Measurement condition Unit
gory for new machine criteria
q Engine coolant temperature: Arm IN
Within operating range relief con- 1,800 ± 100 1,800 ± 100
q Hydraulic oil temperature: dition
2 pumps at relief* Within operating range Travel in rpm
q Engine at full speed relief con-
1,920 ± 100 1,920 ± 100
q Working mode (P) dition
q Arm IN relief condition Mid, Hi
Engine speed
q Engine coolant temperature: Arm IN

Within operating range relief con- 1,800 ± 100 1,800 ± 100
q Hydraulic oil temperature: dition
At 2-pump relief + Within operating range
Travel in rpm
power max.* q Engine at full speed
relief con-
q Working mode: P mode 1,950 ± 100 1,950 ± 100
dition
q Arm IN relief + Left knob
Mid, Hi
switch ON
Speed when auto- q Engine at full speed
deceleration is q Auto-deceleration switch in ON position rpm 700 ± 50 700 ± 50
operated q All control levers in NEUTRAL position
RAISE mm 11.5 ± 0.5 11.5 ± 0.5
Boom control valve
LOWER mm 9.5 ± 0.5 9.5 ± 0.5
IN mm 11.5 ± 0.5 11.5 ± 0.5
Arm control valve
Spool stroke
OUT mm 9.5 ± 0.5 9.5 ± 0.5

q Engine stopped
Bucket control CURL,
q For measuring point, see mm 9.5 ± 0.5 9.5 ± 0.5
valve DUMP
Control valve.
LH, RH
Swing control valve mm 9.5 ± 0.5 9.5 ± 0.5
travel
Forward,
Travel control valve mm 9.5 ± 0.5 9.5 ± 0.5
Reverse
Boom control lever mm 85 ± 10 85 ± 10
Operating effort of control levers and pedal Travel of control levers
q Engine stopped
Arm control lever mm 85 ± 10 85 ± 10
q Control lever grip at center
Bucket control lever mm 85 ± 10 85 ± 10
q Max. value reading up to stroke end
Swing control lever mm 85 ± 10 85 ± 10
(except lever play in NEUTRAL position)
Travel control lever mm 115 ± 12 115 ± 12
Work
mm Max. 15 Max. 20
equipment
Play of control lever
Travel mm Max. 20 Max. 25
N 15.7 ± 3.9 Max. 24.5
Boom control lever
{kg} {1.6 ± 0.4} {Max. 2.5}
N 15.7 ± 3.9 Max. 24.5
Arm control lever
{kg} {1.6 ± 0.4} {Max. 2.5}
N 12.7 ± 2.9 Max. 21.6
Bucket control lever
q Hydraulic oil temperature: Within operat- {kg} {1.3 ± 0.3} {Max. 2.2}
ing range N 12.7 ± 2.9 Max. 21.6
Swing control lever
q Engine at full speed {kg} {1.3 ± 0.3} {Max. 2.2}
q Control lever grip at center N 24.5 ± 5.9 Max. 39.2
Travel control lever
q Pedal at tip {kg} {2.5 ± 0.6} {Max. 4.0}
q Max. value reading up to stroke end
N 74.5 ± 18.6 Max. 107.6

Travel control pedal
{kg} {7.6 ± 1.9} {Max. 11}
* The low idle speed can be set to 2 levels.

1) When auto-decelerator is OFF: 1,050 rpm (Same with PC200-8 standard model)
2) When auto-decelerator is ON: 700 rpm (Exclusive for hybrid model)
PC200, 200LC-8E0 (Hybrid) 20-100 3

SEN05239-00 Standard value table for chassis related parts

q Hydraulic oil temperature: Within operat-
ing range
q Engine at full speed MPa 3.5 ± 1.0 3.5 ± 1.0
Unload pressure
q Working mode: P mode {kg/cm2} {36 ± 10} {36 ± 10}
q Hydraulic pump output pressure with all
control levers in NEUTRAL position
Normal MPa 34.8 ± 1.0 33.3 – 36.8
relief {kg/cm2} {355 ± 10} {340 – 375}
Boom relief
Power MPa 37.3 ± 1.0 36.3 – 39.2
q Hydraulic oil temperature: max. {kg/cm2} {380 ± 10} {370 – 400}
Within operating range MPa
Normal 34.8 ± 1.0 33.3 – 36.8
q Engine at full speed
relief {kg/cm2} {355 ± 10} {340 – 375}
Arm relief q Working mode: P mode
Power MPa 37.3 ± 1.0 36.3 – 39.2
q Hydraulic pump output pres-
sure with all measurement
max. {kg/cm2} {380 ± 10} {370 – 400}
circuits relieved Normal MPa 34.8 ± 1.0 33.3 – 36.8
relief {kg/cm2} {355 ± 10} {340 – 375}
Bucket relief
Hydraulic pressure
Power MPa 37.3 ± 1.0 36.3 – 39.2

max. {kg/cm2} {380 ± 10} {370 – 400}
q Hydraulic oil temperature: Within opera-
tion range
q Engine at full speed MPa 38.7(+1.0/-2.0) 36.8 – 40.2
Travel relief
q Working mode: P mode {kg/cm2} {395(+10/-20)} {375 – 410}
q Hydraulic pump output pressure with all
measurement circuits relieved
ing range
Control circuit q Engine running at full speed MPa 3.23(+0.2/-0.3) 2.75 – 3.43
source pressure q Self pressure reducing valve output pres- {kg/cm2} {33(+2/-3)} {28 – 35}
sure with all control levers in NEUTRAL
position
q Hydraulic oil temperature: When all
Within operating range control MPa 3.5 ± 1.0 3.5 ± 1.0
q Engine at full speed levers in
q Working mode: P mode NEUTRAL {kg/cm2} {36 ± 10} {36 ± 10}
LS differential pres-
q Traveling speed: Hi position
sure
q Run either track idle When
q LS differential pressare = Hy- travel MPa 1.8 ± 0.1 1.8 ± 0.1
draulic oil pump pressure – levers at {kg/cm2} {18 ± 1} {18 ± 1}
LS pressure half stroke
20-100 4 PC200, 200LC-8E0 (Hybrid)


ing range
q Engine running at full speed
Overrun when stop- deg. Max. 100 Max. 130
q Working mode: P mode
ping swing (mm) (—) (—)
q Swing circle misalignment amount when
stopping after one turn
q For measuring posture, see Swing 1
q Hydraulic oil temperature:
Within operating range
q Engine running at full speed 90° sec. 3.1 ± 0.3 Max. 3.7
Time taken to start
q Time required for passing
swing
points 90° and 180° from
starting point 180° sec. 4.4 ± 0.4 Max. 5.5
q For measuring posture, see
Swing
Swing 1
ing range
Time taken to swing q Working mode: P mode sec. 24.2 ± 2.5 Max. 30
q Time required for 5 more turns after mak-
ing initial one turn
ing range
q Engine stopped
q Keeping upper structure transverse on
Drift of upper struc-
slope of 15°, and make a mating mark on mm 0 0
ture
inner and outer races of swing circle
q Mating mark misalignment amount during
5 minutes
PC200, 200LC-8E0 (Hybrid) 20-100 5


q Hydraulic oil temperature: Lo sec. 51.3 ± 5.1 46.2 – 60.4

Travel speed
q Time required for track shoes Mi sec. 37.5 ± 3.8 33.7 – 45.3
(Run the track idle)
to make 5 turns after making
one initial idle turn
Travel 1 Hi sec. 26.5 ± 1.3 25.2 – 29.8

Lo sec. 24 ± 2.5 21.5 – 27.5
Travel speed q Working mode: P mode
Mi sec. 17 ± 2.5 14.5 – 20.5
(actual running) q Time required for traveling 20
m after 10 m trial run
Hi sec. 13 ± 1.0 12.0 – 15.0
Travel 2
Travel

ing range
Travel deviation mm Max. 150 Max. 250
q Travel speed: Lo
q Deviation while traveling 20 m (X) after ini-
tial 10 m trial run on solid and level ground
q For measuring posture, see Travel 2 and 3
ing range
q Engine stopped
Hydraulic drift of
q Parking machine on slope of 12° with mm 0 0
travel
sprocket facing upslope
q Sliding distance for 5 minutes
q For measuring posture, see Travel 4
ing range
Leakage of travel Engine at full speed
q l/min 13.6 27.2
motor q Traveling with sprocket locked by using
pin
20-100 6 PC200, 200LC-8E0 (Hybrid)


ing range
Whole work q Flat and level ground mm Max. 600 Max. 900
equipment
q Fill bucket with dirt or rated load (0.8 m3
14.1 kN {1,440 kg})
q Boom horizontal, arm fully retracted, buck-
Hydraulic drift of work equipment
et cylinder fully extended

q Engine stopped
Boom cylinder q Work equipment control lever in NEU- mm Max. 18 Max. 27
TRAL position
q Fall amount for 15 minutes as measured
every 5 minutes starting immediately after
initial setting
q Whole work equipment: Lowering dis-
Arm cylinder tance of tooth tip mm Max. 160 Max. 240
q Boom cylinder: Retraction distance of cyl-
inder
q Arm cylinder: Extension distance of cylin-
der
Work equipment
q Bucket cylinder: Retraction distance of

Bucket cylinder cylinder mm Max. 40 Max. 58
q For measuring posture, see Work equip-
ment 1
Within operating range RAISE sec. 3.3 ± 0.4 Max. 4.7
Boom q Working mode: P mode
q Time required from RAISE
stroke end till bucket touches LOWER sec. 2.4 ± 0.3 Max. 3.7
Work equipment speed
ground
Within operating range IN sec. 3.3 ± 0.4 Max. 4.7
Arm
q Time required from in stroke
end to OUT stroke end OUT sec. 2.7 ± 0.3 Max. 3.5
q Hydraulic oil temperature: CURL sec. 2.6 ± 0.3 Max. 3.3

Bucket
q Working mode: P mode DUMP sec. 1.9 ± 0.2 Max. 2.7
PC200, 200LC-8E0 (Hybrid) 20-100 7


ing range
q Engine running at low idle
Boom q Time required from RAISE stroke end till sec. Max. 1.0 Max.1.2
bucket touches ground and pushes up
machine front
ment 5
ing range
Work equipment

Time lag
q Time required from IN stroke end till buck-

Arm sec. Max.2.0 Max.2.8
et stops momentarily after control lever is
moved to IN position and starts to move
again
ment 6
ing range
q Time required from CURL stroke end till
Bucket sec. Max. 1.0 Max. 3.6
bucket stops momentarily after control le-
ver is moved to CURL position and starts
to move again
ment 7
Internal leakage
Cylinders ing range cc/min 4.5 20

q Leakage amount for one minute with cylin-
Center swivel der or travel to be measured in relief con- cc/min 10 50
joint dition
Performance in combined operation

ing range
Deviation in com- q Engine at full speed
bined operation of q Working mode: P mode
mm Max. 200 Max. 220
work equipment q Travel speed: Lo
and travel q Deviation while traveling 20 m after initial
10 m trial run on solid and level ground
q For measuring posture, see Travel 2 and 3
20-100 8 PC200, 200LC-8E0 (Hybrid)


Characteristics of PC flow control valve

ing range
Time required for q Rated load applied to bucket (0.8m3: 14.1
swinging from 0 to kN {1,440 kg}) 4.3 ± 0.4
sec.
90° with boom q On solid and level ground, set arm verti- (Reference value)
RASIE cally and lower back of bucket to ground
q Time required for swinging from 0 to 90°
with boom RAISE
ment 8
Hydraulic pump
— See performance of hydraulic pump (next page)
delivery
PC200, 200LC-8E0 (Hybrid) 20-100 9

Applicable model PC200, 200LC-8E0

Standard lower
Item Measurement condition Unit Standard value
limit of delivery
q Pump speed (rpm): 2,000 rpm
q PC-EPC current value (mA): 440 mA
Hydraulic pump
q Discharge pressure of test pump (MPa

Performance of {kg/cm2}) : P1 Q Q
q Discharge pressure of another pump l/min
hydraulic pump (See graph) (See graph)
(MPa {kg/cm2}): P2
q Average discharge pressure (MPa
{kg/cm2}): Pp=(P1+P2)÷2
a As far as possible, measure pump discharge pressure P1 and P2 as close as possible to the average pres-
sure.
Avoid measuring the near turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump delivery and the engine speed at the time of
measurement, and use them as a base for calculating the pump delivery the specified speed.
20-100 10 PC200, 200LC-8E0 (Hybrid)

For all models (Posture of machine for measur- Travel 1: Travel speed (run the track idle)
ing performance and measurement procedure)
Control valve: spool stroke
Travel 2: Travel speed (actual running), travel devi-

ation
Swing 1: Overrun when stopping swing, time taken

to start swing, time taken to swing
Travel 3: Travel deviation
Swing 2: Drift of upper structure
PC200, 200LC-8E0 (Hybrid) 20-100 11

Travel 4: Hydraulic drift of travel Work equipment 3: Arm speed
Work equipment 1: Hydraulic drift of work equipment Work equipment 4: Bucket speed
Work equipment 2: Boom speed Work equipment 5: Boom time lag
20-100 12 PC200, 200LC-8E0 (Hybrid)

Work equipment 6: Arm time lag
Work equipment 7: Bucket time lag
Work equipment 8: Characteristics of PC flow con-

trol valve
PC200, 200LC-8E0 (Hybrid) 20-100 13

SEN05239-00
©2009 KOMATSU
All Rights Reserved
20-100 14
SEN05241-01
SEN05241-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


101 Testing and adjusting, Part 1
Tools for testing, adjusting and troubleshooting ......................................................................................... 3

Testing engine speed.................................................................................................................................. 7
Testing boost pressure................................................................................................................................ 9
Checking exhaust gas color........................................................................................................................ 10
Adjusting valve clearance ........................................................................................................................... 11
Testing compression pressure.................................................................................................................... 13
Testing blowby pressure ............................................................................................................................. 16
Testing engine oil pressure......................................................................................................................... 17
Handling fuel system parts.......................................................................................................................... 18
Releasing remaining pressure from fuel system......................................................................................... 18
Testing fuel system pressure ...................................................................................................................... 19
Cylinder cut-out test mode operation .......................................................................................................... 21
No injection cranking operation................................................................................................................... 21
Testing fuel return rate and leakage ........................................................................................................... 22
Bleeding air from fuel circuit........................................................................................................................ 26
Testing fuel circuit for leakage .................................................................................................................... 27
Handling of controller high-voltage circuit ................................................................................................... 28
Testing and adjusting air conditioner compressor belt tension ................................................................... 29
Replacement of fan belt .............................................................................................................................. 30
Testing swing circle bearing clearance ....................................................................................................... 31
PC200, 200LC-8E0 (Hybrid) 30-101 1

SEN05241-01
Testing and adjusting track tension............................................................................................................. 32

Testing and adjusting hydraulic oil pressure in work equipment and travel circuits.................................... 34
Testing source pressure of control circuit ................................................................................................... 37
Testing and adjusting oil pressure in pump PC control circuit .................................................................... 38
Testing and adjusting oil pressure in pump LS control circuit ..................................................................... 41
Testing solenoid valve output pressure....................................................................................................... 45
Testing PPC valve output pressure............................................................................................................. 48
Adjusting play of work equipment and swing PPC valves........................................................................... 50
Checking parts which cause hydraulic drift of work equipment................................................................... 51
Releasing remaining pressure from hydraulic circuit .................................................................................. 53
Testing oil leakage ...................................................................................................................................... 54
Bleeding air from each part ......................................................................................................................... 56
Checking cab tipping stopper...................................................................................................................... 58
Adjusting mirrors ......................................................................................................................................... 59
Angle adjustment of rear view camera........................................................................................................ 61
Testing swing brake .................................................................................................................................... 62
Cleaning and replacement of oil filter of electric swing motor ..................................................................... 64
Operation check of swing emergency stop switch ...................................................................................... 65
30-101 2 PC200, 200LC-8E0 (Hybrid)

Tools for testing, adjusting and troubleshooting SEN05241-01
Tools for testing, adjusting and troubleshooting

Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
Testing boost pressure A 799-201-2202 Boost gauge kit 1 -101 – 200 kPa {-760 – 1,500 mmHg}
1 799-201-9001 Handy smoke checker 1
Testing exhaust gas color B Commercially Bosch index: 0 – 9
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting valve clearance C Commercially
2 Feeler gauge 1 Intake: 0.25 mm, Exhaust: 0.51 mm
available
1 795-799-6700 Puller 1 107E-1 engine
Testing compression pres-
sure
D 2 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
795-790-4410 Adapter 1 107E-1 engine
3
6754-11-3130 Gasket 1 107E-1 engine
1 799- 201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Testing blow-by pressure E
2 795-790-3300 Blow-by tool 1 107E-1 engine
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Testing engine oil pressure F Pressure gauge: 60 MPa {600
790-261-1204 Digital hydraulic tester 1
kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa {600
790-261-1204 Digital hydraulic tester 1
kg/cm2}
Testing fuel system pres-
G 795-790-4430 Adapter 1
sure 2 10×1.0 mm o R1/8
6215-81-9710 O-ring 1
3 795-790-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
4 795-790-5110 Screw 1
5 799-201-2202 Boost gauge kit 1
1 795-790-4700 Tester kit 1
2 795-790-6700 Adapter 1
6754-71-5340 Connector 1
Testing fuel return rate and 3
H 6754-71-5350 Washer 1
leakage Commercially
4 Measuring cylinder 1
available
Commercially
5 Stopwatch 1
available
Testing swing circle bear- Commercially
J Dial gauge 1
ing clearance available
Testing and adjusting {25, 60, 400, 600 kg/cm2}
1
hydraulic oil pressure in Pressure gauge: 60 MPa {600
K 790-261-1204 Digital hydraulic tester 1
work equipment and travel kg/cm2}
circuits 799-101-5220 Nipple 3
2 Size: 10×1.25 mm
07002-11023 O-ring 3
Pressure gauge:2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
1
Testing source pressure of Pressure gauge: 60 MPa {600
L 790-261-1204 Digital hydraulic tester 1
control circuit kg/cm2}
799-101-5220 Nipple 1
2 Size: 10×1.25 mm
07002-11023 O-ring 1
PC200, 200LC-8E0 (Hybrid) 30-101 3

SEN05241-01 Tools for testing, adjusting and troubleshooting
Sym-
bol
Testing and adjusting oil 1 {25, 60, 400, 600 kg/cm2}
pressure in pump PC con- M 790-261-1204 Digital hydraulic tester 1 Pressure gauge:60 MPa {600 kg/cm2}
trol circuit 799-101-5220 Nipple 6
2 Size: 10×1.25 mm
07002-11023 O-ring 6
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa {600
Testing and adjusting oil 790-261-1204 Digital hydraulic tester 1
pressure in pump LS con- N kg/cm2}
Differential pressure
trol circuit 2 799-401-2701 1 50 MPa {500 kg/cm2}
gauge
799-101-5220 Nipple 6
3 Size: 10×1.25 mm
07002-11023 O-ring 6
{25, 60, 400, 600 kg/cm2}
Testing solenoid valve out- 1
P Pressure gauge: 60 MPa {600
put pressure 790-261-1204 Digital hydraulic tester 1
kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
{25, 60, 400, 600 kg/cm2}
1
Testing PPC valve output Pressure gauge: 60 MPa {600
Q 790-261-1204 Digital hydraulic tester 1
pressure kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
3 799-401-3200 Adapter 1 Size: 03
799-601-4101
or T-adapter assembly 1
799-601-4201
799-601-4130 q T-adapter 1 Ne Sensor
799-601-4150 q T-adapter 1 For oil pressure sensor
Troubleshooting for engine For DRC60, ECONO (Not included in
controller/sensors/actua- R 799-601-4350 q Measurement box 1
799-601-4201)
tors 799-601-4211 q T-adapter 1 Engine controller
799-601-4220 q T-adapter 1 Engine controller
799-601-4250 q T-adapter 1 For boost pressure sensor
799-601-4260 q T-adapter 1 Engine controller
799-601-9020 q T-adapter 1 For injector
30-101 4 PC200, 200LC-8E0 (Hybrid)

Tools for testing, adjusting and troubleshooting SEN05241-01
Sym-
bol
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 T-adapter assembly 1 799-601-2900 is no more available
or
799-601-7100
or
799-601-7400
or
799-601-8000
For ECONO (Not included in
799-601-2600 q T-adapter box 1
799-601-2700)
799-601-4101
or
799-601-4201
799-601-9000
or
799-601-9200
For DRC60, ECONO and DT6P
799-601-4350 q Measurement box 1 (Not included in 799-601-4201,
799-601-9000 and 799-601-9200)
For DT and HD (Not included in
799-601-9320 Measurement box 1
Troubleshooting for chas- 799-601-4101 and 799-601-4201)
sis sensors/wiring har- S 799-601-9020 q Adapter for DT 1 For DT2P
nesses For DT3P (Not included in
799-601-9030 q Adapter for DT 1
799-601-4010 and 799-601-4201)
For DTP4 (Not included in
799-601-4260 q Adapter for DT 1
799-601-9000 and 799-601-9200)
For DT12P (Not included in
799-601-9110 q Adapter for DT (GR) 1
799-601-4100 and 799-601-4201)
For AMP3P (Not included in
799-601-9420 q Adapter for AMP 1
799-601-9000 and 799-601-9200)
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
For X1P (Not included in
799-601-7010 q Adapter for X 1
799-601-7000 and 799-601-7100)
799-601-7020 q Adapter for X 1 For X2P
For SW6P (Not included in
799-601-7050 q Adapter for SWP 1
799-601-8000)
For SW6P (Not included in
799-601-7060 q Adapter for SWP 1
799-601-8000)
799-601-7090 q Adapter for M For M2P
799-601-7140 q Adapter for S For S8P
PC200, 200LC-8E0 (Hybrid) 30-101 5

SEN05241-01 Tools for testing, adjusting and troubleshooting
Sym-
bol
799-601-7500 T-adapter assembly
799-601-7520 qAdapter for 070 For 070-12P
799-601-7540 q Adapter for 070 For 070-18P
799-601-8980 Adapter for multiple For DT-2, 3, 4/DTM-2P
Troubleshooting for chas-
799-601-4280 Measurement box AMP121P (for pump controller)
sis sensors/wiring har- S
nesses 799-601-7310 Adapter for SWP For SW12P
799-601-7360 Adapter for relay For REL-5P
799-601-7370 Adapter for relay For REL-6P
Socket for CRI-T2
799-601-9410 For YAMAZAKI2P
engine
Commercially
Testing oil leakage T Measuring cylinder 1
available
Testing coolant tempera-
— 799-101-1502 Digital thermometer 1 -99.9 – 1,299°C
ture and oil temperature
Testing operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
and depressing effort 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Testing stroke and hydrau- Commercially
— Scale 1
lic drift available
Testing work equipment Commercially
— Stopwatch 1
speed available
Testing voltage and resis- Commercially
— Circuit tester 1
tance available
Removal and installation
Commercially 3.26 mm Torx wrench
of boost pressure and tem- — Torx wrench 1
available (KTC Q4T15 or equivalent)
perature sensors
27 mm hexagonal deep socket
of engine oil pressure sen- — 795-799-6210 Deep socket 1
(inner diameter: 24.5 mm)
sor
19 mm deep socket
of engine coolant tempera- — 795T-981-1010 Deep socket 1
(MITOLOY 4ML-19 or equivalent)
ture sensor
30-101 6 PC200, 200LC-8E0 (Hybrid)

Testing engine speed SEN05241-01
Testing engine speed

3. Testing full speed
a Test the engine speed with the monitoring func- 1) Start the engine and set the fuel control dial
tion of the machine monitor. to the full speed (MAX) position.
a Test the engine speed under the following condi- 2) Keep the bucket lowered to the ground.
tion. 3) Set the working mode in the power mode (P)
q Engine coolant temperature: Within operat- and select the auto-deceleration OFF.
ing range 4) Fine control the travel lever (fine control
q Hydraulic oil temperature: Within operating within the dead band of the travel PPC valve)
range to increase the engine speed and check it
after it has stabilized.
1. Preparation work a Test without supplying oil to the travel
Operate the machine monitor so that the engine motor or moving the travel mechanism.
speed can be monitored. k If the travel lever is tilted too much (ex-
a For the operating method of the machine ceeds the dead band), the machine
monitor, see Special functions of machine starts moving in the travel lever opera-
monitor. tion direction. Accordingly, carry out
a Monitoring code:01002 Engine speed this check in a safe place so that no ac-
cidents occur even if the machine
moves.
4. Testing the engine speed when 2-pumps are

relieved
1) Arm IN relief condition
1] Start the engine and operate the arm
cylinder to the IN stroke end.
2] Set the fuel control dial to the full speed
(MAX) position and set the working mode
to the power mode (P).
3] Operate the left work equipment control
lever to relieve the arm circuit at the IN
stroke end and test the engine speed.
2. Testing low idle speed 2) Travel circuit relief condition
1) Start the engine and set the fuel control dial 1] Start the engine and lock the travel mech-
to the low idle (MIN) position. anism. For the method of locking the
2) Set all the control levers and pedals for work travel mechanism, see Testing and
equipmentl, swing, and travel to the neutral adjusting (Part 1), "Testing travel relief
positon and test the engine speed. pressure".
2] Set the working mode to power mode (P),
travel speed to Mi (medium) or Hi (high),
and fuel control dial to the full speed
(MAX).
k Before operating the travel lever
and pedal, check the lock pin posi-
tion and locking direction (forward
or reverse travel) again.
3] Operate the travel lever to relieve the
travel circuit oil and check the engine
speed at this time.
5. Testing 2-pump relief and power maximizing

speed (near rated speed)
1) Arm IN relief condition
1] Start the engine and operate the arm
cylinder to the IN stroke end.
PC200, 200LC-8E0 (Hybrid) 30-101 7

SEN05241-01 Testing engine speed
2] Set the fuel control dial to the full speed

(MAX) position and set the working mode
to the power mode (P).
3] While operating the left work equipment
control lever to relieve the arm circuit at
the IN stroke end and pressing the one
-touch power maximizing switch, test the
engine speed.
2) Travel circuit relief condition
1] Start the engine and lock the travel mech-
anism. For the method of locking the
travel mechanism, see Testing and
adjusting (Part 1), "Testing travel relief
pressure".
2] Set the working mode to power mode (P),
travel speed to Mi (medium) or Hi (high),
and fuel control dial to the full speed
(MAX) positon.
k Before operating the travel lever
and pedal, check the lock pin posi-
tion and locking direction (forward
or reverse travel) again.
3] While operating the travel lever to relieve
the travel circuit oil and holding down the
one-touch power maximizing switch, test
the engine speed.
a The one-touch power maximizing function is
reset automatically in approximately 8.5 sec-
onds even if the switch is kept pressed. Ac-
cordingly, test the engine speed in that
preiod.
a You may check with the swing lock switch
ON (In this case, you do not need to operate
the one-touch power maximizing switch.)
6. Testing the speed when auto-deceleration is

in operation
1) Start the engine, set the fuel control dial to
the full speed position (MAX), and turn the
auto-deceleration ON.
2) Set all the control levers and pedals for work
equipment, swing, and travel to the neutral
and measure the engine speed when the
auto-deceleration operates.
a If all the control levers and pedals are set to
neutral, the engine speed decreases to the
waiting speed (1,250 rpm). If the machine is
kept under this condition for 4 seconds or
more, the engine speed decreases further to
the deceleration speed (approximately 700
rpm). Check the engine speed at this time.
(Reference: See 10 Structure and function,
800 Electrical equipment, "Auto-deceleration
function".
30-101 8 PC200, 200LC-8E0 (Hybrid)

Testing boost pressure SEN05241-01
Testing boost pressure

a Testing tools for boost pressure 3. Run the engine at middle or higher speed and
Symbol Part No. Part name bleed oil from the hose.
A 799-201-2202 Boost gauge kit a Insert the connectior into the gauge halfway
k Stop the machine on level ground and lower in order to open the selfseal on the hose side
the work equipment to the ground. repeatedly, and the oil will be drained.
a Test the boost pressure under the following con- a If Pm kit (A) is available, use the air bleeding
dition. coupling (790-261-1130) in that kit.
q Engine coolant temperature: Within operat- a If oil is left in the hose, the gauge does not
ing range work. Accordingly, be sure to drain the oil.
q Hydraulic oil temperature: Within operating
range 4. Set the working mode to the power mode (P) and
turn the swing lock switch ON.
1. Open the engine hood and remove boost pres- a If the swing lock switch is turned ON, the
sure pickup port plug (1) (R1/8) from the intake main relief valve is set for high-pressure re-
air connector. lief.
5. While running the engine at full speed, relieve

the arm circuit at the IN and measure the boost
pressure.
2. Install nipple [2] of boost gauge kit A and

connect it to gauge [1].
6. After finishing test, remove the testing tools and

return the removed parts.
PC200, 200LC-8E0 (Hybrid) 30-101 9

SEN05241-01 Checking exhaust gas color
Checking exhaust gas color

a Testing tools for exhaust gas color
Symbol Part No. Part name
1 799-201-9001 Handy smoke checker
B Commercially
2 Smoke meter
available
k Stop the machine on level ground and lower
the work equipment to the ground.
k Be careful not to touch any hot part when re-
moving or installing the testing tools.
a Test the exhaust gas color under the following
condition.
q Engine coolant temperature: Within operat-
ing range 2) Connect the probe hose, plug of the acceler-
a If an air source and an electric power source are ator switch, and air hose to smoke meter B2.
not available in the field, use handy smoke a Limit the supplied air pressure to1.5 MPa
checker B1. When recording official data, use {15 kg/cm2}.
smoke meter B2. 3) Connect the power cable to the AC100V
receptacle.
1. Testing by using handy smoke checker B1 a Check that the smoke meter power switch
1) Place a sheet of filter paper to smoke is in the OFF position, before connecting
checker B1. the power cable to the receptacle.
2) nsert the exhaust gas intake pipe in exhaust 4) Loosen the cap nut of the suction pump and
pipe (1). place the filter paper.
3) Start the engine and accelerate it suddenly or a Place the filter paper securely so that the
run it at full speed and operate the handle of exhaust gas will not leak.
smoke checker B1 so that the filter paper will 5) Turn on the power switch of smoke meter B2.
absorb the exhaust gas.
a Absorbing time: 1.4 ± 0.2 sec
6) Start the engine and accelerate it suddenly or

run it at full speed and depress the acceler-
4) Remove the filter paper and compare it with ator pedal of smoke meter B2 and collect the
the attached scale for judgement. exhaust gas into the filter paper.
5) After finishing testing, remove the testing 7) Put the polluted filter paper on non-polluted
tools and return the removed parts. filter paper (more than 10 sheets) in the filter
paper holder, and read the indicated value.
2. Testing by using smoke meter B2 8) After finishing testing, remove the testing
1) Insert probe [1] of smoke meter B2 in the tools and return the removed parts.
outlet of the exhaust pipe and fix it to the
exhaust pipe with a clip.
30-101 10 PC200, 200LC-8E0 (Hybrid)

Adjusting valve clearance SEN05241-01
Adjusting valve clearance

a Valve clearance adjustment tools 3. Rotate the crankshaft in the normal direction by
Symbol Part No. Part name using gear C1 and align wide slit (a) in the speed
1 795-799-1131 Gear sensor ring with projection top (b) of the front
C Commercially cover.
2 Feeler gauge
available
a Projection top (a) must be within the range of
k Stop the machine on level ground and lower wide slit (b) when it is seen from the air con-
the work equipment to the ground. ditioner compressor side.
a Adjust the valve clearance under the following k Note that this aligning method does not
condition. bring No.1 or No.4 cylinder to TDC posi-
q Engine coolant temperature: Normal temper- tion.
ature
1. Open the engine hood and remove cylinder

head cover (1).
a Since the breather connector on the rear side
of the cylinder head cover is connected to the
flywheel housing by using the O-ring, pull it
together with the cylinder head cover.
4. Check the movement of the rocker arm of the

No. 1 cylinder to determine the valve to be
adjusted.
a If you can move the rocker arms of exhaust
valves (EX) by hand by the valve clearance
amount, adjust the valves marked with q in
the valve arrangement drawing.
a If you cannot move the rocker arm of exhaust
2. Remove plug (2) above the starting motor and valve (EX) by hand ,adjust the valves marked
install gear C1. with Q in the valve arrangement drawing.
a Valve arrangement drawing
PC200, 200LC-8E0 (Hybrid) 30-101 11

SEN05241-01 Adjusting valve clearance
5. Adjust the valve clearance according to the

following procedure.
1) While adjustment screw (3) is being held
from turning, loosen lock nut (4).
2) Place feeler gauge C2 in the clearance
between rocker arm (5) and crosshead (6)
and adjust the valve clearance with adjust-
ment screw (3).
a With the feeler gauge placed, turn the ad-
justment screw until a slight drag is felt on
the feeler gauge.
3) While adjustment screw (3) is being held
from turning, tighten locknut (4).
3 Locknut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
a After tightening the locknut, check the
valve clearance again.
6. Rotate the crankshaft in the normal direction by

1 turn and align wide slit (b) with projection top
(a) according to step 3.
7. Adjust the other valve clearances according to

steps 4 and 5.
a If the valves marked with Q in the valve ar-
rangement drawing were adjusted in steps 4
and 5, adjust the valves marked withq.
a If the valves marked with q in the valve ar-
rangement drawing were adjusted in steps 4
and 5, adjust the valves marked with Q.
8. After finishing adjustment, remove the testing

tools and return the removed parts.
k Be sure to remove gear C1 .
3 Cylinder head cover mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
30-101 12 PC200, 200LC-8E0 (Hybrid)

Testing compression pressure SEN05241-01
Testing compression pressure

k When testing the compression pressure,
take care not to burn yourself on the exhaust
manifold, muffler, ect. or get caught in a rota-
tion part.
a Test the compression pressure when the engine

is warm.
(Engine oil temperature: 40 – 60 °C)
1. Remove cylinder head cover (1).

a For the following procedure, see Disassem-
bly and assembly, "Removal and installation
of fuel injector assembly". 6. Using tool D2, remove injector (5).
2. Loosen injector terminal nuts (4) and remove the 7. Install adapter D3 to the injector mounting hole
harness terminals from the injector. by using the injector holder, and connect
compression gauge D1.
3. Set the cylinder to be tested to the compression a Be sure to install the gasket to the adapter
top dead center. tip.
a See “Adjusting valve clearance" for the bar- a Tighten the holder mounting bolts alternately.
3 Injector holder mounting bolt:
ring method.
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
a If a little quantity of engine oil is applied to the
4. Remove the mounting bolts of rocker arm
joint of the adapter and gauge, air does not
assembly (2) on the exhaust side and remove
leak easily.
rocker arm assembly (2) on the exhaust side.
a When removing the injector, you do not need
to remove the rocker arm assembly on the in-
take side.
5. Remove fuel tube (3) and inlet connector (7)

inside the cylinder head
a The inlet connector is connecting the fuel
tube to the injector.
PC200, 200LC-8E0 (Hybrid) 30-101 13

SEN05241-01 Testing compression pressure
8. Install rocker arm assembly (2) on the exhaust

side and adjust the valve clearance.
3 Rocker arm assembly mounting bolt :
36 ± 5 Nm {3.67 ± 0.5 kgm}
a See “Adjusting valve clearance".
2) Tighten injector holder mounting bolts (10)

three to four threads.
3) Set fuel inlet connector (7) to the injector.
a Press it in until you feel the O-ring clicks
in.
9. Disconnect all the injector wiring harness 4) Tighten partially retainer (6) for connector
connectors. (7).
k If the connectors are not disconnected, 3 Retainer : 15 ± 5Nm {1.5 ± 0.5 kgm}
the engine will start during testing and a Tighten retarner to the specification in
that will be dangerous. Accordingly, be step (6)
sure to disconnect them. 5) Alternately tighten injector holder mounting
k If the engine is cranked with no electric bolts (10).
power supply to the engine controller, the 3 Injector holder mounting bolt :
common rail may be damaged. Ensure 8 ± 0.8 Nm {0.8 ± 0.08 kgm}
that the engine controller is powered. 6) Tighten retainer (6) of the fuel inlet
k Cover the female halves of the discon- connector.
nected connectors with a vinyl sheet etc. 3 Inlet connector retainer : 50 ± 5Nm
to prevent electric leakage and ground {5.1 ± 0.5 kgm}
fault.
10. Rotate the crankshaft by the starting motor and

test the compression pressure.
a Read the pressure gauge pointer when it is
stabilized.
11. After finishing testing, remove the testing tools

and return the removed parts.
a Install the injector and high-pressure fuel
tube according to the following procedure.
1) Mate protrusion (a) of the injector with notch
(b) of the injector holder, and set the injector
to the cylinder head.
a Set the injector with the above mating po-
sition toward the fuel inlet connector
pass-through.
30-101 14 PC200, 200LC-8E0 (Hybrid)

Testing compression pressure SEN05241-01
12. After installing the rocker arm assembly, adjust

the valve clearance. For details, see "Adjusting
valve clearance".
3 Rocker arm assembly mounting bolt :
36 ± 5 Nm {3.67 ± 0.51 kgm}
a Install injector wiring harness terminals (4)
taking care that they will not interfere with
rocker arm (2) wh en the rocker arm moves
up and down.
13. Tighten the injector terminal nuts with the

following torque.
3 Terminal nut :
1.5 ± 0.25 Nm {0.15 ± 0.025 kgm}
a Check that the injector wiring harness does
not interfere with the rocker arm.
14. Tighten the head cover mounting nuts to the

following torque.
3 Head cover mounting nut :
24 ± 4Nm {2.45 ± 0.41 kgm}
PC200, 200LC-8E0 (Hybrid) 30-101 15

SEN05241-01 Testing blowby pressure
Testing blowby pressure

a Testing tools for blowby pressure
1 799-201-1504 Blowby checker
E
2 795-790-3300 Blowby tool
a Test the blowby pressure under the following
condition.
ing range
range
1. Remove the undercover of the hydraulic pump.
2. Install tool and adapter [1] of blowby checker E1 or
blowby tool E2 to breather hose (1) and connect
gauge [2].
3. Start the engine, set the working mode to the

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

the arm circuit at the IN and measure the blowby
pressure.
a Read the blow-by pressure value, when the
needle of the gauge is stabilized.
30-101 16 PC200, 200LC-8E0 (Hybrid)

Testing engine oil pressure SEN05241-01
Testing engine oil pressure 3. Start the engine and turn the auto-deceleration
OFF.
a Testing tools for engine oil pressure
799-101-5002 Hydraulic tester
4. Test the oil pressure during the engine low idling
1 and high idling.
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

a Test the engine oil pressure under the following
condition.
ing range
1. Open the side cover of the pump room and

remove oil pressure pickup port plug (1) from the
engine oil filter head.

2. Install nipple [1] of hydraulic tester F1 and connect

hydraulic tester F2.
PC200, 200LC-8E0 (Hybrid) 30-101 17

SEN05241-01 Handling fuel system parts
Handling fuel system parts Releasing remaining pressure

a Precautions for testing and maintaining fuel sys- from fuel system
tem a Pressure is generated in the low-pressure circuit
The common rail fuel injection system (CRI) and high-pressure circuit of the fuel system while
consists of more precise parts than the conven- the engine is running.
tional fuel injection pump and injectors. If Low-pressure circuit:
contaminant enters this system, it can cause a Feed pump – Fuel main filter – Supply pump
trouble. High pressure circuit:
When testing and maintaining the fuel system, Fuel supply pump – Common rail – Fuel in-
take care more than the past. If dust, etc. sticks jector
to any part, wash that part thoroughly with clean a The pressure in both low-pressure circuit and
fuel. high-pressure circuit lowers to a safety level au-
a Precautions for replacing fuel filter cartridge tomatically after 30 seconds when the engine
Be sure to use the Komatsu genuine fuel filter stops.
cartridge. a Before the fuel circuit is tested and its parts are
Since the common rail fuel injection system removed, the remaining pressure in the fuel cir-
(CRI) consists of more precise parts than the cuit must be released completely. Accordingly,
conventional fuel injection pump and injectors, it observe the following.
employs a high-efficiency special filter to prevent k Before testing the fuel system or removing
contaminant from entering it. If a filter other than its parts, wait at least 30 seconds after stop-
the genuine one is used, the fuel system may ping the engine until the remaining pressure
have a trouble. Accordingly, never use such a in the fuel circuit is released. (Do not start the
filter. work just after stopping the engine since
there is residual pressure.)
30-101 18 PC200, 200LC-8E0 (Hybrid)

Handling fuel system parts SEN05241-01
Testing fuel system pressure

a Testing tools for fuel pressure
Symbol Part number Part name
1
790-261-1204 Digital hydraulic tester
Adapter
795-790-4430
2 (10 × 1.0 mm o R1/8)
G
6215-81-9710 O-ring
3 799-401-2320 Gauge
4 795-790-5110 Screw
5 799-601-2202 Boost gauge kit
k Park the machine on level ground and lower
a Test only the fuel pressure in the low-pressure 3) Start the engine and test the pressure in the
circuit from the feed pump through the fuel main fuel low-pressure circuit with the auto-decel-
filter to the supply pump and the return circuit eration OFF and the engine at low idle.
from the supply pump/common rail/injector to a If the pressure in the fuel low-pressure cir-
fuel tank. cuit is in the following range, it is normal.
k Since the pressure in the high-pressure cir-
0.5 – 1.3 MPa
cuit from the supply pump through the com- At low idle
{5.1 – 13.3 kg/cm2}
mon rail to the injector is very high, it cannot 0.3 – 1.1 MPa
be tested. During cranking
{3.1 – 11.3 kg/cm2}
1. Testing pressure in fuel low-pressure circuit k If the engine cannot be started, you
1) Open the side cover of the pump room and may test the fuel return rate while ro-
remove fuel pressure pickup port plug (on the tating the engine with the starting mo-
fuel inlet side) (1) from the fuel main filter tor. Do not run the starting motor for
head. more than 30 seconds continuously,
however, for protection of the starting
motor.
2) Install adapter G2 and nipple [1] of hydraulic

tester G1 and connect them to oil pressure
gauge [2]. 4) After finishing test, remove the testing tools
a Use the oil pressure gauge of 2.5 MPa and return the removed parts.
3 Fuel pressure pickup port plug:
{25 kg/cm2}.
10 ± 2 Nm {1 ± 0.2 kgm}
PC200, 200LC-8E0 (Hybrid) 30-101 19

SEN05241-01 Handling fuel system parts
2. Testing pressure in fuel return circuit 3. Measuring fuel negative-pressure circuit pres-
1) Disconnect fuel return hose (2). sure
1) Remove joint bolt (2) of fuel hose (1) between
the prefilter and supply pump (3).
2) Install fuel pressure gauge adapter kit G3

and connect it to pressure gauge G4.
2) Connect fuel hose (1) to supply pump (3) by
installing tool G4 instead of joint bolt (2).
a When installing tool G4, place the gas-
kets to both sides of banjor connector on
the fuel hose.
3 Tool G4: 19.6 – 29.4 Nm {2.0 – 3.0
kgm}
3) Connect tool G4 to tool G5.
3) Run the engine at low idle and test the pres-

sure in the fuel return circuit.
a If the pressure in the fuel return circuit is
in the following range, it is normal.
At low idle 0.02 MPa or less
During cranking {0.19 kg/cm2 or less}
q Pressure gauge G4 has an "inHg"
scale.
q Conversion: 5.5 inHg o 18.63 kPa
4) Run the engine and test the circuit negative
k If the engine cannot be started, you
pressure at high idle.
may test the fuel return rate while ro- Circuit standard negative pressure : –50.7
tating the engine with the starting mo- kPa {–380 mmHg} or less.
tor. Do not run the starting motor for 5) If the negative pressure is higher than the
more than 30 seconds continuously, criteria, the fuel prefilter may be clogged. In
however, for protection of the starting this case, replace the fuel prefilter and test
motor. again.
4) After finishing test, remove the testing tools 6) After finishing test, remove the testing instru-
and return the removed parts.3 ments and return the removed parts.
3 Joint bolt (2) :
3 Fuel pressure pickup port plug:
24 ± 4 Nm {2.4 ± 0.4 kgm} 19.6 – 29.4 Nm{ 2.0 – 3.0 kgm}
30-101 20 PC200, 200LC-8E0 (Hybrid)

Cylinder cut-out test mode operation SEN05241-01
Cylinder cut-out test mode opera- No injection cranking operation

tion a No-injection cranking means to rotate the engine
a Cylinder cut-out test mode operation means to by the starting motor while the fuel injection into
run the engine with the fuel injector of one or all the cyliders are stopped electrically. The pur-
more cylinders disabled electrically to reduce the pose and effect of this operation are as follows.
number of active cylinders. The purpose and ef- Before the engine is started after it or the
fect of this operation are as follows. machine has been stored for a long period, the
1. This operation is used to find out a cylinder no-injection cranking is performed to lubricate
which does not output power properly (i.e. the engine parts and protect them from seizure.
combustion in it is abnormal). a See the section of “Special functions of machine
2. When fuel to a cylinder is shut off, if the engine monitor” when performing the no injection
speed and output do not change from those cranking operation.
before cylider cut-out (all-cylinder operation),
that cylinder has one or more problems.
The possible problems are as follows.
Gas leakage through the cylinder head gas-
ket
Defective injection from the injector
Defective piston or piston ring
Defective valve mechanism
Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the technician can perform the cylinder
cut-out test easily by operating the switches to
find out a defective cylinder comparing with the
mechanical fuel injection system.
a See the section of “Special functions of ma-
chine monitor” when performing the cylinder
cut-out operation.
a Use the cylinder cut-out test mode for only
the purpose of troubleshooting.
PC200, 200LC-8E0 (Hybrid) 30-101 21

SEN05241-01 Testing fuel return rate and leakage
Testing fuel return rate and a Do not crank the engine for more than 30
leakage seconds to protect the starting motor in
any case other than this test.
a Testing tools for fuel delivery, return rate and a If the supply pump delivery is in the fol-
leakage lowing standard range, it is normal.
Symbol Part number Part name At cranking speed (125
1 795-790-4700 Tester kit 75 cc or more
rpm)
2 795-790-6700 Adapter At cranking speed (150
6754-71-5340 Connector 90 cc or rmore
3 rpm)
6754-71-5350 Washer
H q [Delivery [Q]:
Commercially
4 Measuring cylinder
available Q=Engine speed x 0.6
Commercially
5 Stopwatch
available
a Since some fuel flows out during test, prepare a
container of approximately 20 l.
1. Testing supply pump delivery

1) Loosen clamp (2) of discharge tube (1) of the
supply pump and disconnect tube (1).
2) Install test hose H1 to the nipple on the

discharge side of the supply pump.
a Tie the hose with a wire etc.
a Put the end as the testing hose in the con-
tainer so that it will not sag.
3) Crank the engine for 30 seconds and

measure the delivery by using measuring
cylinder H4.
30-101 22 PC200, 200LC-8E0 (Hybrid)

Testing fuel return rate and leakage SEN05241-01
2. Testing supply pump return rate 4) Run the engine at low idle and measure the
1) Disconnect quick coupler (2) of the supply return rate in 25 sec by using measuring
pump return hose from connector (3) on the cylinder H4.
pump. a If the return rate from the supply pump is
At low idle 1,000 cc/min or less
During cranking 140 cc/min or less
may test the fuel return rate while ro-
tating the engine with the starting mo-
tor. Do not run the starting motor for
more than 30 seconds continuously,
however, for protection of the starting
motor.
2) Install connector H3 and cap nut [1] of tester

kit H2 to quick coupler (2) side of the return
hose to stop the fuel from flowing out.
a Install the seal washer between connec-
tor H3 and cap nut [1].
3) Connect test hose [2] of tester kit H1 to the
supply pump.
a Put the end of the testing hose in the con-
5) After finishing test, remove the testing tools

a When testing the leakage from the pres-
sure limiter or finishing the test: Return
the removed parts to their original posi-
tions.
a When testing the return rate from the in-
jector: Leave the removed parts as they
are and keep the test hose end in the con-
tainer.
PC200, 200LC-8E0 (Hybrid) 30-101 23

SEN05241-01 Testing fuel return rate and leakage
3. Testing leakage from pressure limiter

1) Disconnect quick coupler (4) of the return
hose of the pressure limiter from connector
(5) on the pump.

3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
2) Install connector H3 and cap nut [1] of tester
kit H1 to the return hose side to stop the fuel 4. Testing return rate from injector
from flowing out. a The fuel return rate from the injector is tested
3) Connect test hose [2] of tester kit H1 to the while the return hose of the pressure limiter is
common rail. connected. Accordingly, before testing the
a Put the end of the testing hose in the con- return rate from the injector, check that the
tainer so that it will not sag. leakage from the pressure limiter is normal.
1) Referring to “Measuring return rate from
supply pump”, set the supply pump for test.
k The fuel returning from the supply
pump flows out during measurement
of the return rate from the injector. Ac-
cordingly, keep the test hose end in
the container.
2) Disconnect return hose (6) of the return
block.
a Keep the seal washer installed to the re-
turn hose.
4) Run the engine at low idle and test the return

rate in 1 minute by using measuring cylinder
H4.
a If the leakage from the pressure limiter is
0 cc/min.
At low idle
(No leakage)
30-101 24 PC200, 200LC-8E0 (Hybrid)

Testing fuel return rate and leakage SEN05241-01
3) Install removed joint bolt (7) and cap nut [1]

of tester kit H1 to the return hose side to stop
the fuel from flowing out.
4) Install connector H3 to the manifold side and
connect test hose [3] of tester kit H1.
a Put the end of the testing hose in the con-
5) Run the engine at low idle and measure the

return rate in 1 minute by using measuring
cylinder H4.
a If the return rate from the injector is in the
following range, it is normal.
During cranking 90 cc or less
At low idle 120 cc or less

may measure the fuel return rate while
rotating the engine with the starting
motor. Do not run the starting motor
for more than 30 seconds continuous-
ly, however, for protection of the start-
ing motor.

3 Joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
PC200, 200LC-8E0 (Hybrid) 30-101 25

SEN05241-01 Bleeding air from fuel circuit
Bleeding air from fuel circuit

a If fuel is used up or if a fuel circuit part is removed
and installed, bleed air from the fuel circuit ac-
cording to the following procedure.
1. Fill the fuel tank with fuel to the brim.

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

then pump it.
a Operate the knob until it becomes heavy.
a The plug at the top of the fuel main filter head
does not need to be removed.
There may be a case where air remains in the

water separator even after air bleeding opera-
tion. In this case, engine can be started if the
feed pump knob is operated until it becomes
heavy. Operate the engine, then stop it and
leave it as it is. Air will disappear by itself.
This phenomenon occurs when the fuel in the
prefilter is removed excessively, and does not
mean the failure in the fuel system.
4. After bleeding air, push in and tighten knob (1).
30-101 26 PC200, 200LC-8E0 (Hybrid)

Testing fuel circuit for leakage SEN05241-01
Testing fuel circuit for leakage 9. Stop the engine and check the fuel piping and
devices for fuel leakage.
k Very high pressure is generated in the
a Check the high-pressure fuel circuit parts
high-pressure circuit of the fuel system. If
coated with the color checker and their pe-
fuel leaks while the engine is running, it is
ripheries for fuel leakage.
dangerous since it can catch fire.
a If any fuel leakage is detected, repair it and
After testing the fuel system or removing its
perform inspection again from step 1.
parts, test it for fuel leakage according to the
a If no fuel leakage is detected, check is com-
pleted.
a Clean and degrease the engine and the parts
around it in advance so that you can find easily
fuel leakage.
1. Spray color checker (developer) over the supply
pump, common rail, fuel injectors, and joints of
the high-pressure fuel piping.
2. Run the engine at a speed below 1,000 rpm and

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

leakage.
4. Start the engine and keep it running at low idle.
5. Stop the engine and check the fuel piping and

6. Start the engine and keep it running at high idle.
7. Stop the engine and check the fuel piping and

perform inpection again from step 1.
8. Start the engine and keep it running at high

speed under the load.
a Relieve the arm circuit at the IN stroke end.
PC200, 200LC-8E0 (Hybrid) 30-101 27

SEN05241-01 Handling of controller high-voltage circuit
Handling of controller
high-voltage circuit
1. When disconnecting or connecting the

connector between the engine controller and the
engine, be sure to turn the starting switch to the
OFF position.
2. Do not start the engine while a T-adapter is

inserted into or connected to the connector
between the engine controller and the engine for
troubleshooting purposes.
a Set the starting switch to the OFF or ON po-
sition and do not set it to the START position.
30-101 28 PC200, 200LC-8E0 (Hybrid)

Testing and adjusting air conditioner compressor belt tension SEN05241-01
Testing and adjusting air condi- Adjusting

tioner compressor belt tension a If the belt deflection is abnormal, adjust it accord-
ing to the following procedure.
the work equipment to the ground. 1. Loosen bolts (1) and (2).
Checking 2. Move compressor (3) and bracket (4) together to

1. Open the engine hood and remove the belt adjust the belt tension.
guard from the top of the air conditioner
compressor. 3. After positioning compressor (3), tighten bolts
(1)(2) and (2).
a Check each pulley for breakage, wear of the
V-groove, and contact of the V-belt and
V-groove.
a If the V-belt is so elongated that no adjust-
ment allowance remains or it has a cut or a
crack, replace it with a new one.
a If the belt is replaced, adjust the tension
again after operating the machine for 1 hour.
a After tightening the bolts, check the belt ten-
sion again according the above procedure.
2. Press the intermediate point of the belt between

fan pulley and compressor pulley with a thumb
and measure deflection (a) of the belt.
q Belt pressing force: 60 N {6.2 kg}
4. After finishing checking and adjusting, return the

removed parts.
PC200, 200LC-8E0 (Hybrid) 30-101 29

SEN05241-01 Replacement of fan belt
Replacement of fan belt

a The auto-tensioner is provided for the fan belt.
Thus, testing and adjustment of the belt is usual-
ly not necessary.
a Disconnect air conditioner compressor belt be-
fore replacing the fan belt.
1. Open the engine hood and remove hose clamps

(1) (3 places).
2. Remove turbocharger cooling hose (2).
3. Remove compressor belt guard (3) and fan belt

guards (4) and (5). 5. Replace the fan belt (2).
q Check each pulley for breakage and crack.
4. Insert a wrench to the portion (A) (width across

flats: 12.7 mm) of the tensioner assembly (3),
and move it in the direction of decreasing the fan
belt (2) tension.
k Make sure that the wrench is applied se-
curely to the portion (A) of the tensioner
assembly (3) before rotating it. (The
spring in the tensioner assembly (3) is
strong. If the wrench is loosely applied,
the wrench may accidentally come off
while being moved and it is extremely
dangerous.)
k After removing the fan belt (2), return the
tensioner assembly (3) slowly with care.
k Be careful not to get your fingers caught
between the pulley and fan belt (2) during
work.
30-101 30 PC200, 200LC-8E0 (Hybrid)

Testing swing circle bearing clearance SEN05241-01
Testing swing circle bearing clear- 4. Set the arm almost perpendicular to the ground
ance and lower the boom until the front part of the
track floats.
a Testing tools for swing circle bearing clearance a At this time the front of the upper structure
Symbol Part No. Part name rises and the rear lowers.
Commercially
J Dial gauge
available
5. Under this condition, read dial gauge J.
a When testing the swing circle bearing clearance a The value indicated by dial gauge J is the
on the complete machine, perform the following clearance of the bearing.
procedure. a For the standard value, see Structure, func-
k Stop the machine on level ground and lower tion and maintenance standard, "Swing cir-
the work equipment to the ground. cle".
k Do not put your hands or feet under the un-
dercarriage during testing.
1. Fix dial gauge J to the track frame and apply the

probe to the lower surface of the outer race.
6. Return the machine to the condition of step 2

and check that dial gauge J indicates zero
a If the dial gauge does not indicate zero, re-
peat steps 2 through 5.
2. Set the work equipment to the maximum reach

posture and set the bucket tip to the height of the
under side of the revolving frame.
a At this time the front of the upper structure
lowers and the rear rises.
3. Set dial gauge J to the zero point.
PC200, 200LC-8E0 (Hybrid) 30-101 31

SEN05241-01 Testing and adjusting track tension
Testing and adjusting track Adjusting

tension a If the track tension is abnormal, adjust it accord-
ing to the following procedure.
Testing
1. Run the engine at low speed and drive the 1. Increasing tension
machine forward by the length of track on 1) Add grease through grease fitting (1) with a
ground, and then stop slowly. grease gun.
2) To check that the tension is normal, run the
2. Place steel bar [1] on the track between the idler engine at low speed and move the machine
and the 1st carrier roller. forward by the length of track on ground, then
a As the steel bar [1], use an angle steel, etc. stop slowly.
which will not deflect. 3) After adjusting, check the track tension again
according to the above procedure.
3. Measure maximum clearance (a) between steel
bar [1] and track shoe.
q Standard maximum clearance (a):
10 – 30 mm
a You may add grease until dimension (b)

between the idler guide and track frame
end becomes 0 mm. If the tension is still
low, the pins and bushings are worn ex-
cessively. In this case, reverse or replace
the pins and bushings.
30-101 32 PC200, 200LC-8E0 (Hybrid)

Testing and adjusting track tension SEN05241-01
2. Decreasing tension
1) Loosen valve (2) to discharge grease, and
then tighten valve (2) .
k Do not loosen the valve more than one
turn. If it is loosened more, it may
jump out because of the internal
high-pressure grease.
2) To check that the tension is normal, run the
engine at low speed and move the machine
forward by the length of track on ground, then
stop slowly.
3) After adjusting, check the track tension again
according to the above procedure.
PC200, 200LC-8E0 (Hybrid) 30-101 33

SEN05241-01 Testing and adjusting hydraulic oil pressure in work equipment and travel circuits
Testing and adjusting hydraulic 2) Install nipples K2 and connect oil pressure
oil pressure in work equipment gauges [1] of hydraulic tester K1.
a Use the oil pressure gauges of 60 MPa
and travel circuits
{600 kg/cm2}.
a Testing and adjusting tools for oil pressure in
work equipment and travel circuits.
1
K
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
the work equipment to the ground. Then, re-
lease the remaining pressure from the hy-
draulic circuit. For details, see "Releasing
remaining pressure from hydraulic circuit".
Testing
a The oil pressure in the work equipment and trav-
el circuits (pump discharge pressure) can be 2. Combination of pump, actuator, and valve
checked by using the monitoring function of the a When the oil from the pumps is divided, the
machine monitor, too (For details, see “Special front pump and rear pump act independently
functions of machine monitor”). on each actuator. Note that the relieved valve
q Monitoring code: 01100 F pump pressure varies depending on the actuator.
q Monitoring code: 01101 R pump pressure a When the work equipment circuit or swing cir-
a Test the oil pressure in the work equipment and cuit is relieved singly, the oils of the pumps
travel circuits under the following condition. are merged. When the travel circuit is re-
q Hydraulic oil temperature: Within operating lieved singly, the oils of the pumps are divid-
range ed.
a The actuators in the table are arranged in the
1. Preparatory for work order when the control valve is seen from the
1) Open the side cover of the pump room and front of the machine (and the service valve is
remove oil pressure pickup port plugs (1) and used for an attachment).
(2). Actuator Valve relieved
(R unload valve) (R main relief valve)
q (1): Front pump discharge pressure pick-
Rear pump
Service Safety-suction valve

up port plug Bucket R main relief valve
q (2): Rear pump discharge pressure pick- Left travel R main relief valve
up port plug RAISE: R main relief valve
Boom
Lower: Safety-suction valve
(Pump merge-divider valve) (Travel junction valve)
(Self pressure reducing valve)
Front pump
Right
F main relief valve
travel
Arm F main relief valve
(F unload valve) (F main relief valve)
(Centralized safety valve) (Back pressure valve)
30-101 34 PC200, 200LC-8E0 (Hybrid)

Testing and adjusting hydraulic oil pressure in work equipment and travel circuits SEN05241-01
3. Testing unload pressure

1) Start the engine, set the working mode to the
power mode (P), and turn the auto-decelera-
tion OFF.
2) Run the engine at full speed, set all the levers
and pedals for work equipment control, swing
control, and travel control to the neutral
positin, and measure the oil pressure.
a The pressure measured when the unload
valve of the control valve functioned is in-
dicated.
2) Set the working mode to the power mode (P).

3) Run the engine at full speed, operate the
travel lever and pedal to relieve the travel
motor, and measure the oil pressure.
k Before operating the travel lever and
pedal, check the lock pin position and
locking direction (forward travel or re-
verse travel) again.
a The pressure measured when the main
relief valve of the control valve is relieved
is indicated. The travel circuit is always
relieved at high pressure.
4. Testing work equipment relief pressure
1) Start the engine and move the cylinder to be 6. Work after finishing test
measured to the stroke end. After finishing test, remove the testing tools and
2) Set the working mode to the power mode (P). return the removed parts.
3 Oil pressure pickup port plug:
20 – 27 Nm {2.0 – 2.8 kgm}
right and left work equipment control levers
to relieve the cylinder, and measure the oil
pressure.
a The pressure measured when the main
relief valve is relieved is indicated (If the
boom is lowered singly, the safety-suction
valve of the control valve for lowering the
boom is relieved).
a If the one-touch power maximizing switch
is released, the main relief valve is re-
lieved at low pressure. If the former is
pressed, the latter is relieved at high pres-
sure.
a If the swing lock switch is turned ON, the
2-stage relief solenoid valve is kept
turned ON and the relief valve is relieved
at high pressure. Accordingly, keep the
swing lock switch turned OFF.
5. Testing travel relief pressure

1) Run the engine and lock the travel mecha-
nism.
k Put pin [2] between the sprocket and
track frame to lock the travel mecha-
nism securely.
PC200, 200LC-8E0 (Hybrid) 30-101 35

SEN05241-01 Testing and adjusting hydraulic oil pressure in work equipment and travel circuits
Adjusting
a The unload valve and safety-suction valve for
lowering the boom cannot be adjusted.
1. Adjusting work equipment and travel relief

pressure
a If the relief pressure of the work equipment
circuit and travel circuit is abnormal, adjust
main relief valves (3) and (4) according to the
q (3): Front (F) main relief valve
q (4): Rear (R) main relief valve
a When adjusting the main relief valves, re-
move the top cover of the control valve. 5) Connect pilot hose (5).
a Adjust only the low relief pressure of the main
6) After finishing adjustment, check again that
relief valve. If the low relief pressure is adjust-
the oil pressure is normal according to the
ed, the high relief pressure is set automati-
above described testing procedure.
cally.
a The low relief pressure is the pressure under
the following condition: the 2-stage relief so-
lenoid valve is turned OFF and the pilot pres-
sure is not applied to the selector port.
1) Disconnect pilot hose (5).

2) While fixing holder (6), loosen locknut (7).
3) Turn holder (6) to adjust the set pressure.
a If the holder is
q turned to the right, the set pressure is
increased.
q turned to the left, the set pressure is
decreased.
a Amount of adjustment per turn of holder:
Approx. 20. 5 MPa {Approx. 209 kg/cm2}
4) While fixing holder (6), tighten locknut (7).
3 locknut: 49 – 58.8 Nm {5 – 6 kgm}
30-101 36 PC200, 200LC-8E0 (Hybrid)

Testing source pressure of control circuit SEN05241-01
Testing source pressure of 3. Start the engine, set the working mode to the
control circuit power mode (P), and turn the auto-deceleration
OFF.
a Testing tools for source pressure of control cir-
cuit 4. Run the engine at high idle, set all the levers and
Symbol Part No. Part name pedals for work equipment control, swing
1 control, and travel control to the neutral positon,
L and measure the oil pressure.
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
draulic circuit. For details, see “Releasing
remaining pressure from hydraulic circuit”.
a Test the source pressure of control circuit under
the following condition.
range
1. Remove the control valve top cover and oil pres-

sure pickup port plug (1).

a The source pressure of control circuit may be
tested by using oil pressure pickup port plug
(2) on the hydraulic pump side.
2. Install nipples L2 and connect oil pressure gauge

[1] of hydraulic tester L1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.
a Do not adjust the relief valve for control circuit
source pressure.
PC200, 200LC-8E0 (Hybrid) 30-101 37

SEN05241-01 Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure

in pump PC control circuit
pump PC control circuit
1
M
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
remaining pressure from hydraulic circuit”. 2) Install nipples M2 and nipples [1] of hydraulic
tester M1 and connect them to oil pressure
Testing gauges [2].
a Before testing the oil pressure in the PC control a Connect the pressure gauge to the mea-
circuit, check that the oil pressure in the work suring part of plug (3) by using joint
equipment, swing, and travel circuits and the (790-301-1271) and elbow
source pressure of the control circuit are normal. (790-301-1530) of hydraulic tester M1
a Test the oil pressure in the pump PC control cir- and nipple [1] so that it will not interfere
cuit under the following condition. with the drain piping.
range {600 kg/cm2}.
1. Testing PC valve output pressure (servo piston

inlet pressure)
a Test the PC valve output pressure (servo pis-
ton inlet pressure) and pump discharge pres-
sure simultaneously and compare them.
1) Open the side cover of the pump room and
remove oil pressure pickup port plugs (1), (2),
(3), and (4).
up port plug
q (2): Rear pump discharge pressure pick-
up port plug
q (3): Front PC valve output pressure pick- 3) Start the engine and operate the arm cylinder
up port plug to the IN stroke end.
q (4): Rear PC valve output pressure pick-
4) Set the working mode to the power mode (P)
up port plug and turn the swing lock switch ON.
a If the swing lock switch is turned ON, the
main relief valve is set for high-pressure
relief.
30-101 38 PC200, 200LC-8E0 (Hybrid)

Testing and adjusting oil pressure in pump PC control circuit SEN05241-01
5) Run the engine at full speed, operate the left 2) Install nipples M2 and connect them to oil
work equipment control lever to relieve the pressure gauges [2].
arm circuit at the IN stroke end, and measure a Use the oil pressure gauges of 6 MPa
the oil pressure. {60 kg/cm2}.
a Testing condition and method of judg- 3) Start the engine and set the working mode to
ment: If the pressures are in the following the power mode (P).
ratio, the PC valve is normal.
4) Set all the levers and pedals for work equip-
Measured oil Operation of Ratio of oil
ment control, swing control, and travel
pressure lever pressures
Pump discharge
control to the neutral position, run the engine
1 at high idle and low idle, and test the oil pres-
pressure
Arm IN relief sure at each speed.
PC valve output Approx. 0.6
pressure (Approx. 3/5)
a If the PC valve or the servo piston is ab-
normal, the PC valve output pressure
(servo piston inlet pressure) is "the same
as the pump discharge pressure" or "al-
most zero".
2. Measuring PC-EPC valve output pressure

remove oil pressure pickup plug (5) and (6).
q (5): Front PC-EPC valve output pressure
a Testing condition and method of judg-
pickup port plug
ment: If the output pressures are in the
q (6): Rear PC-EPC valve output pressure
following ratio, the PC-EPC valve is nor-
pickup port plug
mal.
Operation of
Engine Output pressure
lever
Approx. 2.9 MPa
Low idle All control
{Approx. 30 kg/cm2}
levers and ped-
0 MPa
High idle als in neutral
{Approx. 0 kg/cm2}
5) After finishing test remove the testing tools

PC200, 200LC-8E0 (Hybrid) 30-101 39

SEN05241-01 Testing and adjusting oil pressure in pump PC control circuit
Adjusting 1. Loosen locknut (9).

Adjusting pump PC valve a Before loosening the locknut, put matchmark
a If either of the following phenomena occurs and to the adjustment screw end so that you can
the PC valve seems to be defective, adjust PC see the position of the locknut before the ad-
valves (7) and (8) according to the procedure justment (and you can return the locknut to its
shown below. original position after turning it in reverse).
q As the load increases, the engine speed low-
ers considerably. 2. Turn adjustment screw (10) clockwise or coun-
q The engine speed is normal but the work terclockwise for the adjustment.
equipment speed is low. a Turn the adjustment screw
q (7): Front pump PC valve q clockwise when the work equipment
q (8): Rear pump PC valve speed is low (to increase pump absorp-
a The width across flats of the PC valve locknut is tion torque) and
13 mm and that of the adjustment screw (inside q counterclockwise when the engine speed
width) is 4 mm. lowers (to decrease pump absorption
Do not turn any other locknuts or adjustment torque).
screws since they affects the hydraulic pump
performance. 3. Tighten locknut (9).
3 Locknut:27 – 34 Nm {2.8 – 3.5 kgm}
4. After finishing adjustment, check again that the

PC valve output pressure (servo piston inlet
pressure) is normal according to the above
described measurement procedure.
30-101 40 PC200, 200LC-8E0 (Hybrid)

Testing and adjusting oil pressure in pump LS control circuit SEN05241-01
Testing and adjusting oil pressure

in pump LS control circuit
pump LS control circuit
1
N 2 799-401-2701 Differential pressure gauge
799-101-5220 Nipple(10 × 1.25 mm)
3
07002-11023 O-ring
draulic circuit. For details, see “Releasing 2) Install nipples N3 and nipples N1 of hydraulic
remaining pressure from hydraulic circuit”. tester [1] and connect them to oil pressure
gauges [2].
Testing a Connect the measuring part of plug (3) by
a Before testing the oil pressure in the PC control using joint (790-301-1271) and elbow
circuit, check that the oil pressure in the work (790-301-1530) of hydraulic tester N1
equipment and travel circuits and the source and nipple [1] so that it will not interfere
pressure of the control circuit are normal. with the drain piping.
a Test the oil pressure in the pump LS control cir- a Use the oil pressure gauges of 60 MPa
cuit under the following condition. {600 kg/cm2}.
range
1. Testing LS valve output pressure (servo piston

inlet pressure)
a Test the LS valve output pressure (servo pis-
ton inlet pressure) and pump discharge pres-
sure simultaneously and compare them.
remove oil pressure pickup plugs (1), (2), (3),
and (4).
up port plug
3) Start the engine and push up the track on the
up port plug side to be measured by using the work equip-
q (3): Front LS valve output pressure pick-
ment and prepare for running the track idle.
up port plug q When measuring front circuit: Right track
q (4): Rear LS valve output pressure pickup
q When measuring rear circuit: Left track
k Since the raised track runs during test-
port plug
ing, secure a sufficient working area.
and set the travel speed to the High.
PC200, 200LC-8E0 (Hybrid) 30-101 41

SEN05241-01 Testing and adjusting oil pressure in pump LS control circuit

and pedals for work equipment control and
travel control to the neutral position, and
measure the oil pressure under this condi-
tion. Then, operate the travel lever to run the
track idle and measure the oil pressure.
k While taking extream care for safety,
run the raised track.
a Do not operate the travel lever to the
stroke end (stop it halfway).
q (5): Front LS pressure pickup port plug

q (6): Rear LS pressure pickup port plug

ment: If the pressures are in the following
ratio, the LS valve is normal
Position of
levers and ped- Travel lever
All levers and
als moved half-
Hydraulic pres-
pedals are at 2) Install nipples N3 and connect it to differential
way (track
neutral pressure gauge N2 or the oil pressure gauge
sure to be mea- idle)
sured of hydraulic tester N1.
Pump discharge Actual value a When using differential pressure gauge
pressure is set as 1 N2:
Almost same
Approx. 3/5 Connect the pump discharge pressure to
LS valve out put pressure
of pressure the high pressure side (back side) and
pressure
above connect the LS pressure to the low pres-
6) After finishing test, remove the testing tools sure side (lower side). Since the differen-
and return the removed parts. tial pressure gauge needs a 12V power
source, connect it to a battery.
2. Testing LS differential pressure a When using oil pressure gauge (in N1):
a Test the pump discharge pressure and LS Use the oil pressure gauge of 60 MPa
pressure (actuator load pressure) simultane- {600 kg/cm2} having the unit of 1 MPa
ously and calculate the difference between {10 kg/cm2}. Since the differential pres-
them. sure is about 4 MPa {40 kg/cm2} at
1) Open the side cover of the pump room and maximum, measure it by installing the
remove oil pressure pickup plugs (1), (2), (5), same gauge to the pickup port plugs
and (6). alternately.
up port plug
up port plug
30-101 42 PC200, 200LC-8E0 (Hybrid)

Testing and adjusting oil pressure in pump LS control circuit SEN05241-01
q The figure shows the pump discharge a Do not operate the travel lever to the
pressure side. stroke end (stop it halfway).
ment: If the pressures are in the following
ratio, the LS valve is normal.
LS differential
Operation of lever
pressure
All control levers and pedals Specified LS dif-
are at neutral ferential pres-
sure (See
Travel lever moved halfway
standard values
(track run idle)
table)

q The figure shows the LS pressure side. 3. Testing LS-EPC valve output pressure
remove oil pressure pickup port plug (7).
3) Run the engine, push up the track on the side

to be measured by using the work equip-
ment, and prepare for idling the track.
q When measuring front circuit: Right track
q When measuring rear circuit: Left track
k Since the raised track runs during test-
ing, secure a sufficient working area.
and set the travel speed to the High.
and pedals for work equipment control and
travel control to the neutral position, and
measure the oil pressure under this condi-
tion. Then, operate the travel lever to run the
track idle and measure the oil pressure.
k While taking extream care for safety,
run the raised track.
PC200, 200LC-8E0 (Hybrid) 30-101 43

SEN05241-01 Testing and adjusting oil pressure in pump LS control circuit
2) Install nipple N3 and connect them to oil pres- Adjustment

sure gauge [2]. Adjusting LS valve
a Use the oil pressure gauges of 6 MPa a If the LS differential pressure is abnormal, adjust
{60 kg/cm2}. the LS valve according to the following proce-
dure.
q (8): Front pump LS valve
q (9): Rear pump LS valve
3) Start the engine.

travel speed switch and travel lever, and
measure the output pressure in each case.
1. While fixing adjustment screw (10), loosen lock
nut (11).
ment: If the output pressures are in the
following ratio, the LS-EPC valve is nor-
mal. 2. Turn adjustment screw (10) to adjust the differ-
Operation of
ential pressure.
Travel speed
lever
Output pressure a If the adjustment screw is
Approx.2.9 MPa q turned to the right, the differential pres-
Travel lever in {Approx. sure is increased.
Low
neutral q turned to the left, the differential pressure
30 kg/cm2}
Travel lever is decreased.
0 MPa
High operated a little a Amount of adjustment (LS differential pres-
{0 kg/cm2}
(Note) sure) per turn of adjustment screw:
Note: Move the travel lever to a degree that the PPC Approx. 1.1 MPa {Approx. 10.8 kg/cm2}
oil pressure switch is turned ON (before the track
starts moving). 3. While fixing adjustment screw (10) , tighten
locknut (11).
3 Locknut: 49 – 68.6 Nm {5 – 7 kgm}

4. After finishing adjustment, check again that the

LS differential pressure is normal according to
the above described testing procedure.
30-101 44 PC200, 200LC-8E0 (Hybrid)

Testing solenoid valve output pressure SEN05241-01
Testing solenoid valve output a When testing at hoses (2) – (6), remove the
pressure undercover of the control valve.
a Testing tools for solenoid valve output pressure

1
P 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (size 02)

draulic circuit. For details, see “Remaining
residual pressure from hydraulic circuit”.
a Before testing the solenoid valve output pres-
sure, check that the source pressure of the con-
trol circuit is normal.
2. Install adapter P2 and connect the disconnected
a Test the solenoid valve output pressure under
hose again.
range 3. Install nipple [1] of hydraulic tester P1 and
connect it to oil pressure gauge [2].
a Use the oil pressure gauge of 6 MPa
1. Disconnect one of outlet hoses (1) – (6) of the
solenoid valves to be measured. {60 kg/cm2}.
No Solenoid valve to be measured a The figure shows the testng tools connected
1 PPC lock solenoid valve to outlet hose (1) of the PPC lock solenoid
2 2-stage relief solenoid valve valve.
3 Swing brake solenoid valve
4 Travel speed selector solenoid valve
5 Travel junction solenoid valve
ATT return selector solenoid valve
6
(for the machine with attachment)
a When testing at hose (1), remove the under-
cover (rear side) of the operator's cab.
PC200, 200LC-8E0 (Hybrid) 30-101 45

SEN05241-01 Testing solenoid valve output pressure
4. Start the engine.
5. Run the engine at full speed, operate the control

levers and switches to turn the solenoid valve
ON or OFF, and measure the oil pressure.
a For the conditions for turning the solenoid
valve ON and OFF, see the operation table of
each solenoid valve.
a The operating condition of the solenoid valve
can be checked by using the monitoring func-
tion of the machine monitor (For details, see
“Special functions of machine monitor" ).
q Monitoring code: 02300 Solenoid 1
q Monitoring code: 02301 Solenoid 2
a If the output pressure is as follows, the sole-

noid valve is normal.
Solenoid valve Output pressure
OFF (De-energized) 0 MPa {0 kg/cm2}
ON (Energized) 2.9 MPa {30 kg/cm2}

30-101 46 PC200, 200LC-8E0 (Hybrid)

Testing solenoid valve output pressure SEN05241-01
Operation table of PPC lock solenoid valve

Operating condition Operation
Lock OFF
Lock lever
Free ON
Operation table of 2-stage relief solenoid valve

Opera-
Operating condition
tion
Overheat 1st setting is ON
Overheat 2nd setting is ON OFF
All of work equipment, swing, and travel signals are OFF
Swing lock switch is ON
Travel signal is ON
Boom LOWER signal is ON ON
Signals other than swing single
P/E-mode is
Left knob switch is ON signal are ON
selected
Swing single signal is ON
OFF
Other than above condition
Operation table of swing brake solenoid valve

Opera-
Operating condition
tion
Work equipment, swing, and All are OFF OFF
travel signals Any one is ON ON
Operation table of travel speed switching solenoid valve

Opera-
Operating condition
tion
Overheat 2nd setting is ON
Fuel control dial is at 1,500 rpm or below
Travel speed switch is at Lo/Mi
Travel signal is OFF OFF
F or R pump pressure is 24.5 MPa {250 kg/cm2}
Travel speed switch is at Hi Travel signal is or higher
ON F or R pump pressure is 15.3 MPa {150 kg/cm2}
or higher ON
Other than above condition
Operation table of travel junction solenoid valve

Opera-
Operating condition
tion
Travel steering signal is ON
Travel lever is F or R pump pressure is 24.5 MPa {250 kg/cm2} or ON
Travel steering signal is OFF operated singly higher
Other than above condition OFF
PC200, 200LC-8E0 (Hybrid) 30-101 47

SEN05241-01 Testing PPC valve output pressure
Testing PPC valve output pressure
a The above figure shows the connecting points of

the PPC piping on the control valve on the ma-
chine with an attachment. The colors in ( ) are
the colors of the bands installed for distinction of
the pipes.
a The figure at right shows the check point of the
steering signal voltage of the travel PPC valve.
When measuring the steering signal voltage, re-
move the undercover of the operator's cab (front
side).
30-101 48 PC200, 200LC-8E0 (Hybrid)

Testing PPC valve output pressure SEN05241-01
a Testing tools for PPC valve output pressure

1
Q
2 799-401-3100 Adapter (size 02)
3 799-401-3200 Adapter (size 03)
remaining pressure from hydraulic circuit”.
a Before testing the PPC valve output pressure,
check that the control circuit source pressure is
normal.
a If the output pressure is as follows, the PPC
a Test the solenoid valve output pressure under
valve is normal.
Operation of lever Output pressure
Neutral 0 MPa MPa {0 kg/cm2}
range
Almost same as control
circuit source pressure
1. Disconnect the hose of the PPC circuit to be Stroke end
(See standard values
tested. table)
a For the hose to be disconnected, see
“Connecting points of PPC piping”.
2. Install adapter Q2 and connect the disconnected
hose again.
3. Install nipple [1] of hydraulic tester Q1 and

connect it to oil pressure gauge [2].
{60 kg/cm2}.
a The figure shows the testing tools connected
to the hose of the bucket dump PPC circuit.
4. Start the engine and set the working mode to the

power mode (P).
5. Run the engine at full speed and measure the oil

pressure with the control lever in neutral and
moved to the stroke end.
PC200, 200LC-8E0 (Hybrid) 30-101 49

SEN05241-01 Adjusting play of work equipment and swing PPC valves
Adjusting play of work equipment

and swing PPC valves
a If the right and left work equipment levers have
large play, adjust them according to the following
procedure.
a The play of the lever tip must be 0.5 – 3 mm at a
position of 200 mm from the fulcrum.
1. Remove the work equipment and swing PPC

valve assembly.
2. Remove bellows (1).
3. Loosen locknut (2) and screw down disc (3) until

it touches the heads of 4 pistons (4).
a Do not move the piston while doing this work.
4. Fix disc (3) and tighten locknut (2) to the speci-

fied torque.
3 Locknut: 69 – 88 Nm {7 – 9 kgm}
5. Install bellows (1).
6. Install the work equipment and swing PPC valve

assembly.
30-101 50 PC200, 200LC-8E0 (Hybrid)

Checking parts which cause hydraulic drift of work equipment SEN05241-01
Checking parts which cause 2. Checking arm cylinder

hydraulic drift of work equipment 1) Stop the arm cylinder approximately 100 mm
before the IN stroke end and stop the engine.
a If the work equipment (cylinder) drifts hydrauli-
cally, check to see if the cause is on the cylinder
packing or control valve according to the follow-
ing procedure.
1. Checking boom cylinder and bucket cylinder

1) Set the machine to the posture for testing
hydraulic drift and stop the engine.
a Fill the bucket with a rated load or with dirt
and sand.
2) Operate the arm control lever to the IN posi-

tion.
q If the lowering speed is increased at this
time, the cylinder packing is defective.
q If the lowering speed does not change at
this time, the control valve is defective.
a Operate the control lever while the start-
ing switch is in the ON position.
a If the pressure in the accumulator is lost,
run the engine for approximately 5 sec-
2) When checking the boom cylinder, set the onds to raise the pressure in the accumu-
boom control lever to the RAISE position. lator.
When checking the bucket cylinder, set the [Reference]
bucket control lever to the CURL position. Reason why the lowering speed is increased by
q If the lowering speed is increased at this the above operation when the cylinder packing is
time, the cylinder packing is defective. the cause of the hydraulic drift:
q If the lowering speed does not change at 1) If the machine is set to the above posture
this time, the control valve is defective. (where the holding pressure is applied to the
a Operate the control lever while the start- bottom side), the oil leaks from the bottom
ing switch is in the ON position. side to the head side. Since the volume on
a If the pressure in the accumulator is lost, the head side is less than that on the bottom
run the engine for approximately 5 sec- side by the volume of the rod, the pressure in
onds to raise the pressure in the accumu- the head side is increased by the oil flowing
lator. in from the bottom side.
2) As the pressure in the head side is increased,
it is balanced at a certain level (which
depends on the leakage), and then the
lowering speed is decreased.
3) If the circuit on the head side is opened to the
drain circuit by the abovementioned lever
operation (the bottom side is closed by the
check valve at this time), the oil on the head
side flows in the drain circuit. As a result, the
pressure is balance is lost and the lowering
speed is increased.
PC200, 200LC-8E0 (Hybrid) 30-101 51

SEN05241-01 Checking parts which cause hydraulic drift of work equipment
3. Checking PPC valve

While the pressure in the accumulator is high,
set the lock lever to the LOCK position and
FREE position measure the lowering distance.
a Operate the control lever while the starting
switch is in the ON position.
a If the pressure in the accumulator is lost, run
the engine for approximately 5 seconds to in-
crease the pressure in the accumulator.
a If there is a difference in the lowering dis-
tance between the LOCK position and FREE
position, the PPC valve is defective (it has an
internal defect).
30-101 52 PC200, 200LC-8E0 (Hybrid)

Releasing remaining pressure from hydraulic circuit SEN05241-01
Releasing remaining pressure 4) Repeat the above steps 2) and 3) two to

from hydraulic circuit three times, and the remaining pressure in
the piping is released completely.
1. Releasing remaining pressure from
hydraulic tank 3. Releasing remaining pressure from travel
k Since the hydraulic tank is airtight and motor circuit
pressurized, release the remaining pres- Since the control valve spool of the travel motor
sure from it when removing a hose or a circuit is open, the pressure in this circuit can be
plug connected to it. released by performing “Releasing remaining
1) Lower the work equipment to the ground in a pressure from hydraulic tank”.
stable posture and stop the engine.
2) Loosen oil filler cap (1) of the hydraulic tank
gradually to release the air in the tank.
2. Releasing remaining pressure from

hydraulic cylinder circuit
k When disconnecting a pipe between the
hydraulic cylinder and the control valve,
release the remaining pressure from the
piping according to the following proce-
dure.
1) Lower the work equipment and release the
remaining pressure from the hydraulic tank.
For details, see “Remaining remaining pres-
sure from hydraulic tank”.
a Keep the oil filler cap of the hydraulic tank
removed.
2) Turn the starting switch to ON position and
set the lock lever to the FREE position, and
then operate the right and left work equip-
ment control levers forward, backward, to the
right, and to the left.
a The control valve is operated by the pres-
sure in the accumulator. The pressure in
the accumulator is used up, however, af-
ter the control valve is operated 2 – 3
times.
3) Run the engine at low speed for 5 seconds to
increase the pressure in the accumulator.
a The engine does not start unless the lock
lever is set to the LOCK position once.
PC200, 200LC-8E0 (Hybrid) 30-101 53

SEN05241-01 Testing oil leakage
Testing oil leakage

a Testing tools for oil leakage 2. Testing oil leakage from arm cylinder
Symbol Part No. Part name 1) Move the arm cylinder to the IN stroke end
Commercially and stop the engine.
T Measuring cylinder
k Release the remaining pressure from
available
a Test the oil leakage under the following condi- the piping on the arm cylinder head
tion. side. For details, see Releasing re-
q Hydraulic oil temperature: Within operating maining pressure from hydraulic cir-
range cuit (Operate the lever in the arm IN
direction only, however).
1. Testing oil leakage from boom cylinder 2) Disconnect hose (2) from the cylinder head
1) Move the boom cylinder to the RAISE stroke side and block the hose end with a flange.
end and stop the engine. k Take care not to disconnect the hose
k Release the remaining pressure from from the cylinder bottom.
the piping on the boom cylinder head a Use the following part to block the hose
side. For details, see “Releasing re- end .
maining pressure from hydraulic cir- 07379-00640 (Flange #06)
cuit” (Operate the lever in the boom
RAISE direction only, however).
2) Disconnect hoses (1) from the cylinder head
and block the hose end with a flange.
k Take care not to disconnect the hose
from the cylinder bottom.
a Use the following parts to block the hose
end.
07379-00640 (Flange #06)
3) Run the engine at full speed and relieve the

arm circuit by moving the arm IN.
k Take care not to "move the arm OUT".
4) Start measuring the oil leakage 30 seconds
after relieving is started and measure
leakage for 1 minute.
5) After finishing test, return the removed parts.

boom circuit by raising the boom.
k Take care not to "lower the boom".
after relieving is started and measure
leakage for 1 minute.
30-101 54 PC200, 200LC-8E0 (Hybrid)

Testing oil leakage SEN05241-01
3. Testing oil leakage from bucket cylinder 4. Testing oil leakage from travel motor
1) Move the bucket cylinder to the CURL stroke 1) Remove the travel motor cover.
end and stop the engine. 2) Run the engine, lock the travel mechanism,
k Release the remaining pressure from and stop the engine.
the piping on the bucket cylinder head kPut pin [1] between the sprocket and
side. For details, see Releasing re- track frame to lock the travel mecha-
maining pressure from hydraulic cir- nism securely.
cuit (Operate the lever in the bucket
CURL direction only, however).
2) Disconnect hose (3) from the cylinder head
side and block the hose end with a flange.
k Take care not to disconnect the hose
from the cylinder bottom.
a Use the following part to block the hose
end .
07379-00640 (Flange # 06)
3) Disconnect drain hose (5) of the travel motor

and block the hose end with a plug.
a Use the following part to block the hose
end.
07376-70422 (Plug #04)

bucket circuit by curling the bucket.
k Take care not to “Dump the bucket”.
after relieving is started and measure leak-
gage for 1 minute.
5) After finishing test , return the removed parts.
4) Run the engine at full speed, relieve the

travel circuit, and measure the oil leakage.
k Before operating the travel lever,
check the lock pin position and lock-
ing direction (forward travel or reverse
travel) again.
k Wrong operation of the lever can
cause an accident. Accordingly, make
signals and checks securely.
a Start measuring the oil leakage 30 sec-
onds after relieving is started and mea-
sure leakage for 1 minute.
a Measure several times, moving the motor
a little (changing the position of the valve
plate and cylinder, and that of the cylinder
and piston) each time.
PC200, 200LC-8E0 (Hybrid) 30-101 55

SEN05241-01 Bleeding air from each part
Bleeding air from each part

Air bleeding items
Air bleeding procedure
1 2 3 4 5
Checking oil
Bleeding air Bleeding air
Starting Bleeding air level and
from hydraulic from travel
engine from cylinder operating
pump motor
machine
q Replacing hydraulic oil q
q q q q
q Cleaning strainer (See note)
q Replacing return oil filter element q o o q
q Replacing and repairing hydraulic
Contents of work
pump q q q o q
q Removing suction piping
q Replacing and repairing control valve
q q o q
q Removing control valve piping
q Replacing and repairing cylinder
q q o q
q Removing cylinder piping
q Replacing and repairing travel motor
q o q q
q Removing travel motor piping
q Replacing and repairing swivel joint
q o o q
q Removing swivel joint piping
Note: Bleed air from the travel motors only when the oil in the motor cases is drained.
1. Bleeding air from hydraulic pump 2. Starting engine

1) Loosen air bleeder (1) and check that oil When running the engine after performing step
oozes out through the air bleeder. 1, let it idle at low speed for 10 minutes.
2) After the oil oozes out, tighten air bleeder (1). a If the engine coolant temperature is low and
3 Air bleeder: the automatic warm-up operation is started,
7.8 – 9.8 Nm {0.8 – 1.0 kgm} stop the engine temporarily and cancel the
a Do not use an impact wrench to tighten automatic warm-up operation by using the
the air bleeder. fuel control dial (Set the starting switch to the
ON position and hold the fuel control dial at
the MAX position for 3 seconds. This cancels
the automatic warm-up operation).
3. Bleeding air from cylinder

a In the case of cylinder replacement, bleed air
from the cylinder before connecting it to the
work equipment. In particular, the boom cyl-
inder does not move to the lowering stroke
end, if it is installed to the work equipment.
1) Run the engine at low idle for about 5
minutes.
2) While running the engine at low speed, raise
and lower the boom 4 – 5 times.
a Stop the piston rod approximately 100
mm before each stroke end. Do not re-
lieve the oil.
3) While running the engine at full speed,
perform step 2).
4) While running the engine at low speed, move
the piston rod to the stroke end and relieve
the oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) – 4).
30-101 56 PC200, 200LC-8E0 (Hybrid)

Bleeding air from each part SEN05241-01
4. Bleeding air from travel motor 2) Check the oil level by sight gauge (3) on the
1) Run the engine at low idle. rear side of the hydraulic tank.
2) Loosen air bleeder (2) and check that oil a If the oil level is below line L, it is insuffi-
oozes out through the air bleeder. cient. Add oil.
3) After the oil oozes out, tighten air bleeder (2). a The oil level changes according to the oil
3 Air bleeder:
temperature. Add oil when the oil level is
27.5 – 35.3 Nm {2.8 – 3.6 kgm} out of the following standard ranges.
q When oil temperature is 10 – 30 °C:
Between line H and line L
q When oil temperature is 50 – 80 °C:
Near line H
5. Checking oil level and operating machine

1) Run the engine, retract the arm cylinder and
bucket cylinder to the stroke end, lower the
work equipment to the ground, and stop the
engine.
PC200, 200LC-8E0 (Hybrid) 30-101 57

SEN05241-01 Checking cab tipping stopper
Checking cab tipping stopper
a Check the cab tipping stopper according to the

q Check the tightening torque of the mounting bolt

(1) of the lock plate (2).
3 Bolt (2): 98 – 123 Nm {10 – 12.5 kgm}
[Reference]
q Note that the tightening torque of mounting bolt
(4) of cab tipping stopper (3) is different from that
of a common bolt 30 mm in diameter.
3 Bolt (4): 245 – 309 Nm {25 – 31.5 kgm}
30-101 58 PC200, 200LC-8E0 (Hybrid)

Adjusting mirrors SEN05241-01
Adjusting mirrors
PC200, 200LC-8E0 (Hybrid) 30-101 59

SEN05241-01 Adjusting mirrors
Installation and adjustment of mirrors

1. Installation of retractable mirrors
Install foldable mirrors (a1) and (b1) as shown in
the figure.
1) Foldable mirror (a1): Install at 20 mm from
the bottom of the intermediate stay. Install
mirror stay (1) so that the mirror will be fixed
at (A) position out of the 3 stopping positions
where the mirror is extended most and at an
angle of about 86° to the intermediate stay.
3 Mirror bolt (5):

4.0 – 5.4 Nm {0.41 – 0.55 kgm}
3 Mirror stay bolt (6): 15 Nm {1.52 kgm}
3 Mirror bolt (2):

4.0 – 5.4 Nm {0.41 – 0.55 kgm}
3 Mirror stay bolt (3): 15 Nm {1.52 kgm}
a If the tightening torque is too low, the
joint part may move together with mir-
ror stay (1) when the mirror is folded.
If it is too high, body will be damaged 4) Fold the mirror to position (C) when trans-
when the mirror is folded because mir- porting the machine.
ror stay (1) may not rotate in the joint
part and the folding force is applied to
2. Adjustment of foldable mirrors
the intermediate stay.
With foldable mirrors (a1) and (b1) extended,
loosen mirror bolts (1) and (2) and adjust the
mirrors so that the operator can see the right and
left rear views best which are blind spots from
the operator’s seat.
a Adjust the mirror so that the operator can see
persons (or things 1 m high and about 30 cm
in diameter) at the right and left rear ends of
the machine.
2) Fold the mirror to position (C) when trans-

porting the machine.
3) Foldable mirror (b1): Install at 33 mm from
the top of the stay. Install mirror stay (4) so
that the mirror will be fixed at (A) position out
of the 3 stopping positions where the mirror is
extended most and at an angle of 26° to the
side of the machine body.
30-101 60 PC200, 200LC-8E0 (Hybrid)

Angle adjustment of rear view camera SEN05241-01
Angle adjustment of rear view 4. Loosen camera mounting bolts (4) and adjust
camera camera installation angle (A) so that the center
of mounting bolts (4) matches with 4th gradua-
tion (B) from the bottom.
If the image displayed on the monitor is out of posi- a A part of the machine is displayed on the
tion, remove cover (1) and adjust installation angle monitor screen.
(A) of the rear view camera.
Angle (A) can be adjusted in the range of 35 - 80 de- 5. After adjusting, tighten bolts (4).
3 Camera mounting bolt :
grees.
3 – 5 Nm {0.3 – 0.5 kgm}
1. When removing cover (1), insert an screwdriver

into the hole in cover (2) to press the inside pawl.
2. Remove 2 bolts (3).
3. Remove cover (1).
PC200, 200LC-8E0 (Hybrid) 30-101 61

SEN05241-01 Testing swing brake
Testing swing brake
The swing brake disc is a consumable parts.

If the hybrid system has a problem, the swing brake
stops the upper structure from swinging. However, if
the swing brake has a problem such as a worn
brake disc, it will not be able to stop the swinging
motion.
If the swing emergency stop switch is pressed to
stop the swinging motion, the upper structure
moves downward by its own weight on a slope be-
cause of a swing brake problem, or the customer
complains about swing brake problem, test the
swing brake according to the following procedure.
If the swing brake disc is found worn as a result of
the test, replace it with a new one.
If any related problems are found, repair it securely.
1. Set the work equipment to the posture for the

travel over flat ground.
(Set the arm vertically and raise the bucket to 40
- 50 cm above the ground)
4. Operate the left work equipment control lever

slowly in the right and left swing directions.
5. If the upper structure does not swing to either

right or left direction, the swing brake is normal.
If the upper structure swings, the swing lock
solenoid valve does not operate properly or
there are other problems in the electrical or
hydraulic systems, or the swing brake disc is
worn or there are other problems in the mechan-
2. Move the machine to a flat and rigid surface ical system.
where there are no obstacles to the swinging
operation . 6. Stop the engine.
3. Turn swing lock switch (1) to the ON position 7. Check the swing lock switch, swing lock solenoid
while keeping the machine in the posture valve, etc. in the electrical or hydraulic system
described above. for problems.
8. If there are no problems in the electrical and

hydraulic systems, the mechanical system can
be considered to have a problem. Perform a
disassembly inspection, referring to Disas-
sembly and assembly, "Disassembly and
assembly of swing machinery assembly".
9. If the swing brake disc is worn, replace it with a

new one.
30-101 62 PC200, 200LC-8E0 (Hybrid)

Testing swing brake SEN05241-01
10. After replacement, check that the swing brake

operates normally according to steps 3 - 5
described above.
PC200, 200LC-8E0 (Hybrid) 30-101 63

SEN05241-01 Cleaning and replacement of oil filter of electric swing motor
Cleaning and replacement of oil

filter of electric swing motor
Electric swing motor filter (1) is inserted in the lubri-

cation piping and cooling oil piping to collect foreign
matter in the oil. Clean or replace the oil filter and re-
place the electric swing motor oil every 2,000 hours.
1. Remove the oil filter.

2. Clean or replace the filter as necessary.
q Part No. of filter: 7875-13-3700
q Part No. of O-ring: 07002-11423
q Part No. of O-ring: 07000-11009
3. Return the removed filter.

Tightening torque of filter: 19.6 – 24.5 Nm {2.0
– 2.5 kgm}
30-101 64 PC200, 200LC-8E0 (Hybrid)

Operation check of swing emergency stop switch SEN05241-01
Operation check of swing emer-

gency stop switch
Starting switch
A: OFF position
B: ON position
Check [1] and [2] shown below.
Perform this check together with "Check of swing
holding brake".
[1] Operation check of swing holding brake
1. Start the engine, retract the arm cylinder and
bucket cylinder to the stroke end, and lower the
work equipment to the ground.
q Turn the swing lock switch to the OFF

position.
q Set the lock lever to the FREE position.
Swing emergency stop switch

a: ON position
b: OFF position
To set the switch in OFF position (b), pull the
switch head or turn it to the right.
2. Turn swing emergency stop switch (1) to the

ON position.
Normally, this switch is in the OFF position.
If this switch is in the ON position, the buzzer
sounds and the hybrid monitor lights up.
PC200, 200LC-8E0 (Hybrid) 30-101 65

SEN05241-01 Operation check of swing emergency stop switch
3. Measure the oil pressures of the swing holding 2. Display "09103 Electric swing motor torque".
brake. Confirm that those pressures are as fol- For details, see "Monitoring" in “Testing and
lows. adjusting”.
Output oil
Left work
pressure of swing Monitor screen,
equipment
holding brake etc.
control lever
solenoid valve
Hybrid monitor
Left swing 0 Mpa is displayed.
Right swing {0 Kg/cm2} Alarm buzzer

sounds.
4. Turn swing emergency stop switch and key

switch to the OFF position.
5. If there is abnormality, check the swing lock
solenoid valve and other electrical systems for
abnormality.
[2] Check of electric swing motor torque

1. Start the engine, retract the arm cylinder and
bucket cylinder to the stroke end, and lower the
work equipment to the ground.
Turn the swing lock switch to the OFF position.
Set the lock lever to the FREE position.
3. Turn the swing emergency stop switch to the

ON position. If this switch is turned ON, the
alarm buzzer sounds.
4. Tilt the swing lever and confirm that the electric
swing motor torque displayed on the monitor is
0 kgm and the upper structure does not swing.
5. If a value other than 0 kgm is displayed or the
upper structure swings, check the emergency
stop switch contacts for abnormality, the wiring
for disconnection and short circuit, and the
hybrid controller for failure.
30-101 66 PC200, 200LC-8E0 (Hybrid)

Operation check of swing emergency stop switch SEN05241-01
PC200, 200LC-8E0 (Hybrid) 30-101 67

SEN05241-01
©2010 KOMATSU
All Rights Reserved
30-101 68
SEN05242-02
SEN05242-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


Special functions of machine monitor ......................................................................................................... 2
PC200, 200LC-8E0 (Hybrid) 30-102 1

SEN05242-02 Special functions of machine monitor
Special functions of machine monitor

For the machine with air conditioner
30-102 2 PC200, 200LC-8E0 (Hybrid)

Special functions of machine monitor SEN05242-02
Upper section of machine monitor (Display sec-

tion)
(a): Multi-display
a When the engine is cranked, the battery voltage
may lower suddenly, depending on the ambient
temperature and the condition of the battery. In
this case, the machine monitor goes off for a mo-
ment. This phenomenon is not a failure, howev-
er.
Upper section of machine monitor (Switch sec-

tion)
[F1]: F1 Function switch
a The function of each function switch is indicated
by a graphic in the multi-display (a) above that
function switch.
a If the graphic of a function switch is not dis-
played, that function switch is not working.
Lower section of machine monitor (Switch sec-

tion)
[1]: Numeral 1 input switch/Auto-deceleration switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed selector
switch
[4]: Numeral 4 input switch/Alarm buzzer cancel
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Windshield washer
switch
[7]: Numeral 7 input switch/Air conditioner or heater
switch
switch
switch
switch
Switch having no numerals: Air conditioner or heat-
er switch
a Each switch has the function indicated by a
graphic and the function of inputting a numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of
multi-display (a).
PC200, 200LC-8E0 (Hybrid) 30-102 3

t Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary functions and special functions, and displays information of various
types on the multi-display.
Some items of the information are displayed automatically according to the internal setting of the machine
monitor and the others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The information items in this mode are displayed ordinarily. The operator can display and set them by
operating the switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by oper-
ating the switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting.
Page Page
Operator mode (outline) Service mode
5 20
A Display of KOMATSU logo 5 Monitoring 21
Mechanical Systems 27
A Display of inputting password 6 Abnormality
Electrical Systems 28
Record
A Display of check before starting 6 Air-conditioning System 38
A Display of warning after check before starting 6 Maintenance Record 39
A Display of ending of maintenance time 7 Maintenance Mode Change 40
Display of check of working mode and travel
A 7 Phone Number Entry 42
speed
A Display of ordinary screen 7 Key-on Mode 43
A Display of end screen 7 Unit 44
B Selection of auto-deceleration 8
O (Special operation)
Maintenance Password 45
B Selection of working mode 8 Default
B Selection of travel speed 9 Camera 46
B Operation to stop alarm buzzer 9
ECO Display 47
B Operation of windshield wiper 9
B Operation of window washer 9 Pump Absorption Torque (F) 48
B Operation of air conditioner 10 Pump Absorption Torque (R) 49
Operation of fuel consumption monitor/energy
B 11 Adjustment
monitor * Low Speed 50
Operation to display camera mode
B 12
(if camera is installed)
B Operation to display clock and service meter 13 Discharge of capacitor * 51
B Check of maintenance information 13
Setting and display of user mode Cylinder Cut-Out 52
B 13
(including KOMTRAX messages for user)
C Display of energy-saving guidance 14 No Injection 53
C Display of caution monitor 14 Fuel Consumption 55
Terminal Status 56
C Display of user code and failure code 15
GPS & Communication Status 57
KOMTRAX
O (Special operation)
Settings
Function of checking display of LCD (Liquid MODEM IP Address (TH300) 58
D 17
Crystal Display)
D Function of checking service meter 17 Display of service message 59
D Function of changing maintenance password 18
*: Exclusive mode for hybrid model

a Classification of operator mode
A: Display/Function from time when starting switch is set to ON position to time when screen changes to
ordinary screen and display after starting switch is set to OFF position
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch
30-102 4 PC200, 200LC-8E0 (Hybrid)

t Operator mode (outline) a Display pattern of operator mode

a Only outline of the operator mode is described in The contents of display from the time when
this section. starting switch is set to ON position to time when
For details of contents/operation of each func- screen changes to ordinary screen depends on
tion/display, see the Structure, function and the setting and condition of the machine.
maintenance standard, or Operation and Main- A: When engine start lock is set effective
tenance Manual. B: When engine start lock is set ineffective
a The following are the displays or functions of the C: When there is abnormal item in checkbe-
operator mode explained in this section (includ- fore-starting items
ing some items which need special operations). D: When there is maintenance item which is not
Display pat- maintained after specified interval
tern
A B C D Display of KOMATSU logo
Display of KOMATSU logo 1 1 1 1 When the starting switch is set to ON position, the
Display of inputting password 2 — — —
KOMATSU logo is displayed for 2 seconds.
Display of check before starting 3 2 2 2
Display of warning after check before — — 3 — a After the KOMATSU logo is displayed for 2 sec-
starting onds, the screen changes to “Display of input-
Display of ending of maintenance time — — — 3 ting password”, “Display of check of breaker
Display of check of working mode and 4 3 4 4 mode (if B mode is set)”, or “Display of check
travel speed before starting”.
Display of ordinary screen 5 4 5 5
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of windshield washer
Operation of air conditioner
Operation to display camera mode (if camera is
installed)
Operation to display clock and service meter
Check of maintenance information
Setting and display of user mode
(including KOMTRAX messages for user)
Display of energy-saving guidance
a There may be a case where the following screen
Display of caution monitor
Display of user code and failure code is displayed instead of the above Display of in-
O (Special operation) putting password screen.
Function of checking display of LCD (Liquid Crystal a If this screen is displayed, call the person re-
Display) sponsible to operation of KOMTRAX in your Ko-
Function of checking service meter matsu distributor and ask for remedy.
Function of changing maintenance password
PC200, 200LC-8E0 (Hybrid) 30-102 5

Display of inputting password Display of check before starting

After the KOMATSU logo is displayed, the screen to When the screen changes to the check-before-start-
input the engine start lock password is displayed. ing screen, the check before starting is carried out
a This screen is displayed only when the engine for 2 seconds.
start lock function is set effective. a If any abnormality is detected by the check be-
a If the password is input correctly, the screen fore starting, the screen changes to “Display of
changes to “Display of check of breaker mode warning after check before starting” or “Display
(if B mode is set)” or “Display of check before of ending of maintenance time”.
starting”. a If no abnormality is detected by the check before
a The machine monitor has some password func- starting, the screen changes to “Display of
tions other than the engine start lock. Those check of working mode and travel speed”.
functions are independent from one another. a The monitors (8 pieces) displayed on the screen
are the items under the check before starting.
Display of warning after check before starting

If any abnormality is detected by the check before
starting, the warning monitor is displayed on the
screen.
a The following figure shows that the engine oil
level monitor (a) is warning of low engine oil lev-
el.
30-102 6 PC200, 200LC-8E0 (Hybrid)

Display of ending of maintenance time Display of ordinary screen

When the check before starting is carried out, if a If the machine monitor starts properly, the ordinary
maintenance item is near or after the end of the set screen is displayed.
interval, the maintenance monitor is displayed for 30 a Service meter (a) or a clock is displayed at the
seconds to urge the operator to perform mainte- center upper section of the screen (The service
nance. meter or clock is selected be using [F4]).
a This screen is displayed only when the mainte- a ECO gauge (b) is displayed at the right end of
nance function is effective. The color of the the screen (It is turned ON and OFF in the ser-
maintenance monitor (yellow or red) indicates vice mode).
the length of the time after the maintenance time.
a Set or change the maintenance function in the
service mode.
a After display of this screen is finished, the screen
changes to “Display of check of working mode
and travel speed”.
Display of end screen

When the starting switch is set to OFF position, the
end screen is displayed for 5 seconds.
a Another message may be displayed on the end
screen, depending on the message display func-
tion of KOMTRAX.
Display of check of working mode and travel
speed
If the check before starting is finished successfully,
the screen to check the working mode and travel
speed is displayed for 2 seconds.
a After display of check of the working mode and
travel speed is finished, the screen changes to
“Display of ordinary screen”.
PC200, 200LC-8E0 (Hybrid) 30-102 7

Selection of auto-deceleration 2. Operate the function switches or working mode

While the ordinary screen is displayed, if the au- selector switch to select and enter the working
to-deceleration switch is pressed, large auto-decel- mode which you will use.
eration monitor (a) is displayed for 2 seconds and Function switches
the setting of the auto-deceleration is changed. q [F3]: Move to lower working mode
a Each time the auto-deceleration switch is q [F4]: Move to lower working mode
pressed, the auto-deceleration is turned ON and q [F5]: Cancel selection and return to ordinary
OFF alternately. screen
a If the auto-deceleration is turned ON, large mon- q [F6]: Enter selection and return to ordinary
itor (a) and auto-deceleration monitor (b) are dis- screen
played simultaneously. Working mode selector switch
a If the auto-deceleration is turned OFF, auto-de- q Press: Move to lower working mode
celeration monitor (b) goes off. q Hold down: Enter selection and return to or-
dinary screen
a If you do not touch any of the function switch-
es and working mode selector switch for 5
seconds, the selection is entered and the
screen changes to the ordinary screen.
Selection of working mode

Select a working mode according to the following
procedure.
1. While the ordinary screen is displayed, press the
working mode selector switch, and the working
mode selection screen is displayed. 3. When the ordinary screen is displayed again,
large working mode monitor (a) is displayed for 2
seconds, and then the setting of the working
mode is changed.
a When large monitor (a) is displayed, the dis-
play of working mode monitor (b) is changed,
too.
30-102 8 PC200, 200LC-8E0 (Hybrid)

Selection of travel speed Operation to stop alarm buzzer

While the ordinary screen is displayed, if the travel While the alarm buzzer is sounding, if the alarm
speed selector switch is pressed, large travel speed buzzer cancel switch is pressed, the alarm buzzer
monitor (a) is displayed for 2 seconds and the set- stops.
ting of the travel speed is changed. a Even if the alarm buzzer cancel switch is
a Each time the travel speed selector switch is pressed, the screen does not change.
pressed, the travel speed is changed to Lo, Mi,
Hi, and Lo again in order. Operation of windshield wiper
a When large monitor (a) is displayed, the display While the ordinary screen is displayed, if the wiper
of travel speed monitor (b) is changed, too. switch is pressed, large wiper monitor (a) is dis-
played for 2 seconds and the windshield wiper starts
or stops.
a Each time the wiper switch is pressed, the wind-
shield wiper setting is changed to INT, ON, OFF,
and INT again in order.
a When large monitor (a) is displayed, the display
of wiper monitor (b) is changed or turned OFF,
too.
a If the windshield wiper is turned OFF, large mon-
itor (a) is not displayed.
Operation of window washer

While the ordinary screen is displayed, if the window
washer switch is pressed, the washing liquid is
splashed only while the switch is held down.
a Even if the window washer switch is pressed, the
screen does not change.
PC200, 200LC-8E0 (Hybrid) 30-102 9

Operation of air conditioner

While the ordinary screen is displayed, press the air
conditioner switch and the air conditioner adjust-
ment screen is displayed.
a While the air conditioner adjustment screen is
displayed, if you do not touch any switch for 5
seconds, the screen changes to the ordinary
screen.
a The section applies to the machine with air con-
ditioner
30-102 10 PC200, 200LC-8E0 (Hybrid)

Operation of fuel consumption monitor/energy

monitor
When operating the fuel consumption monitor,
press [F2] to display the fuel consumption monitor
screen while the normal screen is displayed.
a When [F1] is pressed on the fuel consumption

monitor screen, the screen changes to the ener-
gy monitor screen.
a If [F2] is pressed while the fuel consumption

monitor screen is displayed, the screen changes
to show information from the last 60 minutes, last
12 hours, last week, last month and last 60 min-
utes in order repeatedly.
a When [F5] is pressed on the fuel consumption
monitor screen, the screen returns to the normal
screen.
PC200, 200LC-8E0 (Hybrid) 30-102 11

Operation to display camera mode (if camera is

installed)
When a camera is installed, if [F3] is pressed, the
multi-display changes to the camera image (Set the
connection of the camera in the service mode).
a Up to three cameras can be connected. If the

camera mode is selected, however, only the im-
age of camera 1 is always displayed.
a If a caution is generated in the camera mode, the

caution monitor is displayed at the left upper of
the screen (The low hydraulic oil temperature
caution is not displayed there, however).
a When an error "there is a user code" occurs in

the camera mode, if you do not touch any control
lever for 10 seconds, the screen changes to the
ordinary screen and displays the error informa-
tion.
30-102 12 PC200, 200LC-8E0 (Hybrid)

Operation to display clock and service meter Setting and display of user mode
While the ordinary screen is displayed, press [F4], (Including KOMTRAX messages for user)
and section (a) changes to the service meter and While the ordinary screen is displayed, press [F6],
clock alternately. and the user menu screen is displayed.
a When the clock is selected, adjust the time, set
12-hour or 24-hour display, and set the summer
time with the user mode function.
a There are following items in the user menu.
Check of maintenance information

While the maintenance monitor or ordinary screen is
displayed, press [F5], and the maintenance table
screen is displayed.
a To reset the time left after finishing maintenance

(oil/filter replacement) more operations are nec-
essary.
PC200, 200LC-8E0 (Hybrid) 30-102 13

[KOMTRAX message] Display of energy-saving guidance

q There are two types of KOMTRAX message; When the machine is brought to a certain operating
one is for the user and the other is for the ser- condition, the energy-saving guidance screen is dis-
vice. played automatically to urge the operator to the en-
q For user: ergy-saving operation.
A message transmitted from the KOMTRAX a The energy-saving guidance is displayed when
base station for the user. If it is received, the the following condition is satisfied while the dis-
message monitor is displayed on the ordinary play setting is set effective in the service mode.
screen.To see the contents of the message, a Condition for display:
press [F6] switch and operate "Display Engine is running + All levers have been in
message" in the user menu. neutral for 5 minutes + Caution (Note) or user
code is not generated (Note)
Note: Excluding hydraulic oil low temperature
caution
a If any lever or pedal is operated, or [F5] is
pressed, the screen returns to the ordinary
screen.
q For service:
A message transmitted from the KOMTRAX
base station for the service. Even if it is received,
nothing is displayed on the ordinary screen. To
see the contents of the message, operate
"KOMTRAX message" display in the service
menu.
Display of caution monitor

If an abnormality which displays a caution monitor
occurs on the ordinary screen or camera mode
screen, the caution monitor is displayed large for a
moment and then displayed at (a) in the screen.
a On the camera mode screen, the caution moni-
tor flashes at the left upper of the screen when
the caution is generated.
30-102 14 PC200, 200LC-8E0 (Hybrid)

Display of user code and failure code

If an abnormality, which displays a user code and a
failure code, occurs on the ordinary screen or cam-
era mode screen, all the information of the abnor-
mality is displayed.
(a): User code (3 digits)
(b): Failure code (5 or 6 digits)
(c): Telephone mark
(d): Telephone No.
a This screen is displayed only when an abnormal-
ity (failure code) for which a user code is set oc-
curs.
a The telephone mark and telephone number are
displayed only when the telephone number is
registered in the service mode.
a If multiple abnormalities occur simultaneously,
all the codes are displayed repeatedly in order.
a The information of the displayed failure code is
recorded in the abnormality record in the service
mode, so check the details in the service mode.
a When the caution monitor is also displayed, the

telephone mark is not displayed.
PC200, 200LC-8E0 (Hybrid) 30-102 15

a Remedies given by displayed user codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
User code Failure mode Action
When emergency pump drive switch is at the upper (emergency) posi-
E02 Pump control system error tion, normal operations become possible, but have inspection carried
out immediately.
E03 Swing brake system error Have inspection carried out immediately.
Operate machine to a safe posture and have inspection carried out
E09* Hybrid system error
immediately.
Engine controller power source
error
E10 Engine controller drive system Have inspection carried out immediately.
circuit error
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection carried out
E11
Output reduced to protect engine immediately.
E14 Abnormality in throttle system
immediately.
Engine sensor (coolant tempera-
E15 ture, fuel pressure, oil pressure) Operations are possible, but have inspection carried out immediately.
system error
E0E Network error
immediately.
E20 Abnormality in travel system
immediately.
*: User code E09 is a exclusive mode for hybrid model.
30-102 16 PC200, 200LC-8E0 (Hybrid)

Function of checking display of LCD (Liquid Function of checking service meter

Crystal Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are op- as follows. At this time, only the service meter sec-
erated as follows, all the LCD (Liquid Crystal tion displays.
Display) lights up in white. q Operation of switches (simultaneous): [4] + [1]
q Operation of switches (simultaneous): [4] + [F2] a There is some time lag in start of the LCD, so
a When finishing the operation of the switches, re- hold down the switches until the LCD displays
lease [F2] first. normally.
a If there is a display error in the LCD, only that a After the machine monitor is used continuously,
part is indicated in black. blue points (points which do not go off) may be
a The LCD panel sometimes has black points seen on this screen. This phenomenon does not
(points which are not lighted) and bright points indicate a failure or a defect.
(points which do not go off) for the reason of its
characteristics.
If the number of the bright points and black
points does not exceed 10, those points are not
a failure or a defect.
a To return to the former screen, press the function
switch.
PC200, 200LC-8E0 (Hybrid) 30-102 17

Function of changing maintenance password 3. After the New password input screen is
When changing the maintenance password used for displayed, input a new password by using the
the maintenance setting function, perform the foll- numeral input switches and enter it by using the
woing procedures. function switch.
1. While the ordinary screen is displayed, perform a Set a new password of 4 – 6 digits (If it has
the following operation with the numeral input only 3 or less digits or has 7 or more digits, it
switches. is not accepted).
q Operation of switches (While pressing [4], q [F5]: Reset input numeral/Return to ordinary
perform the operation in order): screen
[4] + [5] o [5] o[5] q [F6]: Enter input numeral
a This operation of the switches is not accept-
ed until 10 minutes pass after the starting
switch is set to ON position.
4. After the New password input screen is

displayed again, input a new password again by
the numeral input switches and enter it by the
2. After the Attachment/Maintenance PASSWORD function switch.
screen is displayed, input the current password q [F5]: Reset input numeral/Return to ordinary
with the numeral input switches and enter it with screen
the function switch. q [F6]: Enter input numeral
q [F5]: Reset input numeral/Return to ordinary a If a password different from the password in-
screen put before is input, the message to input
q [F6]: Enter input numeral again is displayed.
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to input the password again is dis-
played.
30-102 18 PC200, 200LC-8E0 (Hybrid)

5. If the screen to notify completion of setting is

displayed and then the ordinary screen is
displayed, the password is changed success-
fully.
PC200, 200LC-8E0 (Hybrid) 30-102 19

t Service mode a The items which can be selected in the ser-

To change the operator mode to the service mode, vice menu are as follows (including some
perform the following operation.This operation is al- items which need special operations).
ways required when you use the service mode. 01 Monitoring
Mechanical Systems
02 Abnormality
1. Check of display of screen and operation of Electrical Systems
Record
switches Air-conditioning System
While the ordinary screen is displayed, perform 03 Maintenance Record
04 Maintenance Mode Change
the following operation by using the numeral 05 Phone Number Entry
input switches. Key-on Mode
q Operation of switches (While pressing [4], Unit
perform the operation in order): 06 Default Maintenance Password
[4] + [1] o [2] o [3] Camera
a This operation of the switches is accepted ECO Display
only while the ordinary screen is displayed. Pump Absorption Torque (F)
07 Adjustment Pump Absorption Torque (R)
Low Speed
08 Discharge of capacitor
09 Cylinder Cut-Out
10 No Injection
11 Fuel Consumption
Terminal Status
12 KOMTRAX
GPS & Communication Status
Settings
MODEM S/N (TH300)
13 Display of service message
2. Selection of service menu

When the Service menu screen is displayed, the
service mode is selected. Select a service menu
you use by using the function switches or
numeral input switches.
q [F3]: Move to lower menu
q [F4]: Move to upper menu
q [F5]: Return to ordinary screen (operator
mode)
q [F6]: Enter selection
a You may input a 2-digit code by using the nu-
meral input switches to select the menu of
that code and enter it by using [F6].
30-102 20 PC200, 200LC-8E0 (Hybrid)

Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which are controlling actuators, etc.
1. Selecting menu
Select “Monitoring” on the service menu screen.
3. Deciding monitoring items

After selecting monitoring items, perform moni-
toring by using the function switch or numeral
input switch.
a Performing by using function switch: Dou-
ble-click or hold down [F6] (about 2 sec-
onds).
a Performing by using numeral input switch: In-
put [99999] and press [F6].
2. Selecting monitoring items a When monitoring only two items, for exam-
After the “Monitoring selection menu screen” is ple, select them and enter by [F6]. If [F6] is
displayed, select items to be monitored with the pressed once more at this time, monitoring is
function switches or numeral input switches. performed.
q [F1]: Move to next page (screen) a If monitoring items are selected up to the limit
q [F2]: Move to previous page (screen) number, monitoring is performed automati-
q [F3]: Move to lower item cally.
q [F4]: Move to upper item
q [F5]: Delete input numeral/Return to service
menu screen
a Selection by using function switches: Select
an item by using [F3] or [F4] and enter it by
using [F6].
a Selection by using numeral input switches:
Enter a 5-digit code, and the item of that code
is selected directly. Enter that item by using
[F6].
a If the color of the selected box changes from
yellow to red, selection of the item of that box
is accepted.
a Up to six monitoring items can be selected at
a time. You may not able to set up to six
items, however, depending on the display
form of those items.
PC200, 200LC-8E0 (Hybrid) 30-102 21

4. Performing monitoring 6. Changing machine mode setting

After the "Performing monitoring" screen is To change the setting of the working mode,
displayed, perform the necessary operation of travel speed, or auto-deceleration during moni-
the machine and check the monitoring informa- toring, operate the corresponding switch under
tion. the current condition, and the mode setting
a Monitoring information is indicated by value, screen is displayed.
ON/OFF, or special display. While this screen is displayed, if the corre-
a The unit of display can be set to SI unit, met- sponding switch is operated further, the corre-
ric unit, or inch unit by the Initialization func- sponding mode is changed.
tion in the service mode. a After finishing changing the setting, press
[F6] to return to the monitoring information
screen.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the ordinary screen after monitor-
ing is finished.
5. Holding monitoring information

The monitoring information can be held and
reset by the function switches.
q [F3]: Cancel holding
q [F4]: Hold information (displayed data is
fixed)
q [F5]: Return to monitoring item selection
menu screen
30-102 22 PC200, 200LC-8E0 (Hybrid)

Monitoring items table

Unit (Initial setting: ISO) Comp-on
Code
Monitoring item (Display on screen) ent in Remarks
No. ISO meter inch charge
00200 Controller Model Select — PUMP
00201 Machine ID — ENG
01002 Engine speed r/min rpm rpm ENG
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 F Pump Pressure MPa kg/cm2 psi PUMP
01101 R Pump Pressure MPa kg/cm2 psi PUMP
07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
07200 Arm Curl PPC Pressure MPa kg/cm2 psi PUMP
07300 Bucket Curl PPC Pressure MPa kg/cm2 psi PUMP
07301 Bucket Dump PPC Pressure MPa kg/cm2 psi PUMP
09001 Swing left PPC Pressure MPa kg/cm2 psi PUMP
09002 Swing right PPC Pressure MPa kg/cm2 psi PUMP
04107 Coolant Temperature °C °C °F ENG
04401 Hydr. Oil Temperature °C °C °F PUMP
01300 PC-EPC Sol. Curr. (F) mA mA mA PUMP
01302 PC-EPC Sol. Curr. (R) mA mA mA PUMP
01500 LS-EPC Sol. Curr. mA mA mA PUMP
08000 Merge-divider Sol. Curr. (Main) mA mA mA PUMP
08001 Merge-divider Sol. Curr. (LS) mA mA mA PUMP
01700 Service Sol. Curr. mA mA mA PUMP
03200 Battery Voltage V V V PUMP
03203 Battery Power Supply V V V ENG
04300 Battery Charge Vol. V V V MON
36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
18500 Charge Temperature °C °C °F ENG
Absolute value indica-
36500 Boost Pressure kPa kg/cm2 psi ENG tion (including atmo-
spheric pressure)
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Fuel Dial Pos Sens Volt V V V ENG
04200 Fuel Level Sensor Vol. V V V MON
04105 Eng. Water Temp. Vol. Lo V V V ENG
04402 Hydr. Temp. Sonser Vol. V V V PUMP
37401 Ambient Press Sens Volt V V V ENG
18501 Charge Temp Sens Volt V V V ENG
36501 Charge Press Sens Volt V V V ENG
36401 Rail Pressure Sens Volt V V V ENG
17500 Engine Power Mode — ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Press Command MPa kg/cm2 psi ENG
36300 Injection Timing Command CA CA CA ENG
37300 Fuel Rate l/h l/h gal/h ENG
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP
Swing ON • OFF PUMP
Travel ON • OFF PUMP
Boom Lower ON • OFF PUMP
01900 Pressure Switch 1
Boom Raise ON • OFF PUMP
Arm Curl ON • OFF PUMP
Arm Dump ON • OFF PUMP
PC200, 200LC-8E0 (Hybrid) 30-102 23


Code
Bucket Curl ON • OFF PUMP
Bucket Dump ON • OFF PUMP
01901 Pressure Switch 2
Service ON • OFF PUMP
Travel Steering ON • OFF PUMP
Travel Junction ON • OFF PUMP
Swing Brake ON • OFF PUMP
02300 Solenoid Valve 1 Merge-divider ON • OFF PUMP
2-Stage Relief ON • OFF PUMP
Travel Speed ON • OFF PUMP
02301 Solenoid Valve 2 Service Return ON • OFF PUMP
Lever Sw ON • OFF PUMP
02200 Switch Input 1 Swing Release Sw. ON • OFF PUMP
Swing Brake Sw. ON • OFF PUMP
Model Select 1 ON • OFF PUMP
02201 Switch Input 2
Overload Alarm ON • OFF PUMP
02202 Switch Input 3 Key Switch (ACC) ON • OFF PUMP
Window Limit SW. ON • OFF PUMP
02204 Switch Input 5 P Limit SW. ON • OFF PUMP
W Limit SW. ON • OFF PUMP
Key Switch ON • OFF MON
Start ON • OFF MON
04500 Monitor Input 1 Preheat ON • OFF MON
Light ON • OFF MON
Rad. Level ON • OFF MON
Air cleaner ON • OFF MON
04501 Monitor Input 2 Eng. Oil Level ON • OFF MON
Battery Charge ON • OFF MON
04502 Monitor Input 3 Swing Brake Sw. ON • OFF MON
F1 ON • OFF MON
F2 ON • OFF MON
Monitor Function F3 ON • OFF MON
04503
Switches F4 ON • OFF MON
F5 ON • OFF MON
F6 ON • OFF MON
SW1 ON • OFF MON
SW2 ON • OFF MON
Monitor 1st & 2nd SW3 ON • OFF MON
04504
Row Switches SW4 ON • OFF MON
SW5 ON • OFF MON
SW6 ON • OFF MON
SW7 ON • OFF MON
SW8 ON • OFF MON
Monitor 3rd & 4th SW9 ON • OFF MON
04505
Row Switches SW10 ON • OFF MON
SW11 ON • OFF MON
SW12 ON • OFF MON
SW13 ON • OFF MON
Monitor 5th Row
04506 SW14 ON • OFF MON
Switches
SW15 ON • OFF MON
18800 Water In Fuel ON • OFF ENG WIF: Water In Fuel
20216 ECM Build Version — ENG
20217 ECM CAL Data Ver — ENG
18900 ECM Internal Temp °C °C °F ENG
20400 ECM Serial No — ENG
20227 Monitor Ass'y P/N — MON
20402 Monitor Serial No — MON
20228 Monitor Prog. P/N — MON
30-102 24 PC200, 200LC-8E0 (Hybrid)


Code
20229 Pump Con. Ass'y P/N — PUMP
20403 Pump Con. Serial No — PUMP
20230 Pump Con. Prog. P/N — PUMP
Unit (Initial setting: ISO) Compo-

Code
Monitoring item (Display on screen) nent in Remarks
09006 Swing-Left PPC Sensor2 Volt. mV mV mV HYB
09007 Swing-Right PPC Sensor2 Volt. mV mV mV HYB
07602 Arm-Dump PPC Pres. Sen2 Voltage mV mV mV HYB
07202 Arm-Dig PPC Pres. Sen2 Voltage mV mV mV HYB
09100 Swing Motor DC Current A A A HYB
09200 DC Current, High-Voltage Side V V V HYB
09300 Capacitor Voltage V V V HYB
09400 Booster Volt., Low-Volt. Side V V V HYB
09301 Capacitor Temperature #1 °C °C °F HYB
09302 Capacitor Temperature #2 °C °C °F HYB
09401 Booster IGBT Temperature °C °C °F HYB
09402 Booster Inductor Temperature °C °C °F HYB
09800 INV Film Condensor Temperature °C °C °F HYB
09101 Swing Motor Coil Temperature °C °C °F HYB
09500 Swing Inverter Phase-U Temp. °C °C °F HYB
09501 Swing Inverter Phase-V Temp. °C °C °F HYB
09502 Swing Inverter Phase-W Temp. °C °C °F HYB
09600 Generator Motor Temperature °C °C °F HYB
09601 Generator Driver Temperature °C °C °F HYB
09503 Swing Inverter JCT Temperature °C °C °F HYB
09700 HYB Controller Relay Output — HYB
09602 Generator Motor Rev. Speed r/min rpm rpm HYB
09603 Generator Motor Torque Nm kgm lbft HYB
09604 Gen. Motor Axial Output kW kW kW HYB
09605 Gen. Motor Target Rev. Speed r/min rpm rpm HYB
09606 Gen. Motor Target Torque Nm kgm lbft HYB
09303 Capacitor Target Voltage V V V HYB
42103 Swing Lever Stroke % % % HYB
42104 Boom Lever Stroke % % % HYB
42105 Arm Lever Stroke % % % HYB
42106 Bucket Lever Stroke % % % HYB
09701 HYB Controller Control Output — HYB
09702 HYB Controller SW Input — HYB
09102 Swing Motor Rev. Speed r/min rpm rpm HYB
09103 Swing Motor Torque Nm kgm lbft HYB
09104 Swing Motor Axial Output kW kW kW HYB
09105 Swing Motor Target Rev. Speed r/min rpm rpm HYB
09106 Swing Motor Torque Limit Value Nm kgm lbft HYB
09900 Bad Insulating Sensor Voltage mV mV mV HYB
20225 Ass'y Part No. (HYB Controller) — HYB
20417 Serial No. (HYB Controller) — HYB
20256 Prog. Part No. (HYB Control.) — HYB
20257 Prog. Version (HYB Control.) — HYB
PC200, 200LC-8E0 (Hybrid) 30-102 25

a Entry order of items in table

The items are entered in the order of display on the monitoring item selection menu screen.
a Unit
The display unit can be set to ISO, meter, or inch freely (Set it with Unit selecting in Initialization of the
service menu).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of monitoring information.
ENG: The engine controller is in charge of detection of monitoring information.
PUMP: The pump controller is in charge of detection of monitoring information.
HYB: The hybrid controller (inverter) is in charge of detection of monitoring Information.
30-102 26 PC200, 200LC-8E0 (Hybrid)

Abnormality Record (Mechanical Systems) 3. Information displayed on “abnormality record”

The machine monitor classifies and records the ab- screen
normalities which occurred in the past or which are On the “Mechanical Systems” screen, the
occurring at present into the mechanical systems, following information is displayed.
electrical systems, and air-conditioning system or (a): Occurrence order of abnormalities from
heater system. latest one/Total number of records
To check the mechanical system abnormality re- (b): Failure code
cord, perform the following procedures. (c): Contents of failure
(d): Number of occurrence time (Displayable
1. Selecting menu range: 0 – 65,535 times)
Select “Abnormality Record” on the “Service (e): Service meter reading at first occurrence
Menu” screen. (f): Service meter reading at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F5]: Return to abnormality record screen
a If no abnormality is recorded, "No abnormal-
ity record" is displayed.
a If the number of occurrence time is one (first
occurrence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring, or restora-
tion has not been confirmed.
a For all the failure codes that the machine
2. Selecting sub menu
monitor can record, see the "Failure codes
After the “Abnormality Record” screen is
table".
displayed, select “Mechanical Systems” by the
function switches or numeral input switches.
q [F3]: Move to lower item
q [F5]: Return to service menu screen
a You may input a 2-digit code by the numeral
input switches to select the record of that
code and enter it by [F6].
a The following figure shows the display of the
machine with air conditioner.
In case of the machine with the heater and
heaterless machine are different from each
other in the display of "03 Air-conditioning
System", which may not be displayed on the
heaterless machine. 4. Deleting abnormality record
The contents of the mechanical system abnor-
mality record cannot be deleted.
PC200, 200LC-8E0 (Hybrid) 30-102 27

Abnormality Record (Electrical Systems) 3. Information displayed on “abnormality record”

normalities which occurred in the past or which are On the “Electrical Systems” screen, the
occurring at present into the mechanical systems, following information is displayed.
electrical systems, and air-conditioning system. (a): Occurrence order of abnormalities from
To check the electrical system abnormality record, latest one/Total number of records
perform the following procedures. (b): Failure code
(c): Contents of failure
1. Selecting menu (d): Number of occurrence time (Displayable
Select “Abnormality Record” on the “Service range: 0 – 65,535 times)
Menu” Screen. (e): Service meter reading at first occurrence
(f): Service meter reading at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F5]: Return to “abnormality record” screen
a If no abnormality is recorded, "No abnormal-
ity record" is displayed.
a If the number of occurrence time is one (first
occurrence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring, or restora-
After the “Abnormality Record” screen is
tion has not been confirmed.
displayed, select “Electrical Systems” by the
a For all the failure codes that the machine
monitor can record, see the "Failure codes
table".
input switches to select the record of that
code and enter it by [F6].
a The following figure shows the display of the
machine with air conditioner. In the case of
the machine with the heater and heaterless
machine are different from each other in the
display of "03 Air-conditioning System",
which may not be displayed on the heater-
less machine.
30-102 28 PC200, 200LC-8E0 (Hybrid)

4. Deleting abnormality record 3) After the “Electrical Sys. Error Reset” screen
1) While the “Electrical Systems” screen is is displayed, operate the function switches.
displayed, perform the following operation by q [F5]: Return to “Electrical systems”
the numeral input switches. screen (Reset mode)
q Operation of switches (While pressing [4], q [F6]: Perform deletion
perform the operation in order): a The following figure shows the screen
[4] + [1] o [2] o [3] displayed when the items are deleted one
by one (which is a little different from the
screen displayed when all the items are
deleted together).
2) Check that the screen is set in the deletion

mode, and then delete the items one by one
or all items together by the function switches.
a If the screen is switched to the deletion 4) If the screen to notify completion of deletion
mode, [CLEAR] graphic is indicated at is displayed and then the "Electrical
[F2]. Systems" (reset mode) screen is displayed,
q [F2]: Delete all items the deletion of the abnormality record is
q [F3]: Move to lower item completed.
q [F4]: Move to upper item a After a while, the screen returns to the
q [F5]: Return to abnormality record screen "Electrical Systems" screen.
q [F6]: Delete selected item
a To delete items one by one: Select the
item to be deleted by [F3] or [F4] and
press [F6].
a To delete all items together: Press [F2],
and all the items are deleted, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the deleting operation is accepted
but the information is not deleted.
PC200, 200LC-8E0 (Hybrid) 30-102 29

Failure codes table

User Component Category of
Failure code Trouble (Displayed on screen)
code in charge record
Electrical sys-
— 989L00 Engine Controller Lock Caution 1 MON
tem
Electrical sys-
— 989M00 Engine Controller Lock Caution 2 MON
tem
Electrical sys-
— 989N00 Engine Controller Lock Caution 3 MON
tem
Mechanical
— AA10NX Air Cleaner Clogging MON
system
Mechanical
— AB00KE Charge Voltage Low MON
system
Mechanical
— B@BAZG Engine Oil Press. Low ENG
system
Mechanical
— B@BAZK Engine Oil Level Low MON
system
Mechanical
— B@BCNS Engine Water Overheat ENG
system
Mechanical
— B@BCZK Engine Water Level Low MON
system
Mechanical
— B@HANS Hydraulic Oil Overheat PUMP
system
Electrical sys-
E10 CA111 ECM Critical Internal Failure ENG
tem
Electrical sys-
E10 CA115 Eng Ne and Bkup Speed Sens Error ENG
tem
Electrical sys-
E10 CA122 Chg Air Press Sensor High Error ENG
tem
Electrical sys-
E11 CA123 Chg Air Press Sensor Low Error ENG
tem
Electrical sys-
E14 CA131 Throttle Sensor High Error ENG
tem
Electrical sys-
E14 CA132 Throttle Sensor Low Error ENG
tem
Electrical sys-
E15 CA144 Coolant Temp Sens High Error ENG
tem
Electrical sys-
E15 CA145 Coolant Temp Sens Low Error ENG
tem
Electrical sys-
E15 CA153 Chg Air Temp Sensor High Error ENG
tem
Electrical sys-
E15 CA154 Chg Air Temp Sensor Low Error ENG
tem
Electrical sys-
E11 CA155 Chg Air Temp Sensor Low Error ENG
tem
Electrical sys-
E15 CA187 Sens Supply 2 Volt Low Error ENG
tem
Electrical sys-
E11 CA221 Ambient Press Sens High Error ENG
tem
Electrical sys-
E11 CA222 Ambient Press Sens Low Error ENG
tem
Electrical sys-
E15 CA227 Sens Supply 2 Volt High Error ENG
tem
Mechanical
— CA234 Eng Overspeed ENG
system
Electrical sys-
E15 CA238 Ne Speed Sens Supply Volt Error ENG
tem
Electrical sys-
E10 CA271 IMV/PCV1 Short Error ENG
tem
Electrical sys-
E10 CA272 IMV/PCV1 Open Error ENG
tem
Electrical sys-
E11 CA322 Inj #1 Open/Short Error ENG
tem
30-102 30 PC200, 200LC-8E0 (Hybrid)

Failure codes table

Electrical sys-
tem
Electrical sys-
tem
Electrical sys-
tem
Electrical sys-
E10 CA342 Calibration Code Incompatibility ENG
tem
Electrical sys-
E10 CA351 Injectors Drive Circuit Error ENG
tem
Electrical sys-
E15 CA352 Sens Supply 1 Volt Low Error ENG
tem
Electrical sys-
E15 CA386 Sens Supply 1 Volt High Error ENG
tem
Electrical sys-
E15 CA428 Water in Fuel Sensor High Error ENG
tem
Electrical sys-
E15 CA429 Water in Fuel Sensor Low Error ENG
tem
Electrical sys-
E15 CA435 Eng Oil Press Sw Error ENG
tem
Electrical sys-
E10 CA441 Battery Voltage Low Error ENG
tem
Electrical sys-
E10 CA442 Battery Voltage High Error ENG
tem
Electrical sys-
E11 CA449 Rail Press Very High Error ENG
tem
Electrical sys-
E11 CA451 Rail Press Sensor High Error ENG
tem
Electrical sys-
E11 CA452 Rail Press Sensor Low Error ENG
tem
Electrical sys-
E11 CA488 Chg Air Temp High Torque Derate ENG
tem
Electrical sys-
E15 CA553 Rail Press High Error ENG
tem
Electrical sys-
E15 CA559 Rail Press Low Error ENG
tem
Electrical sys-
E15 CA689 Eng Ne Speed Sensor Error ENG
tem
Electrical sys-
E15 CA731 Eng Bkup Speed Sens Phase Error ENG
tem
Electrical sys-
E10 CA757 All Continuous Data Lost Error ENG
tem
Electrical sys-
E15 CA778 Eng Bkup Speed Sensor Error ENG
tem
Electrical sys-
E0E CA1633 KOMNET Datalink Timeout Error ENG
tem
Electrical sys-
E14 CA2185 Throt Sens Sup Volt High Error ENG
tem
Electrical sys-
E14 CA2186 Throt Sens Sup Volt Low Error ENG
tem
Electrical sys-
E11 CA2249 Rail Press Very Low Error ENG
tem
Electrical sys-
E11 CA2311 IMV Solenoid Error ENG
tem
Electrical sys-
E15 CA2555 Grid Htr Relay Volt High Error ENG
tem
Electrical sys-
E15 CA2556 Grid Htr Relay Volt Low Error ENG
tem
Electrical sys-
E01 D19JKZ Personal Code Relay Abnormality MON2
tem
PC200, 200LC-8E0 (Hybrid) 30-102 31

Failure codes table

Electrical sys-
— D862KA GPS Antenna Discon MON2
tem
Electrical sys-
E0E DA22KK Lowering of solenoid power supply voltage PUMP
tem
Electrical sys-
— DA25KP 5V sensor power supply output 1 abnormality PUMP
tem
Electrical sys-
— DA26KP 5V sensor power supply output 2 abnormality PUMP
tem
Electrical sys-
— DA29KQ Model Selection Abnormality PUMP
tem
Electrical sys-
E0E DA2RMC CAN Discon (Pump Con Detected) PUMP
tem
Electrical sys-
— DAF8KB Short circuit in camera power supply MON
tem
Electrical sys-
— DAFGMC GPS Module Error MON2
tem
Electrical sys-
E0E DAFRMC CAN Discon (Monitor Detected) MON
tem
Electrical sys-
— DGH2KB Hydr Oil Sensor Short PUMP
tem
Electrical sys-
— DHPAMA F Pump Press Sensor Abnormality PUMP
tem
Electrical sys-
— DHPBMA R Pump Press Sensor Abnormality PUMP
tem
Electrical sys-
— DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP
tem
Electrical sys-
— DHS4MA Bucket Curl PPC Press Sensor Abnormality PUMP
tem
Electrical sys-
E20 DHS5KK Travel PPC pressure sensor abnormality PUMP
tem
Electrical sys-
— DHS8MA Boom Raise PPC Press Sensor Abnormality PUMP
tem
Electrical sys-
— DHSAMA Swing RH PPC Press Sensor Abnormality PUMP
tem
Electrical sys-
— DHSBMA Swing LH PPC Press Sensor Abnormality PUMP
tem
Electrical sys-
— DHSDMA Bucket Dump PPC Press Sensor Abnormality PUMP
tem
HYB Arm Dig PPC Pr. Sen. Electrical sys-
E09 DHV3KZ HYB
Opn/Short Cir tem
HYB Boom Lower PPC Pr. Sen. Electrical sys-
E09 DHV9KZ HYB
Opn/Short Cir. tem
HYB Swing-R PPC Pr. Sen. Electrical sys-
E09 DHVAKZ HYB
Opn/Short Cirt. tem
HYB Swing-L PPC Pr. Sen. Electrical sys-
E09 DHVBKZ HYB
Opn/Short Cir tem
HYB Arm Dump PPC Pr. Sen. Electrical sys-
E09 DHVCKZ HYB
Opn/Short Cir tem
Electrical sys-
— DW43KA Travel Speed Sol Discon PUMP
tem
Electrical sys-
— DW43KB Travel Speed Sol Short PUMP
tem
Electrical sys-
E09 DW45KA Swing Brake Sol. Valve Open Cir. HYB
tem
Electrical sys-
E09 DW45KB Swing Brake Sol. Valve Short Cir. HYB
tem
Swing Brake Sol. Val. Pow. Short Electrical sys-
E09 DW45KY HYB
Cir. tem
Electrical sys-
— DW91KA Travel Junction Sol. Open Circuit PUMP
tem
30-102 32 PC200, 200LC-8E0 (Hybrid)

Failure codes table

Electrical sys-
— DW91KB Travel Junction Sol. Short Circuit PUMP
tem
Electrical sys-
— DWK0KA 2-stage Relief Sol. Open Circuit PUMP
tem
Electrical sys-
— DWK0KB 2-stage Relief Sol. Short Circuit PUMP
tem
Electrical sys-
E02 DXA8KA PC-EPC (F) solenoid system disconnection PUMP
tem
Electrical sys-
E02 DXA8KB PC-EPC (F) Sol Short PUMP
tem
Electrical sys-
E02 DXA9KA PC-EPC (R) Sol Discon PUMP
tem
Electrical sys-
E02 DXA9KB PC-EPC (R) Sol Short PUMP
tem
Electrical sys-
— DXE0KA LS-EPC Sol. Open Circuit PUMP
tem
Electrical sys-
— DXE0KB LS-EPC Sol. Short Circuit PUMP
tem
Electrical sys-
— DXE5KA Merge-divider Main Sol Discon PUMP
tem
Electrical sys-
— DXE5KB Merge-divider Main Sol Short PUMP
tem
Electrical sys-
— DXE6KA Merge-divider LS Sol Discon PUMP
tem
Electrical sys-
— DXE6KB Merge-divider LS Sol Short PUMP
tem
Electrical sys-
— DY20KA Wiper Working Abnormality PUMP
tem
Electrical sys-
— DY20MA Wiper Parking Abnormality PUMP
tem
Electrical sys-
— DY2CKA Washer drive discon PUMP
tem
Electrical sys-
— DY2CKB Window washer drive system short circuit PUMP
tem
Electrical sys-
— DY2DKB Wiper Drive (For) Short PUMP
tem
Electrical sys-
— DY2EKB Wiper motor drive reverse system short circuit PUMP
tem
Electrical sys-
E09 GA01KA Power Cable Interlock Open Circuit HYB
tem
Electrical sys-
E09 GA02KZ DC Line Open & Short Circuit HYB
tem
Abnormal DC HW Volt. Before Electrical sys-
E09 GA04KG HYB
Booster tem
Abnormal DC SW Volt. Before Electrical sys-
E09 GA05KG HYB
Booster tem
Low DC SW Output Volt. Bef. Electrical sys-
E09 GA05KP HYB
Booster tem
DC Vlt. Sen. Opn./Shrt.Cir. Bef. Electrical sys-
E09 GA06KZ HYB
Booster tem
Electrical sys-
E09 GA08KG Abnorm. DC HW Volt. After Booster HYB
tem
Electrical sys-
E09 GA09KG Abnorm. DC SW Volt. After Booster HYB
tem
Low DC SW Output Volt. After Electrical sys-
E09 GA09KP HYB
Booster tem
DC Vlt. Sen. Op./Shrt cir. Aft. Electrical sys-
E09 GA0AKZ HYB
Booster tem
Electrical sys-
E09 GA0BKZ AC line Open & Short Circuit HYB
tem
PC200, 200LC-8E0 (Hybrid) 30-102 33

Failure codes table

HYB Controller In General And Electrical sys-
E09 GA10Z9 HYB
Others tem
Electrical sys-
E09 GA11KK HYB Cont. Low Supply Voltage HYB
tem
Electrical sys-
E09 GA12MC HYB Cont. Pow. Suppl. Failure HYB
tem
HYB Cont. Pow. Suppl. Not Turn. Electrical sys-
E09 GA12NK HYB
ON tem
HYB Cont. Pow. Suppl. Not Turn. Electrical sys-
E09 GA12NL HYB
OFF tem
HYB Control. Sen. Power Sup. Electrical sys-
E09 GA13MC HYB
Failure tem
HYB Control. KOMNET Comm. Electrical sys-
E09 GA14KR HYB
Failure tem
HYB Cont. Bad Insul. Sen. Electrical sys-
E09 GA15KZ HYB
Opn/Short. Cir tem
Electrical sys-
E09 GA16KK Low HYB Cont. VDD Suppl. Volt. HYB
tem
Gen. Mot. Drv. Communication Electrical sys-
E09 GA17KR HYB
Failure tem
Gen. Mot Dr. Power Line Short Electrical sys-
E09 GA17KY HYB
Circuit tem
Gen. Motor Driver Open/Short Electrical sys-
E09 GA17KZ HYB
Circuit tem
Electrical sys-
E09 GA17MB Gen. Mot. Drv. Function Degraded HYB
tem
Gen. Mo.Dr. Excite. Pow. Sup. Electrical sys-
E09 GA18MC HYB
Failure tem
Gen. Mot. Drv. Sub-CPU Low Sup. Electrical sys-
E09 GA19KK HYB
Volt tem
Gen. Motor Driver Sub-CPU Comm. Electrical sys-
E09 GA19KR HYB
Failure tem
Int. Abnorm. Gen. Mot. Drv. Sub- Electrical sys-
E09 GA19KT HYB
CPU Con. tem
Gen. Mot. Drv. Sub-CPU Malfunction Electrical sys-
E09 GA19MA HYB
CPU Con. tem
Gen. Mot. Drv. Sub-CPU Defect. Electrical sys-
E09 GA19MC HYB
Operation tem
Gen. Mot. Drv. Sub-CPU Start Electrical sys-
E09 GA19NA HYB
Disabled tem
Gen. Mot. Dr. Temp. Sens. Electrical sys-
E09 GA1AKZ HYB
Open/Short Cir. tem
Gen. Mot. Dr. DC Vlt. Sens. Electrical sys-
E09 GA1BMA HYB
Malfunction tem
Gen. Motor Driver IPM1 Electrical sys-
E09 GA1DMA HYB
Abnormality tem
Gen. Motor Driver IPM2 Electrical sys-
E09 GA1EMA HYB
Abnormality tem
Swing Mot. Drv. Communication Electrical sys-
E09 GA1FKR HYB
Failure tem
Electrical sys-
E09 GA1FMA Abnormal Swing Motor Driver HYB
tem
Low Sup. Volt., Swing Motor Drv. Electrical sys-
E09 GA1GKK HYB
Sub-CPU tem
Swing Mot. Driver Sub-CPU Comm. Electrical sys-
E09 GA1GKR HYB
Faliure tem
Swing Mot. Drv. Sub-CPU Cont. Electrical sys-
E09 GA1GKT HYB
Abnormal tem
Swing Motor Drv. Sub-CPU Electrical sys-
E09 GA1GMA HYB
Malfunction tem
30-102 34 PC200, 200LC-8E0 (Hybrid)

Failure codes table

Swing Mot. Drv. Sub-CPU Funct. Electrical sys-
E09 GA1GMB HYB
Degraded tem
Swing Mot. Drv. Sub-CPU Defect Electrical sys-
E09 GA1GMC HYB
Op. tem
Swing Mot. Drv. Sub-CPU Start Electrical sys-
E09 GA1GNA HYB
Disabled tem
Swg Mot. Dr. Ph-U Tem. Sens Electrical sys-
E09 GA1HKZ HYB
Opn/Shrt Cir tem
Swg Mot. Dr. Ph-V Tem. Sens Electrical sys-
E09 GA1JKZ HYB
Opn/Shrt Cir tem
Swg Mot. Dr. Ph-W Tem. Sens Electrical sys-
E09 GA1KKZ HYB
Opn/Shrt Cir tem
Swg Mot. Dr. Current. Sens Electrical sys-
E09 GA1LKZ HYB
Opn/Shrt Cir tem
Swg Mot. Dr. DC Vlt. Sen. Electrical sys-
E09 GA1MKZ HYB
Opn/Shrt Cir. tem
Electrical sys-
E09 GA1NNS Swing Motor Driver IGBT Overheat HYB
tem
Swg Mot. Driver IPM Ph-U Not Electrical sys-
E09 GA1PNV HYB
Warm Up tem
Swg Mot. Driver IPM Ph-V Not Electrical sys-
E09 GA1QNV HYB
Warm Up tem
Swg Mot. Driver IPM Ph-W Not Electrical sys-
E09 GA1RNV HYB
Warm Up tem
Electrical sys-
E09 GA1SFS Contractor Locked HYB
tem
Electrical sys-
E09 GA1SMC Contractor Failure HYB
tem
Electrical sys-
E09 GA1TKG Capacitor HVPS Abnormal Voltage HYB
tem
Electrical sys-
E09 GA1TKP Capacitor Low Output Voltage HYB
tem
Electrical sys-
E09 GA1TNS Capacitor Overheat HYB
tem
Capacitor Temp. Sensor Opn/Short Electrical sys-
E09 GA1UKZ HYB
Cir. tem
Electrical sys-
E09 GA1VFS Capacitor Contractor Locked HYB
tem
Electrical sys-
E09 GA1VMC Capacitor Contractor Failure HYB
tem
Electrical sys-
E09 GA1XKZ Boost. Ind. Temp. Sens. Open/Shrt. HYB
tem
Booster Inductor Overheat Electrical sys-
E09 GA1YNS HYB
Circ. tem
Electrical sys-
E09 GA1YNV Booster Inductor Not Warming Up HYB
tem
Booster IGBT Temp. Sens. Electrical sys-
E09 GA1ZKZ HYB
Opn/Shrt. Circ. tem
Booster IGBT Temp. Sens. Electrical sys-
E09 GA1ZNS HYB
Overheat tem
Booster IGBT Temp. Sens. Not Electrical sys-
E09 GA1ZNV HYB
Warm Up tem
Electrical sys-
E09 GA21KB Booster IGBT Open Circuit HYB
tem
Electrical sys-
E09 GA22NS Booster IGBT Junction Overheat HYB
tem
Electrical sys-
E09 GA60MC Generator Motor Failure HYB
tem
Electrical sys-
E09 GA60MD Gen. Bot. Defective Movement HYB
tem
PC200, 200LC-8E0 (Hybrid) 30-102 35

Failure codes table

Electrical sys-
E09 GA60N1 Generator Motor Overrun HYB
tem
Gen. Motor Temp. Sens. Electrical sys-
E09 GA61KZ HYB
Opn/Short Cir. tem
Generator Motor Temp. Sensor Electrical sys-
E09 GA61NS HYB
Overheat tem
Gen. Mot. Ph-A Cur. Sen. Power Electrical sys-
E09 GA62KY HYB
Short Cir tem
Gen. Mot. Ph-A Cur. Sen. Electrical sys-
E09 GA62KZ HYB
Open/Short Cir tem
Gen. Mot. Ph-A Current Sen. Electrical sys-
E09 GA62MA HYB
Malfunction tem
Gen. Mot. Ph-B Cur. Sen. Power Electrical sys-
E09 GA63KY HYB
Short Cir tem
Gen. Mot. Ph-B Cur. Sen. Electrical sys-
E09 GA63KZ HYB
Open/Short Cir. tem
Gen. Mot. Ph-B Current Sen. Electrical sys-
E09 GA63MA HYB
Malfunction tem
Gen. Mot. Ph-C Cur. Sen. Power Electrical sys-
E09 GA64KY HYB
Short Cir tem
Gen. Mot. Ph-C Cur. Sen. Electrical sys-
E09 GA64KZ HYB
Open/Short Cir tem
Electrical sys-
E09 GA64MA Gen. Mot. Ph-C Current Sen. Malfunction HYB
tem
Electrical sys-
E09 GA70KB HYB Swing Motor Short Circuit HYB
tem
HYB Swing Motor Defective Stirr. Electrical sys-
E09 GA70MD HYB
Motion tem
Electrical sys-
E09 GA70NS HYB Swing Motor Overheat HYB
tem
HYB Swing Mot. Temp. Sens. Electrical sys-
E09 GA71KZ HYB
Opn/Shrt Cir. tem
HYB Swing Motor Resolver Electrical sys-
E09 GA72MA HYB
Malfunction tem
HYB Swing Motor Resolver Defect Electrical sys-
E09 GA72MC HYB
Op. tem
Electrical sys-
E09 GA81KZ Swing Motor Power Cable Opn/Shrt Circ. HYB
tem
User code E09 is a exclusive mode for hybrid model.
a Entry order of items in table

The items are entered in the order of their failure codes (incremental order).
a User code
Assigned: If the failure code is generated, the user code, failure code, and telephone number (if registered)
are displayed on the ordinary screen to notify the operator of the abnormality.
Not assigned: Even if the failure code is generated, the machine monitor does not notify the operator of
the abnormality.
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.
HYB: The hybrid controller (inverter) 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.
30-102 36 PC200, 200LC-8E0 (Hybrid)

Abnormality Record (Air-conditioning System) 3. Information displayed on “abnormality record”

normalities which occurred in the past or which are On the "Air-conditioning System", the following
occurring at present into the mechanical systems, information is displayed.
electrical systems, and air-conditioning abnormali- (a): System/Component name
ties or heater abnormalities. (b): Number of occurrence time
To check the air-conditioning abnormality record or (c): Condition(Normal or abnormal)
heater abnormality record, perform the following q [F2]: Delete abnormality record
procedures. q [F5]: Return to abnormality record screen
a All the following figures apply to the machine a If [E] is displayed on the left of a condition, the
with the air conditioner. abnormality is still occurring, or restoration
has not been confirmed.
1. Selecting menu a If CAN open circuit is displayed in Communi-
Select “Abnormality Record” on the “Service cation condition, communication cannot be
Menu” screen. carried out. Accordingly, the conditions of
other items are not displayed.

After the "Abnormality Record" screen is 4. Deleting abnormality record
displayed, select "Air-conditioning System" by While the “abnormality record” screen is
using the function switches or numeral input displayed, press [F2], and the number of occur-
switches. rence time of abnormality is deleted. If it is
q [F3]: Move to lower item confirmed at this time that the problem has been
q [F4]: Move to upper item resolved, the display changes to Normal.
q [F6]: Confirm selection
a You may input a 2-digit code by using the nu-
meral input switches to select the record of
that code and enter it by [F6].
PC200, 200LC-8E0 (Hybrid) 30-102 37

Maintenance Record a The following items can be selected from the

The machine monitor records the maintenance (re- maintenance record.
placement) information of the filters, oils, etc., which 01 Engine oil change
can be displayed for checking by the following oper- 02 Engine oil filter change
ations. When maintenance is carried out, if the timer 03 Fuel main filter change
is reset in the operator mode, the number of the 41 Fuel pre-filter change
times of oil/filter replacement is recorded in this sec- 04 Hydraulic oil filter change
05 Hydraulic tank breather change
tion.
06 Corrosion resistor change
08 Final drive case oil change int.
1. Selecting menu 09 Machinery case oil change
Select “Maintenance Record” on the “Service 10 Hydraulic oil change
Menu” screen. 45 Gen. oil change, filter cleaning
46 Swing motor oil change
3. Information items displayed on maintenance

record screen
The following items are displayed.
(a): Maintenance items
(b): Number of times of replacement up to now
(c): Service meter reading (SMR) at previous
replacement
2. Selecting maintenance record item

After the “Maintenance Record” screen is
displayed, select an item to be checked by the
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
a You may enter a 2-digit code by the numeral
input switches to select the item of that code.
30-102 38 PC200, 200LC-8E0 (Hybrid)

Maintenance Mode Change a The following items can be selected on the

The operating condition for maintenance function in Change of maintenance mode screen.
the operation mode can be set and changed by this 00 Maintenance mode on/off
menu. 01 Engine oil change int.
q Set function effective or ineffective 02 Engine oil filter change int
q Change replacement interval (by items) 03 Fuel main filter change int.
q Initialize all replacement intervals 41 Fuel pre filter change int.
04 Hyd oil filter change int.
05 Hyd tank breather change int.
1. Selecting menu 06 Corrosion resistor change int.
Select "Maintenance Mode Change" on the 08 Final drive case oil change int.
"Service Menu" screen. 09 Machinery case oil change int.
10 Hydraulic oil change int.
45 Gen. oil change, filter cleaning
46 Swing motor oil change
99 Initialize all items
3. Setting of Maintenance mode on/off

After selecting “Maintenance Mode On/Off”, if
the screen is displayed, set the mode to ON or
OFF by the function switches.
q ON: Functions of all maintenance items are
set effective in operator mode
q OFF: Functions of all maintenance items are
set ineffective in operator mode
q [F5]: Cancel selection and return to Mainte-
After the “Maintenance Mode Change” screen
nance mode change screen
is displayed, select an item to change the setting
q [F6]: Enter selection and return to Mainte-
by the function switches or numeral input
nance mode change screen
switches.
a Even if ON/OFF of each item has been set, if
q [F1]: Move to next page (screen)
the above setting is changed, it overrides the
q [F2]: Move to previous page (screen)
individual setting.
input switches to select the item of that code
and enter it by [F6].
PC200, 200LC-8E0 (Hybrid) 30-102 39

4. Contents of setting of each maintenance item

After selecting each maintenance item, if the
screen is displayed, perform the setting for the
item by the function switches.
q Initial value: Maintenance interval being set

in machine monitor (Recommended by man-
ufacturer and not changeable).
q Set value: Maintenance interval which can be
set freely. Maintenance reminder functions in
operator mode operate on basis of this set
time (which is increased or decreased by 50
hours).
q ON: Maintenance reminder function of this
item is set effective in operator mode.
q OFF: Maintenance reminder function of this
item is set ineffective in operator mode.
q [F3]: Reduce set value (Upper) or select OFF
(Lower).
q [F4]: Increase set value (Upper) or select ON
(Lower).
q [F5]: Cancel setting before entering setting
and return to Maintenance mode change
screen.
q [F6]: Enter setting of upper or lower line.
a After the setting of the upper and lower lines
is entered by [F6] and the screen changes to
the Maintenance mode change screen by
[F5], the setting is effective.
a If the set value of an item that is set to “ON”
is changed after 1 or more operating hours
since the start of setting, the change is recog-
nized as a resetting operation.
30-102 40 PC200, 200LC-8E0 (Hybrid)

5. Function of initializing all items

After selecting "Use Default Value", if the screen
is displayed, perform setting by the function
switches.
q If this operation is performed, the set values

of all the maintenance items are initialized.
q [F5]: Return to Maintenance mode change
screen
q [F6]: Perform initialization
a A while after [F6] is pressed, the initialization
completion screen is displayed. Then, if the
“Maintenance Mode Change” screen is dis-
played, initialization is completed.
PC200, 200LC-8E0 (Hybrid) 30-102 41

Phone Number Entry a If [F6] is pressed without inputting any digit,

The telephone number, which is displayed together there is no information of telephone number.
with the user code/failure code in the operator Accordingly, no telephone number is dis-
mode, can be input and changed according to the played in the operator mode.
If a telephone number is not input with this function,
no telephone number is displayed in the operator
mode.
1. Selecting menu
Select "Phone Number Entry" on the "Service
Menu" screen.
2. Registering and changing telephone number

After the "Phone Number Entry" screen is
displayed, register or change the telephone
number
q [F2]: Delete registered phone number
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Delete input digit/Return to service
menu
q [F6]: Enter input
a Up to 14 digits can be input from the left. In-

put nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (orange background) and overwrite
it with the correct digit.
30-102 42 PC200, 200LC-8E0 (Hybrid)

Default (Key-on Mode) q Mode at Previous Key-off: Final mode in pre-

Check or change various settings related to the ma- vious operation is displayed when the start-
chine monitor and machine by using "Default". ing switch is set to ON position
The function of working mode with key ON is used q [F3]: Move to lower item
to set the working mode displayed on the machine q [F4]: Move to upper item
monitor when the starting switch is set to ON posi- q [F5]: Cancel selection and return to “Default”
tion. screen
q [F6]: Enter selection and return to “Default”
1. Selecting menu screen
Select "Default" on the "Service Menu" screen. a When the machine is shipped from the facto-
ry, "Mode at previous key-OFF is set".

After the "Default" screen is displayed, select
"Key-on Mode" by the function switches or
a Select this item similarly to an item on the
“Service Menu” screen.
3. Selecting mode
After the "Key-on Mode" screen is displayed,
select the mode to be set by the function
switches.
q Power Mode: [P] is displayed when the start-
ing switch is set to ON position
q Economy Mode: [E] is displayed when the
starting switch is set to ON position
PC200, 200LC-8E0 (Hybrid) 30-102 43

Default (Unit) a When the machine is shipped from the facto-

Check or change various settings related to the ma- ry, the SI unit system is set.
chine monitor and machine by using "Default".
The unit selection function is used to select the unit
of the data displayed for monitoring, etc.
1. Selecting menu
Select "Default" on the "Service Menu" screen.

"Unit" by the function switches or numeral input
switches.
3. Selecting unit
After the "Unit" screen is displayed, select the
unit to be set by the function switches.
q [F3]: Move to lower unit
q [F4]: Move to upper unit
q [F5]: Cancel selection and return to “Default”
screen
q [F6]: Enter selection and return to “Default”
screen
30-102 44 PC200, 200LC-8E0 (Hybrid)

Default (setting maintenance password) 3. Selecting Disable/Enable

Check or change various settings related to the ma- After the Maintenance Password screen is
chine monitor and machine by "Default". displayed, select the setting by the function
The function of setting maintenance password is switches.
used to set the display of the password screen when q Disable: Password screen is not displayed
the functions related to the and maintenance are q Enable: Password screen is displayed
used in the operator mode. q [F3]: Move to lower item
1. Selecting menu q [F5]: Cancel selection and return to "Default"
Select "Default" on the "Service Menu" screen. screen
q [F6]: Enter selection and return to "Default"
screen

After the “Default” screen is displayed, select
“Maintenance Password” by the function 4. Displaying maintenance password screen
switches or numeral input switches. When the following operation is performed, the
a Select this item similarly to an item on the password screen is displayed in the operator
“Service Menu” screen. mode.
q Maintenance mode: The Maintenance table
screen is changed to the Maintenance inter-
val reset screen.
5. Changing maintenance password

The password can be changed by operating the
switches specially in the operator mode.
a See Maintenance password changing func-
tion in the operator mode.
a Default password: [000000]
a If the password setting is changed from En-
able to Disable, the password is reset to the
default.
When Enable is set again, be sure to set a
new password.
a The Maintenance password is different from
the "engine start lock password".
PC200, 200LC-8E0 (Hybrid) 30-102 45

Default (Camera) 3. Selecting camera setting

Check or change various settings related to the ma- After the "Camera" setting screen is displayed,
chine monitor and machine by using "Default". select the setting by the function switches.
The camera setting function is used to perform nec- q OFF: Camera is not used
essary setting when the camera is installed or re- q Original Image: Image sent from the camera
moved. is displayed in original position (as in mirror,
used as back monitor)
1. Selecting menu q Reverse Image: Image sent from camera is
Select "Default" on the "Service Menu" screen. displayed in reverse position (as seen direct-
ly, used as front or side monitor)
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel setting before entering the set-
ting and return to “Default” screen
q [F6]: Enter selection in each line
a After “Camera” screen is displayed, the set-
ting for the camera 1 can be made.
When two or more cameras are connected, if
setting for camera 1 is made, the screen
changes to setting for camera 2 automati-
cally.
a After entering the setting of each line by [F6],
return to the "Default" screen by [F5], and the
setting becomes effective.
a If the camera is connected but setting is not
made properly by this function, the graphic
"Camera" by the function switches or numeral
mark of camera is not displayed at [F3] in the
input switches.
operator mode. Accordingly, the image sent
from the camera cannot be used.
a If two or more cameras are connected, be
sure to make necessary settings for the use
of them from camera 1 in order.
a The function of displaying two images simul-
taneously is effective when the setting for the
use of camera 1 and camera 2 are made.
a When the camera is installed, check that the
displayed image is not inverted horizontally.
30-102 46 PC200, 200LC-8E0 (Hybrid)

Default (ECO Display) q [F6]: Enter selection in each line

Check or change various settings related to the ma- a After entering the setting of the upper and
chine monitor and machine by using "Default". lower lines by [F6], return to the "Default"
The ECO display setting function is used to set the screen by [F5], and the setting becomes ef-
display of the ECO gauge and energy saving guid- fective.
ance. a If ECO display is turned ON, ECO is dis-
played when the screen changes to the ordi-
1. Selecting menu nary screen. Even if the energy saving
Select "Default" on the "Service Menu" screen. guidance is turned ON, however, it is not dis-
played if the condition for display is not satis-
fied on the ordinary screen.

"ECO Display" by the function switches or a Display of ECO gauge (a)
numeral input switches
a Display of energy saving guidance
3. Selecting display setting

After the "ECO Display" screen is displayed,
select the setting by the function switches.
q ON: Display ECO
q OFF: Do not display ECO
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel setting before entering the set-
ting and return to "Default" screen
PC200, 200LC-8E0 (Hybrid) 30-102 47

Adjustment (Pump Absorption Torque (F)) 3. Selecting absorption torque

The technician can adjust various items related to After the "Pump Absorption Torque (F)" screen
the machine by using the machine monitor. is displayed, select a set value on the right side
The pump absorption torque (F) function is used to by the function switches.
finely adjust the absorption torque of the front hy- q Set value: For the relationship between the
draulic pump. set value and the actual torque adjustment
value, see table.
1. Selecting menu q [F3]: Increase set value
Select “Adjustment” on the “Service Menu” q [F4]: Decrease set value
screen. q [F6]: Enter setting and return to Adjustment
menu screen
a The 3 digits on the left side do not vary be-
cause they are the code of this function.

After the “ Adjustment” screen is displayed,
select “ Pump Absorption Torque (F)” by the
function switches or numeral input switches. a Relationship between set value and torque
a Select this item similarly to an item on the adjustment value
“Service Menu” screen. Set Torque adjustment value
Code
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm}
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}
30-102 48 PC200, 200LC-8E0 (Hybrid)

Adjustment (Pump Absorption Torque (R)) 3. Selecting absorption torque

The technician can adjust various items related to After the "Pump Absorption Torque (R)" screen
the machine by using the machine monitor. is displayed, select a set value on the right side
The pump absorption torque (R) function is used to by the function switches.
finely adjust the absorption torque of the rear hy- q Set value: For the relationship between the
draulic pump. set value and the actual torque adjustment
value, see table.
1. Selecting menu q [F3]: Increase set value
Select “Adjustment” on the “Service Menu” q [F4]: Decrease set value
screen. q [F6]: Enter setting and return to Adjustment
menu screen

After the “Adjustment” screen is displayed,
select “Pump Absorption Torque (R)” by the
function switches or numeral input switches. a Relationship between set value and torque
a Select this item similarly to an item on the adjustment value
“Service Menu” screen. Set Torque adjustment value
Code
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
022 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm}
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}
PC200, 200LC-8E0 (Hybrid) 30-102 49

Adjustment (Low speed) 3. Selecting travel Low speed

The technician can adjust various items related to After the "Low Speed" setting screen is
the machine by using the machine monitor. displayed, select a set value on the right side
The "travel Low speed" setting function is used to with the function switches.
finely adjust the travel speed in Lo mode. q Set value: For the relationship between the
set value and the actual travel Low speed
1. Selecting menu value, see table.
Select “Adjustment” on the “Service Menu” q [F3]: Increase set value
screen. q [F4]: Decrease set value
q [F6]: Enter setting and return to Adjustment
menu screen

After the “Adjustment” screen is displayed,
select “Low speed” by the function switches or
a Select this item similarly to an item on the a Relationship between set value and travel
“Service Menu” screen. Low speed value
Set Travel Low speed value
Code
value
000 3.0 km/h
001 2.8 km/h
020
002 3.2 km/h
003 3.4 km/h
30-102 50 PC200, 200LC-8E0 (Hybrid)

Discharging capacitor
The capacitor can be discharged by operating the
machine monitor.
1. Selecting menu
Select "Discharge capacitor" on the "Service
menu" screen.
2. Discharge operation
See 00 Foreword, Safety, Basic information
"Discharging capacitor" in "Handling hybrid
devices or high-voltage wirings".
PC200, 200LC-8E0 (Hybrid) 30-102 51

Cylinder Cut-Out
The technician can perform "Cylinder Cut-Out" op-
eration by using the machine monitor.
"Cylinder Cut-Out" operation means to run the en-
gine with one or more fuel injectors disabled electri-
cally to reduce the number of active cylinders. This
operation is used to find out a cylinder which does
not output power properly (combustion in it is abnor-
mal).
1. Selecting menu
Select “Cylinder Cut-Out” on the “Service
Menu” screen.
3. Canceling cut-out cylinder

When changing a cylinder to be cut out or when
cylinder cut-out operation is finished, select a cut
out cylinder to be resumed by the function
switches.
a This operation may be performed while the
engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder number becomes blue,
the cylinder is resumed.
a If the machine monitor cancels cut-out of a
cylinder but the engine controller cannot can-
cel the cut-out of cylinder, the background (a)
2. Selecting cylinder to be cut out of the cylinder number becomes red.
After the "Cylinder Cut-Out" screen is displayed, a The cut-out operation is not automatically
select a cylinder to be cut out by the function canceled after the screen returns to the oper-
switches. ator mode. Accordingly, be sure to perform
q [F1]: Move selection mark (R) to left the canceling operation after the cylinder
q [F2]: Move selection mark (R) to right cut-out operation is finished.
q [F3]: Cancel holding
q [F4]: Hold 4. Function of holding displayed information
q [F5]: Return to service menu screen If [F4] is pressed during the cylinder cut-out
q [F6]: Enter selection operation, the displayed information is held (c)
a This operation may be performed while the (The real-time information is kept displayed on
engine is running. the left side).
a When [F6] is pressed, if background (a) of While the information is held, if [F3] is pressed,
the selected cylinder number becomes white, the holding function is canceled.
the cylinder is cut out. a The holding function is effective, regardless
a If the machine monitor cuts out a cylinder but of setting of the cylinder cut-out mode opera-
the engine controller cannot cuts out that cyl- tion.
inder, the background (a) of the cylinder
number becomes yellow.
a One or more cylinders can be cut out.
a In the cylinder cut-out operation, the auto-de-
celeration function can be used. If the au-
to-deceleration is turned ON,
auto-deceleration monitor (b) is displayed.
30-102 52 PC200, 200LC-8E0 (Hybrid)

[Reference] No Injection cranking

q If a properly operating cylinder is cut out, the If the engine is operated after long storage of the
following phenomena occur. machine, it may be worn or damaged because of in-
1) Lowering of engine speed sufficient lubrication. To prevent this problem, the
2) Increase of final injection rate command function to lubricate the engine before starting it by
(increase in fuel amount) cranking it without injecting fuel is provided.
q If the engine is running near the high idle Set the no-injection cranking while the engine is
speed, however, the engine speed may not stopped.
lower for the reason of engine control func-
tion. 1. Selecting menu
q In this case, lower the engine speed by using Select "No Injection" on the "Service Menu"
the fuel control dial and judge by monitoring screen.
the increase of the injection rate command.
2. Displaying check screen

If the "No injection" screen is displayed, the
machine monitor asks you if no injection
cranking should be performed. Answer by using
the function switch.
q [F5]: Do not perform (Return to Service menu
screen)
q [F6]: Perform
a Before the screen is changed to the following
screen, the screen of "Communication be-
tween controllers is being checked" is dis-
played.
PC200, 200LC-8E0 (Hybrid) 30-102 53

3. Starting no injection cranking 5. Prohibiting no injection cranking

If no injection cranking (Fuel injection in no cylin- If the no injection cranking is attempted while the
ders) becomes effective, that is displayed on the engine is running, the message that the "Engine
screen. Under this condition, crank the engine is running" is displayed and the no injection
by the starting motor. cranking is not set effective.
a Before the screen is changed to the following a This function can be selected even while the
screen, the screen of "Setting is being pre- engine is running. If the no injection cranking
pared" is displayed. is attempted, however, the "Engine is run-
a Limit the cranking time to 20 seconds to pro- ning" message is displayed on the screen.
tect the starting motor.
4. Finishing no injection cranking

After completing the no injection cranking opera-
tion, press [F6], and finish of no injection
cranking is displayed and the screen returns to
the “Service Menu” screen automatically.
30-102 54 PC200, 200LC-8E0 (Hybrid)

Fuel Consumption 3. Display and function during measurement

This function calculates the hourly fuel consumption Clock mark (a) flashes during measurement.
from the actual fuel consumption in the measuring a While the fuel consumption is being mea-
period and indicates it. sured, you can work with the operator mode
or other service function. However, measure-
1. Selecting menu ment is not finished until this screen is dis-
Select “Fuel Consumption” on the “Service played again and [F1] is pressed.
Menu” screen. (Even if the starting switch is turned OFF, this
function is kept effective, but fuel consump-
tion is measured only while the engine is
running).
2. Starting measurement
After the screen of "Fuel Consumption" is
displayed, start measurement by the function
switches. 4. Finishing measurement
q [F1]: START Press [F1], and measurement is finished and the
q [F2]: CLEAR data are displayed on the "Stop Time".
q [F5]: Return to Service menu screen
a When "Fuel consumption" screen is dis- 5. Displaying fuel consumption
played, if a data is indicated, it is the data of If the measurement is finished, the hourly fuel
the previous measurement. This data is not consumption obtained from the fuel consump-
an obstacle to new measurement and can be tion calculated by the engine controller and the
deleted by pressing [F2]. elapsed time are displayed.
a If [F1] is pressed, the data is displayed on the
"Start Time" side and measurement starts.
a The display unit of the fuel differs depending

on the unit selection by the default (unit set-
ting) function.
Metric or Imperial: l/h or gal/h
PC200, 200LC-8E0 (Hybrid) 30-102 55

KOMTRAX Settings (Terminal Status) 3. Contents of display of terminal status

The setting condition and operating condition of On the "Terminal Status" screen, the following
KOMTRAX can be checked by Display of items are displayed.
KOMTRAX setting. q Terminal type: model name of KOMTRAX
Terminal Status is used to check the setting condi- communication moden
tion of the KOMTRAX terminal. q KOMTRAX communication: station opening
inspection status
1. Selecting menu q GMT time: Greenwich Mean Time
Select “KOMTRAX Settings” on the “Service q [F5]: Return to KOMTRAX settings screen
Menu” screen.

After the "KOMTRAX Settings" screen is
displayed, select "Terminal Status" by the func-
tion switches or numeral input switches.
a The following figure shows the display when
Model TH300 KOMTRAX is installed.
30-102 56 PC200, 200LC-8E0 (Hybrid)

KOMTRAX Settings (GPS & Communication Sta- 3. Contents of display of GPS & communication
tus) status
The setting condition and operating condition of On the screen of “GPS & Communication
KOMTRAX can be checked with “KOMTRAX Status”, the following items are displayed.
Settings”. q Positioning: positioning condition by GPS
GPS & communication status is used to check the q Communication: communication environ-
condition of positioning and communication of the ment of communication moden and connect-
KOMTRAX terminal. ing condition of communication modem
q Number of message not yet sent: number of
1. Selecting menu mails which are stored in the machine moni-
Select “KOMTRAX Settings” on the “Service tor but not transmitted yet
Menu” screen. q [F5]: Return to KOMTRAX settings screen

displayed, select GPS & communication status
by the function switches or numeral input
switches.
a The following figure shows the display when
Model TH300 KOMTRAX is installed.
PC200, 200LC-8E0 (Hybrid) 30-102 57

KOMTRAX Setting (MODEM S/N: TH300) 3. Contents of display of Modem S/N

The setting condition and operating condition of The serial number of TH300 modem is
KOMTRAX can be checked by Display of displayed.
KOMTRAX Settings. q [F5]: Return to KOMTRAX settings screen
MODEM S/N is used to check the serial number of
the KOMTRAX communication modem.
1. Selecting menu
Select “KOMTRAX Settings” on the “Service
Menu” screen.

displayed, select "Modem S/N" by the function
switches or numeral input switches.
"Service Menu" screen.
30-102 58 PC200, 200LC-8E0 (Hybrid)

Display of Service message 3. Display of message (with return mail function)

Special messages for the technician sent from the If a box to enter a value by the numeral keys is
KOMTRAX base station (a distributor, etc.) can be displayed under the message, input a proper
checked by this function. number by the numeral input switches and func-
If there is setting in a message, a return mail can be tion switches and enter it, and the information is
sent by using numeral input switches. returned to the KOMTRAX base station.
1. Operation to display menu q [F6]: Enter and send input value as a return
Select "Service Message" on the service menu message
screen. a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the techni-
cian, the message monitor is not displayed
when it is received as in the operator mode.
2. Display of message (read-only)

If there is a message, its contents are displayed.
If there is no message, "No message" is
displayed.
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the techni-
cian, the message monitor is not displayed
when it is received as in the operator mode.
PC200, 200LC-8E0 (Hybrid) 30-102 59

SEN05242-02
©2012 KOMATSU
All Rights Reserved
30-102 60
SEN05243-01
SEN05243-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


Handling voltage circuit of engine controller ............................................................................................... 2

Precautions related to hybrid machines...................................................................................................... 3
Preparation work for troubleshooting of electrical system .......................................................................... 4
Procedure for testing diodes ....................................................................................................................... 10
Pm Clinic service ........................................................................................................................................ 11
PC200, 200LC-8E0 (Hybrid) 30-103 1

SEN05243-01 Handling voltage circuit of engine controller
Handling voltage circuit of engine

controller
1. Before disconnecting or connecting a connector
between the engine controller and engine, be
sure to turn the starting switch to OFF position.
2. If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.
30-103 2 PC200, 200LC-8E0 (Hybrid)

Precautions related to hybrid machines SEN05243-01
Precautions related to hybrid machines
k When testing or adjusting a hybrid machine,

ensure you fully understand the following
items.
1. Never disassemble the hybrid devices for quality

assurance purposes.
2. The hybrid devices and high-voltage wiring
(wound with orange conduits) must be replaced
by the unit.
3. When handling hybrid devices, be sure to
discharge the capacitor completely first.
(For details, see 00-200 Index and Forward,
Forward and general information, Handling of
hybrid devices and high-voltage wirings,
"Discharge procedure for capacitor", or 30-102
Testing and adjusting (Part 2), Special functions
of machine monitor, "Discharge of capacitor".)
The capacitor cannot be discharged with the
machine monitor, depending on the error that
occurred.
k Since the items with the above mark are relat-

ed to handling of the hybrid devices, ensure
you understand the contents of 00-200 Index
and Forward, Forward and general informa-
tion, "Handling of hybrid devices and
high-voltage wirings", before beginning
work on them.
PC200, 200LC-8E0 (Hybrid) 30-103 3

SEN05243-01 Preparation work for troubleshooting of electrical system
Preparation work for trouble-

shooting of electrical system
a When carrying out troubleshooting for an electri-

cal circuit related to the machine monitor, engine
controller, pump controller, hybrid controller (in-
verter), or KOMTRAX communication MODEM,
expose the related connectors according to the
a Disconnect and connect the connectors, which
have a special locking device, according to the
3) Remove the one mounting bolt and duct (6).
1. Machine monitor
1) Remove the three mounting bolts and cover
(1).
a One of the mounting bolt is installed in-
side the cover on the right of the sunlight
sensor.
a While removing the cover, disconnect
connector P31 of the sunlight sensor.
2) Remove cover (2).
a Since the cover is fixed with the clip, pull
it up to remove..
a While removing the cover, disconnect the

body and operation portion of emergency 4) Insert or connect test T-adapters into or to
stop switch (3). connectors CM01, CM02, and CM03 of
machine monitor (7) .
a Connectors CM02 and CM03 are the
same type. When returning them, check
the mark plates on the mounting brackets
and exercise care to connect them cor-
rectly.
a Disconnect the operating knob portion

from the body of emergency stop switch
(3) using the following method; While
pressing knob (4) toward the harness
HS01 side, push up lock part (5) of the
switch body and rotate the switch body by
45 degrees in the direction of arrow (a) .
30-103 4 PC200, 200LC-8E0 (Hybrid)

Preparation work for troubleshooting of electrical system SEN05243-01
2. Engine controller 7) Connect test adapters to connectors C01

1) Open the engine hood. and C02 of pump controller (12) .
a The engine controller is mounted on the a Install the adapters to only the wiring har-
engine (on the counterweight side). ness side.
2) Insert or connect test T-adapters into or to
connectors CE01, CE02, and CE03 of
engine controller (5) .
a When disconnecting connectors CE01
and CE02 , loosen their screws first.
a When returning CE01 and CE02, tighten
their screws to the specified torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
a Disconnect each pump controller connec-

tor, which has a special locking device, in
the order of (a) – (c) in the following figure
and connect in the order of (d) – (f) .
Disconnection: (a) Unlock – (b) Slide
lever – (c) Disconnect connector.
Connection: (d) Position connector – (e)
Slide lever – (f) Engage lock.
3. Pump controller
1) Slide the operator seat and seat stand to the
forward end.
2) Remove the five mounting bolts and cool &
hot box (6).
a While removing the cool & hot box, dis-
connect the drain hose.
3) Remove the two mounting bolts and one
fastener and remove magazine box (7).
(8).
5) Remove fuse box cover (9) and cover (10).
a Since cover (10) is fixed with a clamp at
its bottom, pull it up to remove.
6) Remove the seven mounting bolts and cover
(11).
PC200, 200LC-8E0 (Hybrid) 30-103 5

5) Insert or connect test T-adapters into or to

connectors HC01 and HC02 of hybrid
controller (4).
4. Hybrid controller (inverter)
a When disconnecting connectors HC01
1) Open the radiator door. and HC02, loosen their screws first.
a The hybrid controller is mounted in front a When returning HC01 and HC02, tighten
of the radiator. their screws to the specified torque.
2) Remove the two wing nuts and cover (1). 3 Connector mounting screw:
2.6 – 3.1 Nm {0.27 – 0.32 kgm}
3) Remove the bolt and clamp (2) to move the

power harness aside.
4) Remove the four bolts and cover (3).
30-103 6 PC200, 200LC-8E0 (Hybrid)

5. KOMTRAX communication module 6. Ambient pressure sensor (AMBAIR

1) Slide the operator's seat and seat stand to PRESURE)
the forward end. Engine Ne speed sensor (CRANK SENSOR)
2) Remove the five mounting bolts and cool & Engine Bkup speed sensor (CAM SENSOR)
hot box (6). Engine oil pressure switch (OIL PRESSURE
a While removing the cool & hot box, dis- SWITCH)
connect the drain hose. a Disconnection and connection of connec-
3) Remove the two mounting bolts, one tors
fastener, and magazine box (7). The connectors of the ambient pressure
sensor, engine Ne speed sensor, engine
Bkup speed sensor, engine oil pressure
(8).
switch have a special locking device. Discon-
5) Remove fuse box cover (9) and cover (10).
nect them in the order of steps (a) – (c) and
a Since the underside of cover (10) is
connect them in the order of steps (d) – (f) as
clamped, pull it up to remove.
shown below.
6) Remove the seven mounting bolts and cover Disconnection: (a) Slide lever – (b) Unlock –
(11). (c) Disconnect connector.
Connection: (d) Connect connector – (e)
Engage lock – (f) Slide lever.
7) Connect test T-adapters to connectors CK01

and CK02 of KOMTRAX communication
module (13). a Removal and installation of sensor
a Cable (14) is for the communication an- A deep socket is necessary for removal and
tenna. installation of the engine oil pressure switch.
See "Tools for testing, adjusting, and trouble-
shooting".
PC200, 200LC-8E0 (Hybrid) 30-103 7

7. Boost pressure and temperature sensor 8. Supply pump IMV solenoid (FUEL REGU-
(BOOST PRES & IMT) LATOR)
a Disconnection and connection of connec- a Disconnection and connection of connec-
tor tor
The connector of the boost pressure and The connector of the supply pump IMV sole-
temperature sensor has a special locking noid has a special locking device. Disconnect
device. Disconnect it in the order of steps (a) it in the order of steps (a) – (b) and connect it
– (b) and connect it in the oredr of steps (c) – in the order of steps (c) – (d) as shown below.
(d) as shown below. Disconnection: (a) Unlock – (b) Disconnect
Disconnection: (a) Unlock – (b) Disconnect connector.
connector. Connection:(c) Connect connector – (d)
Connection: (c) Connect connector – (d) Engage lock.
Engage lock.
a Precautions for disconnecting connector

a Removal and installation of sensor The direction of the lock of the connector
A torque wrench is necessary for removal varies with the tightened position of the
and installation of the boost pressure and sensor and the lock may be in a direction in
temperature sensor. See "Tools for testing, which it is difficult to release (on the under-
adjusting and troubleshooting". side or engine side).
In this case, pinch the lock in direction (a)
with bent-nose nippers [1] (available on the
market), and the lock is released.
Since the lock clicks when it is released,
disconnect the connector after a click is
heard.
30-103 8 PC200, 200LC-8E0 (Hybrid)

a Precautions for connecting connector 10. Engine coolant temperature sensor

Take care not to connect the connector (COOLANT TEMP)
upside down. a Disconnection and connection of connec-
Engage lock (e) on the harness side with tor
triangular notch (f) on the sensor side (Do not The connector of the engine coolant temper-
engage lock (e) with square guide (g) on the ature sensor has a special locking device.
opposite side of triangular notch (f)) . Disconnect it in the order of steps (a) – (b)
and connect it in the order of steps (c) – (d)
as shown below.
Disconnection: (a) Unlock – (b) Disconnect
connector.
Connection: (c) Connect connector – (d)
Engage lock.
9. Common rail pressure sensor (FUEL RAIL

PRESS)
a Disconnection and connection of connec-
tor
The connector of the common rail pressure
sensor has a special locking device. Discon- a Removal and installation of sensor
nect it in the order of steps (a) – (b) and A deep socket is necessary for removal and
connect it in the order of steps (c) – (d) as installation of the engine coolant temperature
shown below. sensor. See "Tools for testing, adjusting and
Disconnection: (a) Unlock – (b) Disconnect troubleshooting".
connector.
Connection: (c) Connect connector – (d)
Engage lock.
PC200, 200LC-8E0 (Hybrid) 30-103 9

SEN05243-01 Procedure for testing diodes
Procedure for testing diodes

a Test the assembled-type diode (8-pin) and the
single diode (2-pin) according to the following
procedure.
a The conductible directions of the assem-
bled-type diode are as follows.
2. When using analog multimeter

1) Set the multimeter in the resistance range.
2) Apply the leads of the multimeter as
explained below and check the movement of
the pointer.
a The conductible direction of the single diode is
1] Apply the red (+) lead of the multimeter to
indicated on the surface of the diode.
the anode (P) side of the diode and apply
the black (-) lead to the cathode (N) side.
2] Apply the red (+) lead of the multimeter to
the cathode (N) side of the diode and
apply the black (-) lead to the anode (P)
side.
3) Judge the quality of the diode by the move-
ment of the pointer.
q The pointer does not move in 1] but
moves in 2]:
The diode is normal (The moving range
(resistance) depends on the type and
selected range of the tester, however).
q The pointer moves in both 1] and 2]:
The diode is defective (internal short
1. When using digital multimeter circuit).
1) Set the tester in the diode range and check q The pointer moves in neither of 1] and 2]:
the indicated value. The diode is defective (internal disconti-
a When an ordinary multimeter is used, the nuity).
voltage of the internal battery is indicated.
2) Apply the red (+) lead of the multimeter to the
anode (P) side of the diode and apply the
black (-) lead to the cathode (N) side and
check the indicated value.
3) Judge the quality of the diode by the indi-
cated value.
q The indicated value does not change:
continuity (defective)
q The indicated value changes: No continu-
ity (normal)
Note:In the case of a silicon diode, a value in
the range from 460 to 600 is indicated.
30-103 10 PC200, 200LC-8E0 (Hybrid)

Pm Clinic service SEN05243-01
Pm Clinic service
Model Serial No. Service meter
PC200·200LC-8E0 h
User's name Date of clinic Inspector
/ /
Specifications
Main components Shoe width
Boom Standard ( ) 600 mm
Arm Standard ( ) 700 mm
Bucket Standard ( ) ( )
Check of oil/coolant level
Radiator coolant When necessary Machinery case oil
Hybrid radiator coolant Final drive case oil Motor generator case oil
Engine oil Swing electrical motor case oil
Hydraulic oil ( )
Ambient temperature Height above sea level
°C m
Operator's comment
Visual check check
Mechanical equipment system failure record Electrical equipment system failure record
989EKX time/1st time h/last h time/1st time h/last h
AA10NX time/1st time h/last h time/1st time h/last h
AB00KE time/1st time h/last h time/1st time h/last h
B@BAZG time/1st time h/last h time/1st time h/last h
B@BAZK time/1st time h/last h time/1st time h/last h
B@BCNS time/1st time h/last h time/1st time h/last h
B@BCZK time/1st time h/last h time/1st time h/last h
B@HANS time/1st time h/last h time/1st time h/last h
CA234 time/1st time h/last h time/1st time h/last h
Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge
PC200, 200LC-8E0 (Hybrid) 30-103 11

SEN05243-01 Pm Clinic service
Items related to engine
30-103 12 PC200, 200LC-8E0 (Hybrid)

Items related to oil pressure
PC200, 200LC-8E0 (Hybrid) 30-103 13

Check sheet (PC200, 200LC)

Model Serial No. Service meter User's name Date of check Inspector
/ /
1. Engine
Checking condition
Standard
Auto- Mea-
Fuel Work- Left Operation value for Service
Good
NG
No. Check item decel- Unit sured
control ing knob of work new limit value
era- value
dial mode switch equipment machine
tion
All levers 1,990 - 1,990 -
1 Engine speed rpm
in the neu- 2,130 2,130
MAX Mpa
Engine oil pres- tral posi- Min. 0.29 0.25
2
sure tion {kg/cm2} {Min.3.0} {2.5}
OFF
All levers 1,000 - 1,000 -
3 Engine speed rpm
in the neu- 1,100 1,100
MIN OFF
Engine oil pres- tral posi- Mpa Min. 0.10 0.07
4 2}
sure p tion {kg/cm {Min.1.0} {0.7}
1,700 - 1,700 -
5 Engine speed rpm
Arm IN 1,900 1,900
ON
relief Mpa Max.0.98 1.96
6 Blowby pressure
{mmH2O} {Max.100} {200}
MAX
All levers
in the neu- 1,300 - 1,300 -
7 Engine speed ON OFF rpm
tral posi- 1,500 1,500
tion
2. Work equipment speed

Checking condition Standard
Mea-
Fuel Work- value for Service
Good
NG
No. Check item Unit sured
control ing Checking, etc. poisture new limit value
value
dial mode machine
Work equipment
1 Boom RAISE PC200 sec. 2.9 - 3.7 Max. 4.7
p extended fully
PC200 sec. 3.1 - 3.9 Max. 4.5
3 Arm IN
E Boom top horizontal PC200 sec. 3.1 - 3.9 Max. 4.5
4 Arm OUT PC200 sec. 2.4 - 3.0 Max. 3.5
Boom top horizontal
6 Bucket CURL Arm cylinder PC200 sec. 2.3 - 2.9 Max. 3.3
retracted fully
MAX Work equipment extended
6 Swing (5 turns) fully sec. 21.7 - 26.7 Max. 30
p Swing right and left
STD 46.2 - 56.4 46.2 - 60.4
One side of track LO LC sec.
50.3 - 61.5 50.3 - 65.5
Travel raised and turned STD 33.7 - 41.3 33.7 - 45.3
5 MI sec.
(five idle turns) forward and LC 36.7 - 44.9 36.7 - 48.9
backward STD 25.2 - 27.8 25.2 - 29.8
HI sec.
LC 27.3 - 30.3 27.3 - 32.3
30-103 14 PC200, 200LC-8E0 (Hybrid)

3. Hydraulic drift of work equipment

Checking condition Standard
Mea-
Fuel Work- value for Service limit
Good
NG
No. Check item Unit sured
controling Checking posture, etc. new value
value
dial mode machine
Boom top horizontal
Hydraulic drift mm/15
1 Engine stopped Arm cylinder retracted fully Max. 600 Max. 900
of bucket tip min
Bucket loaded
4. Hydraulic circuit
[1] [2] [3] [4] [5]
60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
Checking condition {600 {600 {600 {600 {60
Good
kg/cm2} kg/cm2} kg/cm2} kg/cm2} kg/cm2}
NG
No. Check item
Fuel Work- Auto-de F R
Operation of work F pump R pump Con-
control ing celera- pump pump
equipment main main trol
dial mode tion main main
Self-pressure All levers in the neu- - - - - A
1
reducing valve tral position
Main relief OFF B B B B
2 valve -
(Low pressure)
Arm OUT relief
Main relief C C C C
3 valve ON -
(High pressure)
All levers in the neu- D1 D1 D2 D2
4 Unload valve -
tral position
Right track driven idle E1 E2
MAX P - - -
Lever moved halfway
5 LS valve
Left track driven idle E1 E2
- - -
Lever moved halfway
Right travel lock F
OFF - - - -
Main relief Right forward relief
valve Right travel lock F
- - - -
Travel motor Right reverse relief
6
Safety valve Left travel lock F
- - - -
Travel junction Left forward relief
valve Left travel lock F
- - - -
Left reverse relief
Checked oil pressure Unit Standard value for new machine Service limit value
A (Control circuit source pres-
2.93 - 3.43 {30 - 35} 2.74 - 3.43 {28 - 35}
sure)
Standard value
B (Work equipment relief pres-

33.8 - 35.8 {345 - 365} 33.3 - 36.8 {340 - 375}
sure, low) Mpa
C (Work equipment relief pres-
{kg/cm2} 36.3 - 38.3 {370 - 380} 36.3 - 39.2 {370 - 400}
sure, high)
D (Unload pressure) D1 - D2 = 2.5 - 4.5 {26 - 46} D1 - D2 = 2.5 - 4.5 {26 - 46}
E (LS differential pressure) E1-E2=1.7-1.9{17-19} E1 - E2 = 1.7 - 1.9 {17 - 19}
F (Travel relief pressure) 36.7 - 39.7 {375 - 405} 36.8 - 40.2 {375 - 410}
PC200, 200LC-8E0 (Hybrid) 30-103 15

* Gauge changing work: Change hoses of gauges [3] and [4].

[1] [2] [3a] [4a] [5]
kg/cm2} kg/cm2} kg/cm2} kg/cm2} kg/cm2}
Good
NG
No. Check item
Auto-
Fuel Work-
decel- Operation of work F pump R pump F pump R pump
control ing Control
era- equipment main main main main
dial mode
tion
7 Servo piston MAX P OFF Arm OUT relief H1 H1 H2 H2 -
Standard value
H1: H2 = 1 : 0.6
H (Servo control pressure) -
(Oil pressure ratio)
* Gauge changing work: Change [3] and [4] to 6 MPa {60 kg/cm2} and change hoses of [3], [4], and [5].
[1] [2] [3b] [4b] [5a]
Good
kg/cm2} kg/cm2} kg/cm2 kg/cm2 kg/cm2}
NG
No. Check item
Fuel Work-
Auto-dec Operation of work F pump R pump F pump R pump
control ing Control
eleration equipment main main (F) (R)
dial mode
PC EPC MIN - - J1 J1 -
P
(F) valve All levers in the - - J2 J2 -
8 J3 J3
PC EPC neutral position
E - - -
(R) valve
Travel speed: LO K1
Travel lever in the - - - -
OFF neutral position
MAX
Travel speed: MI K2
9 LS-EPC valve P Travel lever oper- - - - -
ated
Travel speed: HI K3
Travel lever oper- - - - -
ated
J1 (PC-EPC valve output pres-
Approx. 2.9 {Approx. 30}
sure 1)
Approx. 0.7 {Approx. 7}
Standard value
sure 2)
Mpa Approx. 0.78 {Approx. 8}
sure 3)
K1 (LS-EPC valve output pres- {kg/cm2} Approx. 2.45 {Approx. 25}
sure 1)
K2 (LS-EPC valve output pres-
Approx. 0.74 {Approx. 7.5}
sure 2)
K3 (LS-EPC valve output pres-
0 {0}
sure 3)
30-103 16 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 30-103 17

SEN05243-01
©2010 KOMATSU
All Rights Reserved
30-103 18
SEN05245-02
SEN05245-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
100 Failure code table and fuse locations
Failure code table ....................................................................................................................................... 2

Fuse locations............................................................................................................................................. 8
PC200, 200LC-8E0 (Hybrid) 40-100 1

SEN05245-02 Failure code table
Failure code table

a This failure code table is the same as that in Testing and adjusting, “Special functions of machine
monitor”.
User Device to Document No.
Failure code Failure (Displayed on screen) Category of system
code work to refer
- 989L00 Engine Controller Lock Caution 1 MON Electrical system
- 989M00 Engine Controller Lock Caution 2 MON Electrical system
- 989N00 Engine Controller Lock Caution 3 MON Electrical system
- AA10NX Air Cleaner Clogging MON Mechanical system
- AB00KE Charge Voltage Low MON Mechanical system
- B@BAZG Eng Oil Press. Low ENG Mechanical system
- B@BAZK Eng Oil Level Low MON Mechanical system
- B@BCNS Eng Water Overheat ENG Mechanical system
- B@BCZK Eng Water Level Low MON Mechanical system
- B@HANS Hydr Oil Overheat PUMP Mechanical system
E10 CA111 EMC Critical Internal Failure ENG Electrical system
E10 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical system
E11 CA122 Chg Air Press Sensor High Error ENG Electrical system
E10 CA123 Chg Air Press Sensor Low Error ENG Electrical system
E14 CA131 Throttle Sensor High Error ENG Electrical system
E14 CA132 Throttle Sensor Low Error ENG Electrical system Troubleshooting
by failure code
E15 CA144 Coolant Temp Sens High Error ENG Electrical system
(Part 1),
E15 CA145 Coolant Temp Sens Low Error ENG Electrical system SEN05247-00
E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system
E15 CA154 Chg Air Temp Sensor Low Error ENG Electrical system
E11 CA155 Chg Air Temp High Speed Derate ENG Electrical system
E15 CA187 Sens Supply 2 Volt Low Error ENG Electrical system
E11 CA221 Ambient Press Sens High Error ENG Electrical system
E11 CA222 Ambient Press Sens Low Error ENG Electrical system
E15 CA227 Sens Supply 2 Volt High Error ENG Electrical system
- CA234 Eng Overspeed ENG Mechanical system
E15 CA238 Ne Speed Sens Supply Volt Error ENG Electrical system
E10 CA271 IMV/PCV1 Short Error ENG Electrical system
E10 CA272 IMV/PCV1 Open Error ENG Electrical system
E11 CA322 Inj #1 Open/Short Error ENG Electrical system
E10 CA342 Calibration Code Incompatibility ENG Electrical system
E10 CA351 Injectors Drive Circuit Error ENG Electrical system
E15 CA352 Sens Supply 1 Volt Low Error ENG Electrical system
E15 CA386 Sens Supply 1 Volt High Error ENG Electrical system
E15 CA428 Water in Fuel Sensor High Error ENG Electrical system
E15 CA429 Water in Fuel Sensor Low Error ENG Electrical system
E15 CA435 Eng Oil Press Sw Error ENG Electrical system Troubleshooting
E10 CA441 Battery Voltage Low Error ENG Electrical system by failure code
E10 CA442 Battery Voltage High Error ENG Electrical system (Part 2),
E11 CA449 Rail Press Very High Error ENG Electrical system SEN05248-00
E11 CA451 Rail Press Sensor High Error ENG Electrical system
E11 CA452 Rail Press Sensor Low Error ENG Electrical system
E11 CA488 Chg Air Temp High Torque Derate ENG Electrical system
E15 CA553 Rail Press High Error ENG Electrical system
E15 CA559 Rail Press Low Error ENG Electrical system
E15 CA689 Eng Ne Speed Sensor Error ENG Electrical system
40-100 2 PC200, 200LC-8E0 (Hybrid)

Failure code table SEN05245-02

code work to refer
E15 CA731 Eng Bkup Speed Sens Phase Error ENG Electrical system
E10 CA757 All Continuous Data Lost Error ENG Electrical system
E15 CA778 Eng Bkup Speed Sensor Error ENG Electrical system
E0E CA1633 KOMNET Datalink Timeout Error ENG Electrical system
E14 CA2185 Throt Sens Sup Volt High Error ENG Electrical system
E14 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system
E11 CA2249 Rail Press Very Low Error ENG Electrical system Troubleshooting
E11 CA2311 IMV Solenoid Error ENG Electrical system by failure code
E15 CA2555 Grid Htr Relay Volt High Error ENG Electrical system (Part 2),
E15 CA2556 Grid Htr Relay Volt Low Error ENG Electrical system SEN05248-00
E01 D19JKZ Personal Code Relay Abnormality MON2 Electrical system
- D862KA GPS Antenna Discon MON2 Electrical system
E0E DA22KK Pump Solenoid Power Low Error PUMP Electrical system
- DA25KP 5 V Sensor 1 Power Abnormality PUMP Electrical system
- DA26KP 5 V sensor 2 power Abnormality PUMP Electrical system
- DA29KQ Model Selection Abnormality PUMP Electrical system
E0E DA2RMC CAN Discon (Pump Con Detected) PUMP Electrical system
- DAF8KB Short circuit in camera power supply MON Electrical system
- DAFGMC GPS Module Error MON2 Electrical system
E0E DAFRMC CAN Discon (Monitor Detected) MON Electrical system
- DGH2KB Hydr Oil Sensor Short PUMP Electrical system
- DHPAMA F Pump Press Sensor Abnormality PUMP Electrical system
- DHPBMA R Pump Press Sensor Abnormality PUMP Electrical system
Arm Curl PPC Press Sensor
- DHS3MA PUMP Electrical system Troubleshooting
Abnormality
Bucket Curl PPC Press Sensor by failure code
- DHS4MA PUMP Electrical system (Part 3),
Abnormality
E20 DHS5KK Travel PPC pressure sensor Abnormality PUMP Electrical system SEN05249-00
Boom Raise PPC Press Sensor
- DHS8MA PUMP Electrical system
Abnormality
Swing RH PPC Press Sensor
- DHSAMA PUMP Electrical system
Abnormality
Swing LH PPC Press Sensor
- DHSBMA PUMP Electrical system
Abnormality
Bucket Dump PPC Press Sensor
- DHSDMA PUMP Electrical system
Abnormality
HYB Arm Dig PPC Pr. Sen.
E09 DHV3KZ HYB Electrical system
Opn/Short Cir.
HYB Boom Lower PPC Pr. Sen.
E09 DHV9KZ HYB Electrical system
Opn/Short Cir. Troubleshooting
HYB Swing-R PPC Pr. Sen. by failure code
E09 DHVAKZ HYB Electrical system
Opn/Short Cir. (Part 5),
HYB Swing-L PPC Pr. Sen. SEN05251-03
E09 DHVBKZ HYB Electrical system
Opn/Short Cir.
HYB Arm Dump PPC Pr. Sen.
E09 DHVCKZ HYB Electrical system
Opn/Short Cir.
Troubleshooting
- DW43KA Travel Speed Sol Discon PUMP Electrical system
by failure code
(Part 3),
- DW43KB Travel Speed Sol Short PUMP Electrical system SEN05249-00
E09 DW45KA Swing Brake Sol. Valve Open Cir. HYB Electrical system Troubleshooting
E09 DW45KB Swing Brake Sol. Valve Short Cir. HYB Electrical system by failure code
Swing Brake Sol. Valve Pow. Short (Part 5),
E09 DW45KY HYB Electrical system
Cir. SEN05251-03
- DW91KA Travel Junction Sol Discon PUMP Electrical system Troubleshooting
- DW91KB Travel Junction Sol Short PUMP Electrical system by failure code
- DWK0KA 2-stage Relief Sol Discon PUMP Electrical system (Part 3),
- DWK0KB 2-stage Relief Sol Short PUMP Electrical system SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-100 3


code work to refer
E02 DXA8KA PC-EPC (F) Sol Discon PUMP Electrical system
E02 DXA8KB PC-EPC (F) Sol Short PUMP Electrical system
E02 DXA9KA PC-EPC (R) Sol Discon PUMP Electrical system
E02 DXA9KB PC-EPC (R) Sol Short PUMP Electrical system
- DXE0KA LS-EPC Sol Discon PUMP Electrical system
- DXE0KB LS-EPC Sol Short PUMP Electrical system
- DXE5KA Merge-divider Main Sol Discon PUMP Electrical system
Troubleshooting
- DXE5KB Merge-divider Main Sol Short PUMP Electrical system by failure code
- DXE6KA Merge-divider LS Sol Discon PUMP Electrical system (Part 4),
SEN05250-01
- DXE6KB Merge-divider LS Sol Short PUMP Electrical system
- DY20KA Wiper Working Abnormality PUMP Electrical system
- DY20MA Wiper Parking Abnormality PUMP Electrical system
- DY2CKA Washer Drive Discon PUMP Electrical system
- DY2CKB Washer Drive Short PUMP Electrical system
- DY2DKB Wiper Drive (For) Short PUMP Electrical system
- DY2EKB Wiper Drive (Rev) Short PUMP Electrical system
E09 GA01KA Power Cable Interlock Open Circuit HYB Electrical system
E09 GA02KZ DC Line Open & Short Circuit HYB Electrical system
Abnormal DC HW Volt. Before
E09 GA04KG HYB Electrical system
Booster
Abnormal DC SW Volt. Before
E09 GA05KG HYB Electrical system
Booster
Low DC SW Output Volt. Bef.
E09 GA05KP HYB Electrical system
Booster
DC Vlt. Sen. Opn./Shrt.Cir. Bef.
E09 GA06KZ HYB Electrical system
Booster
E09 GA08KG Abnorm. DC HW Volt. After Booster HYB Electrical system
E09 GA09KG Abnorm. DC SW Volt. After Booster HYB Electrical system
Low DC SW Output Volt. After
E09 GA09KP HYB Electrical system
Booster
DC Vlt. Sen. Op./Shrt cir. Aft.
E09 GA0AKZ HYB Electrical system
booster
E09 GA0BKZ AC line Open & Short Circuit HYB Electrical system
HYB Controller In General And Troubleshooting
E09 GA10Z9 HYB Electrical system by failure code
Others
(Part 5),
E09 GA11KK HYB Cont. Low Supply Voltage HYB Electrical system
SEN05251-03
E09 GA12MC HYB Cont. Pow. Suppl. Failure HYB Electrical system
HYB Cont. Pow. Suppl. Not Turn.
E09 GA12NK HYB Electrical system
ON
HYB Cont. Pow. Suppl. Not Turn.
E09 GA12NL HYB Electrical system
OFF
HYB Control. Sen. Power Sup.
E09 GA13MC HYB Electrical system
Failure
HYB Control. KOMNET Comm.
E09 GA14KR HYB Electrical system
Failure
HYB Cont. Bad Insul. Sen.
Open/Short Cir.
E09 GA16KK Low HYB Cont. VDD Suppl. Volt. HYB Electrical system
Gen. Mot. Drv. Communication
Failure
Gen. Mot Dr. Power Line Short
E09 GA17KY HYB Electrical system
Circuit
Gen. Motor Driver Open/Short
Circuit
40-100 4 PC200, 200LC-8E0 (Hybrid)


code work to refer
E09 GA17MB Gen. Mot. Drv. Function Degraded HYB Electrical system
Gen. Mo.Dr. Excite. Pow. Sup.
Failure
Gen. Mot. Drv. Sub-CPU Low Sup.
E09 GA19KK HYB Electrical system
Volt.
Gen. Motor Driver Sub-CPU Comm.
Failure
Int. Abnorm. Gen. Mot. Drv. Sub-
E09 GA19KT HYB Electrical system
CPU Con.
Gen. Mot. Drv. Sub-CPU
E09 GA19MA HYB Electrical system
Malfunction
Gen. Mot. Drv. Sub-CPU Defect.
Operation
Gen. Mot. Drv. Sub-CPU Start
E09 GA19NA HYB Electrical system
Disabled
Gen. Mot. Dr. Temp. Sens.
E09 GA1AKZ HYB Electrical system
Opn/Short Cir.
Gen. Mot. Dr. DC Vlt. Sens.
E09 GA1BMA HYB Electrical system
Malfunction
Gen. Motor Driver IPM1
E09 GA1DMA HYB Electrical system
Abnormality
Gen. Motor Driver IPM2
E09 GA1EMA HYB Electrical system
Abnormality
Swing Mot. Drv. Communication
E09 GA1FKR HYB Electrical system
Failure
E09 GA1FMA Abnormal Swing Motor Driver HYB Electrical system
Low Sup. Volt. Swing Motor Drv.
E09 GA1GKK HYB Electrical system
Sub-CPU
Swing Mot. Driver Sub-CPU Comm.
E09 GA1GKR HYB Electrical system Troubleshooting
Faliure
Swing Mot. Drv. Sub-CPU Cont. by failure code
E09 GA1GKT HYB Electrical system (Part 5),
Abnormal
Swing Motor Drv. Sub-CPU SEN05251-03
E09 GA1GMA HYB Electrical system
Malfunction
Swing Mot. Drv. Sub-CPU Funct.
E09 GA1GMB HYB Electrical system
Degraded
Swing Mot. Drv. Sub-CPU Defect
E09 GA1GMC HYB Electrical system
Op.
Swing Mot. Drv. Sub-CPU Start
E09 GA1GNA HYB Electrical system
Disabled
Swg Mot. Dr. Ph-U Tem. Sens
E09 GA1HKZ HYB Electrical system
Opn/Shrt Cir.
Swg Mot. Dr. Ph-V Tem. Sens
E09 GA1JKZ HYB Electrical system
Opn/Shrt Cir.
Swg Mot. Dr. Ph-W Tem. Sens
E09 GA1KKZ HYB Electrical system
Opn/Shrt Cir.
Swg Mot. Dr. Current. Sens
E09 GA1LKZ HYB Electrical system
Opn/Shrt Cir.
Swg Mot. Dr. DC Vlt. Sens
E09 GA1MKZ HYB Electrical system
Opn/Shrt Cir.
E09 GA1NNS Swing Motor Driver IGBT Overheat HYB Electrical system
Swg Mot. Driver IPM Ph-U Not
E09 GA1PNV HYB Electrical system
Warm Up
Swg Mot. Driver IPM Ph-V Not
E09 GA1QNV HYB Electrical system
Warm Up
Swg Mot. Driver IPM Ph-W Not
E09 GA1RNV HYB Electrical system
Warm Up
E09 GA1SFS Contactor Locked HYB Electrical system
E09 GA1SMC Contactor Failure HYB Electrical system
E09 GA1TKG Capacitor HVPS Abnormal Voltage HYB Electrical system
E09 GA1TKP Capacitor Low Output Voltage HYB Electrical system
PC200, 200LC-8E0 (Hybrid) 40-100 5


code work to refer
E09 GA1TNS Capacitor Overheat HYB Electrical system
Capacitor Temp. Sensor Opn/Short
E09 GA1UKZ HYB Electrical system
Cir.
E09 GA1VFS Capacitor Contactor Locked HYB Electrical system
E09 GA1VMC Capacitor Contactor Failure HYB Electrical system
Boost. Ind. Temp. Sens. Open/Shrt.
E09 GA1XKZ HYB Electrical system
Circ.
E09 GA1YNS Booster Inductor Overheat HYB Electrical system
E09 GA1YNV Booster Inductor Not Warming Up. HYB Electrical system
Booster IGBT Temp. Sens.
E09 GA1ZKZ HYB Electrical system
Opn/Shrt. Circ.
Booster IGBT Temp. Sens.
E09 GA1ZNS HYB Electrical system
Overheat
Booster IGBT Temp. Sens. Not
E09 GA1ZNV HYB Electrical system
Warm Up
E09 GA21KB Booster IGBT Open Circuit HYB Electrical system
E09 GA22NS Booster IGBT Junction Overheat HYB Electrical system
E09 GA60MC Generator Motor Failure HYB Electrical system
E09 GA60MD Gen. Mot. Defective Movement HYB Electrical system
E09 GA60N1 Generator Motor Overrun HYB Electrical system
Gen. Motor Temp. Sens.
Opn/Short Cir.
Generator Motor Temp. Sensor
E09 GA61NS HYB Electrical system
Overheat
Gen. Mot. Ph-A Cur. Sen. Power
E09 GA62KY HYB Electrical system Troubleshooting
Short Cir
Gen. Mot. Ph-A Cur. Sen. by failure code
E09 GA62KZ HYB Electrical system (Part 5),
Open/Short Cir
Gen. Mot. Ph-A Current Sen. SEN05251-03
Malfunction
Gen. Mot. Ph-B Cur. Sen. Power
Short Cir.
Gen. Mot. Ph-B Cur. Sen.
Open/Short Cir.
Gen. Mot. Ph-B Current Sen.
Malfunction
Gen. Mot. Ph-C Cur. Sen. Power
Short Cir.
Gen. Mot. Ph-C Cur. Sen.
Open/Short Cir.
Gen. Mot. Ph-C Current Sen.
Malfunction
E09 GA70KB HYB Swing Motor Short Circuit HYB Electrical system
HYB Swing Motor Defective Stirr.
E09 GA70MD HYB Electrical system
Motion
E09 GA70NS HYB Swing Motor Overheat HYB Electrical system
HYB Swing Mot. Temp. Sens.
Opn/Shrt Cir.
HYB Swing Motor Resolver
Malfunction
HYB Swing Motor Resolver Defect
Op.
Swing Motor Power Cable
Opn/Shrt Circ.
40-100 6 PC200, 200LC-8E0 (Hybrid)

User code E09 is an exclusive code for hybrid models, which is described in "Troubleshooting by failure code
(Part 5)".

k When testing or adjusting a hybrid machine, ensure that you fully understand the following mat-
ters.
1. Never disassemble the hybrid devices.
2. The hybrid devices and high-voltage wiring (covered by orange conduits) must be replaced by the unit.
3. When handling hybrid devices, be sure to discharge the capacitor completely first.
(For details, see 00-200 Introduction, safety and basic information, Handling of hybrid devices and
high-voltage wiring, "Discharge procedure for capacitor", or 30 -102 Testing and adjusting (Part 2), Special
functions of machine monitor, "Discharge of capacitor".)
k Since the items with the above mark are related to handling of the hybrid devices, ensure that you
understand the descriptions of 00-200 Introduction, safety, and basic information, "Handling of hy-
brid devices and high-voltage wiring", before beginning the work on them.
a Order of items described in table

The items are listed in the order of failure codes (incremental order).
a User code
Attached: If the failure code is detected, the user code, failure code, and telephone No. (if registered) are
displayed on the ordinary screen to notify the operator of the failure.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the
failure.
a Device to work
MON: The machine monitor works for detection of failure.
MON2: The KOMTRAX section of the machine monitor works for detection of failure.
ENG: The engine controller works for detection of failure.
PUMP: The pump controller works for detection of failure.
HYB: The hybrid controller works for detection of failure.
a Category of system
Mechanical system: Failure information is recorded in the mechanical system failure history.
Electrical system: Failure information is recorded in the electrical system failure history.
The capacitor cannot be discharged with the machine monitor, depending on the error that occurred.
PC200, 200LC-8E0 (Hybrid) 40-100 7

SEN05245-02 Fuse locations
Fuse locations
Table of fuse box connection
a This connection table shows the devices to which each power supply through the fuse box supplies power
(A switch power supply is a power supplied while the starting switch is turned to the ON position and an
unswitched power supply is a power while the starting switch is turned to the OFF or ON positions).
a When carrying out the troubleshooting related to the electrical system, you should check the fuses and
fusible links to see if the power is supplied normally.
Type of power Fuse
Fusible link Fuse No. Destination of power
supply capacity
Lamp relay, rear lamp relay, cab lamp relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve
1 10A [When emergency pump drive switch is operated]
Swing holding brake solenoid valve
[When swing holding brake release switch is operated]
Pump controller (Solenoid power supply)
2 30A
Switch power F04 Capacitor (M terminal), Inverter (M terminal)
supply (60A) PPC oil pressure lock solenoid valve
3 10A Starting motor cut-out relay (PPC lock)
Starting motor cut-out relay (Personal code)
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Electrical intake air heater relay
7 10A Revolving warning lamp
Switch power F04 8 20A Right headlamp, working lamp (boom), working lamp (rear)
supply (60A) Radio
9 10A
Left knob switch (pump controller input)
10 10A (Spare)
Air conditioner unit
11 20A
Air conditioner compressor electromagnetic clutch
12 10A (Spare)
Switch power F04
13 10A Headlamp
supply (60A)
14 10A Optional power supply (1)
Travel alarm
15 10A
Optional power supply (2)
Radio (backup power supply)
16 10A
Room lamp
Starting switch
Unswitched F05 Machine monitor
17 20A
power supply (30A) Pump controller
Hybrid controller
18 10A (Spare)
19 30A Engine controller
Switch power Starting switch
20 5A Engine controller (ACC signal), Inverter (ACC signal)
supply ACC
40-100 8 PC200, 200LC-8E0 (Hybrid)

Fuse locations SEN05245-02
Locations of fusible links
Location of fuse box and fuse Nos.
PC200, 200LC-8E0 (Hybrid) 40-100 9

Problems 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 simultaneously
(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 canceled.
q The travel speed does not change.
q The one-touch power maximizing function does not work.
q The swing holding brake cannot be canceled 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 Not lighting: The controller power is not supplied.
a Green LED of pump controller (a)
40-100 10 PC200, 200LC-8E0 (Hybrid)

Problems that occur when power supply for pump controller is defective
a The solenoid power supply (F01-2) for the pump controller is used by the controller to drive the solenoids
and relays. Accordingly, if the solenoid power supply is cut off, when the controller works to output 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]: Attachment oil flow throttle EPC system (if attachment is installed)
q [DXE5KA], [DXE5KB]: Merge-divide main solenoid system
q [DXE6KA], [DXE6KB]: Merge-divide LS solenoid system
a If the above problems occur, check the related fuse (F01-2) and input voltage of the pump controller.
1) Disconnect connectors C01 and C02 of the controller and connect a T-adapter box to the connectors
on the wiring harness side.
2) Turn the starting switch ON position.
3) Measure the voltage between each of pins C02(116)(118)(121) and each of pins C01(2)(5).
a Pins C02(116)(118)(121) are the power supply and pins C01(2)(5)are the chassis ground.
a If the voltage is 20 to30V, the solenoid power supply is normal.
a Power supply connectors (C01, C02) of pump controller
PC200, 200LC-8E0 (Hybrid) 40-100 11

Problems when controller power supply of hybrid controller (inverter) is defective

a Controller power supply (F01-17) of the hybrid controller is a power supply that works the controller sys-
tem. Accordingly, if the controller power supply is cut off, the controller cannot control the system, thus the
following problems may occur simultaneously. (The following is only an example of the problems)
q Machine cannot swing the upper structure
q Since the low-speed matching function does not work, the engine speed is maintained at the throttle
indication value.
a If the above problems occur simultaneously, check corresponding fuse (F01-17).
Problems when solenoid power supply of hybrid controller (inverter) is defective

a Solenoid power supply (F01-2) of the hybrid controller is a power supply with which the controller works
the solenoids and relays. Accordingly, if the solenoid power supply is cut off, when the controller works to
output a signal to a solenoid or a relay, power is not supplied to any solenoid or relay circuit, thus all or
some of the following failure codes are displayed simultaneously.
q [GA18MC]: Defective operation of generator motor driver excitation power supply
q [DW45KA], [DW45KB], [DW45KY]: Swing holding brake solenoid system
q [GA1VMC]: Contactor opening failure, contactor output ground fault or disconnection on capacitor side
a If the above problems occur simultaneously, check corresponding fuse (F01-2) and hybrid controller inlet
power supply.
1) Disconnect HC01 of the controller and connect a T-adapter box to the connector on the wiring harness
side.
2) Turn the starting switch to ON position.
3) Measure the voltage between pins HC01 (1), (7) and HC01 (13), (19).
* Pins HC01 (1) and (7) are the power supply and pins HC01 (13) and (19) are the ground.
* If the voltage is in the range of 20 to 30 V, the solenoid power supply is normal.
40-100 12 PC200, 200LC-8E0 (Hybrid)

a Power supply connector (HC01) of hybrid controller (inverter)
PC200, 200LC-8E0 (Hybrid) 40-100 13

SEN05245-02
©2011 KOMATSU
All Rights Reserved
40-100 14
SEN05246-01
SEN05246-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
200 General Information on troubleshooting
Points to remember when troubleshooting ................................................................................................. 2

Sequence of events in troubleshooting ....................................................................................................... 3
Check before troubleshooting ..................................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................................... 5
Probable problems and troubleshooting No................................................................................................ 7
Information in troubleshooting table ............................................................................................................ 9
Connection table for connector pin numbers .............................................................................................. 11
T-adapter and box table .............................................................................................................................. 47
PC200, 200LC-8E0 (Hybrid) 40-200 1

SEN05246-01 Points to remember when troubleshooting
Points to remember when troubleshooting

k Stop the machine on a level ground, and check that the lock pin, blocks, and parking brake are se-
curely installed or applied.
k When carrying out the operation with two or more service technitians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, the hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the cable prom the negative (–) terminal of the bat-
tery first.
k When removing the plug or cap from a component which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of probable causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry 3) Make checks of other items.
to disassemble the components. 4) Check other maintenance matters which can
If components are disassembled immediately be checked externally and are considered to
after any failure occurs: be necessary.
q Parts that have no connection with the failure
or other unnecessary parts may be disas- 4. Checking failure
sembled. See the extent of the failure by yourself, and
q It may become impossible to find the cause judge whether it is a real failure or a problem
of the failure. caused by handling or operating the machine.
It may also cause a waste of manhours, parts, or a When operating the machine to re-occur the
oil or grease, and at the same time, may also problem, do not carry out any investigation or
lose the confidence of the user or operator. measurement that may make the problem
For this reason, when carrying out trouble- worse.
shooting, it is necessary to carry out prior inves-
tigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. Use the results of the investigation and inspec-
tion in Items 2 to 4 to narrow down the causes of
2. Points to ask the user or operator failure, then use the troubleshooting flowchart to
1) Have any other problems occurred apart locate the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is as
2) Was there anything strange about the follows.
machine before the failure occurred? 1] Start from the easy work.
3) Did the failure occur suddenly, or were there 2] Start from the components most likely to
problems with the machine condition before be in failure.
the failure? 3] Investigate other related parts or informa-
4) Under what conditions did the failure occur? tion.
5) Had any repairs been carried out before the
failure? When were those repairs carried 6. Measures to remove root cause of failure
out? Even if the failure is removed, if the root cause of
6) Has the same kind of failure occurred the failure is not repaired, the same failure will
before? occur again.To prevent this, always investigate
why the problem occurred. Then, remove the
3. Check before troubleshooting root cause.
1) Is there any sign of the problem on the
machine?
2) Make checks before starting day's work.
40-200 2 PC200, 200LC-8E0 (Hybrid)

Sequence of events in troubleshooting SEN05246-01
Sequence of events in troubleshooting
PC200, 200LC-8E0 (Hybrid) 40-200 3

SEN05246-01 Check before troubleshooting
Check before troubleshooting

Item Criterion Remedy
1. Check for level and type of fuel - Add oil
2. Check for fuel for foreign matter - Clean and drain
Between H
3. Check for hydraulic oil level Add oil
and L
4. Check of hydraulic oil strainer - Clean and drain
Lubricating Between H
5. Check for swing machinery oil level Add oil
oil/Coolant and L
Between H
6. Check for level and type of engine oil (in oil pan) Add oil
and L
Between H
7. Check for coolant level (in sub tank) Add coolant
and L
8. Check of dust indicator for clogging No red part Clean or replace
9. Check of hydraulic oil filter - Replace
1. Check for abnormal noise/smell - Repair
Hydrau-
lic/Mechanical 2. Check for oil leakage - Repair
equipment
3. Bleeding air - Bleed air
1. Check of battery terminals and wiring for looseness and cor-
- Retighten or replace
rosion
2. Check of alternator terminals and wiring for looseness and
corrosion
3. Check of starting motor terminals and wiring for looseness
and corrosion
4. Check of battery voltage (with engine stopped) 20 to 30 V Charge or replace
Between H
5. Check of battery for electrolyte level Add or replace
and L
6. Check of wires for discoloration, burn, and removal of cover - Repair or replace
Electric, electri-
cal equipment 7. Check for released wire clamp and drooping wire - Repair
8. Check of wiring for wetness (Check connectors and terminals
- Dry
in particular)
9. Check of fuse for disconnection and corrosion - Replace
After operat-
ing for sev-
10. Check of alternator for voltage (while engine speed is at
eral minutes: Replace
middle or higher)
27.5 to 129.5
V
11. Check of battery relay for operating sound (when starting
- Replace
switch is turned ON or OFF)
40-200 4 PC200, 200LC-8E0 (Hybrid)

Classification and procedures for troubleshooting SEN05246-01
Classification and procedures for troubleshooting

Classification of troubleshooting
Mode Description
Display of code Troubleshooting by failure code
E-mode Troubleshooting electrical system
H-mode Troubleshooting hydraulic and mechanical system
Y-mode* Troubleshooting hybrid system
S-mode Troubleshooting engine
*: Exclusive mode for hybrid model
Procedure for troubleshooting

If a problem may indicate a failure occurs in the machine, select a proper troubleshooting No. according to
the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when user code and failure code are displayed on machine
monitor:
If a user code and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding "Display of code" according to the displayed failure code.
2. When electrical system error code or mechanical system error code is recorded in failure history:
If a user code and a failure code are not displayed on the machine monitor, check a mechanical system
failure code and an electrical system failure code with the failure history function of the machine monitor.
If a code is recorded, carry out troubleshooting for the corresponding "Display of code" according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes once and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner failure history or heater failure history by the failure history
function, carry out the corresponding troubleshooting in E-mode.
3. When user code and failure code is not displayed and no failure code is recorded in failure code:
If a user code and a failure code are not displayed on the machine monitor and no failure code is recorded
in the failure history, a failure that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the problem which seems to be a failure again and select the same problem from the
table of "Problem which seems to be failures and troubleshooting Nos.", and then carry out troubleshooting
corresponding to that problem in the "E-mode", "H-mode", "Y-mode", or "S-mode".
PC200, 200LC-8E0 (Hybrid) 40-200 5

SEN05246-01 Classification and procedures for troubleshooting

ters.
high-voltage wiring, "Discharge procedure for capacitor", or 30-102 Testing and adjusting (Part 2), Special
40-200 6 PC200, 200LC-8E0 (Hybrid)

Probable problems and troubleshooting No. SEN05246-01
Probable problems and troubleshooting No.

Troubleshooting
No. Problem seemed to be failure Display of
E-mode H-mode Y-mode S-mode
code
Problem related to user code/failure code
User code and failure code are displayed on ordinary screen
1
of machine monitor
According to
When failure history is checked, failure code is displayed in
2 displayed
mechanical system failure history
code
When failure history is checked, failure code is displayed in
3
electrical system failure history
When failure history is checked, failure code is displayed in air
4 E-23
conditioner or heater failure history
Problem related to engine
5 Starting performance is poor S-1
6 Engine does not start E-3 S-2
7 Engine does not pick up smoothly S-3
8 Engine stops during operations S-4
9 Engine does not run smoothly S-5
10 Engine lacks output (or lacks power) S-6
11 Exhaust smoke is black (incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Oil becomes contaminated quickly S-9
14 Fuel consumption is excessive S-10
Oil is in coolant (or coolant spurts back or coolant level goes
15 S-11
down)
16 Oil pressure drops S-12
17 Oil level rises (Entry of coolant/fuel) S-13
18 Coolant temperature becomes too high (overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
21 Preheater does not operate E-4
22 Automatic warm-up system does not operate (in cold season). E-5
23 Auto-decelerator does not operate normally E-15 H-5
24 Generator motor temperature increases abnormally Y-9
Problem related to work equipment/swing/travel
Work equipment, swing, and travel mechanism do not move
25 E-6 H-3
or cannot be locked
Speed or power of whole work equipment, swing, and travel is
26 H-1
low
27 Engine speed lowers significantly or engine stalls. H-2 S-6
28 Working mode does not change E-16
29 Abnormal sound comes out from around hydraulic pump H-4
30 Fine control performance or response is low. H-6
Problem related to work equipment
31 Speed or power of boom is low H-7
32 Speed or power of arm is low H-8
33 Speed or power of bucket is low. H-9
34 Work equipment does not move singly H-10
35 Hydraulic drift of work equipment is large H-11
36 Time lag of work equipment is large H-12
When work equipment is relieved singly, other work equip-
37 H-13
ment moves
38 Power maximizing function does not operate normally E-20 H-14
Problem related to combined operation
In combined operation of work equipment, speed of equip-
39 H-15
ment loaded more is low.
When machine swings and travels simultaneously, travel
40 H-16
speed lowers largely
Problem related to travel
41 Machine deviates during travel. H-17
42 Travel speed is low. H-18
43 Machine is not steered well or steering power is low H-19
44 Travel speed does not change or travel speed is low/high E-17 H-20
PC200, 200LC-8E0 (Hybrid) 40-200 7

SEN05246-01 Probable problems and troubleshooting No.
Troubleshooting
No. Problem seemed to be failure Display of
E-mode H-mode Y-mode S-mode
code
45 Travel system does not move (only one side). H-21
46 Travel alarm does not sound or does not stop sounding E-22
Problem related to swing
47 Upper structure does not swing H-22 Y-2
48 Swing acceleration or swing speed is low H-23 Y-3
49 Upper structure overruns remarkably when it stops swinging H-24 Y-4
50 Large shock is made when upper structure stops swinging H-25 Y-5
51 Large sound is made when upper structure stops swinging H-26 Y-6
Swing holding brake does not operate normally
52 E-21 H-27 Y-7
Hydraulic drift of swing is large
53 Swing motor temperature increases abnormally Y-8
Problem is related to machine monitor
When starting switch is turned ON, machine monitor displays
54 E-1
nothing.
When starting switch is turned ON (before starting engine),
55 E-2
lamps for basic check items light up
56 Precaution lights up while engine is running E-7
57 Emergency stop item lights up while engine is running E-8
58 Engine coolant temperature gauge does not indicate normally E-9
59 Hydraulic oil temperature gauge does not indicate normally E-10
60 Fuel gauge does not operate normally E-11
Displays by machine monitor are different from ones for appli-
61 E-12
cable machine
62 Machine monitor does not display some items E-13
63 Function switch does not work E-14
64 Alarm buzzer cannot be stopped. E-18
65 Windshield wiper and window washer do not operate E-19
66 Air conditioner does not operate normally E-23
When starting switch is turned OFF, service meter is not dis-
67 E-24
played
68 Machine monitor does not change to service mode. E-25
Monitoring function does not display lever control signal nor-
69 E-26
mally
70 Hybrid monitor does not go off Y-1
Others
71 KOMTRAX system does not operate normally. E-27
40-200 8 PC200, 200LC-8E0 (Hybrid)

Information in troubleshooting table SEN05246-01
Information in troubleshooting table

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand the information fully.
User code Failure code
Description of problem that appears on machine monitor as failure
Display on Display on Trouble
history
machine monitor machine monitor
Failure descrip-
Description of the failure detected by the machine monitor or controller
tion
Action of
Action taken by machine monitor or controller to protect system or devices when machine monitor or
machine moni-
controller detects failure
tor or controller
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller (shown
appears on
above)
machine
Related informa-
Information related to detected failure or troubleshooting
tion
Cause Procedure, measuring location, standard (value) and remarks
<Details of description>
q Procedure
q Measuring location
Probable causes a "Between A - B" means "Measure voltage or resistance and so on between
A and B".
q Standard value in normal condition to evaluate assumed cause if it is good con-
dition or not.
q Remarks required to evaluate the cause is correct
<How to use the troubleshooting sheet>
1 - defective q Perform troubleshoot in the following procedure in numerical order.
q If the testing result shows failure, the cause described on the left column con-
forms.
q If it shows normal, and unless otherwise specified particularly, proceed to the
next step (cause).
Disconnection in wiring har-
q Check that the failure is fixed after a failure was found and repaired.
ness
2 <Failures in wiring harness>
(Disconnection in wiring or
q Disconnection in wiring
defective contact in connector)
The connector connection is defective or the wiring harness is disconnected.
q Ground fault
A harness not connected to ground (earth) circuit contacts the ground (earth) or
machine.
Ground fault of wiring harness q Hot short circuit
3
(Contact with GND circuit) A harness not connected to the power (24 V) circuit contacts the power (24 V)
circuit.
q Short circuit
An independent wire in the harness abnormally contacts another wire.
(Poor insulation at connector and others)
Hot short <Precautions for troubleshooting>
4
(Contact with 24 V circuit) (1) How to indicate connector number and handle T-adapter
For troubleshooting, insert or connect T-adapter as follows unless especially
specified.
q When "male" or "female" is not indicated with a connector number, discon-
nect the connector, and insert T-adapter in both male and female.
q When "male" or "female" is indicated with a connector number, disconnect
5 Short circuit in wiring harness
the connector, and connect T-adapter only to either male or female end.
(2) Description sequence of pin number and handling of tester lead
Connect positive (+) lead and negative (-) lead of tester as explained below for
troubleshooting, unless otherwise specified.
q Connect positive (+) lead to pin No. or wiring harness entered on front side.
q Connect the negative (-) lead to a pin or harness indicated in the rear side.
6 Defective controller
PC200, 200LC-8E0 (Hybrid) 40-200 9

SEN05246-01 Information in troubleshooting table
Related circuit diagram
This drawing is a part of the electric circuit diagram related

to troubleshooting.
q Connector No.: Indicates (Model – Number of pins) and
(Color).
q "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.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed
40-200 10 PC200, 200LC-8E0 (Hybrid)

Connection table for connector pin numbers SEN05246-01
Connection table for connector pin numbers

(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
PC200, 200LC-8E0 (Hybrid) 40-200 11

SEN05246-01 Connection table for connector pin numbers
40-200 12 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 13

40-200 14 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 15

40-200 16 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 17

40-200 18 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 19

40-200 20 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 21

40-200 22 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 23

40-200 24 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 25

40-200 26 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 27

40-200 28 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 29

40-200 30 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 31

40-200 32 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 33

40-200 34 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 35

40-200 36 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 37

40-200 38 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 39

40-200 40 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 41

40-200 42 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 43

40-200 44 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 45

40-200 46 PC200, 200LC-8E0 (Hybrid)

T-adapter and box table SEN05246-01
T-adapter and box table

(Rev. 2009. 08)
a Indicated in the vertical column are the part numbers of T-adapters and boxes while indicated on the hor-
izontal line are the part numbers of harness checker assemblies.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 - q q
799-601-7090 Adapter for M 2 M2P q q q q
PC200, 200LC-8E0 (Hybrid) 40-200 47

SEN05246-01 T-adapter and box table
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 - q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 - q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
40-200 48 PC200, 200LC-8E0 (Hybrid)

T-adapter and box table SEN05246-01
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430*
Socket for engine(CRI-T3) PCV
2 p q q
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine (CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 - q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140
Ambient pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190*
Commonrail fuel pressure
3 1, 2, 3L q q
799-601-4230*
Air intake pressure/temperature
4 1, 2, 3, 4C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1, 2, 3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1, 2, 3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1, 2, 3, G q q
799-601-4340*
Pump actuator
2 2, PA q q
Socket for engine (CRI-T3) (95)
799-601-4380*
Air intake pressure/temperature
4 1, 2, 3, 4T q
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 - q
799-601-4280* Box for controller (PUMP) 121 - q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2 – 4 and DTM2 3, - q
4
“*” Shows not T-adapter but socket.
PC200, 200LC-8E0 (Hybrid) 40-200 49

SEN05246-01
©2010 KOMATSU
All Rights Reserved
40-200 50
SEN05247-00
SEN05247-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
301 Troubleshooting by failure code, Part 1
Failure code [989L00] Engine Controller Lock Caution 1 ........................................................................... 3

Failure code [989M00] Engine Controller Lock Caution 2 .......................................................................... 3
Failure code [989N00] Engine Controller Lock Caution 3........................................................................... 4
Failure code [AA10NX] Air Cleaner Clogging ............................................................................................. 5
Failure code [AB00KE] Charge Voltage Low .............................................................................................. 6
Failure code [B@BAZG] Eng Oil Press Low............................................................................................... 8
Failure code [B@BAZK] Eng oil level low ................................................................................................... 8
Failure code [B@BCNS] Eng Water Overheat ........................................................................................... 9
Failure code [B@BCZK] Eng Water Level Low .......................................................................................... 9
Failure code [B@HANS] Hydr oil overheat ................................................................................................. 10
Failure code [CA111] EMC Critical Internal Failure .................................................................................... 11
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ....................................................................... 11
Failure code [CA122] Chg Air Press Sensor High Error ............................................................................. 12
Failure code [CA123] Chg Air Press Sensor Low Error .............................................................................. 14
Failure code [CA131] Throttle Sensor High Error ....................................................................................... 16
Failure code [CA132] Throttle Sensor Low Error ........................................................................................ 18
Failure code [CA144] Coolant temp. sensor high error............................................................................... 20
Failure code [CA145] Coolant temp. sensor low error ................................................................................ 22
Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................. 24
Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................................. 26
PC200, 200LC-8E0 (Hybrid) 40-301 1

SEN05247-00 Shop Manual
Failure code [CA155] Chg Air Temp High Speed Derate............................................................................ 28

Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................................. 30
Failure code [CA221] Ambient Press Sens High Error ............................................................................... 32
Failure code [CA222] Ambient Press Sens Low Error ................................................................................ 34
Failure code [CA227] Sens Supply 2 Volt High Error.................................................................................. 36
Failure code [CA234] Eng Overspeed ........................................................................................................ 37
Failure code [CA238] Ne Speed Sens Supply Volt Error ............................................................................ 38
Failure code [CA271] IMV/PCV1 Short Error .............................................................................................. 39
Failure code [CA272] IMV/PCV1 Open Error.............................................................................................. 40
Failure code [CA322] Inj #1 (L#1) Open/Short Error................................................................................... 42
Failure code [CA331] Inj #2(L#2) Open/Short Error.................................................................................... 46
40-301 2 PC200, 200LC-8E0 (Hybrid)

Failure code [989L00] Engine Controller Lock Caution 1 SEN05247-00
Failure code [989L00] Engine Controller Lock Caution 1

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

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

Trouble
— 989M00 (Machine monitor system)
Failure descrip-
tion
Action of
machine moni-
tor
Problem that
appears on q Engine cannot be started.
machine
q If this failure code is displayed after machine monitor is replaced, user password must be changed
Related infor-
to one before replacement.
mation
Cause Standard value in normal condition/Remarks on troubleshooting

Probable
Replacement of machine
causes and 1 This trouble may be caused by replacement of machine monitor.
monitor
standard value
If this failure code is displayed while machine monitor is not
in normal condi-
2 Defective machine monitor replaced, machine monitor may be defective. (Since trouble is in
tion
system, troubleshooting cannot be performed.)
PC200, 200LC-8E0 (Hybrid) 40-301 3

SEN05247-00 Failure code [989N00] Engine Controller Lock Caution 3
Failure code [989N00] Engine Controller Lock Caution 3

Trouble
— 989N00 (Machine monitor system)
Failure descrip-
tion
Action of
q Tries automatic resetting.
machine moni-
tor
Problem that
appears on
machine
Related infor- q Method of reproducing failure code: Failure code is not reproduced since system is reset automat-
mation ically.

causes and
If this failure code is displayed repeatedly, engine controller may be
standard value
1 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot be
in normal condi-
performed.)
tion
40-301 4 PC200, 200LC-8E0 (Hybrid)

Failure code [AA10NX] Air Cleaner Clogging SEN05247-00
Failure code [AA10NX] Air Cleaner Clogging

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

Probable
Clogging of air cleaner Air cleaner may be clogged. Check it for clogging and then clean or
causes and 1
(when system is normal) replace if clogged.
standard value
If cause 1 is not detected, air cleaner clogging monitor system may
in normal con- Defective air cleaner clog-
2 be defective. Perform troubleshooting for "E-7 Caution item flashes
dition ging monitor system
while engine is running" in E-mode.
PC200, 200LC-8E0 (Hybrid) 40-301 5

SEN05247-00 Failure code [AB00KE] Charge Voltage Low
Failure code [AB00KE] Charge Voltage Low

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

a Prepare with starting switch OFF, then start engine and perform
Probable troubleshooting.
Defective alternator
causes and 1 E12 (male) Engine speed Voltage
(when system is normal)
standard value Between (1) and
Min. medium speed 27.5 to 29.5 V
in normal condi- chassis ground
tion If cause 1 is not detected, charge level monitor system may be
Defective charge level moni-
2 defective. Perform troubleshooting for "E-7 Caution item flashes
tor
while engine is running" in E-mode.
40-301 6 PC200, 200LC-8E0 (Hybrid)

Failure code [AB00KE] Charge Voltage Low SEN05247-00
Circuit diagram related to preheating/starting of engine and charge of battery
PC200, 200LC-8E0 (Hybrid) 40-301 7

SEN05247-00 Failure code [B@BAZG] Eng Oil Press Low
Failure code [B@BAZG] Eng Oil Press Low

User code Failure code Engine oil pressure low
Trouble
— B@BAZG (Engine controller system)
Failure q While engine was running, signal circuit of engine oil pressure switch detected low engine oil pres-
description sure (sensor contact opened).
Action of
q Displays engine oil pressure monitor on machine monitor.
machine moni-
tor
Problem that
machine
q Engine oil pressure switch signal is input to engine controller and then transmitted to machine mon-
Related infor-
itor.
mation

Probable Lowering of engine oil pres-
Engine oil pressure may be low. Check it and remove cause if it is
causes and 1 sure
low.
standard value (when system is normal)
in normal con- If cause 1 is not detected, engine oil pressure monitor system may
Defective engine oil pressure
dition 2 be defective. Perform troubleshooting for "E-8 Emergency stop item
monitor system
lights up while engine is running" in E-mode.
Failure code [B@BAZK] Eng oil level low

User code Failure code Engine Oil Level Low
Trouble
— B@BAZK (Machine monitor system)
Failure q When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch
description detected low engine oil level (sensor contact opened).
Action of
q Displays engine oil level monitor on machine monitor.
machine moni-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
tor
Problem that
machine
q Engine oil level switch signal can be checked with monitoring function.
Related infor-
mation

Probable Lowering of engine oil level
1 Engine oil level may be low. Check it and add new oil if it is low.
causes and (when system is normal)
standard value If cause 1 is not detected, engine oil level monitor system may be
in normal con- Defective engine oil level defective. Perform troubleshooting for "E-2 Basic check item lights
2
dition monitor system up when starting switch is turned to ON position (but engine is not
started)" in E-mode.
40-301 8 PC200, 200LC-8E0 (Hybrid)

Failure code [B@BCNS] Eng Water Overheat SEN05247-00
Failure code [B@BCNS] Eng Water Overheat

User code Failure code Engine coolant overheat
Trouble
— B@BCNS (Engine controller system)
Failure descrip- q While engine was running, signal circuit of engine coolant temperature sensor detected overheating
tion of engine coolant (above approximately 102 °C)
Action of con- q Displays engine coolant temperature monitor with red on machine monitor.
troller q If cause of failure disappears, system resets itself.
Problem that
appears on q If machine is operated as it is, engine may seize up.
machine
q Engine coolant temperature sensor signal is input to engine controller and then transmitted to ma-
chine monitor through communication system.
Related infor-
q Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant
mation
temperature)

Probable
Overheating of engine coolant Engine coolant may be overheating. Check it and remove cause if it
causes and 1
(when system is normal) is overheating.
standard value
If cause 1 is not detected, engine coolant temperature gauge sys-
in normal con- Defective engine coolant tem-
2 tem may be defective. Perform troubleshooting for "E-9 Engine
dition perature gauge system
coolant temperature gauge does not work normally" in E-mode.
Failure code [B@BCZK] Eng Water Level Low

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

Lowering of engine coolant
Probable Engine coolant level may be low. Check it and add coolant if it is
1 level
causes and low.
standard value
If cause 1 is not detected, engine coolant level monitor system may
in normal con-
Defective engine coolant be defective. Perform troubleshooting for "E-2 Basic check item
dition 2
level monitor system lights up when starting switch is turned to ON position (but engine is
not started)" in E-mode.
PC200, 200LC-8E0 (Hybrid) 40-301 9

SEN05247-00 Failure code [B@HANS] Hydr oil overheat
Failure code [B@HANS] Hydr oil overheat

User code Failure code Hydraulic oil overheat
Trouble
— B@HANS (Pump controller system)
Failure descrip- q While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating
tion of hydraulic oil (above approximately 102 °C).
Action of con- q Displays hydraulic oil temperature monitor with red on machine monitor.
Problem that
appears on q If machine is operated as it is, hydraulic components may be damaged.
machine
q Signal from hydraulic oil temperature sensor is input to engine controller and then transmitted to ma-
chine monitor through communication system.
Related infor-
q Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil tem-
mation
perature

Probable
Overheating of hydraulic oil Hydraulic oil may be overheating. Check it and remove cause if it is
causes and 1
(when system is normal) overheating.
standard value
If cause 1 is not detected, hydraulic oil temperature gauge system
in normal con- Defective hydraulic oil tem-
2 may be defective. Perform troubleshooting for "E-10 Hydraulic oil
dition perature gauge system
temperature gauge does not work normally" in E-mode.
40-301 10 PC200, 200LC-8E0 (Hybrid)

Failure code [CA111] EMC Critical Internal Failure SEN05247-00
Failure code [CA111] EMC Critical Internal Failure

User code Failure code Engine controller internal failure
Trouble
E10 CA111 (Engine controller system)
Failure descrip-
q Memory or power supply circuit in engine controller is defective.
tion
Action of con-
troller
Problem that
appears on q Engine does not start
machine
Related infor-
mation

causes and
standard value
Perform troubleshooting for failure codes[CA757]
in normal con-
dition
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

User code Failure code Engine Ne and Bkup speed sensor error
Trouble
Failure descrip-
q Signals from both engine Ne speed sensor and engine Bkup speed sensor are abnormal.
tion
Action of con-
troller
Problem that
q Engine stops.
appears on
q Engine does not start
machine
Related infor-
mation

Defective Ne speed sensor
1 Perform troubleshooting for Failure code [CA689].
system
Defective Bkup speed sen-
2 Perform troubleshooting for Failure code [CA778].
sor system
Probable
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
causes and 3
sensor installation of sensor, internal of flywheel, etc.)
standard value
Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
in normal con- 4
speed sensor installation of sensor, internal of supply pump, etc.)
dition
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defec-
5
connection) tive connection (wrong connection).
If causes 1 to 5 are not detected, engine controller may be defec-
6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be per-
formed.)
PC200, 200LC-8E0 (Hybrid) 40-301 11

SEN05247-00 Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA122] Chg Air Press Sensor High Error

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

Defective sensor power If failure code [CA227] is also indicated, perform troubleshooting for it
1
supply 2 system first.
a Prepare with starting switch OFF, then turn starting switch to ON
position and perform troubleshooting.
Defective boost pressure BOOST PRESS& IMT Voltage
2 and temperature sensor Between (2) and (4) Power supply 4.75 to 5.25 V
[pressure signal circuit] 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 position and carry out troubleshooting.
3 (Short circuit with 5 V/24 V Wiring harness between CE01 (female) (44)
Probable circuit) in wiring harness and BOOST PRESS & IMT (female) (1), and Voltage Max. 1 V
causes and chassis ground.
standard value a Prepare with starting switch OFF, then perform troubleshooting
in normal con- Short circuit in wiring har- without turning starting switch to ON position.
dition ness Wiring harness between CE01 (female) (44)
4
(with another wiring har- and BOOST PRESS & IMT (female) (1), and Resis-
Min.100 kΩ
ness) harnessesCE01 (female) (37) to JC01 to tance
BOOST PRESS & IMT (female)(2)
Connections between boost pressure/temperature sensor and engine
wiring harness and engine controller may be defective. Check them
Defective wiring harness directly.
5
connector q Looseness of connector, breakage of lock, or breakage of seal
q Corrosion, bend, breakage, push-in, or expansion of pin
q Moisture or dirt in connector or defective insulation
6 Defective engine controller
CE01 Voltage
Between (37) and (47) 4.75 to 5.25 V
40-301 12 PC200, 200LC-8E0 (Hybrid)

Failure code [CA122] Chg Air Press Sensor High Error SEN05247-00
Circuit diagram related to boost pressure/temperature sensor (Combination sensor)
PC200, 200LC-8E0 (Hybrid) 40-301 13

SEN05247-00 Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA123] Chg Air Press Sensor Low Error

User code Failure code Charge air pressure sensor low error
Trouble
Failure descrip-
q Low voltage was detected in pressure signal circuit of boost pressure/temperature sensor.
tion
Action of con-
q Fixes charge pressure value and continues operation.
troller
Problem that
machine
q Signal voltage on boost pressure side of boost pressure/temperature sensor can be checked with
Related infor- monitoring function.
mation (Code: 36501 Boost pressure sensor voltage)

Defective sensor power sup- If failure code [CA187] is also displayed, perform troubleshooting for
1
ply 2 system it first.
Defective boost pressure BOOST PRESS & IMT Voltage
2 and temperature sensor Between (2) and (4) Power supply 4.75 to 5.25 V
[pressure signal circuit] Voltage is measured with wiring harness connected. Accordingly, if
a Prepare with starting switch OFF, position then perform trouble-
Ground fault in wiring har-
shooting without turning starting switch to ON position.
ness
3 Between wiring harness between CE01
(Short circuit with GND cir- Resis-
(female) (44) and BOOST PRESS & IMT Min.100 kΩ
Probable cuit) tance
(female) (1), and chassis ground
causes and
a Prepare with starting switch OFF, then perform troubleshooting
standard value
without turning starting switch to ON position.
in normal con- Short circuit in wiring har-
Between wiring harness between CE01
dition ness
4 (female) (44) and BOOST PRESS & IMT
(with another wiring har- Resis-
(female) (1) and harnesses CE01 ((female) Min.100 kΩ
ness) tance
(47) to JC02 to BOOST PRESS & IMT
(female) (4)
Connections between boost pressure/temperature sensor and engine
harness and engine controller are suspected to be defective. Visually
Defective wiring harness check it.
5
CE01 Voltage
Between (37) and (47) Power supply 4.75 to 5.25 V
40-301 14 PC200, 200LC-8E0 (Hybrid)

Failure code [CA123] Chg Air Press Sensor Low Error SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 15

SEN05247-00 Failure code [CA131] Throttle Sensor High Error
Failure code [CA131] Throttle Sensor High Error

User code Failure code Throttle Sensor High Error
Trouble
Failure descrip-
q High voltage was detected in signal circuit of fuel control dial.
tion
q If trouble occurs while starting switch is in ON position, controller fixes voltage value to value just
Action of con- before detection of trouble and continues operation.
troller q If starting switch is turned to ON position while voltage is abnormally high, controller continues op-
eration with voltage at 100 % value.
Problem that
appears on q Engine speed cannot be controlled with fuel control dial.
machine
q Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control
Related infor-
dial voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON operation.

Connections between fuel control dial and machine wiring harness
and engine controller may be defective. Check them directly.
Defective wiring harness
1 q Looseness of connector, breakage of lock, or breakage of seal
connector
Defective throttle sensor If failure code [CA2185] is also indicated, perform troubleshooting
2
power supply system for it first.
1) Turn starting switch to OFF position.
2) Disconnect P20 and connect T-adapter to male side.
Resis-
Between P20 (male) (1) and (3) 4 to 6 kΩ
tance
3 Defective fuel control dial
Resis-
Between P20 (male) (2) and (1) 0.25 to 5 kΩ
tance
Resis-
tance
Probable 1) Turn starting switch to OFF position.
causes and 2) Disconnect CE02 and connect T-adapter to female side.
standard value Disconnection or short circuit Resis-
4 Between CE02 (female) (22) and (23) 4 to 6 kΩ
in normal con- in wiring harness tance
dition Resis-
Between CE02 (female) (9) and (23) 0.25 to 5 kΩ
tance
a Prepare by setting starting switch to OFF position, then turn start-
Hot short ing switch to ON position and troubleshoot.
5 (Short circuit with 5 V/24 V Between wiring harness between CE02
circuit) in wiring harness (female) (9) and P20 (female) (2), and Voltage Max. 1 V
chassis ground
a Prepare by setting starting switch to OFF position, and trouble-
Short circuit in wiring har- shoot without turning starting switch to ON position.
6 ness Between wiring harnesses between CE02
Resis-
(with another wiring harness) (female) (9) and P20 (female) (2) and Min.100 kΩ
tance
CE02 (female) (22) and P20 (female) (1)
ing switch to ON position and troubleshoot.
7 Defective engine controller CE02 Voltage
Between (9) and
Signal 0.5 to 4.5 V
(23)
40-301 16 PC200, 200LC-8E0 (Hybrid)

Failure code [CA131] Throttle Sensor High Error SEN05247-00
Circuit diagram related to fuel control dial
PC200, 200LC-8E0 (Hybrid) 40-301 17

SEN05247-00 Failure code [CA132] Throttle Sensor Low Error
Failure code [CA132] Throttle Sensor Low Error

User code Failure code Throttle Sensor Low Error
Trouble
Failure
q Low voltage was detected in signal circuit of fuel control dial.
description
q If trouble occurs while starting switch is in ON position, controller fixes voltage value to value just be-
Action of con- fore detection of trouble and continues operation.
troller q If starting switch is turned to ON position while voltage is abnormally high, controller continues oper-
ation with voltage at 100 % value.
Problem that
machine
q Signal voltage of fuel control dial can be checked with monitoring function.
Related infor-
(Code: 03000 Fuel control dial voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON operation.

Connections in fuel control dial to machine wiring harness to engine
controller may be defective. Check them directly.
connector
Defective throttle sensor If failure code [CA2186] is also indicated, perform troubleshooting for
2
power supply system it first.
1) Turn starting switch to OFF position.
2) Disconnect P20 and connect T-adapter to male side.
Resis-
Between P20 (male) (1) and (3) 4 to 6 kΩ
tance
3 Defective fuel control dial
Resis-
tance
Resis-
tance
Probable 1) Turn starting switch to OFF position.
causes and 2) Disconnect CE02 and connect T-adapter to female side.
standard value Disconnection or short circuit Resis-
4 Between CE02 (female) (22) and (23) 4 to 6 kΩ
in normal con- in wiring harness tance
dition Resis-
Between CE02 (female) (9) and (23) 0.25 to 5 kΩ
tance
shoot without turning starting switch to ON position.
ness
(female) (9) and P20 (female) (2), and Min.100 kΩ
cuit) tance
chassis ground
Short circuit in wiring har-
Between wiring harnesses, between
6 ness
CE02 (female) (9) and P20 (female) (2), Resis-
(with another wiring harness) Min.100 kΩ
and CE02 (female) (23) and P20 (female) tance
(3)
CE02 Voltage
Between (9) and (23) Signal 0.5 to 4.5 V
40-301 18 PC200, 200LC-8E0 (Hybrid)

Failure code [CA132] Throttle Sensor Low Error SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 19

SEN05247-00 Failure code [CA144] Coolant temp. sensor high error
Failure code [CA144] Coolant temp. sensor high error

User code Failure code Coolant temperature sensor high error
Trouble
Failure descrip-
q High voltage was detected in signal circuit of coolant temperature sensor.
tion
Action of con-
q Fixes coolant temperature value and continues operation.
troller
Problem that q Engine does not start easily at low temperature.
appears on q Exhaust gas becomes white.
machine q Overheat prevention function does not work.
q Signal voltage of coolant temperature sensor can be checked with monitoring function.
Related infor-
(Code: 04105 Coolant temperature sensor voltage)
mation

Coolant tempera- Resistance
COOLANT TEMP (male)
ture
Defective coolant tempera-
1 0 °C 30 to 37 kΩ
ture sensor
25 °C 9.3 to 10.7 kΩ
Between (A) and (B) 50 °C 3.2 to 3.8 kΩ
80 °C 1.0 to 1.3 kΩ
95 °C 700 to 800 kΩ
Disconnection in wiring har- shoot without turning starting switch to ON position.
ness Wiring harness between CE01 (female) Resis-
Max. 10 Ω
2 (Disconnection in wiring or (15) and COOLANT TEMP (female) (B) tance
defective contact in connec- Between wiring harnesses between CE01
Resis-
tor) (female) (38) and JC03, and JC03 and Max. 10 Ω
Probable tance
COOLANT TEMP (female) (A)
causes and
standard value
in normal con-
3 ness Between CE01 (female) (15) and CE01
dition Resis-
(with another wiring harness) (female) all pins (With all connectors of wir- Min.100 kΩ
tance
ing harness disconnected)
Connections in coolant temperature sensor to engine wiring harness
to engine controller may be defective. Check them directly.
connector
Coolant tempera-
CE01 (female) Resistance
ture
5 Defective engine controller 0 °C 30 to 37 kΩ
25 °C 9.3 to 10.7 kΩ
80 °C 1.0 to 1.3 kΩ
95 °C 700 to 800 kΩ
40-301 20 PC200, 200LC-8E0 (Hybrid)

Failure code [CA144] Coolant temp. sensor high error SEN05247-00
Circuit diagram related to coolant temperature sensor
PC200, 200LC-8E0 (Hybrid) 40-301 21

SEN05247-00 Failure code [CA145] Coolant temp. sensor low error
Failure code [CA145] Coolant temp. sensor low error

User code Failure code Coolant temperature sensor low error
Trouble
Failure
q Low voltage was detected in signal circuit of coolant temperature sensor.
description
Action of con-
q Fixes coolant temperature value and continues operation.
troller
Problem that
q Exhaust gas becomes white.
appears on
q Overheat prevention function does not work.
machine
q Signal voltage of coolant temperature sensor can be checked with monitoring function.
Related infor-
(Code: 04105 Coolant temperature sensor voltage)
mation

Coolant tempera- Resistance
COOLANT TEMP
ture
Defective coolant tempera- 0 °C 30 to 37 kΩ
1
ture sensor 25 °C 9.3 to 10.7 kΩ
80 °C 1.0 to 1.3 kΩ
95 °C 700 to 800 kΩ
Between (B) and chassis ground All range Min.100 kΩ
ness
(female) (15) and COOLANT TEMP Max. 10 Ω
cuit) tance
(female) (B), and chassis ground
Probable
causes and
standard value
in normal con- Resis-
dition tance
Connections coolant temperature sensor to engine wiring harness to
engine controller may be defective. Check them directly.
connector
Coolant tempera-
ture
0 °C 30 to 37 kΩ
25 °C 9.3 to 10.7 kΩ
80 °C 1.0 to 1.3 kΩ
95 °C 700 to 800 kΩ
Between (B) and chassis ground All range Min.100 kΩ
40-301 22 PC200, 200LC-8E0 (Hybrid)

Failure code [CA145] Coolant temp. sensor low error SEN05247-00
Circuit diagram related to coolant temperature sensor
PC200, 200LC-8E0 (Hybrid) 40-301 23

SEN05247-00 Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA153] Chg Air Temp Sensor High Error

User code Failure code Change air temperature sensor high error
Trouble
Failure
q High voltage was detected in temperature signal circuit of boost pressure/temperature sensor.
description
Action of con-
q Fixes charge temperature value and continues operation.
troller
Problem that
appears on
q Engine protection function based on boost temperature does not work.
machine
q 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

Intake air tempera- Resistance
Defective boost pressure/ BOOST PRESS & IMT (male)
ture
1 temperature sensor [temper-
0 °C 5.5 to 6.1 kΩ
ature signal circuit]
25 °C 1.9 to 2.1 kΩ
Between (3) and (4)
40 °C 1.1 to 1.2 kΩ
100 °C 180 to185 Ω
Disconnection in wiring har- shoot without turning starting switch to ON position.
ness Wiring harness between CE01 (female)(23) Resis-
Max.10
2 (Disconnection in wiring or and BOOST PRESS & IMT (female)(2) tance
defective contact in connec- Wiring harness between CE01 (female)(47)
Resis-
tor) andJC02, and JC02 and BOOST PRESS & Min.10
Probable tance
IMT (female)(1)
causes and
standard value
in normal con- Between CE01 (female) (23) and CE01
3 ness
dition Resis-
tance
Connections in boost pressure/temperature sensor to engine wiring
harness to engine controller may be defective. Check them directly.
connector
Intake air tempera-
ture
0 °C 5.5 to 6.1 kΩ
25 °C 1.9 to 2.1 kΩ
Between (23) and (47)
40 °C 1.1 to 1.2 kΩ
100 °C 180 to185 Ω
40-301 24 PC200, 200LC-8E0 (Hybrid)

Failure code [CA153] Chg Air Temp Sensor High Error SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 25

SEN05247-00 Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA154] Chg Air Temp Sensor Low Error

User code Failure code Charge air temperature sensor low error
Trouble
Failure descrip-
q Low voltage was detected in temperature signal circuit of boost pressure/temperature sensor.
tion
Action of con-
troller
Problem that
appears on
q Engine protection function based on boost temperature does not work.
machine
q 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

Intake air temper- Resistance
Defective boost pressure/ BOOST PRESS & IMT (male)
ature
1 temperature sensor [temper- 0 °C 5.5 to 6.1 kΩ
ature signal circuit] 25 °C 1.9 to 2.1 kΩ
Between (3) and (4)
40 °C 1.1 to 1.2 kΩ
100 °C 180 to 185 Ω
Between (3) – chassis ground All range Min.100 kΩ
ness
2 Wiring harness between CE01 (female)
(23) and BOOST PRESS & IMT (female) Min.100 kΩ
cuit) tance
(2) and chassis ground
Probable
causes and
standard value Resis-
(with another wiring harness) (female) all pins (With all connectors of Min.100 kΩ
in normal con- tance
wiring harness disconnected)
dition Connections in between boost pressure/temperature sensor to
engine wiring harness to engine controller may be defective. Check
Defective wiring harness them directly.
4
Intake air temper-
ature
0 °C 5.5 to 6.1 kΩ
25 °C 1.9 to 2.1 kΩ
40 °C 1.1 to 1.2 kΩ
100 °C 180 to185 Ω
Between (23) and chassis
All range Min.100 Ω
ground
40-301 26 PC200, 200LC-8E0 (Hybrid)

Failure code [CA154] Chg Air Temp Sensor Low Error SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 27

SEN05247-00 Failure code [CA155] Chg Air Temp High Speed Derate
Failure code [CA155] Chg Air Temp High Speed Derate

User code Failure code Charge air temperature high speed derate
Trouble
Failure descrip- q Temperature signal of boost pressure/temperature sensor exceeded upper limit of control tempera-
tion ture.
Action of con-
q Limits output and continues operation.
troller
Problem that
q Engine output lowers.
appears on
q Engine stops.
machine
Related infor- q Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature)

The degradation of aftercooler cooling performance is suspected.
Directly check the following points:
Lowering of cooling perfor-
Probable 1 q Looseness and damage of fan belt
mance of aftercooler
causes and q Insufficient cooling air
standard value q Clogging of aftercooler fins
in normal state Abnormal rise of turbo- Outlet temperature of turbocharger may be abnormally high. Check
2
charger outlet temperature related parts directly.
Charge temperature sensor system may be defective. Perform trou-
bleshooting for failure codes [CA153] and [CA154].
40-301 28 PC200, 200LC-8E0 (Hybrid)

Failure code [CA155] Chg Air Temp High Speed Derate SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 29

SEN05247-00 Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error

User code Failure code Sensor power Supply 2 voltage low error
Trouble
Failure descrip-
q Low voltage was detected in sensor power supply 2 circuit.
tion
q Fixes boost pressure value and continues operation.
Action of con-
troller
Problem that
machine
Related infor-
mation
Cause Standard value in normal state/Remarks on troubleshooting

a Disconnect connector with starting switch OFF, then turn start-
ing switch to ON position and perform troubleshooting.
Disconnect sensors Boost pressure/tem- BOOST PRESS &

and wiring harness at perature sensor IMT
right in order and per-
form operation to Common rail pres-
Defective sensor or wiring FUEL RAIL PRESS
1 reproduce trouble. If sure sensor
harness
"E" of failure code
Probable
goes off when a sen-
causes and Bkup sensor CAM SENSOR
sor or wiring harness
standard value
is disconnected, that
in normal con-
sensor or wiring har- Engine wiring har-
dition CE01
ness is defective. ness
Connections in each sensor to engine wiring harness to engine
connector
If causes 1 and 2 are not detected, engine controller may be defec-
formed.)
40-301 30 PC200, 200LC-8E0 (Hybrid)

Failure code [CA187] Sens Supply 2 Volt Low Error SEN05247-00
Circuit diagram related to sensor power supply 2
PC200, 200LC-8E0 (Hybrid) 40-301 31

SEN05247-00 Failure code [CA221] Ambient Press Sens High Error
Failure code [CA221] Ambient Press Sens High Error

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

1
AMBAIR PRESSURE Voltage
Defective ambient pressure Between (1) and (2) Power supply 4.75 to 5.25 V
2
sensor Between (3) and (2) Signal 0.6 to 4.3 V
Voltage is measured with wiring harness connected. Accordingly, if
Hot short (Short circuit with
3 5 V/24 V circuit) in wiring
Probable Wiring harness between CE01 (female) (3)
harness Voltage Max. 1 V
causes and and AMBAIR PRESURE (female) (3)
in normal con- Short circuit in wiring har- without turning starting switch ON.
dition ness Between wiring harnesses between CE01
4
(with another wiring har- (female) (3) and AMBAIR PRESURE Resis-
Min. 100 kΩ
ness) (female) (3) and between CE01 (female) (33) tance
and AMBAIR PRESURE (female) (1)
Connections in ambient pressure sensor to engine wiring harness to
connector
40-301 32 PC200, 200LC-8E0 (Hybrid)

Failure code [CA221] Ambient Press Sens High Error SEN05247-00
Circuit diagram related to ambient pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-301 33

SEN05247-00 Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA222] Ambient Press Sens Low Error

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

1
position and carry out troubleshooting.
AMBAIR PRESSURE Voltage
Defective ambient pres- Between (1) and (2) Power supply 4.75 to 5.25 V
2
sure sensor Between (3) and (2) Signal 0.6 to 4.3 V
ness
3 Between wiring harnesses between CE01
Probable (female) (3) and AMBAIR PRESURE Min.100 kΩ
cuit) tance
causes and (female) (3) and chassis ground
in normal con- without turning starting switch ON.
dition Between wiring harnesses between CE01
ness
4 (female) (3) and AMBAIR PRESURE
(with another wiring har- Resis-
(female) (3), and between CE01 (female) Min.100 kΩ
ness) tance
(38) and JC03, and JC03 and AMBAIR
PRESURE (female) (2)
Connection in ambient pressure sensor to engine wiring harness to
connector
40-301 34 PC200, 200LC-8E0 (Hybrid)

Failure code [CA222] Ambient Press Sens Low Error SEN05247-00
Circuit diagram related to ambient pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-301 35

SEN05247-00 Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA227] Sens Supply 2 Volt High Error

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

causes and
standard value
Perform troubleshooting for failure code [CA187].
in normal con-
dition
40-301 36 PC200, 200LC-8E0 (Hybrid)

Failure code [CA234] Eng Overspeed SEN05247-00
Failure code [CA234] Eng Overspeed

User code Failure code Eng overspeed
Trouble
— CA234 (Engine controller system)
Failure descrip-
q Engine speed exceeded upper limit of control speed.
tion
Action of con-
q Stops injection until engine speed lowers to normal level.
troller
Problem that
appears on q Engine speed fluctuates.
machine
Related infor- q Engine speed can be checked with monitoring function. (Code: 01002 Engine speed)
mation q Method of reproducing failure code: Run engine at high idle.
Cause Standard value in normal condition /Remarks on troubleshooting

Probable 1 Use of improper fuel Fuel used may be improper. Check it directly
causes and Machine may be used improperly. Teach operator proper using
2 Improper use
standard value method.
in normal con- If causes 1 and 2 are not cause of failure, engine controller may be
dition 3 Defective engine controller defective. (Since failure is in it, troubleshooting cannot be per-
formed.)
PC200, 200LC-8E0 (Hybrid) 40-301 37

SEN05247-00 Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA238] Ne Speed Sens Supply Volt Error

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

a Disconnect connector with starting switch OFF, then turn start-
ing switch to ON position and perform troubleshooting.
Disconnect sensor Ne speed sensor CRANK SENSOR
and wiring harness at
right in order and per-
form operation to
Defective sensor or wiring
Probable 1 reproduce trouble. If
harness
causes and "E" of failure code Engine wiring har-
CE01
standard value goes off when sensor ness
in normal con- or wiring harness is
dition disconnected, that
sensor or wiring har-
ness is defective.
Connection in each sensor to engine wiring harness to engine con-
troller may be defective. Check them directly.
connector
Circuit diagrams related to engine Ne speed sensor
40-301 38 PC200, 200LC-8E0 (Hybrid)

Failure code [CA271] IMV/PCV1 Short Error SEN05247-00
Failure code [CA271] IMV/PCV1 Short Error

User code Failure code IMV/PCV1 short circuit error
Trouble
Failure
q Short circuit was detected in drive circuit of supply pump actuator.
description
Action of con-
troller
Problem that q Engine speed does not increase from low idle.
machine q Fuel pressure of common rail increases above command value.
Related infor-
q Method of reproducing failure code: Turn starting switch ON.
mation

Defective supply pump actu- CP3 PUMP REGULATOR
1 Resistance
ator (male)
Min. 100 kΩ
ground
ness
(female) (2) and CP3 PUMP REGULA- Min. 100 kΩ
cuit) tance
Probable TOR (female) (1), and chassis ground
causes and a Prepare with starting switch OFF, then perform troubleshooting
standard value Short circuit in wiring har- without turning starting switch to ON position.
in normal con- 3 ness Between CE01 (female) (2) and CE01
Resis-
dition (with another wiring harness) (female) all pins (With all wiring harness Min. 100 kΩ
tance
connectors disconnected)
Connections in supply pump actuator to engine wiring harness to
connector
5 Defective engine controller CE01 (female) Resistance
Min. 100 kΩ
ground
Circuit diagram related to supply pump actuator (metering unit)
PC200, 200LC-8E0 (Hybrid) 40-301 39

SEN05247-00 Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA272] IMV/PCV1 Open Error

User code Failure code IMV/PCV1 open error
Trouble
Failure descrip-
q Open was detected in drive circuit of supply pump actuator.
tion
Action of con-
troller
Problem that
q Engine runs but it does not stabilize.
appears on
q Common rail fuel pressure rises above command value.
machine
Related infor-
mation

Defective supply pump actu- without turning starting switch to ON position.
1
ator CP3 PUMP REGULATOR (male) Resistance
Between (1) and (2) Max. 5 Ω
ness
Wiring harness between CE01 (female) (2) Resis-
2 (Disconnection in wiring or Max. 10 Ω
and CP3 PUMP REGULATOR (female) (1) tance
defective contact in connec-
tor) Max. 10 Ω
and CP3 PUMP REGULATOR (female) (2) tance
Probable position and perform troubleshooting.
3 (24V circuit) in wiring har-
causes and Between CE01 (female) (2) and CP3 PUMP
ness Voltage Max.3 V
standard value REGULATOR (female) (1)
in normal con- a Prepare with starting switch OFF, then perform troubleshooting
dition Short circuit in wiring har- without turning starting switch to ON position.
4 ness Wiring harness between CE01 (female) (2)
Resis-
(with another wiring harness) and CE01 (female) all pins (With all wiring Max. 100 kΩ
tance
harness connectors disconnected)
Connections in supply pump actuator to engine wiring harness to
engine controller may be defective . Inspect them directly.
connector
Circuit diagram related to supply pump actuator (metering unit)
40-301 40 PC200, 200LC-8E0 (Hybrid)

Failure code [CA272] IMV/PCV1 Open Error SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 41

SEN05247-00 Failure code [CA322] Inj #1 (L#1) Open/Short Error
Failure code [CA322] Inj #1 (L#1) Open/Short Error

User code Failure code Injector #1 (L#1) open/short circuit error
Trouble
Failure descrip-
q Open or short circuit was detected in drive circuit of No. 1 injector.
tion
Action of con-
troller
Problem that
q Combustion becomes irregular or engine hunts.
appears on
machine
Related infor-
mation

1 Defective No. 1 injector INJ CYL1 (male) Resistance
Between (1) and chassis ground Min. 100 kW
ness
Wiring harness between CE01 (female) Resis-
(45) and INJ CYL 1 (female) (1) tance
tor) Max. 2 Ω
(53) and INJ CYL 1 (female) (2) tance
ness
3 Between ground and wiring harness
between CE01 (female) (45) and INJ CYL 1 Min. 100 kW
cuit) tance
(female) (1)
Probable a Prepare with starting switch OFF, then perform troubleshooting
causes and without turning starting switch to ON position.
standard value Wiring harness between CE01 (female)
Short circuit in wiring har- Resis-
in normal con- (45) - each of CE01 (female) pins (With all Min. 100 kW
4 ness tance
dition wiring harness connectors disconnected)
(with another wiring harness)
Wiring harness between CE01 (female)
Resis-
(53) - each of CE01 (female) pins (With all Min. 100 kW
tance
wiring harness connectors disconnected)
Since problem may exist in the connections between No. 1 injector
to engine harness to engine controller, check for a defective con-
Defective wiring harness nection.
5
Defective other cylinder If failure codes of other injectors are displayed, perform trouble-
6
injectors or wiring harness shooting of them, too.
a Prepare with starting switch OFF, then carry out troubleshooting
Min. 100 kW
ground
40-301 42 PC200, 200LC-8E0 (Hybrid)

Failure code [CA322] Inj #1 (L#1) Open/Short Error SEN05247-00
Circuit diagram related to No. 1 injector
PC200, 200LC-8E0 (Hybrid) 40-301 43


Trouble
Failure
q Open or short circuit was detected in drive circuit of No. 3 injector.
description
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

1 Defective No. 3 injector INJ CYL 3 (male) Resistance
Between (1) and(2) Max. 2 Ω
Between (1) and chassis ground Min. 100 kΩ
ness
and INJ CYL 3 (female) (1) tance
tor) Max. 2 Ω
ness
Probable (female) (55) and INJ CYL 3 (female) (1), and Min. 100 Ω
cuit) tance
causes and chassis ground
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normal con- without turning starting switch to ON position.
dition Wiring harness between CE01 (female) (55)
and each of CE01 (female) pins (With all wir- Min. 100 kΩ
4 ness tance
ing harness connectors disconnected)
Wiring harness between CE01 (female) (52)
Resis-
tance
q Looseness of connector, breakage of lock, or breakage of seal
5 q Corrosion, bend, breakage, push-in, or expansion of pin
connector
Defective other cylinder If the failure codes of other injectors are displayed, perform trouble-
6
40-301 44 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-301 45

SEN05247-00 Failure code [CA331] Inj #2(L#2) Open/Short Error
Failure code [CA331] Inj #2(L#2) Open/Short Error

Trouble
Failure
q A disconnection or short circuit was detected in No. 2 injector drive circuit
description
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

ness
tor) Max. 2 Ω
ness
(female) (54) and INJ CYL 2 (female) (1), Min. 100 kΩ
cuit) tance
and chassis ground
Probable
causes and
standard value Wiring harness between CE01 (female) (54)
in normal con- Short circuit in wiring har- Resis-
and each of CE01 (female) pins (With all Min. 100 kΩ
dition 4 ness tance
Resis-
and each of CE01 (female) pins (With all Min. 100 kΩ
tance
Since problem is probably at connections in No. 2 injector to engine
harness to engine controller, check for a defective connection.
connector
Defective other cylinder If the failure codes of other injectors are displayed, perform trouble-
6
Min. 100 kΩ
ground
40-301 46 PC200, 200LC-8E0 (Hybrid)

Failure code [CA331] Inj #2(L#2) Open/Short Error SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 47


Trouble
Failure
q Disconnection or short circuit was detected in No. 4 injector drive circuit
description
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

When following failure codes are displayed simultaneously engine
controller has its internal failure ([CA323] [CA325] [CA332])
ness
tor) Max. 2 Ω
ness
Probable 4 Between Wiring harness between CE01
causes and (female) (56) and INJ CYL 4 (female) (1), and Max. 2 Ω
cuit) tance
standard value chassis ground
in normal con- a Prepare with starting switch OFF, then perform out troubleshoot-
dition ing without turning starting switch to ON position.
Short circuit in wiring har- Wiring harness between CE01 (female) (56)
Resis-
ness and each of CE01 (female) pins (With all wir- Min. 100 kΩ
5 tance
(with another wiring har- ing harness connectors disconnected)
ness) Wiring harness between CE01 (female) (58)
Resis-
tance
Since problem is probably at connections in No. 4 injector to engine
harness to engine controller, check for a defective connection.
connector
without turning starting switch ON.
40-301 48 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-301 49

SEN05247-00
© KOMATSU
All Rights Reserved
40-301 50
SEN05248-00
SEN05248-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
Failure code [CA342] Calibration Code Incompatibility............................................................................... 3

Failure code [CA351] Injectors Drive Circuit Error ...................................................................................... 3
Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................................. 4
Failure code [CA386] Sens Supply 1 Volt High Error ................................................................................. 6
Failure code [CA428] Water in Fuel Sensor High Error .............................................................................. 8
Failure code [CA429] Water in Fuel Sensor Low Error............................................................................... 10
Failure code [CA435] Eng Oil Press Sw Error ............................................................................................ 12
Failure code [CA441] Battery Voltage Low Error ........................................................................................ 14
Failure code [CA442] Battery Voltage High Error ....................................................................................... 16
Failure code [CA449] Rail Press Very High Error ....................................................................................... 18
Failure code [CA451] Rail Press Sensor High Error ................................................................................... 20
Failure code [CA452] Rail Press Sensor Low Error.................................................................................... 22
Failure code [CA488] Chg Air Temp High Torque Derate .......................................................................... 24
Failure code [CA553] Rail Press High Error ............................................................................................... 24
Failure code [CA559] Rail Press Low Error ................................................................................................ 25
Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................... 26
Failure code [CA731] Eng Bkup Speed Sens Phase Error......................................................................... 28
Failure code [CA757] All Continuous Data Lost Error................................................................................. 30
Failure code [CA778] Eng Bkup Speed Sensor Error................................................................................. 32
Failure code [CA1633] KOMNET Datalink Timeout Error........................................................................... 34
PC200, 200LC-8E0 (Hybrid) 40-302 1

Failure code [CA2185] Throt Sens Sup Volt High Error.............................................................................. 35

Failure code [CA2186] Throt Sens Sup Volt Low Error............................................................................... 36
Failure code [CA2249] Rail Press Very Low Error ...................................................................................... 37
Failure code [CA2311] IMV Solenoid Error ................................................................................................. 37
Failure code [CA2555] Grid Htr Relay Volt High Error ................................................................................ 38
Failure code [CA2556] Grid Htr Relay Volt Low Error................................................................................. 40
Failure code [D19JKZ] Personal Code Relay Abnormality ......................................................................... 42
Failure code [D862KA] GPS Antenna Discon ............................................................................................. 44
Failure code [DA22KK] Pump Solenoid Power Low Error .......................................................................... 46
Failure code [DA25KP] 5V Sensor 1 Power Abnormality............................................................................ 48
Failure code [DA26KP] 5V Sensor 2 Power Abnormality............................................................................ 52
Failure code [DA29KQ] Model Selection Abnormality................................................................................. 54
40-302 2 PC200, 200LC-8E0 (Hybrid)

Failure code [CA342] Calibration Code Incompatibility SEN05248-00
Failure code [CA342] Calibration Code Incompatibility

User code Failure code Calibration code incompatibility
Trouble
Failure descrip-
q Incompatibility of data occurred in engine controller.
tion
Action of con-
troller
Problem that
q Continues normal operation.
appears on
q Engine stops or does not start.
machine
Related infor-
mation

causes and
standard value
Perform troubleshooting for failure code [CA757]
in normal con-
dition
Failure code [CA351] Injectors Drive Circuit Error

User code Failure code Injectors drive circuit error
Trouble
Failure
q There is error in drive power circuit of injector.
description
Action of con-
troller
q Exhaust gas becomes black.
Problem that
q Combustion becomes irregular.
appears on
machine
q Engine cannot be started.
Related infor-
mation

causes and 1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
standard value
Defective power supply volt-
in normal con- 2 Perform troubleshooting for failure code [CA441].
age system
dition
PC200, 200LC-8E0 (Hybrid) 40-302 3

SEN05248-00 Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA352] Sens Supply 1 Volt Low Error

User code Failure code Sensor power supply 1 voltage low error
Trouble
Failure
q Low voltage was detected in sensor power supply 1 circuit.
description
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

a Disconnect connector with starting switch OFF, then turn starting
switch to ON position and perform troubleshooting.
Disconnect sensor and
wiring harness at right in
Ambient pressure sen-
order and perform oper- AMBAI RPRESURE
sor
Defective sensor or wir- ation to reproduce trou-
1
ing harness ble. If "E" of failure
Probable
code goes off when
causes and
sensor or wiring har-
standard value
ness is disconnected, Engine wiring harness CE01
in normal con-
that sensor or wiring
dition
harness is defective.
Connections in ambient pressure sensor to engine wiring harness to
connector
Defective engine control- If causes 1 and 2 are not detected, engine controller may be defective.
4
ler (Since trouble is in system, troubleshooting cannot be performed.)
40-302 4 PC200, 200LC-8E0 (Hybrid)

Failure code [CA352] Sens Supply 1 Volt Low Error SEN05248-00
Circuit diagram related to sensor power supply 1
PC200, 200LC-8E0 (Hybrid) 40-302 5

SEN05248-00 Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA386] Sens Supply 1 Volt High Error

User code Failure code Sensor power supply 1 voltage high error
Trouble
Failure descrip-
q High voltage was detected in sensor power supply 1 circuit.
tion
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

causes and
standard value
in normal con-
dition
40-302 6 PC200, 200LC-8E0 (Hybrid)

Failure code [CA386] Sens Supply 1 Volt High Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 7

SEN05248-00 Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA428] Water in Fuel Sensor High Error

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

Defective water-in-fuel sen- without turning starting switch to ON position.
1
sor P47(female) Resistance
Between (1) and (2) 10 to 100 kΩ
a Prepare with starting switch to OFF position, then perform trou-
bleshooting without turning starting switch to ON position.
ness
and P47 (male) (1) tance
Wiring harnesses in CE01 (female) (47) to Resis-
tor) Max. 10 Ω
Probable JC02 to P47 (male)(2) tance
causes and a Prepare with starting switch to OFF position, then perform trou-
standard value Short circuit in wiring har- bleshooting without turning starting switch to ON position.
in normal con- 3 ness Wiring harness betweenCE01 (female) (14)
Resis-
dition (with another wiring harness) and each of CE01 (female) pins (With all wir- Min.100 kΩ
tance
Connections in water-in-fuel sensor to engine wiring harness to
connector
Between(14) and(47) 10 to100 kΩ
40-302 8 PC200, 200LC-8E0 (Hybrid)

Failure code [CA428] Water in Fuel Sensor High Error SEN05248-00
Circuit diagram related to water-in-fuel sensor
PC200, 200LC-8E0 (Hybrid) 40-302 9

SEN05248-00 Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA429] Water in Fuel Sensor Low Error

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

Defective water-in-fuel sen-
1 P47(female) Resistance
sor
Between (1) and(2) 10 to 100 kΩ
Between (1) and chassis ground Min.100 kΩ
Ground fault in wiring har- a Prepare with starting switch OFF, then perform troubleshooting
ness without turning starting switch to ON position.
2
(Short circuit with GND cir- Wiring harness between CE01(female) (14) Resis-
Min.100 kΩ
cuit) and P47 (male)(1) tance
Probable without turning starting switch to ON position.
causes and Wiring harness between CE01 (female) (14)
3 ness
standard value and each of CE01 (female) all pins Resis-
in normal con- (With all wiring harness connectors discon- tance
dition nected)
Connections in water-in-fuel sensor to engine wiring harness to
connector
a Prepare with starting switch to OFF position, then perform trou-
bleshooting without turning starting switch to ON position.
Between(14) and(47) 10 to100 kΩ
Min.100 kΩ
ground
40-302 10 PC200, 200LC-8E0 (Hybrid)

Failure code [CA429] Water in Fuel Sensor Low Error SEN05248-00
Circuit diagram related to water-in-fuel sensor
PC200, 200LC-8E0 (Hybrid) 40-302 11

SEN05248-00 Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA435] Eng Oil Press Sw Error

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

Defective engine oil pressure without turning starting switch to ON position.
1
switch OIL PRESURE SWITCH(male) Resistance
Between (1) and body Max. 10 Ω
Disconnection in wiring har- a Prepare with starting switch OFF, then perform troubleshooting
2 (Disconnection in wiring or
defective contact in connec- Max. 10 Ω
and OIL PRESSURE SWITCH (male) (1) tance
tor)
standard value Wiring harness between CE01 (female) (17)
3 ness
in normal con- and each of CE01 (female) pins Resis-
dition (With all wiring harness connectors discon- tance
nected)
Connections in engine oil pressure switch to engine wiring harness
connector
Between(17) and chassis ground Max. 10 Ω
Circuit diagram related to engine oil pressure switch
40-302 12 PC200, 200LC-8E0 (Hybrid)

Failure code [CA435] Eng Oil Press Sw Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 13

SEN05248-00 Failure code [CA441] Battery Voltage Low Error
Failure code [CA441] Battery Voltage Low Error

User code Failure code Battery voltage low error
Trouble
Failure descrip-
q Low voltage was detected in controller power supply circuit.
tion
Action of con-
troller
Problem that
q Engine stops.
appears on
machine
Related infor-
mation

Loose or corroded battery
1 Battery cable may be loosened or corroded. Check it directly.
terminal
a Prepare with starting switch OFF, then keep starting switch OFF
and turn it to START and perform troubleshooting in each case.
2 Low battery voltage Battery (1 piece) Starting switch Voltage
Between (+) and (-) 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.)
Defective relay for engine position and perform troubleshooting.
4 Replace relays for engine controller power supply (R23, R24) with
controller power supply other relays. If mark E of failure code disappears after reproduction
operation is performed, that relay has defect.
a Prepare with starting switch OFF, then cperform troubleshooting
Disconnection in wiring har- without turning starting switch to ON position.
Wiring harness between F01-19 and R23, Resis-
ness Max. 10 Ω
R24 (female) (3) tance
5 (Disconnection in wiring or Wiring harness between R23, R24 (female) Resis-
defective contact in connec- (5) and CE03 (female) (3) Max. 10 Ω
tance
tor) Wiring harness between CE03 (female) (1) Resis-
Max. 10 Ω
and chassis ground (T12) tance
causes and Between wiring harness between F01-19 and Resis-
ness Min.100 kΩ
standard value 6 R23, R24 (female) (3), and chassis ground tance
(Short circuit with GND cir-
in normal con- Between wiring harness between R23, R24
cuit) Resis-
dition (female) (5) and CE03 (female) (3), and chas- Max. 10 Ω
tance
sis ground
Wiring harness between CE03 (female) (3),
Resis-
and pins of CE03 (female) (1) Min. 100 kΩ
tance
Short circuit in wiring har- (With battery terminal disconnected)
7 ness Wiring harness between CE03 (female) (3),
Resis-
(with another wiring harness) and CE02 (female) all pins Min. 100 kΩ
tance
(With battery terminal disconnected)
Resis-
and CE02 (female) all pins Min. 100 kΩ
tance
(With battery terminal disconnected)
Connections in fuse No. 19 to engine unit wiring harness to engine
controller are suspected. Inspect them directly.
connector
position and start engine and perform troubleshooting in each
case.
CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) and (1)
START Min. 12 V
40-302 14 PC200, 200LC-8E0 (Hybrid)

Failure code [CA441] Battery Voltage Low Error SEN05248-00
Circuit diagram related to engine controller power supply
PC200, 200LC-8E0 (Hybrid) 40-302 15

SEN05248-00 Failure code [CA442] Battery Voltage High Error
Failure code [CA442] Battery Voltage High Error

User code Failure code Battery voltage high error
Trouble
Failure
q High voltage (36 V or higher) was detected in controller power supply circuit.
description
Action of con-
troller
Problem that
appears on q Engine may stop.
machine
Related infor-
mation

1 Low battery voltage
Battery Voltage
Between (+) and (-) terminals Max. 32 V
Probable
causes and
troubleshooting.
standard value
2 Defective alternator E12( (male) Engine speed Voltage
in normal con-
Between (1) and
dition Medium or higher 27.5 to 29.5 V
chassis ground
CE03 (female) Voltage
Between(3) and(1) Max. 32 V
40-302 16 PC200, 200LC-8E0 (Hybrid)

Failure code [CA442] Battery Voltage High Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 17

SEN05248-00 Failure code [CA449] Rail Press Very High Error
Failure code [CA449] Rail Press Very High Error

User code Failure code Common rail pressure very high error
Trouble
Failure descrip-
q High voltage was detected in common rail circuit.
tion
Action of con-
troller
Problem that
q Engine sound becomes large when no or light load is applied.
appears on
machine
q Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pres-
Related infor-
sure)
mation

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
There may be air in low pressure circuit. Check it directly according
to the following procedure.
1) Remove pressure pickup part plug (outlet side) from fuel main fil-
2 Air in low pressure circuit
ter.
2) Operate feed pump of fuel prefilter.
Probable 3) Check pressure pickup plug for leakage of fuel and air.
causes and a For check of fuel return circuit pressure, see Testing and adjust-
standard value Defect in fuel return circuit ing, Checking fuel pressure.
3 Max. 0.02 MPa
in normal con- parts Fuel return circuit Low idle running or
dition pressure cranking {Max. 0.19 kg/cm2}
Defective common rail pres- Common rail pressure sensor system may be defective. Perform
4
sure sensor troubleshooting for failure codes [CA451] and [CA452].
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 to 5 are not detected, supply pump may be defective.
40-302 18 PC200, 200LC-8E0 (Hybrid)

Failure code [CA449] Rail Press Very High Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 19

SEN05248-00 Failure code [CA451] Rail Press Sensor High Error
Failure code [CA451] Rail Press Sensor High Error

User code Failure code Common rail pressure sensor high error
Trouble
Failure
q High voltage was detected in signal circuit of common rail pressure sensor.
description
Action of con-
troller
Problem that
appears on
q Engine speed or output lowers.
machine
q Signal voltage of common rail pressure sensor can be checked with monitoring function.
Related infor-
(Code: Common rail pressure sensor voltage)
mation

Defective sensor power sup- If failure code [CA227] is also displayed, perform troubleshooting for
1
ply 2 line it first.
FUEL RAIL PRESS Voltage
Defective common rail pres-
2 Between(3) and(1) Power supply 4.75 to 5.25 V
sure sensor
3 5V/24V circuit) in wiring har-
Probable ness Voltage Max. 1 V
and FUEL RAIL PRESS (female) (2)
causes and
standard value
in normal con- Short circuit in wiring har- Between wiring harnesses between CE01
dition 4 ness (female) (25) and FUEL RAIL PRESS
Resis-
(with another wiring harness) (female)(2), and between CE01 (female) Min.100 kΩ
tance
(37) and JC01-FUEL RAIL
PRESS(female)(3)
Connections in common rail pressure sensor to engine wiring har-
ness to engine controller may be defective. Check them directly.
connector
CE01 Voltage
Between(37) and(47) Power supply 4.75 to5.25 V
40-302 20 PC200, 200LC-8E0 (Hybrid)

Failure code [CA451] Rail Press Sensor High Error SEN05248-00
Circuit diagram related to common rail pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-302 21

SEN05248-00 Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA452] Rail Press Sensor Low Error

User code Failure code Common rail pressure sensor low error
Trouble
Failure
q Low voltage was detected in signal circuit of common rail pressure sensor.
description
Action of
controller
Problem that
appears on
q Engine speed or output lowers.
machine
q Signal voltage of common rail pressure sensor can be checked with monitoring function.
Related
(Code: 36401 Common rail pressure sensor voltage)
information

Defective sensor power sup- If failure code [CA187] is also displayed, perform troubleshooting for it
1
ply 2 line first.
FUEL RAIL PRESS Voltage
2 Between (3) and(1) Power supply 4.75 to5.25 V
sure sensor
ness
3 Wiring harness between CE01 (female) (25)
Probable and FUEL RAIL PRESS (female) (2), and Min.100 kΩ
cuit) tance
standard a Prepare with starting switch OFF, then perform troubleshooting
value in nor- without turning starting switch to ON position.
mal condition Short circuit in wiring har- Between wiring harnesses between CE01
4 ness (female) (25) and FUEL RAIL PRESS
Resis-
(with another wiring harness) (female) (2), and between CE01 (female) Min.100 kΩ
tance
(47) and JC02 and FUEL RAIL PRESS
(female) (1)
Connections in common rail pressure sensor to engine wiring harness
connector
CE01 Voltage
Between (37) and(47) Power supply 4.75 to 5.25 V
40-302 22 PC200, 200LC-8E0 (Hybrid)

Failure code [CA452] Rail Press Sensor Low Error SEN05248-00
Circuit diagram related to common rail pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-302 23

SEN05248-00 Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA488] Chg Air Temp High Torque Derate

User code Failure code Charge air temperature high torque derate
Trouble
Failure q Temperature signal of boost pressure/temperature sensor exceeded, upper limit of control temper-
description ature.
Action of con-
troller
Problem that
machine
Related infor- q Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature)

The degradation of aftercooler cooling performance is suspected.
Directly check the following points:
Probable Lowering of cooling perfor-
1 q Looseness and damage of fan belt
causes and mance of aftercooler
q Insufficient cooling air
standard value
q Clogging of aftercooler fins
in normal con-
Abnormal rise of turbo- Outlet temperature of turbocharger may be abnormally high. Check
dition 2
charger outlet temperature related parts directly.
Charge temperature sensor system may be defective. Perform
troubleshooting for failure codes [CA153] and [CA154] .
Failure code [CA553] Rail Press High Error

User code Failure code Common rail pressure high error
Trouble
Failure
q High voltage 1 was detected in common rail circuit.
description
Action of
machine mon- q None in particular.
itor
Problem that
q Engine sound becomes large when no or light load is applied.
appears on
machine
Related infor- q Common rail pressure can be checked with monitoring function.(Code: 36400 Common rail pressure)

Connection at ground terminal may be defective. Check following ter-
minals directly.
Probable
Defective connection at q Ground terminal of machine ((–) terminal of battery)
causes and 2
ground terminal q Ground terminal of engine
standard
q Ground terminal of engine controller
value in nor-
q Ground terminal of starting motor
mal condition
Breakage of O-ring of supply
3 O-ring of supply pump actuator may be broken. Check it directly.
pump actuator
4 Perform troubleshooting for failure codes [CA451] and [CA452].
sure sensor system
40-302 24 PC200, 200LC-8E0 (Hybrid)

Failure code [CA559] Rail Press Low Error SEN05248-00
Failure code [CA559] Rail Press Low Error

User code Failure code Common rail pressure low error
Trouble
Failure descrip-
q Low pressure error (1) was detected in common rail circuit.
tion
Action of con-
troller
Problem that q Engine does not start at all or does not start easily.
appears on q Exhaust gas becomes black.
machine q Engine output lowers.
q 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 0.3 to1.1 MPa
Defective parts in low pres- (if engine cannot be
2
sure circuit Pressure in low-pres- started) {3.1 to 11.3 kg/cm2}
sure fuel circuit During low idle 0.5 to1.3 MPa
(if engine can be
started) {5.1 to 13.3 kg/cm2}
a For check of leakage through pressure limiter, see Testing and
adjusting, Checking fuel return rate and leakage.
3 Defective pressure limiter
Probable Leakage through
During low idle 0 cc (No leakage)
causes and pressure limiter
standard value a For check of return rate from injector, see Testing and adjusting,
in normal con- Checking fuel return rate and leakage.
dition During cranking
Defective injector
(if engine cannot be Max. 90 cc/min.
4 (including high pressure pip-
Return rate from started)
ing in cylinder head)
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 ad-
justing, Checking fuel return rate and leakage.
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)
Note1: Check the following items for defective parts in low pressure circuit parts.
1) Fuel level
2) Clogging of fuel tank breather
3) Leakage through and clogging of low-pressure fuel piping
4) Clogging of fuel prefilter
5) Clogging of fuel main filter
6) If failure is not solved with no clogging checked, replace the fuel filter with a new one.
PC200, 200LC-8E0 (Hybrid) 40-302 25

SEN05248-00 Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA689] Eng Ne Speed Sensor Error

User code Failure code Engine Ne speed sensor error
Trouble
Failure
q Signal from engine Ne speed sensor are abnormal.
description
Action of
q Continues control with signal from engine Bkup speed sensor.
controller
Problem that q Engine hunts.
appears on q Engine does not start easily.
Related infor-
mation

Defective Ne speed sensor If failure code [CA238] is also displayed, perform troubleshooting
1
power supply line for it first.
CRANK SENSOR Voltage
Defective engine Ne speed sen-
2 Between (1) and (2) Power supply 4.75 to 5.25 V
sor
Breakage or improper clear-
Engine Ne speed sensor may be broken or may have improper
3 ance of engine Ne speed sen-
clearance. Check it directly.
sor
Breakage of rotation sensor
4 Rotation sensor wheel may be broken. Check it directly.
wheel
Disconnection in wiring harness
defective contact in connector) Max. 10 Ω
(27) and CRANK SENSOR (female) (3) tance
Ground fault in wiring harness without turning starting switch ON.
6
Probable (Short circuit with GND circuit) Wiring harness between CE01 (female) Resis-
Min.100 kΩ
causes and (27) and CRANK SENSOR (female) (3) tance
value in nor- 7 without turning starting switch to ON position.
5V/24V circuit) in wiring har-
mal condition Wiring harness between CE01 (female)
ness Voltage Max.1 V
(27) and CRANK SENSOR (female) (3)
Between wiring harnesses between CE01
(female) (27) and CRANK SENSOR Resis-
Min.100 kΩ
Short circuit in wiring harness (female) (3) and between CE01 (female) tance
8
(with another wiring harness) (16) and CRANK SENSOR (female)(1)
Between wiring harnesses between CE01
(female) (27) and CRANK SENSOR Resis-
Min.100 kΩ
(female) (3) and between CE01 (female) tance
(48) and CRANK SENSOR (female)(2)
Connections in engine Ne speed sensor to engine wiring harness to
Defective wiring harness con-
nector
Between (16) and
Power supply 4.75 to5.25 V
(48)
40-302 26 PC200, 200LC-8E0 (Hybrid)

Failure code [CA689] Eng Ne Speed Sensor Error SEN05248-00
Circuit diagrams related to engine Ne speed sensor
PC200, 200LC-8E0 (Hybrid) 40-302 27

SEN05248-00 Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error

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

Breakage of engine Ne speed
1 Engine Ne speed sensor may be broken. Check it directly.
sensor
Breakage of engine Bkup speed
2 Engine Bkup speed sensor may be broken. Check it directly.
sensor
Speed sensing wheel on crankshaft side may be installed defec-
tively or broken. Check it according to the following procedure.
Defective installation or break-
1)Set No. 1 piston at compression top dead center (Match stamped
3 age of speed sensing wheel on
mark).
crankshaft side
2)If tip of Ne speed sensor is aligned to center of oblong hole of
speed sensing wheel, it is installed normally.
Probable
Speed sensing ring on camshaft side may be installed defectively
causes and
or broken. Check it according to the following procedure.
standard
Defective installation or break- 1)Set No. 1 piston at compression top dead center (Match stamped
value in nor-
4 age of speed sensing ring on mark).
mal condition
camshaft side 2)Remove Bkup speed sensor.
3)If 2 grooves (1 crest) of speed sensor ring are seen through sen-
sor mounting hole, speed sensor ring is installed normally.
Defective timing of crankshaft Timing of crankshaft and camshaft may be defective. Check it
5
and camshaft directly.
Connection at ground terminal may be defective. Check following
terminals directly.
Defective connection at ground q Ground terminal of machine ((–) terminal of battery)
6
terminal q Ground terminal of engine
q Ground terminal of engine controller
q Ground terminal of starting motor
40-302 28 PC200, 200LC-8E0 (Hybrid)

Failure code [CA731] Eng Bkup Speed Sens Phase Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 29

SEN05248-00 Failure code [CA757] All Continuous Data Lost Error
Failure code [CA757] All Continuous Data Lost Error

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

Loose connection at or cor- Battery terminal connection may be loosened or corroded. Check it
2
roded battery terminal directly.
and turn it to START and perform troubleshooting in each case.
3 Low battery voltage Battery (1 piece) Starting switch Voltage
Between (+) and (–) OFF Min. 12 V
terminals START Min. 6.2 V
4 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.
Defective relay for engine
5 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
this time, replaced relay is defective.
Probable
causes and
standard value Disconnection in wiring har-
Wiring harness between F01-19 and R23, Resis-
in normal con- ness Max. 10 Ω
dition 6 (Disconnection in wiring or
Wiring harness between R23, R24 (female) Resis-
(5) and CE03 (female) (3) tance
tor)
Max. 10 Ω
and chassis ground (T12) tance
Connections in fuse No. 19 to machine wiring harness to engine
connector
position and start engine and perform troubleshooting in each
case.
CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) and(1)
START Min. 12 V
40-302 30 PC200, 200LC-8E0 (Hybrid)

Failure code [CA757] All Continuous Data Lost Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 31

SEN05248-00 Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA778] Eng Bkup Speed Sensor Error

User code Failure code Engine Bkup speed sensor error
Trouble
Failure descrip-
q Failure was detected in signal from engine Bkup speed sensor.
tion
Action of con-
q Continues control with signal from engine Ne speed sensor.
trolle
Problem that
appears on
machine
Related infor-
mation

Defective sensor power sup- If failure code [CA187] is also displayed, perform troubleshooting
1
ply 2 line for it first.
CAM SENSOR Voltage
Defective engine Bkup
2 Between (1) and(2) Power supply 4.75 to5.25 V
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 speed sensing
4 Speed sensing ring may be broken. Check it directly.
ring
Wiring harnesses in CE01 (female) (26) to Resis-
JC03 to CAM SENSOR (female) (3) tance
tor)
ness
6 Between wiring harnesses in CE01(female)
Probable (Short circuit with GND cir- Resis-
(26) to JC03 to CAM SENSOR (female) (3) Min.100 kΩ
causes and cuit) tance
and chassis ground.
standard value
in normal con-
Hot short (Short circuit with position and perform troubleshooting.
dition
7 5V/24V circuit) in wiring har- Between wiring harnesses in CE01(female)
ness (26) to JC03 to CAM SENSOR (female) (3) Voltage Max. 1 V
and chassis ground.
Between wiring harnesses in CE01 (female)
(26) to JC03 to CAM SENSOR (female)(3) Resis-
Short circuit in wiring har- Min.100 kΩ
and in CE01 (female) (37) to JC01 to CAM tance
8 ness
SENSOR(female) (1)
Between wiring harnesses in CE01 (female)
(26) to JC03 to CAM SENSOR (female) (3) Resis-
Min.100 kΩ
and in CE01 (female) (47) to JC02 to CAM tance
SENSOR (female) (2)
Connections in engine Bkup speed sensor to engine wiring harness
connector
Between (37) and
Power supply 4.75 to 5.25 V
(47)
40-302 32 PC200, 200LC-8E0 (Hybrid)

Failure code [CA778] Eng Bkup Speed Sensor Error SEN05248-00
Circuit diagram related to engine Bkup speed sensor
PC200, 200LC-8E0 (Hybrid) 40-302 33

SEN05248-00 Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA1633] KOMNET Datalink Timeout Error

User code Failure code KOMNET Datalink timeout error
Trouble
E0E CA1633 (Engine controller system)
Failure descrip- q Engine controller detected communication error in KOMNET communication circuit between pump
tion controller and machine monitor.
Action of con- q Continues operation in default mode.
Problem that q Machine may not operate normally because information which is exchanged through KOMNET
appears on communication is not transmitted properly.
machine (Trouble phenomenon depends on failed section.)
Related infor-
mation

causes and
standard value
Perform troubleshooting for failure code [DA2RMC].
in normal con-
dition
40-302 34 PC200, 200LC-8E0 (Hybrid)

Failure code [CA2185] Throt Sens Sup Volt High Error SEN05248-00
Failure code [CA2185] Throt Sens Sup Volt High Error

User code Failure code Throttle sensor supply voltage high error
Trouble
Failure descrip-
q High voltage(5.25 V or higher) was detected in throttle sensor power supply circuit.
tion
q If trouble occurs while starting switch is in ON position, controller fixes voltage value to value just
Action of con- before detection of trouble and continues operation.
ation with voltage at 100% value.
Problem that
machine
Related infor-
mation

and CE02 (female) all pins Min.100 kΩ
1 ness tance
(with P20 also disconnected)
Probable Wiring harness between CE02 (female) (22)
Resis-
causes and and CE03 (female) (3) Min.100 kΩ
tance
standard value (with P20 also disconnected)
in normal con- Connections in fuel control dial to machine wiring harness to engine
dition controller may be defective. Check them directly.
connector
If causes 1 and 2 are not detected, engine controller may be defec-
formed.)
PC200, 200LC-8E0 (Hybrid) 40-302 35

SEN05248-00 Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2186] Throt Sens Sup Volt Low Error

User code Failure code Throttle sensor supply low error
Trouble
Failure
q Low voltage was detected in throttle sensor power supply circuit.
description
q If trouble occurs while starting switch is in ON position, controller fixes voltage value to value just be-
Action of con- fore detection of trouble and continues operation.
ation with voltage at 100% value.
Problem that
machine
Related infor-
mation

ness
(female) (22) and P20 (female) (1), and Min.100 kΩ
cuit) tance
chassis ground
Probable
Short circuit in wiring har- without turning starting switch to ON position.
causes and
standard value Resis-
(with another wiring harness) and CE02 (female) all pins Min.100 kΩ
in normal con- tance
(with P20 also disconnected)
dition Connections in fuel control dial to machine wiring harness to engine
connector
If causes 1 to 3 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be performed.)
40-302 36 PC200, 200LC-8E0 (Hybrid)

Failure code [CA2249] Rail Press Very Low Error SEN05248-00
Failure code [CA2249] Rail Press Very Low Error

User code Failure code Common rail pressure very low error
Trouble
Failure descrip-
q Low pressure was detected in common rail circuit.
tion
Action of con-
troller
Problem that q Engine does not start easily.
appears on q Exhaust gas becomes black.
q Common rail pressure can be checked with monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation

causes and
standard value
in normal con-
dition
Failure code [CA2311] IMV Solenoid Error

User code Failure code IMV solenoid error
Trouble
Failure descrip-
q Resistance of supply pump actuator circuit is abnormally high or low.
tion
Action of con-
troller
Problem that
machine
Related infor-
mation

causes and
standard value
Perform troubleshooting for failure code [CA271] and [CA272].
in normal con-
dition
PC200, 200LC-8E0 (Hybrid) 40-302 37

SEN05248-00 Failure code [CA2555] Grid Htr Relay Volt High Error
Failure code [CA2555] Grid Htr Relay Volt High Error

User code Failure code Intake air heater relay voltage high error
Trouble
Failure descrip-
q Disconnection was detected in drive circuit of intake air heater relay.
tion
Action of con-
troller
Problem that
q Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position when engine coolant tem-
mation perature is below –4 °C.

without turning starting switch to ON position. (Troubleshooting
for relay unit)
R18 (male) Resistance
Defective automatic pre- Between (1) and (2) 300 to 600 Ω
1 heater relay (Internal discon- a Prepare with starting switch OFF, then turn starting switch to ON
nection) position and perform troubleshooting. (Troubleshooting by re-
placement)
Replace auto preheater relay (R18) with other relay. If mark E of fail-
ure code disappears after reproduction operation is performed, that
relay has defect.
Probable ness
causes and 2 (Disconnection in wiring or Max. 10 Ω
(40) and R18 (female) (1) tance
standard value defective contact in connec-
in normal condi- tor) Max. 10 Ω
(42) and R18 (female) (2) tance
tion a Prepare with starting switch OFF, then perform troubleshooting
3 ness Between CE02 (female) (40) and each of
Resis-
(with another wiring harness) CE02 (female) pins Min.100 kΩ
tance
(With R18 disconnected)
Connections in automatic preheater relay to machine wiring har-
ness to engine controller may be defective. Check them directly.
connector
Between (40) and (42) 300 to 600 Ω
40-302 38 PC200, 200LC-8E0 (Hybrid)

Failure code [CA2555] Grid Htr Relay Volt High Error SEN05248-00
Circuit diagram related to engine preheater/starting motor/charging system
PC200, 200LC-8E0 (Hybrid) 40-302 39

SEN05248-00 Failure code [CA2556] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt Low Error

User code Failure code Intake air heater relay voltage low error
Trouble
Failure descrip-
q Short circuit was detected in drive circuit of intake air heater relay.
tion
Action of con-
troller
Problem that
q Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position when engine coolant tem-
mation perature is below –4 °C.

without turning starting switch to ON position. (Troubleshooting
for relay unit)
Defective automatic pre- Between (1) and (2) 300 to 600 Ω
1 heater relay (Internal discon- a Prepare with starting switch OFF, then turn starting switch to ON
nection) position and perform troubleshooting. (Troubleshooting by re-
placement)
Replace automatic preheater relay (R18) with another relay and per-
form reproducing operation. If "E" of failure code goes off at this
time, replaced relay is defective.
ness
causes and 2 Between wiring harness between CE02
standard value (female) (40) and R18 (female) (1), and Min.100 kΩ
cuit) tance
in normal con- chassis ground
dition a Prepare with starting switch OFF, then perform troubleshooting
Resis-
(with another wiring harness) and CE02 (female) all pins Min.100 kΩ
tance
(With R18 disconnected)
Connections in automatic preheater relay to machine wiring harness
connector
Between(40) and (42) 300 to 600 Ω
40-302 40 PC200, 200LC-8E0 (Hybrid)

Failure code [CA2556] Grid Htr Relay Volt Low Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 41

SEN05248-00 Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D19JKZ] Personal Code Relay Abnormality

User code Failure code Personal code relay abnormality
Trouble
E01 D19JKZ (KOMTRAX system in machine monitor)
Failure
q Disconnection or short circuit was detected in primary coil side of personal code relay circuit.
description
q None in particular (when disconnection is detected).
Action of q Turns output to personal code relay OFF (when short circuit is detected).
machine mon- q If cause of failure disappears, system resets itself (when disconnection is detected).
itor q 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
q This failure code is displayed only when engine lock function is effective.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position (Disconnection). Trouble can-
mation
not be reproduced on machine (Short circuit).

If the fuse is broken, the circuit probably has a grounding fault, etc.
1 Defective fuse No. 3
(See cause 4)
without turning starting switch to ON position. (Troubleshooting for
relay unit)
Defective personal code Between (1) and (2) (300 to 600 Ω)
2 relay (Internal disconnection a Prepare with starting switch OFF, then turn starting switch to ON
or short circuit) position and perform troubleshooting. (Troubleshooting by re-
placement)
Replace personal code relay (R07) with another relay and perform
reproducing operation. If "E" of failure code goes off at this time,
Probable replaced relay is defective.
standard without turning starting switch to ON position.
ness
value in nor- Wiring harness between F01(3) and R07 Resis-
mal condition (female)(1) tance
Wiring harness between R07 (female) (2) and Resis-
tor) Max. 1 Ω
CM01 (female) (6) tance
Ground fault in wiring har- Between wiring harness between F01(3) and
Resis-
ness R07 (female) (1) wiring harness, and chassis Min. 1 MΩ
4 tance
(Short circuit with GND cir- ground
cuit) Between wiring harness between R07
Resis-
(female) (2) and CM01 (female) (6), and Min. 1 MΩ
tance
chassis ground
If causes 1 to 4 are not detected, machine monitor (KOMTRAX) may
Defective machine monitor
5 be defective. (Since trouble is in system, troubleshooting cannot be
(KOMTRAX section)
performed.)
40-302 42 PC200, 200LC-8E0 (Hybrid)

Failure code [D19JKZ] Personal Code Relay Abnormality SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 43

SEN05248-00 Failure code [D862KA] GPS Antenna Discon
Failure code [D862KA] GPS Antenna Discon

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

causes and
Probable causes are defective GPS antenna, disconnection or short
standard value Defective GPS antenna or
1 circuit in antenna cable, and defective connection of antenna cable
in normal con- antenna cable
connector (GPS).
dition
Configuration drawing
40-302 44 PC200, 200LC-8E0 (Hybrid)

Failure code [D862KA] GPS Antenna Discon SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 45

SEN05248-00 Failure code [DA22KK] Pump Solenoid Power Low Error
Failure code [DA22KK] Pump Solenoid Power Low Error

User code Failure code Lowering of solenoid power supply voltage
Trouble
E0E DA22KK (Pump controller system)
Failure
q Solenoid power supply voltage of controller is below 20 V.
description
q While this failure code is displayed, detection of failure codes (disconnection/short circuit) for all the
Action of con- solenoid systems is stopped.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to OFF
position.
Problem that
appears on q 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.)
a Prepare with starting switch OFF, then carry out troubleshooting
Wiring harness between C02 (female) Resis-
ness Max. 1 Ω
(116), (118), (121) and F01-2 tance
Wiring harness between F01-1A and F04 Resis-
(male) (2) tance
tor)
Wiring harness between F04 (male) (1) and Resis-
Max. 1 Ω
R03 tance
Probable
causes and
standard value
Between wiring harness between C02
in normal con- Resis-
(female) (116)(118)(121) and F01-2, and Min. 1 MΩ
dition Ground fault in wiring harness tance
ground
3 (Short circuit with GND cir-
Between wiring harness between F01-1A
cuit) Resis-
and F04 (male) (2), or circuit branch end, Min. 1 MΩ
tance
and chassis ground
Between wiring harness betweenF04 (male) Resis-
Min. 1 MΩ
(1) and R03, and chassis ground tance
4 Defective pump controller C01(female), C02(female) Voltage
Between C02, (116), (118), (121)
20 to 30 V
and C01(2), (5)
40-302 46 PC200, 200LC-8E0 (Hybrid)

Failure code [DA22KK] Pump Solenoid Power Low Error SEN05248-00
Circuit diagram related to pump controller power supply
PC200, 200LC-8E0 (Hybrid) 40-302 47

SEN05248-00 Failure code [DA25KP] 5V Sensor 1 Power Abnormality
Failure code [DA25KP] 5V Sensor 1 Power Abnormality

Overload alarm monitor non-display specification
User code Failure code 5V sensor power supply output 1 abnormality

Trouble
— DA25KP (Pump controller system)
Failure descrip-
q Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
tion
q Cuts output of 5V sensor power supply output 1 OFF.
Action of control-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
ler
OFF position.
Problem that q Automatic gear shifting function does not work (pump pressure sensor system).
appears on q Auto-decelerator keeps working and is not reset or fine control performance of work equipment is
machine lowered (PPC pressure sensor system).
Related informa-
tion

Bucket CURL PPC pres-
P01
sure sensor
Swing LEFT PPC pres-
P03
sure sensor
Arm IN PPC pressure
P04
Disconnect sensors at right in sensor
Pressure sensor defec- order and perform operation to Bucket DUMP PPC pres-
1 P05
tive (Internal short circuit) reproduce trouble. If "E" of fail- sure sensor
ure code goes off when a sen- Boom RAISE PPC pres-
P06
sor is disconnected, that sensor sure sensor
is defective. Swing RIGHT PPC pres-
P07
sure sensor
F Pump pressure sensor P25
R Pump pressure sensor P26

a Prepare with starting switch to OFF position , then perform trouble-
Probable causes shooting without turning starting switch to ON position.
and standard Between wiring harness in C01 (female) (9) to
value in normal J06 to P01 (female) (3) and chassis ground Resistance Min. 1 MΩ
condition [Bucket CURL PPC pressure sensor system]
Between wiring harness in C01 (female) (9) to
J06 to P03 (female) (3) and chassis ground Resistance Min. 1 MΩ
[Swing LEFT PPC pressure sensor system]
[Arm IN PPC pressure sensor system]
Ground fault in wiring Between wiring harness in C01 (female) (9) to
harness J06 to P05 (female) (3) and chassis ground Resistance Min. 1 MΩ
2
(Short circuit with GND [Bucket DUMP PPC pressure sensor system]
circuit) Between wiring harness in C01 (female) (9) to
[Boom RAISE PPC pressure sensor system]
J06 to P07 (female) (3) and chassi ground Resistance Min. 1 MΩ
[Swing RIGHT PPC pressure sensor system]
[F Pump pressure sensor system]
[R Pump pressure sensor system]
40-302 48 PC200, 200LC-8E0 (Hybrid)

Failure code [DA25KP] 5V Sensor 1 Power Abnormality SEN05248-00

J06 to P01 (female) (3) and chassis ground Voltage Max. 1 V
[Bucket CURL PPC pressure sensor system]
[Swing LEFT PPC pressure sensor system]
[Arm IN PPC pressure sensor system]
Probable causes Hot short (Short circuit
and standard 3 with 24V circuit) in wiring
[Bucket DUMP PPC pressure sensor system]
value in normal harness
condition
[Boom RAISE PPC pressure sensor system]
[Swing RIGHT PPC pressure sensor system]
[F Pump pressure sensor system]
[R Pump pressure sensor system]
If causes 1 to 3 are not detected, pump controller may be defective.
4 Defective pump controller
PC200, 200LC-8E0 (Hybrid) 40-302 49

Circuit diagram related to pump controller 5V sensor power supply output 1 (Overload alarm monitor
non-display specification)
40-302 50 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-302 51

Failure code [DA26KP] 5V Sensor 2 Power Abnormality

User code Failure code 5V sensor power supply output 2 abnormality
Trouble
- DA26KP (Pump controller system)
Failure
q Voltage of 5V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V.
description
q Cut output of 5V sensor power supply output 2 OFF.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to OFF
troller
position.
Problem that
appears on
machine
Action of con-
troller

Ground fault in wiring harness without turning starting switch to ON position.
1 (Short circuit with GND cir- Between wiring harness
Resis-
cuit) betweenC01(female (8) and A08 (female) Max. 1 MΩ
Probable tance
(7), and chassis ground
causes and
Hot short a Prepare with starting switch OFF, then perform troubleshooting
standard value
(Short circuit with 24V circuit) without turning starting switch to ON position.
in normal con-
2 in wiring harness Between wiring harness
dition
betweenC01(female) (8) and A08 (female) Voltage Max. 1 V
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 per-
formed.)
40-302 52 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-302 53

SEN05248-00 Failure code [DA29KQ] Model Selection Abnormality
Failure code [DA29KQ] Model Selection Abnormality

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

Defective model selection without turning starting switch ON.
connector S30 (female) Resistance
1
(Internal disconnection or Between (1), (2), (4) and (7) ,and
Min. 1 MΩ
short circuit) (8)
ness
Wiring harness between C01 (female) (77) Resis-
and S30 (male) (3) tance
Wiring harnesses in S30 (male) (8) to J05 to Resis-
tor) Max. 1 Ω
chassis ground (T07) tance
Probable
causes and Resis-
(female) (40) and S30 (male) (1), and chas- Min. 1 MΩ
standard value tance
sis ground
in normal con-
Ground fault in wiring har- Between wiring harness between C01
dition Resis-
ness (female) (21) and S30 (male) (2), and chas- Min. 1 MΩ
3 tance
(Short circuit with GND cir- sis ground
cuit) Between wiring harness between C01
Resis-
tance
sis ground
Resis-
tance
sis ground
C01 (female) Resistance
4 Defective pump controller Between (21),(39), (40),(58) and
Min. 1 MΩ
ground
Max. 1 Ω
ground
40-302 54 PC200, 200LC-8E0 (Hybrid)

Failure code [DA29KQ] Model Selection Abnormality SEN05248-00
Circuit diagram related to model selection connector (PC200, 200LC-8)
PC200, 200LC-8E0 (Hybrid) 40-302 55

SEN05248-00
©2009 KOMATSU
All Rights Reserved
40-302 56
SEN05249-00
SEN05249-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
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 [DHS5KK] Travel Speed PPC Sensor Abnormality................................................................ 22
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality....................................................... 24
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality .......................................................... 26
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality .......................................................... 28
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality .................................................... 30
Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Shrt Cir ............................................................. 32
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir .................................................... 33
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir .......................................................... 34
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir ........................................................... 35
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir ....................................................... 36
Failure code [DW43KA] Travel Speed Sol Discon...................................................................................... 38
PC200, 200LC-8E0 (Hybrid) 40-303 1

Failure code [DW43KB] Travel Speed Sol Short ........................................................................................ 40

Failure code [DW45KA] Swing Brake Sol. Valve Open Cir......................................................................... 42
Failure code [DW45KB] Swing Brake Sol. Valve Short Cir ......................................................................... 43
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir................................................................... 44
Failure code [DW91KA] Travel Junction Sol Discon ................................................................................... 46
Failure code [DW91KB] Travel Junction Sol Short ..................................................................................... 48
Failure code [DWK0KA] 2-stage Relief Sol Discon..................................................................................... 50
Failure code [DWK0KB] 2-stage Relief Sol Short ....................................................................................... 52
40-303 2 PC200, 200LC-8E0 (Hybrid)

Shop Manual SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 3

SEN05249-00 Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Failure code [DA2RMC] CAN Discon (Pump Con Detected)

User code Failure code CAN disconnection (Pump controller detected)
Trouble
E0E DA2RMC (Pump controller system)
Failure q Pump controller detected communication error in CAN communication circuit between machine mon-
description itor and engine controller.
Action of con- q Continues operation with information of CAN communication just before detection of error.
Problem that
q Information may not be transmitted normally by CAN communication and machine may not operate
appears on
normally. (Problem depends on failed section.)
machine
Related infor-
mation

Disconnection in wiring har- Wiring harness between CM02 (female) (8),
ness (Disconnection in (9) and C01 (female) (45), or CE02 (female) Resistance Max. 1
1
wiing or defective contact (46), or K02 (female) (A)
in connector) Wiring harness between CM02 (female) (10)
and C01 (female) (64), or CE02 (female) Resistance Max. 1
(47), or K02 (female) (B)
Between wiring harness between CM02
(female) (8), (9) or C01 (female) (45), or
Ground fault in wiring har- Resistance Min. 1 M
CE02 (female) (46), or K02 (female) (A), or
2 ness (Short circuit with
N08 (male) (3) and chassis ground
GND circuit)
Possible
(female) (10) and C01 (female) (64), or
causes and Resistance Min. 1 M
CE02 (female) (47), or K02 (female) (B), or
standard value
N08 (male) (10), and chassis ground
in normal state
(female) (8), (9) and C01 (female) (45), or
Hot short Voltage Max. 5.5 V
CE02 (female) (46), or K02 (female) (A), or
3 (Short circuit with 24 V cir-
cuit) in wiring harness
Voltage Max. 5.5 V
Defective CAN terminal
4 resistance (Internal short
K02 (male) Resistance
circuit or disconnection)
Between (A) and (B) 120 ± 12 Ω
40-303 4 PC200, 200LC-8E0 (Hybrid)

Failure code [DA2RMC] CAN Discon (Pump Con Detected) SEN05249-00
Circuit diagram related to CAN communication
PC200, 200LC-8E0 (Hybrid) 40-303 5

SEN05249-00 Failure code [DAF8KB] Short circuit in camera power supply
Failure code [DAF8KB] Short circuit in camera power supply

User code Failure code Short circuit in camera power supply
Trouble
― DAF8KB (Machine monitor system)
Failure q Output power supply voltage (Rating: 8 V) from machine monitor to camera is below 6.0 V or above
description 10 V.
Action of q Cuts output power supply voltage (Rating: 8 V) to camera OFF.
machine moni- q Even if cause of failure disappears, system does not reset itself until starting switch is turned to OFF
tor position.
Problem that
appears on q Camera image is not displayed on monitor screen.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch ON.
mation

a Disconnect camera with starting switch OFF, then turn starting
Defective camera (Internal switch to ON position and perform troubleshooting.
1
short circuit) Disconnect camera and perform failure reproduction operation. If fail-
ure code disappears at this time, camera is defective.
a Disconnect camera with starting switch OFF, then turn starting
Probable Ground fault in wiring har- switch to ON position and perform troubleshooting.
causes and 2 ness (Contact with GND (Disconnect camera and check that it is not defective in advance.)
standard value circuit) Between CM05 (female) (1) and CAMERA
Voltage Min. 6 V
in normal con- (female) (F) wiring harness and ground
dition a Disconnect camera with starting switch OFF, then turn starting
switch to ON position and perform troubleshooting.
Hot short (Contact with 24
3 (Disconnect camera and check that it is not defective in advance.)
V circuit) in wiring harness
Between CM05 (female) (1) and CAMERA
Voltage Max. 10 V
(female) (F) wiring harness and ground
If causes 1 to 3 are not detected, machine monitor may be detective.
4 Defective machine monitor
40-303 6 PC200, 200LC-8E0 (Hybrid)

Failure code [DAF8KB] Short circuit in camera power supply SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 7

SEN05249-00 Failure code [DAFGMC] GPS Module Error
Failure code [DAFGMC] GPS Module Error

User code Failure code GPS module operation error
Trouble
― DAFGMC (KOMTRAX system in machine monitor)
Failure q Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication MO-
description DEM in 50 seconds after KOMTRAX started.
Action of
machine moni-
tor
Problem that
appears on
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position (At least 50 seconds after
mation starting switch is turned to ON position).

causes and
standard value GPS module of machine monitor may be defective. (Since trouble is
in normal con- in system, troubleshooting cannot be performed.)
dition
40-303 8 PC200, 200LC-8E0 (Hybrid)

Failure code [DAFGMC] GPS Module Error SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 9

SEN05249-00 Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [DAFRMC] CAN Discon (Monitor Detected)

User code Failure code CAN disconnection (Monitor detected)
Trouble
E0E DAFRMC (Machine monitor system)
Failure q Machine monitor detected communication error in CAN communication circuit between pump con-
description troller and engine controller.
Action of
machine moni- q If cause of failure disappears, system resets itself.
tor
Problem that
q Information may not be transmitted normally by CAN communication and machine may not operate
appears on
normally. (Problem on failed section.)
machine
Related infor-
mation

Disconnection in wiring har- Wiring harness between CM02 (female) (8)
ness (Disconnection in wiring (9), (9) and C01 (female) (45), or CE02 Resistance Max. 1 Ω
1
or defective contact in con- (female) (46), or K02 (female) (A)
nector) Wiring harness between CM02 (female)
(10) and C01 (female) (64), or CE02 Resistance Max. 1 Ω
(female) (47), or K02 (female) (B)
(female) (8) (9), (9) and C01 (female) (45),
Ground fault in wiring har- Resistance Min. 1 MΩ
or CE02 (female) (46), or K02 (female) (A),
2 ness (Short circuit with GND
or N08 (male) (3), and chassis ground
circuit)
Probable Between wiring harness between CM02
causes and (female) (10) and C01 (female) (64), or
Resistance Min. 1 MΩ
standard value CE02 (female) (47), or K02 (female) (B), or
in normal con- N08 (male) (10), and chassis ground
dition a Prepare with starting switch OFF, then turn starting switch to ON
(female) (8) (9), (9) and C01 (female) (45),
Hot short (Short circuit with Voltage Max. 5.5 V
or CE02 (female) (46), or K02 (female) (A),
3 (24 V circuit) in wiring har-
or N08 (male) (3), and chassis ground
ness
Voltage Max. 5.5 V
4 resistance (Internal short cir-
K02 (male) Resistance
cuit or disconnection)
Between (A) and (B) 120 ± 12 Ω
If causes 1 to 4 are not detected, machine monitor may be defective.
40-303 10 PC200, 200LC-8E0 (Hybrid)

Failure code [DAFRMC] CAN Discon (Monitor Detected) SEN05249-00
Circuit diagram related to CAN communication
PC200, 200LC-8E0 (Hybrid) 40-303 11

SEN05249-00 Failure code [DGH2KB] Hydr Oil Sensor Short
Failure code [DGH2KB] Hydr Oil Sensor Short

User code Failure code Hydraulic oil temperature sensor short circuited to ground
Trouble
― DGH2KB (Pump controller system)
Failure
q Ground fault was detected in hydraulic oil temperature sensor circuit.
description
Action of con- q Fixes hydraulic oil temperature value at 40 °C and continues operation.
Problem that
q 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
q 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-
perature sensor
1 P22 (male) Resistance
(Internal disconnection or
Between (1) and (2) 3.5 to 90 kΩ
short circuit)
Between (2) and chassis ground Min. 1 MΩ
Probable
causes and Ground fault in wiring har-
standard value 2 ness
Wiring harness between C01 (female) (29)
in normal con- (Short circuit to GND circuit) Resistance Min. 1 MΩ
and P22 (female) (2), and chassis ground
dition
Between (29) and (46) 3.5 to 90 kΩ
Min. 1 MΩ
ground
Circuit diagram related to hydraulic oil temperature sensor
40-303 12 PC200, 200LC-8E0 (Hybrid)

Failure code [DGH2KB] Hydr Oil Sensor Short SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 13

SEN05249-00 Failure code [DHPAMA] F Pump Press Sensor Abnormality
Failure code [DHPAMA] F Pump Press Sensor Abnormality

User code Failure code F pump pressure sensor abnormality
Trouble
― DHPAMA (Pump controller system)
Failure descrip-
q Signal voltage of F pump pressure sensor circuit is below 0.3 V or above 4.5 V.
tion
Action of con- q Fixes F pump pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
q Automatic gear shifting function does not work.
appears on
q Straight travel performance or steering performance lowers.
machine
a If 5 V 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 q F pump pressure can be checked with monitoring function. (Code: 01100 F pump pressure)

Defective 5 V sensor power If failure code [DA25KP] is also displayed, perform troubleshooting
1
supply 1 system for it first.
position or start engine and perform troubleshooting in each
case.
Defective F pump pressure P25 Voltage
2 sensor Between (3) and (1) Power supply 4.5 to 5.5 V
(Internal defect) Between (2) and (1) Signal 0.5 to 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.)
Probable Disconnection in wiring har-
causes and ness Resistance Max. 1 Ω
and P25 (female) (1)
standard value 3 (Disconnection in wiring or
in normal con- defective contact in connec- Resistance Max. 1 Ω
dition tor)
Wiring harnesses in C01 (female) (9) to
Resistance Max. 1 Ω
J06 to P25 (female) (3)
ness
4 Between wiring harness between C01
(female) (49) and P25 (female) (2), and Resistance Min. 1 MΩ
cuit)
chassis ground
Hot short (Short circuit to 24
5 Between wiring harness between C01
V circuit) in wiring harness
(female) (49) and P25 (female) (2), and Voltage Max. 4.5 V
chassis ground
40-303 14 PC200, 200LC-8E0 (Hybrid)

Failure code [DHPAMA] F Pump Press Sensor Abnormality SEN05249-00
Circuit diagram related to F pump pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 15

SEN05249-00 Failure code [DHPBMA] R Pump Press Sensor Abnormality
Failure code [DHPBMA] R Pump Press Sensor Abnormality

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

Defective 5 V sensor power If failure code[DA25KP] is also displayed, perform troubleshooting
1
position or start engine and perform troubleshooting in each case.
P26 Voltage
Defective R pump pressure
2 sensor
(Internal defect) 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.)
Probable without turning starting switch ON.
causes and Wiring harness between C01 (female) (18)
ness Resistance Max. 1 Ω
standard value and P26 (female) (1)
in normal con- Wiring harness between C01 (female) (68)
defective contact in connec- Resistance Max. 1 Ω
dition and P26 (female) (2)
tor)
Wiring harness in C01 (female) (9) to J06
4 ness
(Short circuit to GND circuit) Resistance Min. 1 MΩ
Hot short (Short circuit to 24 position and perform troubleshooting.
5
V circuit) in wiring harness Wiring harness between C01 (female) (68)
Voltage Max. 4.5 V
40-303 16 PC200, 200LC-8E0 (Hybrid)

Failure code [DHPBMA] R Pump Press Sensor Abnormality SEN05249-00
Circuit diagram related to R pump pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 17

SEN05249-00 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality

User code Failure code Arm curl PPC pressure sensor abnormality
Trouble
― DHS3MA (Pump controller system)
Failure
q Signal voltage of arm curl PPC pressure sensor circuit is below 0.5 V or above 4.5 V.
description
Action of con- q Fixes arm curl PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
q Automatic decelerator cannot be canceled.
appears on
q Arm curl performance lowers.
machine
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will
be broken. Accordingly, take extreme care when checking.
Related infor-
q Arm curl PPC pressure can be checked with monitoring function. (Code: 07200 Arm curl PPC pres-
mation
sure)

Defective 5V sensor power If failure code [DA25KP] is also displayed, perform troubleshooting
1
P04 Voltage
Defective arm curl PPC pres-
2 Between (2) and (1) Signal 0.5 to 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 failure
code goes off at this time, arm curl PPC pressure sensor is defec-
tive.)
Probably
causes and Disconnection in wiring har-
standard ness Resistance Max. 1 Ω
value in nor- 3 (Disconnection in wiring or
mal condition defective contact in connec- Resistance Max. 1 Ω
tor)
Wiring harnesses in C01 (female) (9) to J06
to P04 (female) (3)
4 ness
5
Voltage Max. 4.5 V
40-303 18 PC200, 200LC-8E0 (Hybrid)

Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality SEN05249-00
Circuit diagram related to arm curl PPC pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 19

SEN05249-00 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality

User code Failure code Bucket curl PPC pressure sensor abnormality
Trouble
— DHS4MA (Pump controller system)
Failure descrip-
q Signal voltage of bucket curl PPC pressure sensor circuit is below 0.5 V or above 4.5 V.
tion
Action of con- q Fixes bucket curl PPC pressure at 0 MPa {0 kg/cm2}and continues control.
Problem that
appears on
q Bucket curl performance lowers.
machine
will be broken. Accordingly, take extreme care when checking.
Related infor-
q Bucket curl PPC pressure can be checked with monitoring function. (Code: 07300 Bucket curl PPC
mation
pressure)
Cause Standard value in normal conditions/Remarks on troubleshooting

Defective 5V sensor power If failure code [DA25KP] is also displayed, perform troubleshooting
1
position or start engine and perform troubleshooting in each
case.
P01 Voltage
Defective bucket curl PPC
2 pressure sensor (Internal
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.)
standard value Wiring harness between C01 (female) (18)
ness Resistance Max. 1 Ω
in normal con- and P01 (female) (1)
dition Wiring harness between C01 (female) (73)
defective contact in connec- Resistance Max. 1 Ω
tor)
to P01 (female) (3)
4 ness
5
Voltage Max. 1 V
40-303 20 PC200, 200LC-8E0 (Hybrid)

Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality SEN05249-00
Circuit diagram related to bucket curl PPC pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 21

SEN05249-00 Failure code [DHS5KK] Travel Speed PPC Sensor Abnormality
Failure code [DHS5KK] Travel Speed PPC Sensor Abnormality

User code Failure code Travel PPC pressure sensor abnormality
Trouble
E20 DHS5KK (Pump controller system)
Failure descrip-
q Signal voltage of travel PPC pressure sensor is below 0.5 V or above 4.5 V.
tion
Action of con- q Fixes travel PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
appears on
q Travel performance is poor.
machine
Related infor-
q Travel PPC pressure can be checked with monitoring function.
mation
(Code: 01882 Travel PPC pressure)
Standard value under normal conditions/Remarks about trouble-

Cause
shooting
Defective 5 V sensor power
1 If failure code [DA26KP] is also displayed, troubleshoot it first.
supply 1 system
a Prepare with starting switch at OFF position, then turn starting
switch to ON position or start engine and troubleshoot.
Y17 Voltage
Defective travel PPC pres-
2 Between (2) and (1) Signal 0.5 to 4.5 V
sure sensor (Internal defect)
If power supply voltage is normal and signal voltage is abnormal,
replace PPC pressure sensor with another one and make judgment
based on the failure code (If failure code "E" goes off, travel PPC
pressure sensor is defective).
a Prepare with starting switch at OFF position, and troubleshoot
Probable
Disconnection in wiring har- Between wiring harness C01 (female) (70)
causes and Resistance Max. 1 Ω
ness and Y11 (female) (1)
standard value 3
(Disconnection or defective Between wiring harness C01 (female) (48)
under normal Resistance Max. 1 Ω
contact in connector) and Y11 (female) (2)
conditions Between wiring harness C01 (female) (8)
and Y11 (female) (3)
a Prepare with starting switch at OFF position, and troubleshoot
Ground fault in wiring har- without turning starting switch to ON position.
4 ness Between wiring harness between C01
(Contact with ground circuit) (female) (48) and Y11 (female) (2), and Resistance Min. 1 MΩ
chassis ground
a Prepare with starting switch at OFF position, then turn starting
Hot short in wiring harness switch to ON position and troubleshoot.
5 (Contact with 5 V or 24 V cir- Between wiring harness between C01
cuit) (female) (48) and P09 (female) (2), and Voltage Max. 4.5 V
chassis ground
If causes 1 to 5 are not detected, the hybrid system controller may
6 Defective pump controller be defective (Since trouble exists in system, troubleshooting cannot
be performed.)
40-303 22 PC200, 200LC-8E0 (Hybrid)

Failure code [DHS5KK] Travel Speed PPC Sensor Abnormality SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 23

SEN05249-00 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality

User code Failure code Boom raise PPC pressure sensor abnormality
Trouble
― DHS8MA (Pump controller system)
Failure
q Signal voltage of boom raise PPC pressure sensor circuit is below 0.5 V or above 4.5 V.
description
Action of con- q Fixes boom raise PPC pressure at 0 MPa {0 kg/cm2}and continues control.
Problem that
appears on
q Boom raise performance lowers.
machine
Related infor-
q Boom raise PPC pressure can be checked with monitoring function. (Code: 07400 Boom raise PPC
mation
pressure)

1
P06 Voltage
Defective boom raise PPC Between (3) and (1) Power supply 4.5 to 5.5 V
2 pressure sensor (Internal Between (2) and (1) Signal 0.5 to 4.5 V
defect) If voltage is abnormal, replace boom raise PPC pressure sensor with
another PPC pressure sensor and check failure code. (If "E" of fail-
ure code goes off at this time, boom raise PPC pressure sensor is
defective.)
Probable
causes and
Disconnection in wiring har- Wiring harness between C01 (female) (18)
standard value Resistance Max. 1 Ω
ness and P06 (female) (1)
in normal con- 3
(Short circuit with GND cir- Wiring harness between C01 (female) (53)
dition Resistance Max. 1 Ω
cuit) and P06 (female) (2)
Wiring harness in C01 (female) (9) to J06 to
P06 (female) (3)
4 ness
5
Voltage Max. 4.5 V
40-303 24 PC200, 200LC-8E0 (Hybrid)

Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality SEN05249-00
Circuit diagram related to boom raise PPC pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 25

SEN05249-00 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality

User code Failure code Swing right PPC pressure sensor abnormality
Trouble
― DHSAMA (Pump controller system)
Failure
q Signal voltage of swing right PPC pressure sensor circuit is below 0.5 V or above 4.5 V.
description
Action of con- q Fixes swing right PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
q Automatic deceleration function and swing holding brake function are not cancelled.
appears on
q Poor operability of swing RH operation.
machine
Related infor-
q Swing right PPC pressure can be checked with monitoring function. (Code: 09200 Swing right PPC
mation
pressure)

1
P07 Voltage
Defective swing right PPC Between (3) and (1) Power supply 4.5 to 5.5 V
2 pressure sensor Between (2) and (1) Signal 0.5 to 4.5 V
(Internal defect) If voltage is abnormal, replace swing right PPC pressure sensor with
code goes off at this time, swing right PPC pressure sensor is defec-
tive.)
Probable
standard value ness Resistance Max. 1 Ω
in normal con- 3 (Disconnection in wiring or
dition defective contact in connec- Resistance Max. 1 Ω
tor)
P07 (female) (3)
4
cuit) and P07 (female) (2), and chassis ground
Hot short (Short circuit to
ness Voltage Max. 4.5 V
40-303 26 PC200, 200LC-8E0 (Hybrid)

Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality SEN05249-00
Circuit diagram related to swing right PPC pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 27

SEN05249-00 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality

User code Failure code Swing left PPC pressure sensor abnormality
Trouble
― DHSBMA (Pump controller system)
Failure
q Signal voltage of swing left PPC pressure sensor circuit is below 0.5 V or above 4.5 V.
description
Action of con- q Fixes swing left PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
q Automatic decelerator and swing holding brake cannot be reset.
appears on
q Swing left performance lowers.
machine
Related infor-
q Swing left PPC pressure can be checked with monitoring function. (Code: 09200 Swing left PPC
mation
pressure)

1
P03 Voltage
Defective swing left PPC Between (3) and (1) Power supply 4.5 to 5.5 V
2 pressure sensor Between (2) and (1) Signal 0.5 to 4.5 V
(Internal defect) If voltage is abnormal, replace swing left PPC pressure sensor with
code goes off at this time, swing left PPC pressure sensor is defec-
tive.)
Probable
in normal con- 3 (Disconnection in wiring or
dition defective contact in connec- Resistance Max. 1 Ω
tor)
P03 (female) (3)
4
cuit) and P03 (female) (2), and chassis ground
40-303 28 PC200, 200LC-8E0 (Hybrid)

Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality SEN05249-00
Circuit diagram related to swing left PPC pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 29

SEN05249-00 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality

User code Failure code Bucket dump PPC pressure sensor abnormality
Trouble
― DHSDMA (Pump controller system)
Contents of
q Signal voltage of bucket dump PPC pressure sensor circuit is below 0.5 V or above 4.5 V.
trouble
Action of con- q Fixes bucket dump PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
appears on
q Bucket dump performance lowers.
machine
Related infor-
q Bucket dump PPC pressure can be checked with monitoring function. (Code: 07301 Bucket dump
mation
PPC pressure)

Defective 5V sensor power If failure code [DA25KP] is also displayed, carry out troubleshooting
1
P05 Voltage
Defective bucket dump PPC Between (3) and (1) Power supply 4.5 to 5.5 V
2 pressure sensor (Internal Between (2) and (1) Signal 0.5 to 4.5 V
defect) If voltage is abnormal, replace bucket dump PPC pressure sensor
with another PPC pressure sensor and check failure code. (If "E" of
failure code goes off at this time, bucket dump PPC pressure sensor
is defective.)
Probable
in normal condi- 3 (Disconnection in wiring or
tion defective contact in connec- Resistance Max. 1 Ω
tor)
to P05 (female) (3)
4 ness
40-303 30 PC200, 200LC-8E0 (Hybrid)

Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality SEN05249-00
Circuit diagram related to bucket dump PPC pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 31

SEN05249-00 Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Shrt Cir
Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Shrt Cir
User code Failure code Disconnection or short circuit in HYB Arm IN PPC pressure sensor
Trouble
E09 DHV3KZ (Hybrid system controller)
Related infor- a Since this failure code is related to hybrid system, it is described in "Troubleshooting by failure code
mation (Display of code) (Part 5), Codes related to hybrid system".
40-303 32 PC200, 200LC-8E0 (Hybrid)

Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir SEN05249-00
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir
User code Failure code Disconnection or short circuit in HYB boom LOWER PPC pressure
Trouble sensor
E09 DHV9KZ
(Hybrid system controller)
PC200, 200LC-8E0 (Hybrid) 40-303 33

SEN05249-00 Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir
User code Failure code Disconnection or short circuit in HYB swing RIGHT PPC pressure
Trouble sensor
E09 DHVAKZ
40-303 34 PC200, 200LC-8E0 (Hybrid)

Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir SEN05249-00
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir
User code Failure code Disconnection or short circuit in HYB swing LEFT PPC pressure
Trouble sensor
E09 DHVBKZ
PC200, 200LC-8E0 (Hybrid) 40-303 35

SEN05249-00 Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir
User code Failure code Disconnection or short circuit in HYB Arm OUT PPC pressure sen-
Trouble sor
E09 DHVCKZ
40-303 36 PC200, 200LC-8E0 (Hybrid)

Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 37

SEN05249-00 Failure code [DW43KA] Travel Speed Sol Discon
Failure code [DW43KA] Travel Speed Sol Discon

User code Failure code Travel speed solenoid system disconnection
Trouble
― DW43KA (Pump controller system)
Failure descrip-
q On energizing travel speed shifting solenoid, disconnection was detected in circuit.
tion
Action of con- q None in particular. (Since no current flows, solenoid does not operate.)
Problem that
q Speed is low at High travel speed range (Machine monitor is set to High but actual speed is approx-
appears on
imately Middle).
machine
q Operating condition of travel speed shifting solenoid can be checked with monitoring function.
Related infor-
(Code: 02300 : Solenoid 1)
mation
q Method of reproducing failure code: Start engine, set travel speed to High and Operate travel lever.

Defective travel speed shift-
1 ing solenoid (Internal discon-
V04 (male) Resistance
nection)
Between (1) and (2) 20 to 60 Ω
causes and ness
standard value 2 (Disconnection in wiring or Resistance Max. 1 Ω
and V04 (female) (1)
in normal con- defective contact in connec-
Wiring harness between C02 (female) and
dition tor) Resistance Max. 1 Ω
(115), (117), (120) and V04 (female) (2)
3 Defective pump controller C01 (female) Resistance
Between (87) and (115), (117),
20 to 60 Ω
(120)
40-303 38 PC200, 200LC-8E0 (Hybrid)

Failure code [DW43KA] Travel Speed Sol Discon SEN05249-00
Circuit diagram related to travel speed shifting solenoid
PC200, 200LC-8E0 (Hybrid) 40-303 39

SEN05249-00 Failure code [DW43KB] Travel Speed Sol Short
Failure code [DW43KB] Travel Speed Sol Short

User code Failure code Travel speed solenoid system short
Trouble
― DW43KB (Pump controller system)
Failure descrip-
q On energizing travel speed shifting solenoid, short circuit was detected in circuit.
tion
q Cuts output to travel speed shifting solenoid OFF.
Action of con-
troller
position.
Problem that
q Speed is low at High travel speed range (Machine monitor is set to High but actual speed is approx-
appears on
imately Middle).
machine
q Operating condition of travel speed shifting solenoid can be checked with monitoring function.
Related infor-
mation
q Method of reproducing failure code: Start engine, set travel speed to High and Operate travel lever.

Defective travel speed shift-
1 ing solenoid (Internal discon-
nection)
Min. 1 MΩ
ground
Probable
standard value 2 ness
in normal con- (Short circuit to GND circuit) Resistance Min. 1 MΩ
and V04 (female) (1), and chassis ground
dition a Prepare with starting switch OFF, then perform troubleshooting
3 Defective pump controller Between (87) and (115), (117),
20 to 60 Ω
(120)
Min. 1 MΩ
ground
40-303 40 PC200, 200LC-8E0 (Hybrid)

Failure code [DW43KB] Travel Speed Sol Short SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 41

SEN05249-00 Failure code [DW45KA] Swing Brake Sol. Valve Open Cir
Failure code [DW45KA] Swing Brake Sol. Valve Open Cir
User code Failure code Disconnection of swing brake solenoid system

Trouble
E09 DW45KA (Hybrid system controller)
40-303 42 PC200, 200LC-8E0 (Hybrid)

Failure code [DW45KB] Swing Brake Sol. Valve Short Cir SEN05249-00
Failure code [DW45KB] Swing Brake Sol. Valve Short Cir
User code Failure code Swing Brake Sol Short

Trouble
E09 DW45KB (Hybrid system controller)
PC200, 200LC-8E0 (Hybrid) 40-303 43

SEN05249-00 Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir
User code Failure code Short circuit in swing brake solenoid valve power supply line
Trouble
E09 DW45KY (Hybrid system controller)
40-303 44 PC200, 200LC-8E0 (Hybrid)

Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 45

SEN05249-00 Failure code [DW91KA] Travel Junction Sol Discon
Failure code [DW91KA] Travel Junction Sol Discon

User code Failure code Travel junction solenoid system disconnection
Trouble
― DW91KA (Pump controller system)
Failure descrip-
q When output was made to travel junction solenoid, disconnection was detected in circuit.
tion
Problem that
appears on q Machine is not steered easily during travel.
machine
q Operating condition of travel junction solenoid can be checked with monitoring function.
Related infor-
mation
q Method of reproducing failure code: Start engine and steer machine with right and left travel levers.

Defective travel junction
1 solenoid
(Internal disconnection)
causes and ness
Wiring harness between C02 (female)
(110) and V05 (female) (1)
(115), (117), (120) and V05 (female) (2)
Between (110) and (115), (117),
20 to 60 Ω
(120)
40-303 46 PC200, 200LC-8E0 (Hybrid)

Failure code [DW91KA] Travel Junction Sol Discon SEN05249-00
Circuit diagram related to travel junction solenoid
PC200, 200LC-8E0 (Hybrid) 40-303 47

SEN05249-00 Failure code [DW91KB] Travel Junction Sol Short
Failure code [DW91KB] Travel Junction Sol Short

User code Failure code Travel junction solenoid system short circuit
Trouble
― DW91KB (Pump controller system)
Failure descrip-
q When output was made to travel junction solenoid, short circuit was detected in circuit.
tion
q Cuts output to travel junction solenoid OFF.
Action of con-
troller
position.
Problem that
appears on q Machine is not steered easily during travel.
machine
q Operating condition of travel junction solenoid can be checked with monitoring function.
Related infor-
mation
q Method of reproducing failure code: Start engine and steer machine with right and left travel levers.

Defective travel junction without turning starting switch to ON position.
solenoid V05 (male) Resistance
1
(Internal short circuit or Between (1) and (2) 20 to 60 Ω
ground fault) Between (1) and chassis
Min. 1 MΩ
ground
causes and Ground fault in wiring har- without turning starting switch to ON position.
standard value 2 ness Wiring harness between C02 (female)
in normal condi- (Short circuit to GND circuit) (110) and V05 (female) (1), and chassis Resistance Min. 1 MΩ
tion ground
20 to 60 Ω
(120)
Min. 1 MΩ
ground
40-303 48 PC200, 200LC-8E0 (Hybrid)

Failure code [DW91KB] Travel Junction Sol Short SEN05249-00
Circuit diagram related to travel junction solenoid
PC200, 200LC-8E0 (Hybrid) 40-303 49

SEN05249-00 Failure code [DWK0KA] 2-stage Relief Sol Discon
Failure code [DWK0KA] 2-stage Relief Sol Discon

User code Failure code 2-stage relief solenoid system disconnection
Trouble
― DWK0KA (Pump controller system)
Failure
q When output to 2–stage relief solenoid was cut OFF, disconnection was detected in circuit.
description
Problem that
q Power one-Touch power maximizing function does not work.
appears on
q Travel power is low.
machine
q Operating condition of 2–stage relief solenoid can be checked with monitoring function.
Related infor- (Code: 02300 : Solenoid 1)
mation q Method of reproducing failure code: Turn starting switch to ON position and set machine in mode
other than (L).

Defective 2–stage relief sole- without turning starting switch to ON position.
1
noid (Internal disconnection) V02 (male) Resistance
causes and ness
(109) and V02 (female) (1)
(115), (117), (120 and V02 (female) (2)
Between (109) to (115), (117),
20 to 60 Ω
(120)
40-303 50 PC200, 200LC-8E0 (Hybrid)

Failure code [DWK0KA] 2-stage Relief Sol Discon SEN05249-00
Circuit diagram related to 2-stage relief solenoid
PC200, 200LC-8E0 (Hybrid) 40-303 51

SEN05249-00 Failure code [DWK0KB] 2-stage Relief Sol Short
Failure code [DWK0KB] 2-stage Relief Sol Short

User code Failure code 2-stage relief solenoid system short circuit
Trouble
— DWK0KB (Pump controller system)
Failure
q When output was made to 2-stage relief solenoid, short circuit was detected in circuit.
description
q Cuts output to 2-stage relief solenoid OFF.
Action of con-
troller
position.
Problem that
q One-touch power maximizing function does not work.
appears on
q Travel power is low.
machine
q Operating condition of 2–stage relief solenoid can be checked with monitoring function.
Related infor- (Code: 02300 : Solenoid 1)
mation q Method of reproducing failure code: Turn starting switch to ON position and set machine in working
mode (L).

Defective 2-stage relief sole- without turning starting switch to ON position.
1 noid(Internal short circuit or V02 (male) Resistance
ground fault) Between (1) and (2) 20 to 60 Ω
Between (1) and chassis ground Min. 1 MΩ
Probable
causes and
2 ness Wiring harness between C02 (female)
standard value
(Short circuit to GND circuit) (109) and V02 (female) (1), and chassis Resistance Min. 1 MΩ
in normal con-
ground
dition
20 to 60 Ω
(120)
Min. 1 MΩ
ground
40-303 52 PC200, 200LC-8E0 (Hybrid)

Failure code [DWK0KB] 2-stage Relief Sol Short SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 53

SEN05249-00
©2009 KOMATSU
All Rights Reserved
40-303 54
SEN05250-01
SEN05250-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
Failure code [DXA8KA] PC-EPC (F) Sol Discon......................................................................................... 2

Failure code [DXA8KB] PC-EPC (F) Sol Short ........................................................................................... 4
Failure code [DXA9KA] PC-EPC (R) Sol Discon ........................................................................................ 6
Failure code [DXA9KB] PC-EPC (R) Sol Short........................................................................................... 8
Failure code [DXE0KA] LS-EPC Sol Discon ............................................................................................... 10
Failure code [DXE0KB] LS-EPC Sol Short ................................................................................................. 12
Failure code [DXE5KA] Merge-divider Main Sol Discon ............................................................................. 14
Failure code [DXE5KB] Merge-divider Main Sol Short ............................................................................... 16
Failure code [DXE6KA] Merge-divider LS Sol Discon ................................................................................ 18
Failure code [DXE6KB] Merge-divider LS Sol Short................................................................................... 20
Failure code [DY20KA] Wiper Working Abnormality ................................................................................... 22
Failure code [DY20MA] Wiper Parking Abnormality ................................................................................... 24
Failure code [DY2CKA] Washer Drive Discon ............................................................................................ 26
Failure code [DY2CKB] Washer Drive Short............................................................................................... 28
Failure code [DY2DKB] Wiper Drive (For) Short......................................................................................... 30
Failure code [DY2EKB] Wiper Drive (Rev) Short ........................................................................................ 32
PC200, 200LC-8E0 (Hybrid) 40-304 1

SEN05250-01 Failure code [DXA8KA] PC-EPC (F) Sol Discon
Failure code [DXA8KA] PC-EPC (F) Sol Discon

User code Failure code PC-EPC (F) solenoid system disconnection
Trouble
E02 DXA8KA (Pump controller system)
Failure
q On energizing PC-EPC (F) solenoid, disconnection was detected in circuit.
description
Problem that
appears on q If pump load increases, engine speed lowers largely and engine may stall.
machine
q 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-
1 noid
Between (1) to (2) 7 to 14
Emergency pump
Defective emergency pump S25 (male) Resistance
drive switch
2 drive switch (Internal discon-
Normal Max. 1
nection) Between (3) and (2)
Emergency Min. 1 M
Normal Max. 1
Probable Between (6) and (5)
Emergency Min. 1 M
causes and
standard
value in nor- Wiring harness between C02 (female) (96) Resis-
mal condition Disconnection in wiring har- Max. 1
and S25 (female) (3) tance
ness
Wiring harness between S25 (female) (2) and Resis-
3 (Disconnection in wiring or Max. 1
V11 (female) (1) tance
Wiring harness between C02 (female) (115), Resis-
tor) Max. 1
(117), (120) and S25 (female) (6) tance
Max. 1
V11 (female) (2) tance
Between (96) and (115), (117),
7 to 14
(120)
40-304 2 PC200, 200LC-8E0 (Hybrid)

Failure code [DXA8KA] PC-EPC (F) Sol Discon SEN05250-01
Circuit diagram related to PC-EPC (F) solenoid and PC-EPC (R) solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 3

SEN05250-01 Failure code [DXA8KB] PC-EPC (F) Sol Short
Failure code [DXA8KB] PC-EPC (F) Sol Short

User code Failure code PC-EPC (F) solenoid system short
Trouble
E02 DXA8KB (Pump controller system)
Failure
q On energizing PC-EPC (F) solenoid, short circuit was detected in circuit.
description
q Cuts output to PC-EPC (F) solenoid OFF.
Action of con-
troller
position.
Problem that
machine
q 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-
noid
1 V11 (male) Resistance
(Internal short circuit or
Between (1) and (2) 7 to 14
ground fault)
Between (1) and chassis ground Min. 1 M
Emergency pump
drive switch
2 drive switch (Internal short
Between (2), (3) and
circuit or ground fault) Min. 1 M
(4)
Normal
Probable Between (2), (3) and
Min. 1 M
dition Between wiring harness between C02
(female) (96) and S25 (female) (3) and Resistance Min. 1 M
3 ness
chassis ground
(Contact to ground circuit)
Between wiring harness between S25
(female) (5) and V11 (female) (2) and chas- Resistance Min. 1 M
sis ground
7 to 14
(120)
Min. 1 M
ground
40-304 4 PC200, 200LC-8E0 (Hybrid)

Failure code [DXA8KB] PC-EPC (F) Sol Short SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 5

SEN05250-01 Failure code [DXA9KA] PC-EPC (R) Sol Discon
Failure code [DXA9KA] PC-EPC (R) Sol Discon

User code Failure code PC-EPC (R) solenoid system disconnection
Trouble
E02 DXA9KA (Pump controller system)
Failure
q On energizing PC-EPC (R) solenoid, disconnection was detected in circuit.
description
Problem that
machine
q 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-
1 noid
Emergency pump
drive switch
2 drive switch (Internal discon-
Normal Max.1
nection) Between (9) and (8)
Emergency Min. 1 M
Between (12) and Normal Max.1
Probable
(11) Emergency Min. 1 M
causes and
standard
value in nor-
mal condition Disconnection in wiring har- Resistance Max.1
and S25 (female) (9)
ness
Wiring harness between S25 (female) (8)
3 (Disconnection in wiring or Resistance Max.1
tor) Resistance Max.1
(115), (117), (120) and S25 (female) (12)
Wiring harness between S25 (female) (11)
Resistance Max.1
Between (104) and (115), (117),
7 to 14
(120)
40-304 6 PC200, 200LC-8E0 (Hybrid)

Failure code [DXA9KA] PC-EPC (R) Sol Discon SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 7

SEN05250-01 Failure code [DXA9KB] PC-EPC (R) Sol Short
Failure code [DXA9KB] PC-EPC (R) Sol Short

User code Failure code PC-EPC (R) solenoid system short circuit
Trouble
E02 DXA9KB (Pump controller system)
Failure
q On energizing PC-EPC (R) solenoid, short circuit was detected in circuit.
description
Action of con- q Cuts output to PC-EPC (R) solenoid OFF.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
machine
q 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-
noid
1 V12 (male) Resistance
(Internal short circuit or
ground fault)
Emergency pump
drive switch
2 drive switch (Internal short
Between (8), (9) and
circuit or ground fault) Min. 1 M
(10)
Normal
Probable Between (8), (9) and
Min. 1 M
(female) (104) and S25 (female) (9), and Resistance Min. 1 M
3 ness
chassis ground
(Contact to GND circuit)
Between wiring harness between S25
(female) (8) and V12 (female) (1), and Resistance Min. 1 M
chassis ground
7 to 14
(120)
Min. 1 M
ground
40-304 8 PC200, 200LC-8E0 (Hybrid)

Failure code [DXA9KB] PC-EPC (R) Sol Short SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 9

SEN05250-01 Failure code [DXE0KA] LS-EPC Sol Discon
Failure code [DXE0KA] LS-EPC Sol Discon

User code Failure code LS-EPC solenoid system disconnection
Trouble
— DXE0KA (Pump controller system)
Failure
q On energizing LS-EPC solenoid, disconnection was detected in circuit.
description
Action of q None in particular. (Since no current flows, solenoid does not operate.)
controller q If cause of failure disappears, system resets itself.
Problem that
appears on q Travel speed is high at Lo and Mi.
machine
q 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 to ON position.
1
(Internal disconnection) V19 (male) Resistance
causes and ness
standard 2 (Disconnection in wiring or Resistance Max.1
value in nor- defective contact in connec-
Wiring harness between C02 (female) (115),
mal condition tor) Resistance Max.1
(117), (120) and V19 (female) (2)
Between (88) and (115), (117),
7 to 14
(120)
40-304 10 PC200, 200LC-8E0 (Hybrid)

Failure code [DXE0KA] LS-EPC Sol Discon SEN05250-01
Circuit diagram related to LS-EPC solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 11

SEN05250-01 Failure code [DXE0KB] LS-EPC Sol Short
Failure code [DXE0KB] LS-EPC Sol Short

User code Failure code LS-EPC solenoid system short circuit
Trouble
— DXE0KB (Pump controller system)
Failure
q On energizing LS-EPC solenoid, short circuit was detected in circuit.
description
q Cuts output to LS-EPC solenoid OFF.
Action of con-
troller
position.
Problem that
q Travel speed is high at Lo and Mi.
appears on
q Work equipment speed and swing speed are high in economy mode (E).
machine
q 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 to ON position.
1 (Internal short circuit or V19 (male) Resistance
ground fault) Between (1) and (2) 7 to 14
Probable
causes and
standard value
(Short circuit to GND circuit) (female) (88) and V19 (female) (1), and Resistance Min. 1 M
in normal con-
chassis ground
dition
7 to 14
(120)
Min. 1 M
ground
40-304 12 PC200, 200LC-8E0 (Hybrid)

Failure code [DXE0KB] LS-EPC Sol Short SEN05250-01
Circuit diagram related to LS-EPC solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 13

SEN05250-01 Failure code [DXE5KA] Merge-divider Main Sol Discon
Failure code [DXE5KA] Merge-divider Main Sol Discon

User code Failure code Merge-divider main solenoid disconnection
Trouble
Failure
q On energizing merge-divider main EPC solenoid, disconnection was detected in circuit.
description
Problem that
appears on q Single operation speed of work equipment and swing is high in economy mode (E).
machine
q 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
1 main EPC solenoid (Internal
open circuit)
causes and ness
standard value 2 (Disconnection in wiring or Max.1
and V23 (female) (1) tance
dition tor) Max.1
(117), (120) and V23 (female) (2) tance
Between (112) and (115), (117),
7 to 14
(120)
40-304 14 PC200, 200LC-8E0 (Hybrid)

Failure code [DXE5KA] Merge-divider Main Sol Discon SEN05250-01
Circuit diagram related to merge-divider main EPC solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 15

SEN05250-01 Failure code [DXE5KB] Merge-divider Main Sol Short
Failure code [DXE5KB] Merge-divider Main Sol Short

User code Failure code Merge-divider main solenoid short circuit
Trouble
Failure
q On energizing merge-divider main EPC solenoid, short circuit was detected in circuit.
description
q Cuts output to merge-divider main EPC solenoid OFF.
Action of con-
troller
position.
Problem that
machine
q 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 without turning starting switch to ON position.
1 main EPC solenoid (Internal V23 (male) Resistance
short circuit or ground fault) Between (1) and (2) 7 to 14
Probable
causes and
standard value
(Short circuit to GND circuit) (female) (112) and V23 (female) (1), and Resistance Min. 1 M
in normal con-
chassis ground
dition
7 to 14
(120)
Min. 1 M
ground
40-304 16 PC200, 200LC-8E0 (Hybrid)

Failure code [DXE5KB] Merge-divider Main Sol Short SEN05250-01
Circuit diagram related to merge-divider main EPC solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 17

SEN05250-01 Failure code [DXE6KA] Merge-divider LS Sol Discon
Failure code [DXE6KA] Merge-divider LS Sol Discon

User code Failure code Merge-divider LS solenoid disconnection
Trouble
Failure
q On energizing merge-divider LS EPC solenoid, disconnection was detected in circuit.
description
Action of con- q None in particular (Since no current flows, solenoid does not operate).
Problem that
machine
q 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
1 EPC solenoid (Internal open
circuit)
causes and ness
standard value 2 (Disconnection in wiring or Max. 1
dition tor) Max. 1
(117), (120) and V24 (female) (2) tance
Between (89) and (115), (117),
7 to 14
(120)
40-304 18 PC200, 200LC-8E0 (Hybrid)

Failure code [DXE6KA] Merge-divider LS Sol Discon SEN05250-01
Circuit diagram related to merge-divider LS EPC solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 19

SEN05250-01 Failure code [DXE6KB] Merge-divider LS Sol Short
Failure code [DXE6KB] Merge-divider LS Sol Short

User code Failure code Merge-divider LS solenoid short circuit
Trouble
Failure
q On energizing merge-divider LS EPC solenoid, short circuit was detected in circuit.
description
q Cuts output to merge-divider LS EPC solenoid OFF.
Action of con-
troller
position.
Problem that
machine
q 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 without turning starting switch to ON position.
1 EPC solenoid (Internal short V24 (male) Resistance
circuit or ground fault) Between (1) and (2) 7 to 14
causes and Ground fault in wiring har- without turning starting switch to ON position.
standard 2 ness Between Wiring harness between C02
Resis-
value in nor- (Short circuit to GND circuit) (female) (89) and V24 (female) (1), and Min. 1 M
tance
mal condition chassis ground
Between (89) and (115), (117),
7 to 14
(120)
40-304 20 PC200, 200LC-8E0 (Hybrid)

Failure code [DXE6KB] Merge-divider LS Sol Short SEN05250-01
Circuit diagram related to merge-divider LS EPC solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 21

SEN05250-01 Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20KA] Wiper Working Abnormality

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

M05 (female) Wiper blade Resistance
Defective wiper motor Both ends of operat-
1 Max. 1
(Internal disconnection) ing range
Between (6) and (5)
Other than both ends
Min. 1 M
of operating range
Between (1) and (3) Whole range Max. 20
without turning starting switch to ON position .
Probable Disconnection in wiring har- Resistance Max. 1
and M05 (male) (6)
causes and ness
Wiring harness in M05 (female) (5) to J04 to
standard 2 (Disconnection in wiring or Resistance Max. 1
chassis ground (T05, T06)
value in nor- defective contact in connec-
mal condition tor) Resistance Max. 1
and M05 (male) (1)
Resistance Max. 1
– M05 (male) (3)
C01 (female) Wiper blade Resistance
Both ends of operat-
Max. 1
3 Defective pump controller Between (56) and ing range
chassis ground Other than both ends
Min. 1 M
of operating range
Between (114) and
Whole range Max. 20
(119)
40-304 22 PC200, 200LC-8E0 (Hybrid)

Failure code [DY20KA] Wiper Working Abnormality SEN05250-01
Circuit diagram related to windshield wiper and window washer
PC200, 200LC-8E0 (Hybrid) 40-304 23

SEN05250-01 Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY20MA] Wiper Parking Abnormality

User code Failure code Wiper resting abnormality
Trouble
— DY20MA (Pump controller system)
Failure
q When windshield wiper rests, P signal for rest area is not input.
description
Action of con- q Cuts output for resting to wiper motor OFF.
Problem that
appears on q Wiper motor does not rest.
machine
q Condition of P contact signal of wiper resting area can be checked with monitoring function.
Related infor- (Code:: 02204 switch 5)
mation q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to
INT/ON .

Defective wiper motor M05 (female) Wiper blade Resistance
1
(Internal disconnection) Storage area Max. 1
Between (4) and (5)
Working area Min. 1 M
Between (1) and (3) Whole range Max. 20
Probable Disconnection in wiring har- Resistance Max. 1
and M05 (male) (4)
causes and ness
Wiring harness in M05 (female) (5) to J04 to
standard value 2 (Disconnection in wiring or Resistance Max. 1
chassis ground (T05, T06)
Wiring harness between C02( (female)
dition tor) Resistance Max. 1
(114) and M05 (male) (1)
Resistance Max. 1
and M05 (male) (3)
C01 (female) Wiper blade Resistance
3 Defective pump controller Between (75) and Storage area Max. 1
chassis ground Working area Min. 1 M
Between (114) and
Whole range Max. 20
(119)
40-304 24 PC200, 200LC-8E0 (Hybrid)

Failure code [DY20MA] Wiper Parking Abnormality SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 25

SEN05250-01 Failure code [DY2CKA] Washer Drive Discon
Failure code [DY2CKA] Washer Drive Discon

User code Failure code Window washer drive system disconnection
Trouble
— DY2CKA (Pump controller system)
Failure q When output to window washer drive system was cut OFF (when ground circuit was cut off), discon-
description nection was detected in circuit.
Action of con- q None in particular (Since no current flows, washer motor does not operate).
Problem that
appears on q 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 disconnection or
ground fault)
Between (1), (2) and chassis
Min. 1 M
ground
Defective diode array D02 without turning starting switch to ON position.
3
(Internal short circuit) D02 (female) Continuity (Resistance)
Between (3) and (7) No continuity (Min.1 M )
causes and ness
Wiring harness in F01(4) to J03 to M06
standard value 4 (Disconnection in wiring or Resistance Max. 1
(female) (1)
dition tor) Resistance Max. 1
M06 (female) (2)
Between wiring harnesses in F01 (4) to J03
to M06 (female) (1), or D02 (female) (3), Resistance Min. 1 M
5 ness
and chassis ground
(Short circuit to GND circuit)
Between wiring harnesses in C01 (female)
(3) to J04 to M06 (female) (2), or D02 Resistance Min. 1 M
(female) (7), and chassis ground
C01 (female) Voltage
Between (3) and chassis ground 20 to 30 V
40-304 26 PC200, 200LC-8E0 (Hybrid)

Failure code [DY2CKA] Washer Drive Discon SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 27

SEN05250-01 Failure code [DY2CKB] Washer Drive Short
Failure code [DY2CKB] Washer Drive Short

User code Failure code Window washer drive system short circuit
Trouble
— DY2CKB (Pump controller system)
Failure q When output to window washer drive system was made (ground circuit was connected), short circuit
description was detected in circuit.
q Cuts output to washer motor OFF.
Action of con-
troller
position.
Problem that
appears on q Window washer does not operate.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and turn washer switch to ON
mation position.

a Prepare with starting switch OFF, and perform troubleshooting
Defective washer motor
M06 (male) Resistance
ground fault)
Between (1), (2) and chassis
Min. 1 MΩ
ground
3
(Internal short circuit) D02 (female) Continuity (Resistance)
Between (3) and (7) No continuity (Min. 1 MΩ)
ness
Wiring harness in F01 (4) to J03 to M06
Possible 4 (Disconnection in wiring or Resistance Max. 1 Ω
(female) (1)
causes and defective contact in connec-
standard tor) Resistance Max. 1 Ω
M06 (female) (2)
value in nor- a Prepare with starting switch OFF, then turn starting switch to ON
mal condition Hot short (Short circuit with
5 24 V circuit) in wiring har-
Wiring harness in C01(3) to M06 (2), to D02
ness Voltage Max. 1 V
Wiring harness in F01 (4) to J03 to M06
(female) (1), or D02 (female) (3) and chassis Resistance Min. 1 Ω
6 ness
ground
(Short circuit to GND circuit)
M06 (female) (2) , or D02(female) (7) and Resistance Min. 1 Ω
chassis ground
C01(female) Voltage
Between (3) and chassis ground 20 to 30 V
40-304 28 PC200, 200LC-8E0 (Hybrid)

Failure code [DY2CKB] Washer Drive Short SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 29

SEN05250-01 Failure code [DY2DKB] Wiper Drive (For) Short
Failure code [DY2DKB] Wiper Drive (For) Short

User code Failure code Wiper motor drive forward system short circult
Trouble
— DY2DKB (Pump controller system)
Failure
q When output to wiper motor drive forward side was made, short circuit was detected in circuit.
description
q Cuts output to wiper motor drive forward side OFF.
Action of con-
troller
position.
Problem that
appears on q Windshield wiper does not operate.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT or
mation ON.

Defective wiper motor without turning starting switch to ON position.
1 (Internal short circuit or M05 (female) Resistance
Probable ground fault) Between (3) and (1) Continuity
causes and Between (3) and chassis ground Min. 1 M
value in nor- Ground fault in wiring har- without turning starting switch to ON position.
mal condition 2 ness Between wiring harness between C02
(Short circuit to GND circuit) (female) (119) and M05 (male) (3), and Resistance Min. 1 M
chassis ground
If causes 1 and 2 are not detected, pump controller may be defective.
40-304 30 PC200, 200LC-8E0 (Hybrid)

Failure code [DY2DKB] Wiper Drive (For) Short SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 31

SEN05250-01 Failure code [DY2EKB] Wiper Drive (Rev) Short
Failure code [DY2EKB] Wiper Drive (Rev) Short

User code Failure code Wiper motor drive reverse system short circuit
Trouble
— DY2EKB (Pump controller system)
Failure
q When output to wiper motor drive reverse side was made, short circuit was detected in circuit.
description
Action of con- q Cuts output to wiper motor drive reverse side OFF.
Problem that
appears on q Windshield wiper does not operate.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and and set wiper switch to
mation INT or ON.

Defective wiper motor
M05 (female) Continuity/Resistance
1 (Internal short circuit or
Between (1) and (3) Continuity
Probable ground fault)
causes and Min. 1 M
ground
standard value
in normal con-
2 ness
(Short circuit to GND circuit) (female) (114) and M05 (male) (1), and Resistance Min. 1 M
chassis ground
If causes 1 and 2 are not detected, pump controller may be defective.
40-304 32 PC200, 200LC-8E0 (Hybrid)

Failure code [DY2EKB] Wiper Drive (Rev) Short SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 33

SEN05250-01
© 2010 KOMATSU
All Rights Reserved
40-304 34
SEN05251-03
SEN05251-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
Precautions related to hybrid machines...................................................................................................... 4

Common troubleshooting of hybrid components and high voltage wiring (high voltage section)................ 9
Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Short Cir ........................................................... 24
Failure code [DHV9KZ] HYB boom Lower PPC Pr. Sen. Opn/Shrt Cir....................................................... 26
Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt........................................................... 28
Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen Opn/Short Cir. ............................................................ 31
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/Short Cir. ...................................................... 34
Failure code [DW45KA] Swing Brake Sol. Valve Open Cir. ........................................................................ 36
Failure code [DW45KB] Swing Brake Sol. Valve Short Cir. ........................................................................ 40
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir. .................................................................. 42
Failure code [GA01KA] Power Cable Interlock Open Circuit ...................................................................... 44
Failure code [GA02KZ] DC Line Open/Short Circuit................................................................................... 46
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster ................................................................ 47
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster ................................................................ 48
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster .................................................................. 49
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster .............................................................. 50
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster .................................................................. 51
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster .................................................................. 52
Failure code [GA09KP] Low DC SW Output Volt. After Booster ................................................................. 53
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster................................................................. 54
PC200, 200LC-8E0 (Hybrid) 40-305 1

SEN05251-03
Failure code [GA0BKZ] AC Line Open/Short Circuit................................................................................... 55

Failure code [GA11KK] HYB Cont. Low Supply Voltage ............................................................................. 56
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure............................................................................. 59
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON ................................................................... 60
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF.................................................................. 61
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure................................................................. 62
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure ................................................................ 64
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir ............................................................ 67
Failure code [GA16KK] Low HYB Cont. VDD Suppl. Volt. .......................................................................... 68
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure ................................................................. 69
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit .................................................................. 70
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit ................................................................... 71
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded ....................................................................... 72
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure ................................................................. 73
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt ................................................................ 74
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure......................................................... 75
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. .......................................................... 76
Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction ................................................................... 76
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation ......................................................... 78
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled ............................................................... 79
Failure code [GA1AKZ] Gen. Mot. Dr. Temp. Sens. Opn/Short Cir. ............................................................ 80
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction .............................................................. 81
Failure code [GA1DMA] Gen. Motro Driver IPM1 Abnormality ................................................................... 82
Failure code [GA1EMA] Gen. Motor Driver IPM 2 Abnormality .................................................................. 83
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure ............................................................... 84
Failure code [GA1FMA] Abnormal Swing Motor Driver............................................................................... 85
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU .......................................................... 86
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure ........................................................ 87
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal .......................................................... 88
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfuuction .............................................................. 89
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded ........................................................ 90
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op. ................................................................. 91
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled............................................................. 92
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. ........................................................ 93
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir. ......................................................... 94
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir......................................................... 95
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir. ............................................................. 96
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir. ............................................................... 97
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat...................................................................... 98
Failure code [GA1PNV] Swg Mot. Driver IPM Ph-U Not Warm up.............................................................. 99
Failure code [GA1QNV] Swg Mot. Driver IPM Ph-V Not Warm Up............................................................. 100
Failure code [GA1RNV] Swng Mot. Driver IPM Ph-W Not Warm Up .......................................................... 101
Failure code [GA1SFS] Contactor Locked .................................................................................................. 102
Failure code [GA1SMC] Contactor Failure.................................................................................................. 103
Failure code [GA1TKG] Capacitor HVPS Abnormal Voltage ...................................................................... 104
Failure code [GA1TKP] Capacitor Low Output Voltage .............................................................................. 105
Failure code [GA1TNS] Capacitor Overheat............................................................................................... 106
40-305 2 PC200, 200LC-8E0 (Hybrid)

SEN05251-03
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir. ............................................................... 108
Failure code [GA1VFS] Capacitor Contactor Locked.................................................................................. 110
Failure code [GA1VMC] Capacitor Contactor Failure ................................................................................. 112
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. ............................................................. 113
Failure code [GA1YNS] Booster Inductor Overheat ................................................................................... 114
Failure code [GA1YNV] Booster Inductor Not Warming Up........................................................................ 115
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ............................................................ 116
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat ................................................................... 117
Failure code [GA1ZNV] Booster IGBT Temp. Sens. Not Warm Up ............................................................ 118
Failure code [GA21KB] Booster IGBT Short Circuit.................................................................................... 119
Failure code [GA22NS] Booster IGBT Junction Overheat .......................................................................... 120
Failure code [GA60MC] Generator Motor Failure ....................................................................................... 121
Failure code [GA60MD] Gen. Mot. Defective Movement............................................................................ 122
Failure code [GA60N1] Generator Motor Overrun ...................................................................................... 123
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir............................................................... 124
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat............................................................. 126
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir ........................................................... 127
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir............................................................. 128
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction ............................................................ 129
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir. .......................................................... 130
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir............................................................. 131
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction ............................................................ 132
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir. .......................................................... 133
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir............................................................. 134
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction............................................................ 135
Failure code [GA70KB] HYB Swing Motor Short Circuit ............................................................................. 136
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion ............................................................. 137
Failure code [GA70NS] HYB Swing Motor Overheat.................................................................................. 138
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. ......................................................... 139
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction............................................................... 141
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op................................................................. 143
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. ............................................................. 145
PC200, 200LC-8E0 (Hybrid) 40-305 3

SEN05251-03 Precautions related to hybrid machines
ters.

high-voltage wiring, "Discharge procedure for capacitor", or 30-102 Testing and adjusting (Part 2), Special
a See the list on "Separate sheet 1" for the monitoring items applied to the troubleshooting of hybrid system
components.
a See "Separate sheet 2" about the check sheet for recording check results when hybrid system compo-
nents have problems.
(Use this check sheet for making inquiries when you contact the Komatsu plant.)
40-305 4 PC200, 200LC-8E0 (Hybrid)

List of monitoring items applied to troubleshooting of hybrid system components

(Separate sheet 1)
Motor- Swing Unit
Capac- Rem
No. Monitoring item Code gener- Inverter electric Monitoring item •
itor arks
ator motor Range
Swing LEFT PPC pressure
1 09006 mV
sensor 2 voltage
Swing RIGHT PPC pressure
2 09007 mV
sensor 2 voltage
Arm OUT PPC pressure sen-
3 07602 mV
sor 2 voltage
Arm IN PPC pressure sensor
4 07202 mV
2 voltage
5 Direct current in swing motor 09100 A A A
6 DC current, high-voltage side 09200 V V V
7 Capacitor voltage 09300 V
Voltage at booster low-volt-
8 09400 V
age side
9 Capacitor temperature #1 09301 °C
10 Capacitor temperature #2 09302 °C
11 Booster IGBT temperature 09401 °C
12 Booster inductor temperature 09402 °C
INV film capacitor tempera-
13 09800 °C
ture
14 Swing motor coil temperature 09101 °C
Swing inverter U-phase tem-
15 09500 °C
perature
Swing inverter V-phase tem-
16 09501 °C
perature
Swing inverter W-phase tem-
17 09502 °C
perature
18 Motor-generator temperature 09600 °C
Motor-generator driver tem-
19 09601 °C
perature
Swing Inverter JCT Tempera-
20 09503 °C
ture
ON •
HYB travel buzzer
OFF
ON •
Engine stop relay
OFF
Hybrid system controller relay ON •
21 09700 HYB PPC lock
output OFF
HYB swing holding ON •
brake OFF
ON •
HYB starter operation
OFF
22 Motor-generator speed 09602 r/min
23 Motor-generator torque 09603 Nm
24 Motor-generator shaft output 09604 kW
25 Target motor-generator speed 09605 r/min
Target motor-generator
26 09606 Nm
torque
27 Target capacitor voltage 09303 V
28 Swing lever stroke 42103 %
29 Boom lever stroke 42104 %
30 Arm lever stroke 42105 %
31 Bucket lever stroke 42106 %
PC200, 200LC-8E0 (Hybrid) 40-305 5

Motor- Swing Unit

Capac Rem
No. Monitoring item Code gener- Inverter electric Monitoring item •
itor arks
ator motor Range
Motor-generator speed ON •
control OFF
Motor-generator torque ON •
control OFF
Control output of hybrid sys- Motor-generator servo ON •
32 09701
tem controller ON OFF
ON •
Swing motor servo ON
OFF
Low speed matching ON •
ON OFF
Key SW ON •
Hybrid system controller SW (HYB controller) OFF
33 09702
input ON •
Emergency stop input
OFF
34 Swing motor speed 09102 r/min
35 Swing motor torque 09103 Nm
36 Swing motor shaft output 09104 kW
37 Swing motor target speed 09105 r/min
38 Swing motor torque limit 09106 Nm
Insulation degradation sen-
39 09900 mV
sor voltage
Assembly part number
40 20225
Serial number
41 20417
Program part number
42 20256
Program version
43 20257
40-305 6 PC200, 200LC-8E0 (Hybrid)

Check sheet for hybrid system component abnormality

(Separate sheet 2)
Model PC200-8E0 Operation No.
Serial number # Date of testing / /
Engine SAA4D107E-1 Service meter h
Engine serial No. # Operator's name
A. Failure
B. Visual check OK NG
1 Damage of wire and cable

2 Poor connection of connectors
C. Testing on the machine monitor (abnormality record, monitoring) OK NG

3 Checking the error and failure codes
Checking the monitoring information
Testing Mea-
Display item Code condi- Unit Reference value sured OK NG
tions value
Engine speed 01002 r/min 600 – 2,200
Throttle opening 31701 % 0 – 100
DC in swing motor 09100 A ± 400
Capacitor voltage 09300 V 150 – 300
Voltage at booster low-voltage
09400 V 150 – 300
side
Capacitor temperature #1 09301 °C -30 – 65
Capacitor temperature #2 09302 °C -30 – 65
Booster IGBT temperature 09401 °C -30 – 100
Booster inductor temperature 09402 °C -30 – 130
INV film capacitor temperature 09800 °C -30 – 130
Swing motor coil temperature 09101 °C -30 – 160
Swing inverter U-phase tem-
09500 °C -30 – 85
perature
4 Swing inverter V-phase tem- 09501 °C -30 – 85
perature
Swing inverter W-phase tem-
09502 °C -30 – 85
perature
Motor-generator motor tem-
09600 °C -30 – 180
perature
Motor-generator driver tem-
09601 °C -30 – 70
perature
Swing inverter JCT tempera-
09503 °C -30 – 135
ture
Hybrid system controller relay
09700 —
output
Same as engine
Motor-generator speed 09602 r/min
speed
Target motor-generator speed 09605 r/min 600 – 2,500
Target capacitor voltage 09303 V 185 – 298
-100 – 100
Swing lever stroke 42103 % (Zero when lever is
in neutral position)
PC200, 200LC-8E0 (Hybrid) 40-305 7

Mea-
Display item Code Testing conditions Unit Reference value sured OK NG
value
-100 – 100
Boom lever stroke 42104 % (Zero when lever is in
neutral position)
-100 – 100
Arm lever stroke 42105 % (Zero when lever is in
neutral position)
-100 – 100
Bucket lever stroke 42106 % (Zero when lever is in
neutral position)
Control output of hybrid sys-
09701 —
tem controller
Hybrid system controller SW
09702 —
4 input
Swing motor speed 09102 r/min ± 8311
Swing motor target speed 09105 r/min ± 8311
When the key is
turned to the ON
Insulation degradation sen-
09900 position but mV – 4650
sor voltage
before the engine
is started
Assembly part number
20225 — —
Serial number
20417 — 1001 –
Program part number
20256 — 787523R205 –
Program version
20257 — MAIN_080124-R3180 –
40-305 8 PC200, 200LC-8E0 (Hybrid)

Common troubleshooting of hybrid components and high voltage wiring (high voltage section) SEN05251-03
Common troubleshooting of hybrid components and high voltage wiring

(high voltage section)
If it is judged as a result of the troubleshooting that the common troubleshooting of the high voltage section is
necessary, find out the defective portion according to the following procedure.
k Using discharge tool (generator): 796-426-1800, discharge the capacitor in advance.
(For details, see 00-200 Introduction, safety, and basic information, "Handling of hybrid devices and
high-voltage wirings", "Discharge procedure for capacitor" or 30-102 Testing and adjusting (Part 2), Spe-
cial functions of machine monitor, "Discharge of capacitor".)
k After discharging the capacitor, check that both of capacitor charge state LED (3) are turned OFF.
k Even after the capacitor is discharged, 30 V or below charged voltage is still remained in it. Accordingly,
do not work with empty hands. Be sure to insulate your hands before working.
a If HB01 (capacitor portion) is removed, cover the removed connectors (wiring harness and capacitor)
with vinyl sheets etc. to seal from foreign matter.
a Stop the engine before performing troubleshooting.
a Do not apply the tester probes directly to the connectors on the capacitor unit side (female side of HB01)
PC200, 200LC-8E0 (Hybrid) 40-305 9

SEN05251-03 Common troubleshooting of hybrid components and high voltage wiring (high voltage section)
Flow chart of common troubleshooting of high voltage sections
40-305 10 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-305 11

40-305 12 PC200, 200LC-8E0 (Hybrid)

q If the high voltage section seems to be defective as a result of the troubleshooting by failure code,
disconnect the power cable from each component and perform troubleshooting steps 1 – 7 on the
following page.
High voltage components, power cables, and layout drawing of connector
1. Capacitor case
2. Inverter case
3. Capacitor charge state LED
1)Both ON: Outputting high voltage
2)Only right ON: Being charged at high voltage
3)Both OFF: Charge voltage 30 V or below
PC200, 200LC-8E0 (Hybrid) 40-305 13

1. Troubleshooting of capacitor
If the capacitor seems to be defective as a result of the troubleshooting by failure code, perform the following
troubleshooting.

1. Turn starting switch to OFF position.
2. Disconnect power cable connector HC06 of inverter.
(Keep connector HB01 on capacitor side connected)
a Wipe off dirt from capacitor case.
a If measured value does not stabilize, read value 1 minute after.
a It is desirable to measure with a insulation resistance tester.
Probable Between HC06 (DC+) (male) (red of tester)
causes and Deteriorated insulation of Resistance Min. 10 M
1 and capacitor case (black of tester)
standard capacitor system
value under Between HC06 (DC+) (male) (black of
Resistance Min. 10 M
normal tester) and capacitor case (red of tester)
conditions Between HC06 (DC-) (male) (red of tester)
and capacitor case (black of tester)
Between HC06 (DC-) (male) (black of
tester) and capacitor case (red of tester)
If cause 1 is not detected, another high voltage section may be defective.
Then, perform troubleshooting of another high voltage section that seems to be defective.
If abnormality is detected, perform 5. Troubleshooting of capacitor power cable. If result is normal,
replace capacitor.
2.Troubleshooting of electric swing motor
If the electric swing motor seems to be defective as a result of the troubleshooting by failure code, perform the following
troubleshooting.

2. Disconnect power cable connector HC05 of inverter.
a Swing motor has motor coil resistance.
Phase disconnection in Between HC05 (U) (male) and HC05 (V)
Resistance Max. 10
1 electric swing motor (male)
system Between HC05 (V) (male) and HC05 (W)
Resistance Max. 10
(male)
Between HC05 (W) (male) and HC05 (U)
Resistance Max. 10
(male)
Probable
causes and 1. Turn starting switch to OFF position.
standard 2. Disconnect power cable connector HC05 of inverter and power cable
value under connector HB01 of capacitor.
normal a Wipe off dirt from inverter case.
conditions Deteriorated insulation of a If measured value does not stabilize, read value 1 minute after.
2 electric swing motor a It is desirable to measure with a insulation resistance tester.
system a Measurement of only 1 phase of U, V, and W is enough.
Between HC05 (U) (male) (red of tester)
and inverter case (ground) (black of tester)
Between HC05 (U) (male) (black of tester)
and inverter case (ground) (red of tester)
If causes 1 and 2 are not detected, another high voltage section may be defective.
If abnormality is detected, perform 6. Troubleshooting of electric swing motor power cable. If result is
normal, replace electric swing motor.
40-305 14 PC200, 200LC-8E0 (Hybrid)

Circuit diagram related to high voltage
PC200, 200LC-8E0 (Hybrid) 40-305 15

3. Troubleshooting of motor-generator
If the motor-generator seems to be defective as a result of the troubleshooting by failure code, perform the following
troubleshooting.

2. Disconnect power cable connectors HC03 and HC04 of inverter.
a Motor-generator has motor coil resistance.
Between HC03 (A1) (male) and HC04 (A2)
Phase disconnection in Resistance Max. 10
1 (male)
motor-generator system
Between HC03 (B1) (male) and HC04 (B2)
Resistance Max. 10
(male)
Between HC03 (C1) (male) and HC04 (C2)
Resistance Max. 10
(male)
2. Disconnect power cable connectors HC03 and HC04 of inverter.
a Measurement of either of connectors HC03 and HC04 is enough.
Between HC03 (A1) (male) and HC03 (B1)
Phase short circuit in Resistance Min. 10 M
2 (male)
motor-generator system
Between HC03 (B1) (male) and HC03 (C1)
(male)
Between HC03 (C1) (male) and HC03 (A1)
(male)
Probable 1. Turn starting switch to OFF position.
causes and
2. Disconnect power cable connectors HC03 and HC04 of inverter
standard value
and power cable connector HB01 of capacitor.
under normal
a Wipe off dirt from inverter case.
conditions
a Measurement of either of connectors HC03 and HC04 is enough.
Between HC03 (A1) (male) (red of tester)
Deteriorated insulation of Between HC03 (A1) (male) (black of tester)
3 Resistance Min. 10 M
motor-generator system and inverter case (ground) (red of tester)
Between HC03 (B1) (male) (red of tester)
Between HC03 (B1) (male) (black of tester)
Between HC03 (C1) (male) (red of tester)
Between HC03 (C1) (male) (black of tester)
If causes 1 – 3 are not detected, another high voltage section may be defective.
If abnormality is detected, perform 7. Troubleshooting of motor-generator power cable. If result is
normal, replace electric motor-generator.
40-305 16 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-305 17

4. Troubleshooting of inverter
If the inverter seems to be defective as a result of the troubleshooting by failure code, perform the following
troubleshooting.

2. Disconnect power cable connectors HC03 – HC06 of inverter and
power cable connector HB01 of capacitor.
a Wipe off dirt from inverter case.
Probable
causes and Between HC06 (DC+) (female) (red of
Deteriorated insulation of Resistance Min. 10 M
standard 1 tester) and inverter case (black of tester)
inverter
value under Between HC06 ((DC+) (female) (black of
normal tester) and inverter case (red of tester)
conditions
Between HC06 (DC-) (female) (red of tester)
and inverter case (black of tester)
Between HC06 (DC-) (female) (black of
tester) and inverter case (red of tester)
If cause 1 is not detected, another high voltage section may be defective.
If there is any abnormality, replace inverter.
5. Troubleshooting of capacitor power cable

If the capacitor power cable seems to be defective as a result of the troubleshooting by failure code, perform the following
troubleshooting.

2. Disconnect power cable connector HC06 of inverter and power cable
connector HB01 of capacitor.
Disconnection in power
1 Between HC06 (DC+) (male) and HB01
cable Resistance Max. 1
(DC+) (male)
Between HC06 (DC-) (male) and HB01
Resistance Max. 1
(DC-) (male)
Probable 2. Disconnect power cable connector HC06 of inverter and power cable
Internal short circuit of
causes and 2 connector HB01 of capacitor.
power cable
standard Between HC06 (DC+) (male) and HC06
value under (DC-) (male)
normal 1. Turn starting switch to OFF position.
conditions 2. Disconnect power cable connector HC06 of inverter and power cable
connector HB01 of capacitor.
a Wipe off dirt from metallic portions of cable housing.
Deteriorated insulation of a If measured value does not stabilize, read value 1 minute after.
3 a It is desirable to measure with a insulation resistance tester.
power cable
Between HC06 (DC+) (male) and metallic
portion of cable housing (part P)
Between HC06 (DC-) (male) and metallic
portion of cable housing (part P)
If any of causes 1 – 3 is detected, replace capacitor power cable.
40-305 18 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-305 19

6. Troubleshooting of electric swing motor power cable

If the electric swing motor power cable seems to be defective as a result of the troubleshooting by failure code, perform
the following troubleshooting.
*: To "keep connector HB01 on capacitor side disconnected" is to leave connector HB01 as it is if it has been
disconnected.

2. Disconnect power cable connector HC05 of inverter and power
cable connector PM02 of electric swing motor.
(Keep connector HB01 on capacitor side disconnected)*
Disconnection in power Between HC05 (U) (male) and PM02 (U)
1 Resistance Max. 1
cable (male)
Between HC05 (V) (male) and PM02 (V)
Resistance Max. 1
(male)
Between HC05 (W) (male) and PM02 (W)
Resistance Max. 1
(male)
cable connector PM02 of swing motor.
Probable causes Internal short circuit of Between HC05 (U) (male) and HC05 (V)
and standard power cable (male)
value under Between HC05 (V) (male) and HC05 (W)
normal (male)
conditions Between HC05 (W) (male) and HC05 (U)
(male)
cable connector PM02 of electric swing motor.
Deteriorated insulation a It is desirable to measure with a insulation resistance tester.
3
of power cable Between HC05 (U) (male) and metallic part
of cable housing (part P)
Between HC05 (V) (male) and metallic part
Between HC05 (W) (male) and metallic part
If any of causes 1 – 3 is detected, replace swing motor power cable.
40-305 20 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-305 21

7. Troubleshooting of motor-generator power cable
If the motor-generator power cable seems to be defective as a result of the troubleshooting by failure code, perform the
following troubleshooting.
*: To "keep connector HB01 on capacitor side disconnected" means to leave connector HB01 as it is if it has been
disconnected.

2. Disconnect power cable connectors HC03 and HC04 of inverter and
power cable connectors GM02 and GM03 of motor-generator.
Between HC03 (A1) (male) and GM02 (A1) (male) Resistance Max. 1
Disconnection in Between HC03 (B1) (male) and GM02 (B1) (male) Resistance Max. 1
1
power cable
Between HC03 (C1) (male) and GM02 (C1) (male) Resistance Max. 1
Between HC04 (A2) (male) and GM03 (A2) (male) Resistance Max. 1
Between HC04 (B2) (male) and GM03 (B2) (male) Resistance Max. 1
Between HC04 (C2) (male) and GM03 (C2) (male) Resistance Max. 1
Between HC03 (A1) (male) and HC03 (B2) (male) Resistance Min. 10 M
Internal short
2 circuit of power Between HC03 (B1) (male) and HC03 (C1) (male) Resistance Min. 10 M
cable
Between HC03 (C1) (male) and HC03 (A1) (male) Resistance Min. 10 M
Probable
causes and Between HC04 (A2) (male) and HC04 (B2) (male) Resistance Min. 10 M
standard value Between HC04 (B2) (male) and HC04 (C2) (male) Resistance Min. 10 M
under normal
conditions Between HC04 (C2) (male) and HC04 (A2) (male) Resistance Min. 10 M
Between HC03 (A1) (male) (red of tester) and
metallic portion of cable housing (part P)
Deteriorated
Between HC03 (B1) (male) (red of tester) and
3 insulation of power Resistance Min. 10 M
metallic portion of cable housing (part p)
cable
Between HC03 (C1) (male) (red of tester) and
Between HC04 (A2) (male) (black of tester) and
Between HC04 (B2) (male) (red of tester) and
Between HC04 (C2) (male) (black of tester) and
If any of causes 1 – 3 is detected, replace related motor-generator power cable
40-305 22 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-305 23

SEN05251-03 Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Short Cir
Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Short Cir
User code Failure code Open or short circuit in HYB Arm IN PPC pressure sensor
Failure
E09 DHV3KZ (Hybrid controller system)
Detail of failure q Signal voltage of HYB Arm IN PPC pressure sensor circuit is below 0.3 V or above 4.7 V.
q Controls system by setting Arm IN PPC pressure at 0 MPa {0 kg/cm2}.
Action of con- q Inoperative low speed matching
position.
Problem on
q Disabled low speed matching
machine
Related infor-
q Stroke of Arm IN PPC pressure sensor can be checked with monitoring function.
mation
(Code: 42105 Arm lever stroke)

Defective sensor power sup-
1 If error code [GA13MC] is displayed, troubleshoot it first.
ply system
a Prepare by setting starting switch to OFF position, then start en-
gine and troubleshoot.
HP05 Voltage
Defective Arm OUT PPC Power
Between (3) and (1) 4.5 - 5.5 V
2 pressure sensor supply
(Internal defect) Between (2) and (1) Signal 0.5 - 4.5 V
If the voltage is abnormal, replace the PPC pressure sensor with
another one and make a judgment based on the failure code. (If fail-
ure code "E" goes off, arm OUT PPC pressure sensor is defective.)
Probable shoot without turning starting switch to ON position.
causes and Open circuit in wiring har- Wiring harness between HC02 (female) (31) Resis-
Max. 1
standard value ness and HP05 (female) (3) tance
3
under normal (Open circuit or defective Wiring harness between HC02 (female) (34) Resis-
Max. 1
conditions contact in connector) and HP05 (female) (2) tance
Wiring harness between HC02 (female) (62) Resis-
Max. 1
and HP05 (female) (1) tance
Ground fault in wiring har- shoot without turning starting switch to ON position.
4 ness Between wiring harness (between HC02
Resis-
(Contact with ground circuit) (female) (34) and HP05 (female) (2)) and Min. 1 M
tance
ground
Hot short in wiring harness
5 Between wiring harness (between HC02
(Contact with 24V circuit)
(female) (34) and HP05 (female) (2)) and Voltage Max. 1 V
ground
If causes 1 - 5 are not detected, the hybrid system controller may be
Defective inverter (Hybrid
6 defective (Since trouble exists in system, troubleshooting cannot be
system controller)
performed.)
40-305 24 PC200, 200LC-8E0 (Hybrid)

Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Short Cir SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 25

SEN05251-03 Failure code [DHV9KZ] HYB boom Lower PPC Pr. Sen. Opn/Shrt Cir
Failure code [DHV9KZ] HYB boom Lower PPC Pr. Sen. Opn/Shrt Cir
User code Failure code Open or short circuit in HYB boom LOWER PPC pressure sensor
Failure
E09 DHV9KZ (Hybrid controller system)
Detail of failure q Signal voltage of HYB boom LOWER PPC pressure sensor circuit is below 0.3 V or above 4.7 V.
q Controls system by setting boom LOWER PPC pressure at 0 MPa {0 kg/cm2}.
Action of con- q Inoperative low speed matching
troller q Inoperative hoist matching function
position.
Problem on
q Disabled low speed matching and hoist matching
machine
Related infor-
q Stroke of boom LOWER PPC pressure sensor can be checked with monitoring function.
mation
(Code: 42104 boom lever stroke)

ply system
HP07 Voltage
Power
Defective boom LOWER Between (3) and (1) 4.5 – 5.5 V
supply
2 PPC pressure sensor
(Internal defect) Between (2) and (1) Signal 0.5 – 4.5 V
ure code "E" goes off, boom Lower PPC pressure sensor is defec-
tive.)
standard value Max. 1
ness and HP07 (female) (3) tance
under normal 3
(Open circuit or defective Wiring harness between HC02 (female) (53) Resis-
conditions Max. 1
contact in connector) and HP07 (female) (2) tance
Max. 1
Resis-
tance
ground
(Contact with 24 V circuit)
ground
If causes 1 – 5 are not detected, the hybrid system controller may be
6 defective (Since trouble exists in system, troubleshooting cannot be
system controller)
performed.)
40-305 26 PC200, 200LC-8E0 (Hybrid)

Failure code [DHV9KZ] HYB boom Lower PPC Pr. Sen. Opn/Shrt Cir SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 27

SEN05251-03 Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt.
Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt.
User code Failure code Open or short circuit in HYB swing RIGHT PPC pressure sensor
Failure
E09 DHVAKZ (Hybrid controller system)
q Signal voltage of swing RIGHT PPC pressure sensor for hybrid system is below 0.3 V or above 4.7 V.
q When control lock lever is shifted down, swing RIGHT PPC hydraulic pressure sensor is 0.5 MPa {5
kg/cm2} or swing RIGHT PPC pressure sensor for hybrid system is 0.5 MPa {5 kg/cm2} and generator
Detail of failure
speed is 500 rpm or more.
q When generator speed is 500 rpm or more, pressure of hybrid swing right PPC pressure sensor is
0.5 MPa {5 kg/cm2} or more higher than pressure of swing PPC right pressure sensor 1.
2
Action of con- q Controls system by setting swing RIGHT PPC pressure at 0 MPa {0 kg/cm }.
q Even if cause of failure disappears,system does not reset itself until starting switch is turned to OFF
troller
position.
q Swinging stops suddenly during right swinging motion. Continues swinging during left swinging mo-
Problem on
tion. After stopping, machine cannot swing to the right.
machine
q Operator cannot control the swinging motion.
a If pressure sensor 5 V circuit (3) and ground circuit (1) are connected reversely, sensor will be broken.
Accordingly, take extreme care when checking.
q Voltage of swing right PPC pressure sensor can be checked with monitoring function.
Related infor-
(Code: 09007 Swing right PPC pressure sensor 2 voltage)
mation
q This failure code may be displayed when communication with pump controller has abnormality. Ac-
cordingly, if [DA2RMC] or [GA14KR] is also displayed, perform troubleshooting for it first.
Cause Standard value in normal condition/ Remarks on troubleshooting

Defective sensor power If error code [DA25KP], [GA13MC] or [GA14KR] is displayed, trouble-
1
supply system shoot it first.
a Prepare by setting starting switch to OFF position ,then start engine
and troubleshoot.
P03 Voltage
Defective swing RIGHT Power
Between (3) and (1) 4.5 – 5.5 V
2 PPC pressure sensor supply
If the voltage is abnormal , replace the PPC pressure sensor with
another one and make a judgment based on the failure code.(If failure
code "E" goes off, swing RIGHT PPC pressure sensor is defective.)
a Prepare by setting starting switch to OFF position ,and troubleshoot
Open circuit in wiring har- Wiring harness between C01 (female) (18)
Resistance Max. 1
Probable ness and P07(female) (1)
3
cause and (Open circuit or defective Wiring harness between C01 (female) (72)
Resistance Max. 1
standard value contact in connector) and P07 (female) (2)
under normal Wiring harness between C01 (female) (9),
Resistance Max. 1
conditions and P07(female) (3) via J06
a Prepare by setting starting switch to OFF position ,and troubleshoot
ness
4 Between wiring harness (between C01
(Contact with ground cir-
(female) (72) and P07 (female) (2) and Resistance Min. 1 M
cuit )
ground
a Prepare by setting starting switch to OFF position ,then turn starting
switch to ON position.
(female) (72) and P07 (female) (2) and Voltage Max. 1 V
ground
When any of causes 1 – 5 is not detected, even if right swing operation
is not performed, if 09002 Swing right PPC pressure displayed by
6 Defective pump controller monitoring function exceeds 0.5 MPa {5 kg/cm2}, pump controller may
be defective. (Since trouble is in system, troubleshooting cannot be
performed.)
40-305 28 PC200, 200LC-8E0 (Hybrid)

Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt. SEN05251-03
Cause Standard value in normal condition/ Remarks on troubleshooting

a Prepare by setting starting switch to OFF position ,then start en-
gine and troubleshoot..
HP06 Voltage
Power sup-
Defective swing RIGHT Between (3) and (1) 4.5 – 5.5 V
ply
7 PPC pressure sensor
Between (2) and (1) Signal 0.5 – 4.5 V
(Internal defect)
If the voltage is abnormal , replace the PPC pressure sensor with
another one and make a judgment based on the failure code.(If fail-
ure code "E" goes off, swing RIGHT PPC pressure sensor is defec-
tive.)
a Prepare by setting starting switch to OFF position ,and trouble-
Open circuit in wiring har- Wiring harness between HC02 (female) (31) Resis-
Max. 1
8
Max. 1
Max. 1
a Prepare by setting starting switch to OFF position ,and trouble-
Ground fault of wiring har-
ness
(Contact with ground cir- Resis-
(female) (33) and HP06 (female) (2)) and Min. 1 M
cuit ) tance
ground
a Prepare by setting starting switch to OFF position ,then turn start-
Probable
ground
cause and
standard value
under normal
Wiring harness between H16 (female) (7) and Resis-
conditions Max. 1
Disconnection in wiring har- HR06 (female) (1) tance
ness (Disconnection in wir- Wiring harness between HR06 (female) (2) and Resis-
11 Max. 1
ing or defective contact in HC01 (female) (13) tance
connector) Wiring harness between HC02 (female) (37) Resis-
Max. 1
and HR06 (female) (5) tance
Wiring harness between HR06 (female) (3) and Resis-
Max. 1
HC01 (female) (13) tance
Between wiring harness H16 (female) (7) – Resis-
12 ness (contact with ground Min. 1 M
HR06 (female) (1) and ground tance
circuit)
Between wiring harness HC02 (female) (37) – Resis-
Min. 1 M
Defective PPC pressure
without turning starting switch to ON position (troubleshooting of
lock sensing relay (internal
13 unit).
disconnection or short cir-
HR06 (male) Resistance
cuit)
Between (1) and (2) 300 - 600
Defective PPC pressure Terminal PPC lock lever position Voltage
14 lock sensing relay (defec- Between HC02 (37)
Lock Min. 10 V
tive internal contact) and HC01 (13)
Between HC02 (37)
Released (operation side) Max. 2 V
and HC01 (13)
If causes 7– 14 are not detected, the hybrid system controller may be
15 defective (Since trouble exists in system ,troubleshooting cannot be
system controller)
performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 29

SEN05251-03 Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt.
40-305 30 PC200, 200LC-8E0 (Hybrid)

Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen Opn/Short Cir. SEN05251-03
Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen Opn/Short Cir.
User code Failure code Open or short circuit in HYB swing LEFT PPC pressure sensor
Failure
E09 DHVBKZ (Hybrid controller system)
q Signal voltage of swing LEFT PPC pressure sensor for hybrid system is below 0.3 V or above 4.7 V.
q When control lock lever is shifted down, swing LEFT PPC hydraulic pressure sensor is 0.5 MPa {5
kg/cm2} or swing LEFT PPC pressure sensor for hybrid system is 0.5 MPa {5 kg/cm2} and generator
Detail of failure
speed is 500 rpm or more.
q When generator speed is 500 rpm or more, pressure of hybrid swing right PPC pressure sensor is
0.5 MPa {5 kg/cm2} or more higher than pressure of swing PPC right pressure sensor 1.
2
Action of con- q Controls system by setting swing LEFT PPC pressure at 0 MPa {0 kg/cm }.
troller
position.
q Swinging stops suddenly during left swinging motion. Continues swinging during left swinging mo-
Problem on
tion. After stopping, machine cannot swing to the left.
machine
q Operator cannot control the swinging motion.
a If pressure sensor 5V circuit (3) and ground circuit (1) are connected reversely, sensor will be broken.
Accordingly, take extreme care when checking.
q Voltage of swing left PPC pressure sensor can be checked with monitoring function.
Related infor-
(Code: 09006 Swing left PPC pressure sensor 2 voltage)
mation
q This failure code may be displayed when communication with pump controller has abnormality. Ac-
cordingly, if [DA2RMC] or [GA14KR] is also displayed, perform troubleshooting for it first.

Defective sensor power sup- If error code [DA25KP], [GA13MC] or [GA14KR] is displayed, trou-
1
ply system bleshoot it first.
a Prepare by setting starting switch to OFF position, then start engi-
en and troubleshoot.
P03 Voltage
Power
Defective swing LEFT PPC Between (3) and (1) 4.5 – 5.5 V
supply
2 pressure sensor
(Internal defect)
ure code "E" goes off, swing LEFT PPC pressure sensor is defec-
tive.)
Disconnection in wiring har- Wiring harness between C02 (female) (18) Resis-
Probable Max. 1
ness and P03 (female) (1) tance
causes and 3
(Disconnection or defective Wiring harness between C02 (female) (16) Resis-
standard value Max. 1
contact in connector) and P03 (female) (2) tance
under normal Wiring harness between C02 (female) (9), Resis-
conditions Max. 1
J06 and P03 (female) (3) tance
4 ness Between wiring harness (between C01
Resis-
(Contact with ground circuit) (female) (16) and P03 (female) (2)) and Min. 1 M
tance
ground
(female) (16) and P03 (female) (2)) and Voltage Max. 1 V
ground
When any of causes 1 – 5 is not detected, even if left swing opera-
tion is not performed, if 09001 swing left PPC pressure displayed by
6 Defective pump controller monitoring function exceeds 0.5 MPa {5 kg/cm2}, pump controller
may be defective. (Since trouble is in system, troubleshooting can-
not be performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 31

SEN05251-03 Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen Opn/Short Cir.

HP04 Voltage
Power
Defective swing LEFT PPC Between (3) and (1) 4.5 – 5.5 V
supply
7 pressure sensor
(Internal defect)
ure code "E" goes off, swing LEFT PPC pressure sensor is defec-
tive.)
Max. 1
8
Max. 1
Max. 1
Ground fault of wiring har- shoot without turning starting switch to ON position.
Resis-
tance
ground
(female) (43) and HP04 (female) (2)) and Voltage Max. 1V
Probable ground
causes and a Prepare with starting switch OFF, then turn starting switch to ON
standard value position and perform troubleshooting.
under normal Wiring harness between H16 (female) (7) and Resis-
Max. 1
conditions Disconnection in wiring har- HR06 (female) (1) tance
ness (Disconnection in wiring Wiring harness between HR06 (female) (2) Resis-
11 Max. 1
or defective contact in con- and HC01 (female) (13) tance
nector) Wiring harness between HC02 (female) (37) Resis-
Max. 1
and HR06 (female) (5) tance
Wiring harness between HR06 (female) (3) Resis-
Max. 1
and HC01 (female) (13) tance
Between wiring harness H16 (female) (7) – Resis-
12 ness (contact with ground Min. 1 M
circuit)
Between wiring harness HC02 (female) (37) Resis-
Min. 1 M
– HR06 (female) (5) and ground tance
Defective PPC pressure lock without turning starting switch to ON position (troubleshooting of
13 sensing relay (internal dis- unit).
connection or short circuit) HR06 (male) Resistance
Between (1) and (2) 300 - 600
PPC lock lever posi-
Defective PPC pressure lock Terminal Voltage
tion
14 sensing relay (defective
Between HC02 (37)
internal contact) Lock Min. 10 V
and HC01 (13)
Between HC02 (37) Released (operation
Max. 2 V
and HC01 (13) side)
If causes 7 – 14 are not detected, the hybrid system controller may
15 be defective (Since trouble exists in system, troubleshooting cannot
system controller)
be performed.)
40-305 32 PC200, 200LC-8E0 (Hybrid)

Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen Opn/Short Cir. SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 33

SEN05251-03 Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/Short Cir.
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/Short Cir.
User code Failure code Open or short circuit in HYB Arm OUT PPC pressure sensor
Failure
E09 DHVCKZ (Hybrid controller system)
Detail of failure q Signal voltage of HYB Arm OUT PPC pressure sensor circuit is below 0.3 V or above 4.7 V.
q Controls the system by setting Arm OUT PPC pressure at 0 MPa {0 kg/cm2}.
Action of con- q Low speed matching function does not operate.
position.
Problem on
q Disabled low speed matching
machine
will break. Accordingly, exercise extreme care when checking.
Related infor-
q Stroke of Arm OUT PPC pressure sensor can be checked with monitoring function.
mation
(Code: 42105 Arm lever stroke)

ply system
HP03 Voltage
Defective Arm OUT PPC Power
Between (3) and (1) 4.5 – 5.5 V
2 pressure sensor supply
ure code "E" goes off, Arm OUT PPC pressure sensor is defective.)
Max. 1
standard value ness and HP03 (female) (3) tance
3
under normal (Open circuit or defective Wiring harness between HC02 (female) (34) Resis-
Max. 1
conditions contact in connector) and HP03 (female) (2) tance
Max. 1
Resis-
tance
ground
ground
If causes 1 - 5 are not detected, the hybrid system controller may be
6 defective (Since a trouble exists in the system, troubleshooting can-
system controller)
not be performed.)
40-305 34 PC200, 200LC-8E0 (Hybrid)

Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/Short Cir. SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 35

SEN05251-03 Failure code [DW45KA] Swing Brake Sol. Valve Open Cir.
Failure code [DW45KA] Swing Brake Sol. Valve Open Cir.
User code Failure code Swing holding brake solenoid system open circuit
Failure
E09 DW45KA (Hybrid controller system)
Detail of failure q Open circuit was detected when output to swing holding brake solenoid is turned to OFF.
q Turns output to break solenoid to OFF.
Action of con-
troller
position.
Problem on
q Machine cannot swing upper structure (Swing holding brake cannot be reset).
machine
q If solenoid valve system and wiring harness are normal, machine can swing if turning the swing hold-
ing break release switch to RELEASE position. (However, swing holding brake does not operate
when machine is stopped).
Related infor- q During troubleshooting, turn swing lock switch to OFF position, and turn swing holding brake release
mation switch to RELEASE position.
q The operating condition of swing holding brake solenoid can be checked with monitoring function.
(Code: 09700 Hybrid system controller relay output)

Defective swing holding
1 brake solenoid
Between (1) and (2) 20 – 60
Defective diode array D01 shoot without turning starting switch to ON position.
2
Probable (Internal disconnection) D01 (male) Digital circuit tester Continuity
Between (7) and (3) Diode mode Continuity
causes and
standard value
under normal Defective swing lock switch
3 S04 (male) Swing lock switch Continuity
conditions (Internal disconnection)
OFF Max. 1
Between (3) and (4)
ON Min. 1 M
Defective emergency stop
Emergency stop
4 switch HS01 (Ring terminal) Continuity
switch
OFF Max. 1
ON Min. 1 M
40-305 36 PC200, 200LC-8E0 (Hybrid)

Failure code [DW45KA] Swing Brake Sol. Valve Open Cir. SEN05251-03

Max. 1
and D01 (female) (7) tance
Wiring harness between D01 (female) (3) and Resis-
Max. 1
S04 (female) (3) via J02 tance
Max. 1
Open circuit in wiring har- HH12 (female) (1) tance
Probable
ness Wiring harness between HH12 (male) (1) and Resis-
causes and 5 Max. 1
(Open circuit or defective HS01 (22) tance
standard value
contact in connector) Wiring harness between HS01 (21) and Resis-
under normal Max. 1
HH12 (male) (2) tance
conditions
Wiring harness between HH12 (female) (2) Resis-
Max. 1
Wiring harness between V03 (female) (2) and Resis-
Max. 1
C02 (female) (120) tance
Wiring harness between C01 (female) (3) and Resis-
Max. 1
T04 tance
Defective inverter (Hybrid If causes 1 – 5 are not detected, the hybrid system controller may be
6 system controller) defective (Since a trouble exists in the system, troubleshooting can-
not be performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 37

SEN05251-03 Failure code [DW45KA] Swing Brake Sol. Valve Open Cir.
40-305 38 PC200, 200LC-8E0 (Hybrid)

Failure code [DW45KA] Swing Brake Sol. Valve Open Cir. SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 39

SEN05251-03 Failure code [DW45KB] Swing Brake Sol. Valve Short Cir.
Failure code [DW45KB] Swing Brake Sol. Valve Short Cir.
User code Failure code Short circuit in swing holding brake solenoid system
Failure
(Hybrid controller system)
E09 DW45KB
Detail of failure q Short circuit is detected when output to swing holding brake solenoid is turned to ON.
Action of con-
troller
position.
Problem on
machine
q If solenoid valve system and wiring harness are normal, machine can swing if turning the swing
break release switch to RELEASE position. (However, swing holding brake does not operate when
machine is stopped).
Related infor-
q Turn swing lock switch to OFF position during troubleshooting.
mation
q The operating condition of swing holding brake solenoid can be checked with monitoring function.
(Code 09700: Hybrid system controller relay output)
q Method of reproducing failure code: Turn starting switch to ON position

1 If failure code [GA13MC] is displayed, troubleshoot it first.
ply system
Defective swing holding shoot without turning starting switch to ON position.
2 brake solenoid (Internal short V03 (male) Resistance
circuit or ground fault) Between (1) and (2) 20 – 60
Probable Between (1) and ground Min. 1 M
causes and a Prepare by setting starting switch to OFF position, and trouble-
standard value shoot without turning starting switch to ON position.
under normal Between wiring harness (between HC01
conditions Resis-
Ground fault wiring harness (female) (8) and D01 (female) (7)) and Min. 1 M
3 tance
(Contact with ground circuit) ground
Between wiring harness (between HC01
Resis-
(female) (8) and V03 (female) (1) via J02) Min. 1 M
tance
and ground
4 be defective (Since a trouble exists in the system, troubleshooting
system controller)
cannot be performed.)
40-305 40 PC200, 200LC-8E0 (Hybrid)

Failure code [DW45KB] Swing Brake Sol. Valve Short Cir. SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 41

SEN05251-03 Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir.
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir.
User code Failure code Short circuit in swing holding brake solenoid valve power line
Failure
E09 DW45KY
Detail of failure q Short circuit is detected when output to swing holding brake solenoid is turned to ON.
Action of con-
troller
OFF position.
Problem on
machine
q If solenoid valve system and wiring harness are normal, machine can swing if turning the swing
holding break release switch to RELEASE position. (However, swing holding brake does not oper-
ate when machine is stopped).
Related infor-
q Turn swing lock switch to OFF position during troubleshooting.
mation
q The operating condition of swing brake solenoid can be checked with monitoring function.
(Code: 09700 Hybrid system controller relay output)

ply system
a Prepare by setting starting switch to OFF position, then turn
Probable starting switch to ON position and troubleshoot.
causes and Between wiring harness (between HC01
standard value Hot short in wiring harness (female) (8) and D01 (female) (7)) and Voltage Max. 1 V
2
under normal (Contact with 24 V circuit) ground
conditions Between wiring harness (between
D01(female) (3) and V03 (female) (1) via Voltage Max. 1 V
J02) and ground
Defective inverter (Hybrid If causes 1 – 2 are not detected, the hybrid system controller may
3 system controller) be defective (Since a trouble exists in the system, troubleshooting
40-305 42 PC200, 200LC-8E0 (Hybrid)

Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir. SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 43

SEN05251-03 Failure code [GA01KA] Power Cable Interlock Open Circuit
Failure code [GA01KA] Power Cable Interlock Open Circuit
User code Failure code Open circuit in power cable interlock circuit
Failure
E09 GA01KA (Hybrid controller system)
q Power cable connectors that connects inverter, motor-generator, capacitor and swing electric motor
Detail of fail- has open circuit.
ure q The cover is removed from the power cable connector of the inverter, generator motor or swing motor.
q Power cable connector is connected upside down.
q Stops swing motor and motor generator control, then turns swing holding brake ON.
Action of con-
troller
position.
Problem on
q Machine cannot swing upper structure.
machine
Related infor-
q If failure code [GA1VFS] is displayed at the same time, the power cable connector HC06 may not be
mation
fitted securely.

Disconnected power cable
1 a Visually check that the power cable connector is disconnected.
connector
Defective fit or failure of
2 Visually check that the power cable connector is fitted securely.
power cable connector
Removed cover from Visually check that cover of connecting part of power cable is mounted
3
power cable connector normally.
Visually check that the mark on power cable connector is on the same
Improper connection of
4 side of the mark on the component to be connected. (See part (a) in the
following figure.)
a Prepare by setting starting switch to OFF position, and troubleshoot
Open circuit in wiring har- without turning starting switch to ON position.
Probable 5 ness (Internal disconnec- a Connect all power cable connectors and troubleshoot.
causes and tion) Wiring harness between HC02 (female) (38) and Resis-
standard Max. 1
value under a Prepare by setting starting switch to OFF position, and troubleshoot
normal condi- without turning starting switch to ON position.
tions Wiring harness between HC02 (female) (38) and Resis-
Open circuit in wiring har- Max. 1
PM01 (female) (10) tance
6 ness
Wiring harness between PM01 (female) (9) and Resis-
(Internal disconnection) Max. 1
GM01 (female) (8) tance
Wiring harness between GM 01 (female) (7) and Resis-
Max. 1
Ground fault in wiring har- Between wiring harness (between HC02 (female) Resis-
Min. 1 M
ness (38) and PM01 (female) (10)) and ground tance
7
(Contact with ground cir- Between wiring harness (between PM01 (female) Resis-
Min. 1 M
cuit) (9) and GM01 (female) (8)) and ground tance
Between wiring harness (between GM01 (female) Resis-
Min. 1 M
(7) and HC02 (female) (48)) and ground tance
40-305 44 PC200, 200LC-8E0 (Hybrid)

Failure code [GA01KA] Power Cable Interlock Open Circuit SEN05251-03

a Prepare by setting starting switch to OFF position, then turn starting
switch to ON position and troubleshoot.
Between wiring harness (between HC02 (female)
Voltage Max. 1 V
Hot short in wiring harness (38) and PM01 (female) (10)) and ground
8
(Contact with 24V circuit) Between wiring harness (between PM01 (female)
Voltage Max. 1 V
(9) and GM01 (female) (8)) and ground
Between wiring harness (between GM01 (female)
Voltage Max. 1 V
Probable (7) and HC02 (female) (48)) and ground
causes and a Prepare by setting starting switch to OFF position, and troubleshoot
standard Open circuit in wiring of without turning starting switch to ON position.
value under 9 motor-generator a Connect all power cable connectors and troubleshoot.
normal condi- (Internal disconnection) Wiring harness between GM 01 (male) (7) and Resis-
tions Max. 1
GM01 (male) (8) tance
Open circuit in wiring of without turning starting switch to ON position.
10 swing motor a Connect all power cable connectors and troubleshoot.
(Internal disconnection) Wiring harness between PM 01 (male) (9) and Resis-
Max. 1
PM01 (male) (10) tance
If causes 1 – 10 are not detected, the hybrid system controller may be
11 defective (Since a trouble exists in the system, troubleshooting cannot
system controller)
be performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 45

SEN05251-03 Failure code [GA02KZ] DC Line Open/Short Circuit
Failure code [GA02KZ] DC Line Open/Short Circuit
User code Failure code Open or short circuit in DC line

Failure
E09 GA02KZ (Hybrid controller system)
Detail of failure q The insulation of cable connecting capacitor and inverter has deteriorated.
q Stops swing motor and motor-generator control, then turns swing holding brake ON.
Action of con-
troller
OFF position.
Problem on q Machine cannot swing upper structure.
machine q Engine speed increases to speed indicated by throttle.
Related infor-
mation

Probable
causes and Defective insulation between
standard value 1 hybrid system components q Visually check that cable is not damaged.
under normal and chassis ground
conditions Defective high voltage sec-
2 Perform high-voltage section common troubleshooting 1 – 7.
tion of hybrid component
40-305 46 PC200, 200LC-8E0 (Hybrid)

Failure code [GA04KG] Abnormal DC HW Volt. Before Booster SEN05251-03
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster
User code Failure code HW source voltage high error in direct current line before boosting
Failure
E09 GA04KG (Hybrid controller system)
Detail of failure q 390 V or higher capacitor voltage is detected by the hardware.

Action of con-
troller
OFF position.
q Capacitor voltage can be checked with monitoring function.
Related infor-
(Code: 09300 Capacitor voltage)
mation

Probable
causes and 1 Defective capacitor Perform high-voltage section common troubleshooting 1.
standard value Defective capacitor power
2 Perform high-voltage section common troubleshooting 5.
under normal cable
conditions Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be
3
system controller) performed.
PC200, 200LC-8E0 (Hybrid) 40-305 47

SEN05251-03 Failure code [GA05KG] Abnormal DC SW Volt. Before Booster
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster
User code Failure code SW source voltage high error in direct current line before boosting
Failure
Detail of failure q 340 V or higher capacitor voltage is detected by the hardware.

Action of con-
troller
position.
Related infor-
mation

Probable
under normal cable
3
40-305 48 PC200, 200LC-8E0 (Hybrid)

Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster SEN05251-03
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster
User code Failure code SW output voltage low error in direct current line before boosting
Failure
E09 GA05KP (Hybrid controller system)
Detail of failure q The 100 V or lower capacitor voltage is detected by the software.
Action of con-
troller
OFF position.
Related infor-
(Code 09300: Capacitor voltage)
mation

Probable
under normal cable
3
PC200, 200LC-8E0 (Hybrid) 40-305 49

SEN05251-03 Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster
User code Failure code Open or short circuit in voltage sensor in direct current line before
Failure boosting
Detail of failure q Abnormality of capacitor voltage sensor in the inverter is detected.
Action of con-
troller
OFF position.
Related infor-
mation
causes and
standard value Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be
under normal 1
conditions
40-305 50 PC200, 200LC-8E0 (Hybrid)

Failure code [GA08KG] Abnormal. DC HW Volt. After Booster SEN05251-03
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster
User code Failure code HW source voltage high error in direct current line after boosting
Failure
Detail of failure q Overvoltage abnormality of power train Is detected by the hardware.

Action of con-
troller
OFF position.
q Voltage of power train can be checked with monitoring function.
Related infor-
(Code: 09200 DC voltage of power train)
mation

Check if swing emergency stop switch was operated in normal
Operation of swing emer- state.
1 gency stop switch If it was operated, turn it to OFF position and turn starting switch to
Probable
(when system is normal) ON position. If failure code is not displayed and abnormal phenom-
causes and
enon does not occur, machine can be operated as it is.
standard value
under normal 2 Defective motor-generator
conditions 3 Defective swing motor
Defective inverter (Hybrid Perform high-voltage section common troubleshooting 1 – 7.
4
system controller)
5 Defective capacitor
PC200, 200LC-8E0 (Hybrid) 40-305 51

SEN05251-03 Failure code [GA09KG] Abnormal. DC SW Volt. After Booster
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster
User code Failure code SW source voltage high error in direct current line after boosting
Failure
Detail of failure q Overvoltage abnormality of power train is detected by the hardware.

Action of con-
troller
OFF position.
Related infor-
mation

1 gency stop switch (when If it was operated, turn it to OFF position and turn starting switch to
Probable
system is normal) ON position. If failure code is not displayed and abnormal phenom-
causes and
enon does not occur, machine can be operated as it is.
standard value
under normal 2 Defective motor-generator
conditions 3 Defective swing motor
Defective inverter (Hybrid Perform high-voltage section common troubleshooting 1 – 7.
4
system controller)
40-305 52 PC200, 200LC-8E0 (Hybrid)

Failure code [GA09KP] Low DC SW Output Volt. After Booster SEN05251-03
Failure code [GA09KP] Low DC SW Output Volt. After Booster
User code Failure code SW output voltage low error in direct current line after boosting
Failure
E09 GA09KP (Hybrid controller system)
Detail of failure q Overvoltage abnormality of power train is detected by the hardware.

Action of con-
troller
OFF position.
Related infor-
mation
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 53

SEN05251-03 Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster
User code Failure code Open or short circuit in voltage sensor in direct current line before
Failure boosting
E09 GA0AKZ (Hybrid controller system)
Detail of failure q Abnormality of capacitor voltage sensor in the inverter is detected.
Action of con-
troller
OFF position.
Related infor-
mation
causes and
under normal 1
conditions
40-305 54 PC200, 200LC-8E0 (Hybrid)

Failure code [GA0BKZ] AC Line Open/Short Circuit SEN05251-03
Failure code [GA0BKZ] AC Line Open/Short Circuit
User code Failure code Open or short circuit in alternate current line
Failure
E09 GA0BKZ (Hybrid controller system)
q The insulation of cable connecting between swing motor or power generating motor and inverter
Detail of failure
has deteriorated.
Action of con-
troller
OFF position.
Related infor-
q Method of reproducing failure code: Start engine and key OFF
mation

Probable
causes and Defective insulation between
standard value 1 hybrid system components q Visually check that cable is not damaged.
under normal and chassis ground
conditions Defective high voltage sec-
2 Perform high-voltage section common troubleshooting 1 – 7.
tion of hybrid component
PC200, 200LC-8E0 (Hybrid) 40-305 55

SEN05251-03 Failure code [GA11KK] HYB Cont. Low Supply Voltage
Failure code [GA11KK] HYB Cont. Low Supply Voltage
User code Failure code HYB system controller source voltage low error
Failure
E09 GA11KK (Hybrid controller system)
Detail of failure q The voltage of hybrid system controller power supply circuit is low.
Action of con- q Stops swing motor and motor-generator control, then turns swing holding brake ON.
Problem on
machine
Related infor-
q This power supply is commonly used for the machine monitor.
mation
q Troubleshooting (E-1)

Loose contact or corrosion of a Battery terminal may be loose or have corroded. Check it direct-
1
battery terminals ly.
Starting switch Voltage
Between positive and
2 Defective battery voltage OFF Min. 12 V
negative terminals
START Min. 6.2 V
3 Defective fuse No. 2 If fuse is broken, circuit probably has ground fault. (See Cause 6)
4 See fuse No. 17. If fuse is broken, circuit probably has ground fault. (See Cause 6)

Wiring harness between F01 to 17 and Resis-

Max. 1
HH07 (female) (2) tance
Wiring harness between HH07 (male) (2) Resis-
Max. 1
Probable and HC01 (female) (5), (11) tance
causes and Wiring harness between F01 to 17 and H15 Resis-
Max. 1
standard value (female) (1) tance
under normal Wiring harness between H15 (male) (1) and Resis-
Max. 1
conditions starting switch (B) tance
Wiring harness between starting switch Resis-
Max. 1
Open circuit in wiring har- (ACC) and H15 (male) (5) tance
ness Wiring harness between H15 (male) (5) and Resis-
5 Max. 1
(Open circuit or defective HH07 (female) (1) tance
contact in connector) Wiring harness between HH07 (male) (1) Resis-
Max. 1
and HC01 (female) (6), (12) tance
Wiring harness between F01 to 2 and HH07 Resis-
Max. 1
(female) (4) tance
Wiring harness between HH07 (male) (4) Resis-
Max. 1
and HC01 (female) (1), (7) tance
Wiring harness between HC01 (female) Resis-
Max. 1
(13), (19) and HH07 (male) (5) tance
Max. 1
and ground (T04), (T07) tance
Wiring harness between HC01 (female) Resis-
Max. 1
(17), (23) and HH07 (male) (3) tance
Max. 1
and ground (T05), (T06) tance
40-305 56 PC200, 200LC-8E0 (Hybrid)

Failure code [GA11KK] HYB Cont. Low Supply Voltage SEN05251-03

Between wiring harness (between F01 to 17 Resis-
Min. 1 M
and HH07 (female) (2)) and ground tance
Between wiring harness (between HH07
Resis-
(male) (2) and HC01 (female) (5), (11)) and Min. 1 M
tance
ground
Between wiring harness (between F01 to 17 Resis-
Min. 1 M
and H15 (female) (1)) and ground tance
Between wiring harness (between H15
Resis-
(male) (1) and starting switch (B)) and Min. 1 M
tance
Ground fault in wiring har- ground
6 ness (Contact with ground Between wiring harness (between starting
circuit) Resis-
switch (ACC) and H15 (male) (5)) and Min. 1 M
tance
ground
Between wiring harness (between H15
Resis-
(female) (5) and HP07 (female) (1)) and Min. 1 M
tance
ground
Probable Between wiring harness (between HH07
causes and Resis-
(male) (1) and HC01 (female) (6), (12)) and Min. 1 M
standard value tance
ground
under normal
conditions Between wiring harness (F01 to 02 and Resis-
Min. 1 M
HH07 (female) (4)) and ground tance
Between wiring harness (HH07 (male) (4) Resis-
Min. 1 M
and HC01 (female) (1), (7)) and ground tance
Short circuit in wiring har- Between HC01 (female) (1), (5), (6), (7),
7 ness (11), (12) and HC01 (female) (13), (17),
(with another wiring harness) (19), (23) pins Resis-
Max. 1
tance
(Cables are disconnected form battery ter-
minals.)
Connecting parts between fuse No. 2 and 17, wiring harness and
HH07, between HH07, wiring harness and hybrid system controller
Defective wiring harness may be defective. Check them directly.
8
connector 1. Looseness of connector, breakage of lock, or breakage of seal
2. Corrosion, bending, breakage, push-in, or expansion of pin
3. Moisture or dirt in connector or defective insulation
If causes 1 – 8 are not detected, the inverter (hybrid system control-

Defective inverter (hybrid
9 ler) may be defective (Since a trouble exists in the system, trouble-
system controller)
shooting cannot be performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 57

SEN05251-03 Failure code [GA11KK] HYB Cont. Low Supply Voltage
40-305 58 PC200, 200LC-8E0 (Hybrid)

Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure SEN05251-03
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure
User code Failure code Defective operation of HYB system controller high power supply
Failure
E09 GA12MC (Hybrid controller system)
Defail of failure q Voltage of power train does not drop below the specified level.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
under normal cable
conditions Defective high voltage sec- Since trouble is in system, testing and troubleshooting cannot be
3
tion of hybrid component performed.
PC200, 200LC-8E0 (Hybrid) 40-305 59

SEN05251-03 Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON
User code Failure code HYB system controller high power supply does not increase.
Failure
E09 GA12NK (Hybrid controller system)
Detail of failure q Electrical system in the inverter does not start.

Action of con-
troller
OFF position.
Related infor-
mation

1 Defective capacitor Perform high-voltage section common troubleshooting 1.
Probable
causes and 2 Defective motor-generator Perform high-voltage section common troubleshooting 3.
under normal cable
conditions Defective generator power
cable
Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be
5
40-305 60 PC200, 200LC-8E0 (Hybrid)

Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF SEN05251-03
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF
User code Failure code HYB system controller high power supply does not drop.
Failure
E09 GA12NL (Hybrid controller system)
Detail of failure q Although a certain time has passed, voltage of power train does not drop below the specified level.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and 1 Defective motor-generator Perform high-voltage section common troubleshooting 3.
standard value Defective generator power
under normal cable
3
PC200, 200LC-8E0 (Hybrid) 40-305 61

SEN05251-03 Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure
User code Failure code Defective operation of HYB system controller sensor power supply
Failure
E09 GA13MC (Hybrid controller system)
Detail of failure q Voltage of 5 V sensor power output circuit dropps below 2.5 V or exceeds above 6.0 V.
Action of con- q Turns OFF the 5 V sensor power output.
Problem on q Because swing PPC pressure sensor data is not obtained, machine cannot swing the upper struc-
machine ture.
Related infor-
mation

HP03–07 Voltage
Defective PPC pres-
Between (3) and (1) Power supply 4.5 – 5.5 V
1 sure sensor
(Internal failure) Between (2) and (1) Signal 0.5 – 4.5 V
If the voltage is abnormal, replace the PPC pressure sensor with another
one and make a judgment based on the failure code. (If failure code "E"
goes off, swing RIGHT PPC pressure sensor is defective.)
Wiring harness between HC02 (female) (31) and
HP03 (female) (3), HC02 (female) (31) and
Resis-
HP04 (female) (3), HP05 (female) (3) and HP06 Max. 1
tance
(female) (3), HP05 (female) (3) and HP07
(female) (3)
Wiring harness between HC02 (female) (53) and Resis-
Max. 1
Probable Open circuit in wiring HP03 (female) (2) tance
causes and harness Wiring harness between HC02 (female) (43) and Resis-
Max. 1
standard value 2 (Open circuit or defec- HP04 (female) (2) tance
under normal tive contact in connec- Wiring harness between HC02 (female) (34) and Resis-
Max. 1
conditions tor) HP05 (female) (2) tance
Max. 1
HP06 (female) (2) tance
Max. 1
HP07 (female) (2) tance
Wiring harness between HC02 (female) (62),
(63) and HP03 (female) (1), HP04 (female) (1), Resis-
Max. 1
HP05 (female) (1), HP06 (female) (1), and HP07 tance
(female) (1)
Between wiring harness (between HC02 Resis-
Min. 1 M
(female) (53) and HP03 (female) (2)) and ground tance
Ground fault in wiring Min. 1 M
3 harness (Contact with
ground circuit) Min. 1 M
Min. 1 M
Min. 1 M
40-305 62 PC200, 200LC-8E0 (Hybrid)

Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure SEN05251-03

Voltage Max. 1 V
(female) (53) and HP03 (female) (2)) and ground
Probable Between wiring harness (between HC02
Hot short in wiring har- Voltage Max. 1 V
causes and (female) (43) and HP04 (female) (2)) and ground
4 ness (Contact with 24V
standard value circuit) Voltage Max. 1 V
under normal
conditions Voltage Max. 1 V
Voltage Max. 1 V
Defective inverter If causes 1 – 4 are not detected, the hybrid system controller may be
5 (Hybrid system control- defective (Since a trouble exists in the system, troubleshooting cannot
ler) be performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 63

SEN05251-03 Failure code [GA14KR] HYB Control. KOMNET Comm. Failure
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure
User code Failure code KOMNET communication error of HYB system controller
Failure
E09 GA14KR (Hybrid controller system)
q Hybrid system controller detects a communication error in CAN communication circuit that is linked
Detail of failure
to the pump controller and engine controller.
Action of con- q Continues to control by using CAN information that was obtained before failure detection.
q Information may not correctly transmitted normally by KOMNET communication and machine may
Problem on
not operate normally.
machine
(Type of trouble depends on failed section.)
Related infor-
mation

Wiring harness between CM02 (female) (8,
9) and C01 (female) (45), CM02 (female) (8,
Resis-
9) and N10 (female) (1), CM02 (female) (8, Max. 1
tance
9) and CE02 (female) (46), CM02 (female)
Open circuit in wiring har- (8, 9) and K02 (female) (A)
ness Wiring harness between K02 (male) (A) and Resis-
1 Max. 1
(Open circuit or defective HK02 (female) (A), HCO2 (25) tance
contact in connector) Wiring harness between CM02 (female) (10)
and C01 (female) (64), CM02 (female) (10)
Resis-
and N10 (female) (2), CM02 (female) (10) Max. 1
tance
and CE02 (female) (47), CM02 (female) (10)
and K02 (female) (B)
Wiring harness between K02 (male) (B) and Resis-
Max. 1
HK02 (female) (B), HC02 (35) tance
Probable a Prepare by setting starting switch to OFF position, and trouble-
causes and shoot without turning starting switch to ON position.
standard value Between wiring harness (between CM02
under normal (female) (8), (9) and N08 (male) (3), CM02
conditions (female) (8), (9) and C01 (female) (45),
Resis-
CM02 (female) (8), (9) and N10 (female) (1), Min. 1 M
tance
CM02 (female) (8), (9) and CE02 (female)
(46), CM02 (female) (8), (9) and K02
(female) (A)) and ground
Between wiring harness (between K02
Ground fault in wiring har- Resis-
(male) (A) and HK02 (female) (A), HC02 Min. 1 M
2 ness tance
(25)) and ground
(Contact with ground circuit)
Between wiring harness (between CM02
(female) (10) and N08 (male) (10), CM02
(female) (10) and C01 (female) (64), CM02
Resis-
(female) (10) and N10 (female) (2), CM02 Min. 1 M
tance
(female) (10) and CE02 (female) (47), CM02
(female) (10) and K02 (female) (B)) and
ground
Resis-
(male) (B) and HK02 (female) (B), HC02 Min. 1 M
tance
(35)) and ground
40-305 64 PC200, 200LC-8E0 (Hybrid)

Failure code [GA14KR] HYB Control. KOMNET Comm. Failure SEN05251-03

starting switch to ON position and troubleshoot.
Between wiring harness (between CM02
(female) (8), (9) and N08 (male) (3), CM02
(female) (8), (9) and C01 (female) (45),
CM02 (female) (8), (9) and N10 (female) (1), Voltage Max. 5.5 V
CM02 (female) (8), (9) and CE02 (female)
(46), CM02 (female) (8), (9) and K02
(female) (A)) and ground
Hot short in wiring harness (male) (A) and HK02 (female) (A), HC02 Voltage Max. 5.5 V
3
(Contact with 24V circuit) (25)) and ground
Probable Between wiring harness (between CM02
causes and (female) (10) and N08 (male) (10), CM02
standard value (female) (10) and C01 (female) (64), CM02
under normal (female) (10) and N10 (female) (2), CM02 Voltage Max. 5.5 V
conditions (female) (10) and CE02 (female) (47), CM02
(female) (10) and K02 (female) (B)) and
ground
(male) (B) and HK02 (female) (B), HC02 Voltage Max. 5.5 V
(35)) and ground
resistance
4 HK02 (male) Resistance
(Internal short circuit or dis-
connection) Between (A) and (B) 120 ± 12
5 be defective (Since a trouble exists in the system, troubleshooting
system controller)
PC200, 200LC-8E0 (Hybrid) 40-305 65

SEN05251-03 Failure code [GA14KR] HYB Control. KOMNET Comm. Failure
40-305 66 PC200, 200LC-8E0 (Hybrid)

Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir SEN05251-03
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir
User code Failure code Open or short circuit of HYB controller insulation deterioration sen-
Failure sor
q Sensor failed that detects insulation deterioration of hybrid system components and chassis
Detail of failure
ground.
Action of con-
troller
Problem on
q No current leakage can be detected.
machine
Related infor-
mation
causes and
standard value Defective hybrid system
under normal 1 Perform high-voltage section common troubleshooting 1. - 7.
components
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 67

SEN05251-03 Failure code [GA16KK] Low HYB Cont. VDD Suppl. Volt.
Failure code [GA16KK] Low HYB Cont. VDD Suppl. Volt.
User code Failure code HYB system controller VDD power supply voltage low error
Failure
E09 GA16KK
Detail of failure q Failure of sensor power supply voltage inside inverter is detected.
q Stops swing motor and motor-generator control, then applies swing holding brake.
Action of con-
troller
OFF position.
Related infor-
mation
probable Cause Standard value in normal condition/Remarks on troubleshooting

causes and
under normal 1
conditions
40-305 68 PC200, 200LC-8E0 (Hybrid)

Failure code [GA17KR] Gen. Mot. Drv. Communication Failure SEN05251-03
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure
User code Failure code Communication error of motor-generator driver

Failure
(Hybrid controller system )
E09 GA17KR
Detail of failure q Internal communication failure 2 of inverter is detected by motor-generator controller.
Action of con-
troller
OFF position.
Related infor-
mation
Probable
causes and Cause Standard value in normal condition/Remarks on troubleshooting
standard value
under normal Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be
1
conditions system controller) performed.
PC200, 200LC-8E0 (Hybrid) 40-305 69

SEN05251-03 Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit
User code Failure code Short circuit of motor-generator driver power line
Failure
E09 GA17KY
Detail of failure q Short circuit of power line is detected in motor-generator driver.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
40-305 70 PC200, 200LC-8E0 (Hybrid)

Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit SEN05251-03
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit
User code Failure code Motor-generator driver open/short circuit error

Failure
E09 GA17KZ
Detail of failure q Disconnection or short circuit of motor-generator driver circuit was detected.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 71

SEN05251-03 Failure code [GA17MB] Gen. Mot. Drv. Function Degraded
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded
User code Failure code Reduced performance of motor-generator driver

Failure
E09 GA17MB
Detail of failure q Internal communication failure 1 of inverter is detected by motor-generator controller.
Action of con-
troller
position.
Related infor-
mation

causes and
under normal 1
conditions
40-305 72 PC200, 200LC-8E0 (Hybrid)

Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure SEN05251-03
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure
User code Failure code Defective operation of motor-generator driver excitation power
Failure supply
E09 GA18MC (Hybrid controller system )
Detail of failure q Electrical system in the inverter does not start.

Action of con-
troller
OFF position.
Related infor-
mation

Probable
1 Defective motor-generator Perform high-voltage section common troubleshooting 3.
causes and
under normal 2 Perform high-voltage section common troubleshooting 7.
cable
conditions
3
PC200, 200LC-8E0 (Hybrid) 40-305 73

SEN05251-03 Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt
User code Failure code Motor-generator driver sub-CPU power supply voltage drop
Failure
E09 GA19KK
Detail of failure q Abnormal power supply voltage to motor-generator controller is detected.
Action of control-
ler
OFF position.
Related informa-
tion

Probable causes
and standard
value under nor- Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be
1
mal conditions system controller) performed.
40-305 74 PC200, 200LC-8E0 (Hybrid)

Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure SEN05251-03
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure
User code Failure code Communication failure of motor-generator driver sub-CPU

Failure
E09 GA19KR
Detail of failure q Communication failure is detected in sub-CPU of motor-generator driver.
Action of con-
troller
position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 75

SEN05251-03 Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con.
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con.
User code Failure code Internal failure of motor-generator driver sub-CPU controller
Failure
E09 GA19KT
Detail of failure q Internal communication failure 3 of the inverter is detected by motor-generator controller.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
40-305 76 PC200, 200LC-8E0 (Hybrid)

Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction SEN05251-03
Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction
User code Failure code Malfunction of motor-generator driver sub-CPU

Failure
E09 GA19MA
Detail of failure q Program written in the motor-generator controller is abnormal.
Action of con-
troller
position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 77

SEN05251-03 Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation
User code Failure code Defective operation of motor-generator driver sub-CPU

Failure
E09 GA19MC
Detail of failure q CPU reset of the motor-generator controller occures.
Action of control-
ler
OFF position.
Related informa-
tion

Probable causes
and standard
value under nor- 1 Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be
40-305 78 PC200, 200LC-8E0 (Hybrid)

Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled SEN05251-03
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled
User code Failure code Startup failure of motor-generator driver sub-CPU

Failure
E09 GA19NA
q Internal communication initialization failure of the inverter is detected by the motor-generator con-
Detail of failure
troller.
Action of controller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Related informa-
tion

Probable causes
and standard
value under nor- Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be
1
PC200, 200LC-8E0 (Hybrid) 40-305 79

SEN05251-03 Failure code [GA1AKZ] Gen. Mot. Dr. Temp. Sens. Opn/Short Cir.
Failure code [GA1AKZ] Gen. Mot. Dr. Temp. Sens. Opn/Short Cir.
User code Failure code Open or short circuit of temperature sensor of motor-generator
Failure driver
E09 GA1AKZ (Hybrid controller system)
Detail of failure q Open or short circuit of temperature sensor of motor-generator driver is detected.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 80 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction SEN05251-03
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction
User code Failure code Malfunction of motor-generator driver DC voltage sensor

Failure
E09 GA1BMA
Detail of failure q Malfunction of motor-generator driver DC voltage sensor is detected.
q Stops swing motor and motor-generator control, then swing holding brake.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 81

SEN05251-03 Failure code [GA1DMA] Gen. Motro Driver IPM1 Abnormality
Failure code [GA1DMA] Gen. Motro Driver IPM1 Abnormality
User code Failure code Failure of IPM1 motor-generator driver

Failure
E09 GA1DMA
Detail of failure q Failure of IPM1 motor-generator driver is detected.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal cable
3
40-305 82 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1EMA] Gen. Motor Driver IPM 2 Abnormality SEN05251-03
Failure code [GA1EMA] Gen. Motor Driver IPM 2 Abnormality
User code Failure code Abnormality of IPM2 motor-generator driver

Failure
E09 GA1EMA
Detail of failure q Failure of IPM2 motor-generator driver
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal cable
3
PC200, 200LC-8E0 (Hybrid) 40-305 83

SEN05251-03 Failure code [GA1FKR] Swing Mot. Drv. Communication Failure
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure
User code Failure code Communication failure of swing motor driver

Failure
E09 GA1FKR
Detail of failure q Internal communication failure 2 of the inverter is detected by the swing motor controller.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 84 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1FMA] Abnormal Swing Motor Driver SEN05251-03
Failure code [GA1FMA] Abnormal Swing Motor Driver
User code Failure code Failure of swing motor driver

Failure
E09 GA1FMA
Detail of failure q Abnormality of swing motor inverter output circuit is detected.
q Stops swing motor and motor generator control, then applies swing holding brake.
Action of con-
troller
OFF position.
Problem on q Machine cannot swing the upper structure.
Related infor-
mation

Probable
causes and 1 Defective swing motor Perform high-voltage section common troubleshooting 2.
standard value
under normal Defective swing motor
conditions power cable
3
PC200, 200LC-8E0 (Hybrid) 40-305 85

SEN05251-03 Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU
User code Failure code Voltage drop of swing motor driver sub-CPU power supply
Failure
E09 GA1GKK
Detail of failure q Abnormal power supply voltage of swing motor controller power supply is detected.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 86 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure SEN05251-03
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure
User code Failure code Communication failure of swing motor driver sub-CPU
Failure
E09 GA1GKR
Detail of failure q Communication failure is detected in the swing motor driver sub-CPU.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 87

SEN05251-03 Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal
User code Failure code Internal failure of swing motor driver sub-CPU controller
Failure
E09 GA1GKT
Detail of failure q Internal communication failure 3 of inverter is detected by swing motor controller.
q Stops swing motor and motor-generator control, then applies swing holding brake .
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 88 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfuuction SEN05251-03
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfuuction
User code Failure code Malfunction of swing motor driver sub-CPU

Failure
E09 GA1GMA
Detail of failure q Program written in swing motor controller is abnormal.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 89

SEN05251-03 Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded
User code Failure code Startup failure of swing motor driver sub-CPU
failure
E09 GA1GMB
Detail of failure q Internal communication initialization failure of inverter is detected by the swing motor controller.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 90 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op. SEN05251-03
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op.
User code Failure code Defective operation of swing motor driver sub-CPU
Failure
E09 GA1GMC
Detail of failure q CPU reset of swing motor controller has occures.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 91

SEN05251-03 Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled
User code Failure code Performance drop of swing motor driver sub-CPU
Failure
E09 GA1GNA
Detail of failure q Internal communication failure 1 of inverter is detected by swing motor controller.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 92 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. SEN05251-03
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir.
User code Failure code U-phase temperature sensor of swing motor driver open/short cir-
Failure cuit error
E09 GA1HKZ (Hybrid controller system)
Detail of failure q Temperature sensor failure is detected in the U-phase output circuit of swing motor inverter.
Action of con-
troller
OFF position.
q Swing motor coil temperature can be checked with monitoring function.
Related infor-
(Code 09500: Swing inverter U-phase temperature)
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 93

SEN05251-03 Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir.
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir.
User code Failure code V-phase temperature sensor of swing motor driver open/short cir-
Failure cuit error
E09 GA1JKZ (Hybrid controller system)
Detail of failure q Temperature sensor failure is detected in the V-phase output circuit of swing motor inverter.
Action of con-
troller
OFF position.
Related infor-
(Code 09501: Swing inverter V-phase temperature)
mation

causes and
under normal 1
conditions
40-305 94 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir SEN05251-03
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir
User code Failure code W-phase temperature sensor of swing motor driver open/short cir-
Failure cuit error
E09 GA1KKZ (Hybrid controller system)
Detail of failure q Temperature sensor error is detected in the W-phase output circuit of swing motor inverter.
Action of con-
troller
OFF position.
Related infor-
(Code 09502: Swing inverter U-phase temperature)
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 95

SEN05251-03 Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir.
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir.
User code Failure code Swing motor driver current sensor open/short circuit error
Failure
E09 GA1LKZ
Detail of failure q Open/short circuit of swing motor inverter current sensor is detected.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
40-305 96 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir. SEN05251-03
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir.
User code Failure code Swing motor driver current sensor open/short circuit error
Failure
E09 GA1MKZ
Detail of failure q Abnormality of DC voltage sensor of swing motor inverter is detected.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 97

SEN05251-03 Failure code [GA1NNS] Swing Motor Driver IGBT Overheat
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat
User code Failure code Overheat of IGBT swing motor driver

Failure
E09 GA1NNS
q Estimated junction temperature of IGBT swing motor driver (mounted on the inverter) exceeds 135
Detail of failure
°C.
Action of con-
troller
position.
Related infor-
mation
Probable Excessive charging or dis-

1 Check for excessive swinging or swing stop.
causes and charging of capacitor
standard value Defective inverter (Hybrid Check the radiator water level, clogging of radiator fins, and water
under normal 2
system controller) pump operation of hybrid system cooling water circuit.
conditions
Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be per-
3
system controller) formed.
40-305 98 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1PNV] Swg Mot. Driver IPM Ph-U Not Warm up SEN05251-03
Failure code [GA1PNV] Swg Mot. Driver IPM Ph-U Not Warm up
User code Failure code Failure of U-phase warming up of IPM swing motor driver
Failure
E09 GA1PNV
Detail of failure q U-phase temperature of IPM swing motor driver drops below -35°C.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 99

SEN05251-03 Failure code [GA1QNV] Swg Mot. Driver IPM Ph-V Not Warm Up
Failure code [GA1QNV] Swg Mot. Driver IPM Ph-V Not Warm Up
User code Failure code Failure of V-phase warming up of IPM swing motor driver
Failure
E09 GA1QNV
Detail of failure q V-phase temperature of IPM swing motor driver drops below -35°C.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 100 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1RNV] Swng Mot. Driver IPM Ph-W Not Warm Up SEN05251-03
Failure code [GA1RNV] Swng Mot. Driver IPM Ph-W Not Warm Up
User code Failure code Failure of W-phase warming up of IPM swing motor driver
Failure
E09 GA1RNV
Detail of failure q W-phase temperature of IPM swing motor driver drops below -35°C.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 101

SEN05251-03 Failure code [GA1SFS] Contactor Locked
Failure code [GA1SFS] Contactor Locked
User code Failure code Contactor locked

Failure
E09 GA1SFS
Detail of failure q Contactor inside inverter is molten.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
40-305 102 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1SMC] Contactor Failure SEN05251-03
Failure code [GA1SMC] Contactor Failure
User code Failure code Defective of contactor operations

Failure
E09 GA1SMC
Detail of failure q Contactor inside inverter cannot be connected.
Action of con-
troller
OFF position.
q Capacitor voltage and booster low voltage can be checked with monitoring function.
Related infor-
(Code 09300: Capacitor voltage; code 09400: Booster low voltage)
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 103

SEN05251-03 Failure code [GA1TKG] Capacitor HVPS Abnormal Voltage
Failure code [GA1TKG] Capacitor HVPS Abnormal Voltage
User code Failure code Abnormality of capacitor high power supply voltage
Failure
E09 GA1TKG
Detail of failure q Capacitor voltage exceeds 335 V.
Action of con-
troller
OFF position.
Related infor-
mation
Probable 1 Defective capacitor Perform high-voltage section common troubleshooting 1.

causes and
under normal 2 Perform high-voltage section common troubleshooting 5.
cable
conditions
3
40-305 104 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1TKP] Capacitor Low Output Voltage SEN05251-03
Failure code [GA1TKP] Capacitor Low Output Voltage
User code Failure code Capacitor output voltage drops

Failure
E09 GA1TKP
Detail of failure q Capacitor voltage drops below 140 V.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal cable
3
PC200, 200LC-8E0 (Hybrid) 40-305 105

SEN05251-03 Failure code [GA1TNS] Capacitor Overheat
Failure code [GA1TNS] Capacitor Overheat
User code Failure code Capacitor overheat

Failure
E09 GA1TNS
Detail of failure q Capacitor temperature #1 or capacitor temperature #2 exceeds 65°C.
Action of con-
troller
position.
Problem on
machine
q Capacitor temperature #1 and capacitor temperature #2 can be checked with monitoring function.
Related infor-
(Code 09301: Capacitor temperature #1; code 09302: Capacitor temperature #2)
mation

Excessive charging or dis-
charging of capacitor
2. Disconnect connector HP01 and connect T-adapter to male side.
Internal disconnection of
Capacitor temperature sensor #1 Between Resis- 0.1 - 500
2 capacitor temperature sen-
HP01 (male) (4) and (8) tance k
sors #1 or #2
Capacitor temperature sensor #2 Between Resis- 0.1 - 500
HP01 (male) (5) and (8) tance k
Probable 2. Disconnect connectors HC02 and HP01 and connect T-adapters
causes and to female side.
Grounding fault in capacitor
standard value Capacitor temperature sensor #1: Between
temperature sensor #1 wir- Resis-
under normal 3 HC02 (female) (51) or HP01 (female) (4) Min. 1 M
ing harness tance
conditions and ground
(Contact with ground circuit)
Capacitor temperature sensor #2: Between
Resis-
HC02 (female) (61) or HP01 (female) (5) Min. 1 M
tance
and ground
Defective water pump (inter- 2. Disconnect connector HK01 and connect T-adapter to male side.
4
nal disconnection) Resis-
Between HK01 (male) (1) and (2) Min. 1
tance
Check radiator coolant level of coolant circuit of hybrid system, clog-
Defective operation of
5 ging of radiator fins, and operation of water pump. For details, see Y
hybrid system cooling circuit
mode, "Y-11 Capacitor temperature increases abnormally".
40-305 106 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1TNS] Capacitor Overheat SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 107

SEN05251-03 Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir.
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir.
User code Failure code Open or short circuit of capacitor temperature sensor
Failure
E09 GA1UKZ
Detail of failure q Difference between capacitor temperature #1 and capacitor temperature #2 is 20°C or more.
Action of con- q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller OFF position.
Problem on
q None.
machine
Related infor-
(Code 09301: Capacitor temperature #1; code 09302: Capacitor temperature #2)
mation

Defective capacitor tempera- shoot without turning starting switch to ON position.
ture sensor #1 HP01 Resistance
1
short circuit) Between (4) and (12) 0.1 – 500 k
Between (4) and ground Min. 1 M
Defective capacitor tempera- shoot without turning starting switch to ON position.
ture sensor #2 HP01 Resistance
2
short circuit) Between (5) and (12) 0.1 – 500 k
Between (5) and ground Min. 1 MΩ
causes and Wiring harness between HC01 (female) (7) Resis-
Max. 1
standard value and HP01 (female) (1) tance
Open circuit in wiring har-
under normal
ness Wiring harness between HC01 (female) (20) Resis-
conditions 3 Max. 1
(Open circuit or defective and HP01 (female) (12) tance
contact in connector)
Max. 1
Max. 1
Hot short in the wiring har- starting switch to ON position and troubleshoot.
ness of capacitor tempera-
4
ture sensor #1 (Contact with Between wiring harness (between HC02
24 V circuit) (female) (51) and HP01 (female) (4)) and Voltage Max. 5.5 V
ground
Hot short in the wiring har- starting switch to ON position and troubleshoot.
ness of capacitor tempera-
5
ture sensor #2 (Contact with Between wiring harness (between HC02
24 V circuit) (female) (61) and HP01 (female) (5)) and Voltage Max. 5.5 V
ground
40-305 108 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir. SEN05251-03
Probable Malfunction of cooling circuit Check radiator coolant level of coolant circuit of hybrid system,
6
causes and of hybrid system clogging of radiator fins, and operation of water pump.
standard value
under normal 7 Defective capacitor Perform high-voltage section common troubleshooting 1.
conditions If causes 1 - 5 are not detected, the inverter (hybrid system con-
8 troller) may be defective (Since a trouble exists in the system,
system controller)
troubleshooting cannot be performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 109

SEN05251-03 Failure code [GA1VFS] Capacitor Contactor Locked
Failure code [GA1VFS] Capacitor Contactor Locked
User code Failure code Capacitor contactor locked

Failure
E09 GA1VFS
q Contactor inside of capacitor is molten.
Detail of failure
q Power cable HC06 connector is not fitted securely.
Action of con-
troller
OFF position.
Related infor-
mation
q If failure code [GA01KA] is displayed at the same time, the power cable connector HC06 may not
be fitted securely.

Improper fitting of power Visually check that the power cable HC06 connector is fitted se-
1
cable connector curely.
Visually check that the mark on power cable HC06 connector is on
Improper connection of
2 the same side of the mark (blue) on the component to be connected.
Probable (See part (a) in the following figure.)
causes and a Prepare with starting switch OFF, then turn starting switch ON
standard value and perform troubleshooting.
under normal 3 Between ground and wiring harness
(contact with 24 V circuit) Power
conditions between HC01 (female) (3) and HP01 Max. 1 V
supply
(female) (6)
Before discharging (if capacitor voltage is 30 V or higher), check
4 Defective capacitor capacitor LED through window with power at OFF. If both LEDs
light up, capacitor is defective.
Defective inverter (Hybrid Since this is an internal defect, troubleshooting cannot be per-
5
system controller) formed.
40-305 110 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1VFS] Capacitor Contactor Locked SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 111

SEN05251-03 Failure code [GA1VMC] Capacitor Contactor Failure
Failure code [GA1VMC] Capacitor Contactor Failure
User code Failure code Defective operation of capacitor contactor

Failure
E09 GA1VMC
Detail of failure q Contactor inside of capacitor cannot be connected.
Action of con-
troller
OFF position.
Related infor-
mation

aPrepare with starting switch OFF, then perform
troubleshooting without turning starting switch to ON position.
Probable
Disconnection in wiring har- Wiring harness between HC01 (female) (3) Resis-
Max. 1
causes and 1 and HC01 (female) (6) CAN tance
ness
standard value
under normal Max. 1
and HC01 (female) (7) CAN tance
conditions
Since trouble is in system, testing and troubleshooting cannot be
Defective inverter (hybrid performed.
3
controller)
40-305 112 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. SEN05251-03
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ.
User code Failure code Open or short circuit of booster inductor temperature sensor
Failure
E09 GA1XKZ
Detail of failure q Abnormality of booster inductor temperature sensor in the inverter is detected.
Action of con-
troller
OFF position.
q Booster inductor temperature can be checked with monitoring function.
Related infor-
(Code 09402: Booster inductor temperature)
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 113

SEN05251-03 Failure code [GA1YNS] Booster Inductor Overheat
Failure code [GA1YNS] Booster Inductor Overheat
User code Failure code Booster inductor overheat

Failure
E09 GA1YNS
Detail of failure q Temperature of booster inductor inside inverter exceeds 130°C.
Action of con-
troller
position.
Booster inductor temperature can be checked with monitoring function.
q
Related infor-
mation
a See Y-10 of "Troubleshooting for hybrid system (Y mode)" and perform troubleshooting for this failure code.
40-305 114 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1YNV] Booster Inductor Not Warming Up SEN05251-03
Failure code [GA1YNV] Booster Inductor Not Warming Up
User code Failure code Booster inductor is not warmed up.

Failure
E09 GA1YNV
Detail of failure q Temperature of booster inductor inside inverter drops below -35°C.
Action of con-
troller
position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 115

SEN05251-03 Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ.
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ.
User code Failure code Open or short circuit of booster IGBT temperature sensor
Failure
E09 GA1ZKZ
Detail of failure q Abnormality of booster IGBT temperature sensor in inverter is detected.
Action of con-
troller
position.
Related infor-
(Code 09401: Booster IGBT temperature)
mation

Probable
causes and
under normal 1
conditions
40-305 116 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat SEN05251-03
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat
User code Failure code Booster IGBT temperature sensor overheat

Failure
E09 GA1ZNS
Detail of failure q Temperature of booster IGBT inside the inverter exceeds 100°C.
Action of con-
troller
position.
Booster inductor temperature can be checked with monitoring function.
q
Related infor-
mation
PC200, 200LC-8E0 (Hybrid) 40-305 117

SEN05251-03 Failure code [GA1ZNV] Booster IGBT Temp. Sens. Not Warm Up
Failure code [GA1ZNV] Booster IGBT Temp. Sens. Not Warm Up
User code Failure code Booster IGBT temperature sensor is not warmed up.
Failure
E09 GA1ZNV
Detail of failure q Temperature of booster IGBT inside inverter drops below -35°C.
Action of con-
troller
position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 118 PC200, 200LC-8E0 (Hybrid)

Failure code [GA21KB] Booster IGBT Short Circuit SEN05251-03
Failure code [GA21KB] Booster IGBT Short Circuit
User code Failure code Short circuit of booster IGBT

Failure
E09 GA21KB
Detail of failure q Overcurrent flows through booster IGBT inside inverter.
Action of con-
troller
position.
Related infor-
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 119

SEN05251-03 Failure code [GA22NS] Booster IGBT Junction Overheat
Failure code [GA22NS] Booster IGBT Junction Overheat
User code Failure code Booster IGBT junction overheat

Failure
E09 GA22NS
Detail of failure q Estimated junction temperature of booster IGBT inside inverter exceeds 135°C.
Action of con-
troller
position.
q Swing inverter junction temperature can be checked with monitoring function.
Related infor-
(Code 09503: Swing inverter junction temperature)
mation

Probable Excessive charging or dis-
causes and charging of capacitor
standard value Defective operation of hybrid Check the radiator water level, clogging of radiator fins, and water
2
under normal system cooling circuit pump operation of hybrid system cooling water circuit.
3
40-305 120 PC200, 200LC-8E0 (Hybrid)

Failure code [GA60MC] Generator Motor Failure SEN05251-03
Failure code [GA60MC] Generator Motor Failure
User code Failure code Defective operation of motor-generator

Failure
E09 GA60MC
Detail of failure q Difference between motor-generator and engine speed is 200 rpm or more.
Action of con- q Even if cause of failure disappears, system does not reset itself until starting switch is turned to OFF
troller position.
Problem on
q No power can be generated by the generator motor.
machine
q Motor-generator speed and engine speed can be checked with monitoring function.
Related infor-
(Code 09602: Generator motor speed; code 01002: Engine speed)
mation

1 Defective motor-generator
performed.
Open circuit in wiring har- Max. 1
and GM01 (female) (2) tance
ness
2
Max. 1
contact in connector) and GM01 (female) (1) tance
Probable Wiring harness between HC02 (female) (57) Resis-
causes and Max. 1
standard value a Prepare by setting starting switch to OFF position, and trouble-
under normal shoot without turning starting switch to ON position.
conditions
Resis-
(Contact with ground circuit) (female) (28) and GM01 (female) (2)) and Min. 1 M
tance
ground
(female) (28) and GM01 (female) (2)) and Voltage Max. 20 V
ground
5
PC200, 200LC-8E0 (Hybrid) 40-305 121

SEN05251-03 Failure code [GA60MD] Gen. Mot. Defective Movement
Failure code [GA60MD] Gen. Mot. Defective Movement
User code Failure code Abnormal generator motor speed

Failure
E09 GA60MD
Detail of failure q Abnormal motor-generator speed is detected by measurement with inverter.
q Stop swing motor and motor-generator control, then applies swing holding brake.
Action of con-
troller
position
Related infor-
mation

performed.
Max. 1
ness and GM01 (female) (2) tance
2
contact in connector) Max. 1
Probable
causes and Max. 1
standard value
under normal a Prepare by setting starting switch to OFF position, and trouble-
conditions Ground fault of wiring har- shoot without turning starting switch to ON position.
(Contact with ground circuit) (female) (28) and GM01 (female) (2)) and Resis-
Min. 1 M
tance
ground
ground
5
40-305 122 PC200, 200LC-8E0 (Hybrid)

Failure code [GA60N1] Generator Motor Overrun SEN05251-03
Failure code [GA60N1] Generator Motor Overrun
User code Failure code Overrun of motor-generator

Failure
E09 GA60N1
Detail of failure q Overrun of motor-generator is detected.
Action of con-
troller
position.
Related infor-
mation

performed.
Max. 1
ness and GM01 (female) (2) tance
2
contact in connector) Max. 1
Probable Max. 1
causes and
standard value
under normal
conditions 3 ness Between wiring harness (between HC02
Min. 1 M
tance
ground
ground
5
PC200, 200LC-8E0 (Hybrid) 40-305 123

SEN05251-03 Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir.
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir.
User code Failure code Open or short circuit of motor-generator temperature sensor
Fialure
E09 GA61KZ
Detail of failure q Open or short circuit of motor-generator temperature sensor is detected.
Action of con-
troller
position.
Related infor-
mation

Resis-
GM01 Reference value at normal
tance
Resis- Approx.
-40°C
tance 4,200 k
Defective temperature sen- Resis- Approx.
1 10°C
sor of motor-generator 0.5 - tance 210 k
Between (4) and (5)
5,000 k Resis- Approx.
25°C
tance 100 k
Resis- Approx.
40°C
tance 50 k
Between (4) and
Min.1 M
ground
causes and Open circuit in wiring har-
standard value ness Wiring harness between HC02 (female) (52) Resis-
2 Max. 1
under normal (Open circuit or defective and GM01 (female) (4) tance
conditions contact in connector)
Max. 1 Ω
Min. 1 M
tance
ground
ground
Defective inverter (Hybrid performed.
6
system controller)
40-305 124 PC200, 200LC-8E0 (Hybrid)

Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir. SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 125

SEN05251-03 Failure code [GA61NS] Generator Motor Temp. Sensor Overheat
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat
User code Failure code Motor-generator temperature sensor overheat

Failure
E09 GA61NS
Detail of failure q Temperature of motor-generator exceeds 180°C.
Action of con-
troller
position.
Related infor-
mation
40-305 126 PC200, 200LC-8E0 (Hybrid)

Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir SEN05251-03
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir
User code Failure code Short circuit of A-phase current sensor power line of motor-genera-
Failure tor
E09 GA62KY (Hybrid controller system)
Detail of failure q Overcurrent is detected in A-phase of motor-generator .

Action of con-
troller
position.
Related infor-
mation

Probable 1 Defective motor-generator Perform high-voltage section common troubleshooting 3.
causes and Failure of power cable that
standard value 2 connects between generator Perform high-voltage section common troubleshooting 7.
under normal motor and inverter
conditions
3
PC200, 200LC-8E0 (Hybrid) 40-305 127

SEN05251-03 Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir
User code Failure code Open or short circuit of A-phase current sensor of motor-generator
Failure
E09 GA62KZ
Detail of failure q Open or short circuit is detected in A-phase of motor-generator.
Action of con-
troller
position.
Related infor-
mation

system is normal) ON position. If failure code is not displayed and abnormal phenome-
Probable non does not occur, machine can be operated as it is.
causes and
standard value Failure of power cable that
under normal 2 connects between Perform high-voltage section common troubleshooting 7.
conditions motor-generator and inverter

4
40-305 128 PC200, 200LC-8E0 (Hybrid)

Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction SEN05251-03
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction
User code Failure code Malfunction of motor-generator A-phase current sensor

Failure
E09 GA62MA
Detail of failure q Malfunction of motor-generator A-phase current sensor is detected.
Action of con-
troller
position.
Related infor-
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 129

SEN05251-03 Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir.
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir.
User code Failure code Short circuit of B-phase current sensor power line of motor-genera-
Failure tor
Detail of failure q Overcurrent is detected in B-phase of motor-generator.

Action of con-
troller
position.
Related infor-
mation

standard value 2 connects between Perform high-voltage section common troubleshooting 7.
under normal motor-generator and inverter
conditions
3
40-305 130 PC200, 200LC-8E0 (Hybrid)

Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir SEN05251-03
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir
User code Failure code Open or short circuit of B-phase current sensor of motor-generator
Failure
E09 GA63KZ
Detail of failure q Open or short circuit is detected in B-phase of motor-generator.
Action of con-
troller
position.
Related infor-
mation

Probable enon does not occur, machine can be operated as it is.
causes and

4
PC200, 200LC-8E0 (Hybrid) 40-305 131

SEN05251-03 Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction
User code Failure code Malfunction of motor-generator B-phase current sensor

Failure
E09 GA63MA
Detail of failure q Malfunction of motor-generator B-phase current sensor is detected.
Action of con-
troller
position.
Related infor-
mation

causes and
under normal 1
conditions
40-305 132 PC200, 200LC-8E0 (Hybrid)

Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir. SEN05251-03
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir.
User code Failure code Short circuit of C-phase current sensor power line of motor-genera-
Failure tor
Detail of failure q Overcurren is detected in C-phase of motor-generator.

Action of con-
troller
position.
Related infor-
mation

standard value 2 connects between Perform high-voltage section common troubleshooting 7.
under normal motor-generator and inverter
conditions
3
PC200, 200LC-8E0 (Hybrid) 40-305 133

SEN05251-03 Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir.
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir.
User code Failure code Open or short circuit of C-phase current sensor of motor-generator
Failure
E09 GA64KZ
Detail of failure q Open or short circuit is detected in C-phase of motor-generator.
Action of con-
troller
position.
Related infor-
mation

causes and

4
40-305 134 PC200, 200LC-8E0 (Hybrid)

Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction SEN05251-03
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction
User code Failure code Malfunction of motor-generator C-phase current sensor

Failure
E09 GA64MA
Detail of failure q Malfunction of motor-generator C-phase current sensor is detected.
Action of con-
troller
position.
Related infor-
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 135

SEN05251-03 Failure code [GA70KB] HYB Swing Motor Short Circuit
Failure code [GA70KB] HYB Swing Motor Short Circuit
User code Failure code Short circuit of HYB system swing motor
Failure
E09 GA70KB
Detail of failure q Short circuit of swing motor is detected.
Action of con-
troller
position.
Related infor-
mation
1 Defective swing motor Perform high-voltage section common troubleshooting 2.

Probable
causes and
under normal 2 connects between swing Perform high-voltage section common troubleshooting 6.
conditions motor and inverter
3
40-305 136 PC200, 200LC-8E0 (Hybrid)

Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion SEN05251-03
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion
User code Failure code Abnormal speed of HYB system swing motor
Failure
E09 GA70MD
Detail of failure q Abnormal swing motor speed is detected by measurement with inverter.
Action of con-
troller
position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 137

SEN05251-03 Failure code [GA70NS] HYB Swing Motor Overheat
Failure code [GA70NS] HYB Swing Motor Overheat
User code Failure code HYB system swing motor overheat

Faiure
E09 GA70NS
Detail of failure q Swing motor temperature exceeds 160°C.
Action of con-
troller
position.
qSwing motor coil temperature can be checked with monitoring function.
Related infor-
(Code 09101: Swing motor coil temperature)
mation
40-305 138 PC200, 200LC-8E0 (Hybrid)

Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. SEN05251-03
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir.
User code Failure code Open or short circuit of hybrid system swing motor temperature
Failure sensor
Detail of failure q Abnormality of swing motor temperature sensor is detected.

q Stops swing motor and motor-generator control, then applied swing holding brake.
Action of con-
troller
position.
Related infor-
mation
(Code 09101: Swing motor coil temperature)

Resis-
Reference value at normal
tance
Resis- Approx.
-40 °C
tance 4,200 k
Defective temperature sen- Between PM01 Resis- Approx.
1 10 °C
sor of motor-swing (male) (7) and (8) 0.5 - tance 210 k
5,000 k Resis- Approx.
25 °C
tance 100 k
Resis- Approx.
40 °C
tance 50 k
Between PM01
Min. 1 M
(male) (7) and ground
ness Wiring harness between HC02 (female) (42) Resis-
standard value 2 Max. 1
under normal (Disconnection or defective and PM01 (female) (7) tance
conditions contact in connector)
Max. 1
and PM01 (female) (8) tance
(Contact with ground circuit) (female) (42) and PM01 (female) (7)) and Resis- Min.
tance 1M
ground
starting switch to ON position and troubleshoot.
(female) (42) and PM01 (female) (7)) and Voltage Max. 1 V
ground
5 Defective swing motor
Defective inverter (Hybrid performed.
6
system controller)
PC200, 200LC-8E0 (Hybrid) 40-305 139

SEN05251-03 Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir.
40-305 140 PC200, 200LC-8E0 (Hybrid)

Failure code [GA72MA] HYB Swing Motor Resolver Malfunction SEN05251-03
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction
User code Failure code Malfunction of HYB system swing motor resolver
Failure
E09 GA72MA
Detail of failure q Malfunction of swing motor resolver is detected.
Action of con-
troller
position.
Related infor-
mation

Max. 1
Open circuit in wiring Max. 1
harness
1 (Open circuit or defec- Max. 1
tive contact in connec-
tor) Max. 1
Max. 1
Max. 1
Between wiring harness (between HC02 (female) Resis- Min.
Prabable (29) and PM01 (female) (1)) and ground tance 1M
causes and Between wiring harness (between HC02 (female) Resis- Min.
Ground fault of wiring (30) and PM01 (female) (3)) and ground tance 1M
standard value harness
2 Between wiring harness (between HC02 (female) Resis- Min.
under normal (Contact with ground cir- (39) and PM01 (female) (2)) and ground tance 1M
conditions cuit) Between wiring harness (between HC02 (female) Resis- Min.
(40) and PM01 (female) (5)) and ground tance 1M
Voltage Max. 1 V
(29) and PM01 (female) (1)) and ground
Voltage Max. 1 V
Hot short in wiring har-
3 ness (Contact with 24 V Voltage Max. 1 V
circuit)
Voltage Max. 1 V
Voltage Max. 1 V
Voltage Max. 1 V
PC200, 200LC-8E0 (Hybrid) 40-305 141

SEN05251-03 Failure code [GA72MA] HYB Swing Motor Resolver Malfunction

Probable 4 Defective swing motor
causes and
Failure of inverter Since trouble is in system, testing and troubleshooting cannot be per-
standard value
5 (Hybrid system control- formed.
under normal
ler)
conditions
40-305 142 PC200, 200LC-8E0 (Hybrid)

Failure code [GA72MC] HYB Swing Motor Resolver Defect Op. SEN05251-03
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op.
User code Failure code Defective operation of HYB system swing motor resolver
Failure
E09 GA72MC
Detail of failure q Defective operation of swing motor resolver is detected.
Action of con-
troller
position.
Related infor-
mation
Max. 1
Open circuit in wiring Wiring harness between HC02 (female) (30) and Resis-
Max. 1
harness PM01 (female) (3) tance
1 (Open circuit or defec- Wiring harness between HC02 (female) (39) and Resis-
Max. 1
tive contact in connec- PM01 (female) (2) tance
tor) Wiring harness between HC02 (female) (40) and Resis-
Max. 1
Max. 1
Max. 1
Probable (29) and PM01 (female) (1)) and ground tance 1M
causes and Between wiring harness (between HC02 (female) Resis- Min.
Ground fault of wiring (30) and PM01 (female) (3)) and ground tance 1M
standard value harness
2 Between wiring harness (between HC02 (female) Resis- Min.
under normal (Contact with ground (39) and PM01 (female) (2)) and ground tance 1M
conditions circuit) Between wiring harness (between HC02 (female) Resis- Min.
Voltage Max. 1 V
Voltage Max. 1 V
Hot short in wiring har- (30) and PM01 (female) (3)) and ground
3 ness (Contact with 24 Between wiring harness (between HC02 (female) Voltage Max. 1 V
V circuit) (39) and PM01 (female) (2)) and ground
Voltage Max. 1 V
Voltage Max. 1 V
Voltage Max. 1 V
PC200, 200LC-8E0 (Hybrid) 40-305 143

SEN05251-03 Failure code [GA72MC] HYB Swing Motor Resolver Defect Op.

Probable 4 Defective swing motor
causes and
standard value Since trouble is in system, testing and troubleshooting cannot be per-
Defective inverter
under normal
5 (Hybrid system control- formed.
conditions
ler)
40-305 144 PC200, 200LC-8E0 (Hybrid)

Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. SEN05251-03
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ.
User code Failure code Open or short circuit of swing motor power cable
Failure
E09 GA81KZ
Detail of failure q Open or short circuit of swing motor power cable is detected.
Action of con-
troller
position.
Related infor-
mation

causes and
under normal 2 connects between swing Perform high-voltage section common troubleshooting 6.
conditions motor and inverter
3 Defective swing motor Perform high-voltage section common troubleshooting 2.

4
PC200, 200LC-8E0 (Hybrid) 40-305 145

SEN05251-03
©2011 KOMATSU
All Rights Reserved
40-305 146
SEN05252-00
SEN05252-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
400 Troubleshooting of electrical system
(E-mode)
Before performing troubleshooting of electrical system .............................................................................. 3

Information in troubleshooting table............................................................................................................ 5
E-1 When starting switch is turned to ON position, machine monitor displays nothing .............................. 6
E-2 When starting switch turned ON (before starting engine), basic check monitor lights up .................... 8
E-3 Engine does not start (Engine does not crank) .................................................................................... 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 Caution monitor lights up while engine is running ................................................................................ 20
E-8 Emergency monitor lights up while engine is running .......................................................................... 25
E-9 Engine coolant temperature gauge does not indicate normally ........................................................... 26
E-10 Hydraulic oil temperature gauge does not indicate normally.............................................................. 27
E-11 Fuel level gauge does not indicate normally ...................................................................................... 29
E-12 Contents of display by machine monitor are different from applicable machine ................................ 31
E-13 Some areas of the machine monitor screen are not displayed .......................................................... 32
E-14 Function switch does not work ........................................................................................................... 33
E-15 Auto-deceleration does not operate normally..................................................................................... 34
E-16 Working mode does not change......................................................................................................... 35
PC200, 200LC-8E0 (Hybrid) 40-400 1

400 Troubleshooting of electrical system (E-mode)
E-17 Travel speed does not change ........................................................................................................... 36

E-18 Alarm buzzer cannot be stopped........................................................................................................ 37
E-19 Windshield wiper and window washer do not operate........................................................................ 38
E-20 One-touch power maximizing function does not operate normally..................................................... 40
E-21 Swing brake does not operate normally ............................................................................................. 43
E-22 Travel alarm does not sound or does not stop sounding.................................................................... 46
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) .................. 48
E-24 While starting switch is in OFF position, service meter is not displayed ............................................ 59
E-25 Machine monitor cannot be set in service mode ................................................................................ 60
E-26 Monitoring function does not display lever control signal normally..................................................... 61
E-27 KOMTRAX system does not operate normally................................................................................... 67
40-400 2 PC200, 200LC-8E0 (Hybrid)

Before performing troubleshooting of electrical system SEN05252-00
Before performing troubleshooting of electrical system
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 performing troubleshooting related to the electrical system, you should check the fuses and fusible
links to see if the power is supplied normally.
Type of power Fuse
Fusible link Fuse No. Destination of power
supply capacity
Lamp relay, rear lamp relay, cab lamp relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve [When
1 10 A pump drive switch is operated in emergency]
Swing brake solenoid valve
[When swing brake cancel switch is operated]
Pump controller (Solenoid power supply)
Switch power F04 2 30 A Hybrid controller (solenoid power supply)
supply (60 A) Capacitor (M terminal), Invertor (M terminal)
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
Wind 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 head lamp, 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 Head lamp
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 Machine monitor, Invertor
17 20 A
power supply (30 A) Pump controller
Hybrid controller
18 10 A (Spare)
19 30 A Engine controller
Switch power Starting
20 5A Engine controller (ACC signal), Invertor (ACC signal)
supply switch ACC
PC200, 200LC-8E0 (Hybrid) 40-400 3

SEN05252-00 Before performing troubleshooting of electrical system
Locations of fusible links
Location of fuse box and fuse Nos.
40-400 4 PC200, 200LC-8E0 (Hybrid)

Information in troubleshooting table SEN05252-00

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.
Trouble Trouble which occurred in the machine
Related
Information related to detected trouble or troubleshooting
information
<Contents of description>
q Standard value in normal condition to judge probable causes
q Remarks on judgment
1
<Troubles in wiring harness>
q Disconnection
Connector is connected imperfectly or wiring harness is discon-
nected.
q Ground fault
Wiring harness which is not connected to chassis ground circuit is
in contact with chassis ground circuit.
q Hot short
Wiring harness which is not connected to power source (24 V)
2 circuit is in contact with power source (24 V) circuit.
q Short circuit
Probable Independent wiring harnesses are in contact with each other abnor-
causes and mally.
Probable causes of trouble
standard
(Given numbers are refer-
value in nor-
ence numbers, which do not
mal condi-
indicate priority)
tion <Precautions for troubleshooting>
(1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting,
3 unless otherwise specified.
q If connector No. has no marks of “male” and “female”, dis-
connect connector and insert T-adapters in both male side and
female side.
q If connector No. has marks of “male” and “female”, disconnect
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 ex-
plained below for troubleshooting, unless otherwise specified.
4 q Connect positive (+) lead to pin No. or wiring harness entered
on front side.
q Connect negative (-) lead to pin No. or harness entered on rear
side.

This drawing is a part of the circuit diagram related to troubleshoot-
ing.
q Connector No.: Indicates (Model – Number of pins) and (Color).
q “Connector No. and pin No.” from each branching/merging point:
Shows the ends of branch or source of merging within the parts of
the same wiring harness.
q Arrow(io): Roughly shows the location on the machine.
PC200, 200LC-8E0 (Hybrid) 40-400 5

SEN05252-00 E-1 When starting switch is turned to ON position, machine monitor displays nothing
E-1 When starting switch is turned to ON position, machine monitor

displays nothing
Trouble q When starting switch is turned to ON position, machine monitor displays nothing.
q When starting switch is turned to ON position, machine monitor displays KOMATSU logo, screen to
input password (if set), screen to check breaker mode (if set), screen of check before starting, screen
Related
to check working mode and travel speed, and standard screen in order.
information
q When the engine is started, the battery voltage may lower suddenly, depending on the ambient tem-
perature and the condition of the battery.

1 Insufficient battery capacity Electrolyte specific gravity (1
Battery voltage (2pieces)
piece)
Min. 24 V Min. 1.26
Defective fusible link F05 or If fusible link or fuse is broken, circuit probably has ground fault. (See
2
fuse No.17 Cause 5.)
Machine monitor connector may be connected wrongly. Check it
Wrong connection of connec-
3 directly.
tor
(Check mounting bracket plate with connector.)
Wiring harness between battery (–) – chassis Resis-
Max.1
ground tance
Wiring harness between battery (+) – R04 – Resis-
Max.1
F05 (male) (1) tance
Wiring harness between F05 (male) (2) Resis-
ness Max.1
–F01-16D tance
Wiring harness between F01-17 – J06 – Resis-
Probable defective contact in connec- Max.1
CM01 (female) (1)(2) tance
causes and tor)
Wiring harness between CM01 (female) (3)(4) Resis-
standard Max.1
– chassis ground (T05) tance
value in nor-
Wiring harness between F01-17 and H15 Resis-
mal condi- Max.1
(female)(1) tance
tion
Wiring harness between H15 (female) (5), – Resis-
Max.1
J03CM01 (female) (14) tance
a Prepare with starting switch OFF, then troubleshoot without turning
starting switch to ON position.
Between ground and wiring harness between Resis-
Min. 1M
battery (+) – R04 – F05 (male) (1) tance
Min. 1M
Ground fault in wiring harness F05 (male) (2) – F01 - 16D tance
5
(Short circuit with GND circuit) Between ground and wiring harness between Resis-
Min. 1M
F01-17 – J06 – CM01 (female) (1)(2) tance
Between ground and wiringiring harness Resis-
Min. 1M
between F01-17 – H15 (female) (1) tance
Min. 1M
H15 (female) (5) – J03 – CM01 (female) (14) tance
a Prepare with starting switch OFF, then hold starting switch OFF
and ON and perform troubleshooting in each case.
CM01 Starting switch Voltage
Between (1)(2) –
OFF 20 – 30 V
(3)(4)
Between (14) – (3)(4) ON 20 – 30 V
40-400 6 PC200, 200LC-8E0 (Hybrid)

E-1 When starting switch is turned to ON position, machine monitor displays nothing SEN05252-00
Circuit diagram related to machine monitor power supply
PC200, 200LC-8E0 (Hybrid) 40-400 7

SEN05252-00 E-2 When starting switch turned ON (before starting engine), basic check monitor lights up
E-2 When starting switch turned ON (before starting engine), basic check
monitor lights up
Trouble (1) Radiator coolant level monitor lights up red.
q Although radiator coolant level monitor is basic check item, it is also checked while engine is run-
ning.
Related infor-
(If monitor lights up red while engine is running, perform this troubleshooting, too.)
mation
q Condition of radiator coolant level switch signal can be checked by using monitoring function.

Lowering of radiator coolant
Coolant level in radiator sub tank may be low. Check it and add
1 level
coolant if necessary.
Defective radiator coolant Sub-tank coolant
P24 Resistance
2 level switch level
(Internal disconnection) Between FULL and
Max.1
Between (1) – (2) LOW
Probable
Below LOW Min. 1M
causes and
standard value Disconnection in wiring har-
in normal condi- ness
Wiring harness between CM02 (female) (3) Resis-
tion 3 (Disconnection in wiring or Max.1
– P24 (female) (1) tance
Wiring harness between P24 (female) (2) – Resis-
tor) Max.1
Sub-tank coolant
CM02 Voltage
4 Defective machine monitor level
Between FULL and
Between (3) – chas- Max.1 V
LOW
sis ground
Below LOW 20 –30 V
40-400 8 PC200, 200LC-8E0 (Hybrid)

E-2 When starting switch turned ON (before starting engine), basic check monitor lights up SEN05252-00
Circuit diagram related to radiator coolant level switch
PC200, 200LC-8E0 (Hybrid) 40-400 9

SEN05252-00 E-2 When starting switch turned ON (before starting engine), basic check monitor lights up
Trouble (2) Engine oil level monitor lights up red.

Related infor- q Condition of engine oil level switch signal can be checked by using 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.
Defective engine oil level without turning starting switch to ON position.
2 switch P44 Engine oil level Resistance
(Internal disconnection) Between (1) – chas- Between H – L Max.1
Probable
sis ground Below L Min. 1M
causes and
standard
value in nor-
mal condition Wiring harness between CM02 (female) (2) Resis-
defective contact in connec- Max.1
– P44 (female) (1) tance
tor)
4 Defective machine monitor CM02 Engine oil level Voltage
Between (2) – chas- Between H – L Max.1 V
sis ground Below L 20 –30 V
Circuit diagram related to engine oil level switch
40-400 10 PC200, 200LC-8E0 (Hybrid)

E-3 Engine does not start (Engine does not crank) SEN05252-00
E-3 Engine does not start (Engine does not crank)

Trouble q Engine does not start (Engine does not crank).
q Engine starting circuit has following 2 start lock mechanisms.
Related
1) Start lock with password of machine monitor
information
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
2 Defective fuse No. 3 If fuse is broken, circuit probably has ground fault. (See cause 10.)
and turn it to START position and perform troubleshooting in each
Defective starting switch case.
3
(Internal disconnection) H15 (male) Starting switch Resistance
OFF Min. 1M
Between (1) – (4)
START Max. 1
Defective lock lever switch
4 S14 (female) Lock lever Resistance
Free Min. 1M
Between (1) – (3)
Lock Max. 1
Defective starting motor cut- without turning starting switch to ON position.
out relay R06 or R07 (Inter- R06 (male), R07 (male) Resistance
5
Probable nal disconnection or short Between (1) – (2) 300 – 600
causes and circuit) Between (3) – (4) Max. 1
standard Between (3) – (5) Min. 1M
value in nor- a Prepare with starting switch OFF (with only terminal C disconnect-
mal condi- ed), then turn starting switch to START position and perform trou-
tion bleshooting.
Safety relay terminal Voltage
Defective starting motor Between B – E Power supply 20 – 30 V
6
safety relay (Internal defect) Between R(R17-2) – E Generation input Max. 1 V
Between S(R17-1) – E Starting input 20 – 30 V
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.
a Prepare with starting switch OFF, then turn starting switch to
START position and perform troubleshooting.
Starting motor terminals Voltage
Between B (SB) –
Defective starting motor Power supply 20 – 30 V
7 ground
(Internal defect)
Between C (SC) –
Starting input 20 – 30 V
ground
If power supply and starting input are normal but starting motor does
not rotate, starting motor is defective.
a Prepare with starting switch OFF, then turn starting switch to ON po-
sition and perform troubleshooting
Defective alternator (Internal
8 Alternator Voltage
short circuit)
Between L – chassis
Alternator output Max. 1 V
ground
PC200, 200LC-8E0 (Hybrid) 40-400 11

SEN05252-00 E-3 Engine does not start (Engine does not crank)

Wiring harness between H15 (female) (4) – J01 Resis-
Max. 1
– R06 (female) (5) tance
Wiring harness between R06 (female) (3) – Resis-
Max. 1
Wiring harness between R07 (female) (3) – Resis-
Max. 1
Disconnection in wiring har- Wiring harness between starting motor safety Resis-
Max. 1
ness (Disconnection in wiing relay B – heater relay – battery relay B tance
9
or defective contact in con- Wiring harness between starting motor safety Resis-
Max. 1
nector) relay E – chassis ground tance
Wiring harness between starting motor safety Resis-
Max. 1
relay C – starting motor C(SC) tance
Wiring harness between F01-3 – S14 (male) Resis-
Max. 1
(1) tance
Wiring harness between S14 (male) (3) – R06 Resis-
Max. 1
(female) (1) tance
Wiring harness between R06 (female) (2) – J04 Resis-
Probable Max. 1
– chassis ground (T04) tance
causes and
standard
value in nor-
Between ground and wiring harness between
mal condi- Resis-
H15 (female) (4) – J01 – R06 (female) (5) – cir- Min. 1M
tion tance
cuit branch end
Min. 1M
R06 (female) (3) – R07 (female) (4) tance
Min. 1M
Ground fault in wiring har- R07 (female) (3) – R17 (female) (1) tance
10 ness (Short circuit with GND Between ground and wiring harness between
Resis-
circuit) starting motor safety relay B – heater relay – Min. 1M
tance
battery relay B
Resis-
starting motor safety relay C – starting motor C Min. 1M
tance
(SC)
Min. 1M
F01-3 – S14 (male) (1) tance
Min. 1M
S14 (male) (3) – R06(female) (1) tance
Hot short (Short circuit with sition and perform troubleshooting.
11 24 V circuit) in wiring har- Between ground and wiring harness between
ness R17 (female) (2) – alternator L, – circuit branch Voltage Max. 1V
end
40-400 12 PC200, 200LC-8E0 (Hybrid)

E-3 Engine does not start (Engine does not crank) SEN05252-00
PC200, 200LC-8E0 (Hybrid) 40-400 13

SEN05252-00 E-4 Preheater does not operate
E-4 Preheater does not operate

Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up or flash.
q Preheater monitor lights up when starting switch is turned to HEAT position and starts flashing about
30 seconds after to notify completion of preheating (It stops flashing about 10 seconds after).
Related infor- q If engine coolant temperature is below 20 °C, automatic warm-up system operates and preheating
mation monitor lights up for up to 30 seconds.
q Condition of starting switch (preheating) signal can be checked by using the monitoring function.(Code:
04500 Monitor input 1)

and turn it to HEAT position and perform troubleshooting in each
Defective starting switch case.
1
(Internal disconnection) H15 (male) Starting switch Resistance
OFF Min. 1 M
Between (1) – (3)
HEAT Max.1
Probable
causes and
standard
value in nor- Wiring harness between CM01 (female) (16) –
defective contact in connec- Resistance Max.1
mal condition J02 – H15 (female) (3)
tor)
a Prepare with starting switch OFF, then keep starting switch in OFF
and turn it to HEAT position and perform troubleshooting in each
case.
CM01 Starting switch Voltage
OFF Max.1 V
Between (16) – ground
HEAT 20 – 30 V
(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become
Trouble
warm.
Related infor- q Check that engine can be turned with starting motor (If engine cannot crank, perform troubleshooting
mation for E-1 Engine does not start (Engine does not crank))

a Prepare with starting switch OFF (with wiring harness connected),
then keep starting switch OFF and turn it to HEAT position and per-
form troubleshooting in each case.
Defective heater relay Heater relay Starting switch Continuity/Resistance
1
(Internal disconnection) Between R15 –
OFF Continuity
ground
Between power sup-
HEAT Max.1
ply terminal – R16
a Prepare with starting switch OFF (with wiring harness connected),
Probable then turn starting switch to HEAT position and perform trouble-
causes and shooting in each case.
standard Defective intake air heater E01 Starting switch Voltage
3
value in nor- (Internal disconnection) Between terminal –
HEAT 20 – 30 V
mal condition ground
If voltage is normal but heater mounting part does not become warm,
intake air heater is defective.
Wiring harness between H15 (female) (3) – Resis-
ness Max.1
J02 – heater relay R15 tance
Wiring harness between battery relay R03 – Resis-
heater relay contact terminal tance
tor)
Wiring harness between heater relay R16 – Resis-
Max.1
intake air heater E01 tance
40-400 14 PC200, 200LC-8E0 (Hybrid)

E-4 Preheater does not operate SEN05252-00
PC200, 200LC-8E0 (Hybrid) 40-400 15

SEN05252-00 E-5 Automatic warm-up system does not operate (in cold season)
E-5 Automatic warm-up system does not operate (in cold season)
Trouble q Automatic warm-up system does not operate (in cold season).
q When engine coolant temperature is below 30 °C automatic warm-up system raises engine speed to
1,200 rpm.
q If fuel control dial is opened more than 70 % for 3 seconds when starting switch is turned ON position
Related infor-
or after engine is started, automatic warm-up system is turned off. (Automatic warm-up system stops
mation
automatically after operating for 10 minutes.)
q 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 perform troubleshoot-
ing.
Engine coolant tem- Coolant temperature
Monitoring code
perature level
Probable 105 °C 6 (a: Red)
102 °C 5 (a: Red)
causes and Defective engine coolant tem- 04107
1 100 °C 4 (a: Blue)
standard perature signal system Engine coolant tem-
85 °C 3 (a: Blue)
value in nor- perature
60 °C 2 (a: Blue)
mal condition 30 °C 1 (a: White)
If level of coolant temperature gauge is different from actual coolant
temperature, perform troubleshooting for E-9 Engine coolant temper-
ature gauge does not indicate normally.
If cause 1 is not detected, engine controller may be defective. (Since
trouble is in system, troubleshooting cannot be performed.)
Engine coolant temperature gauge and engine

coolant temperature monitor
40-400 16 PC200, 200LC-8E0 (Hybrid)

E-5 Automatic warm-up system does not operate (in cold season) SEN05252-00
PC200, 200LC-8E0 (Hybrid) 40-400 17

SEN05252-00 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked
E-6 All work equipment, swing, and travel mechanism do not move or
cannot be locked
Trouble (1) All work equipment, swing, and travel mechanism do not move.
Related infor-
mation

2 S14 (female) Lock lever Resistance
Lock Min. 1 M
Between (1) – (2)
Free Max.1
Defective PPC lock solenoid without turning starting switch to ON position.
3 (Internal disconnection or V01 (male) Resistance
short circuit) Between (1) – (2) 20 – 60
Between (1) – chassis ground Min. 1 M
Defective assembled-type
4 diode D01
causes and D01 (male) Resistance (Continuitiy)
(Internal short circuit)
standard Between (4) – (8) Min. 1 M (No continuitiy)
value in nor- a Prepare with starting switch OFF, then perform troubleshooting
mal condition without turning starting switch to ON position.
Wiring harness between F01-3 – S14 (male) Resis-
ness Max.1
(1) tance
Wiring harness between S14 (male) (2) – V01 Resis-
(female) (1) tance
tor)
Wiring harness between V01 (female) (2) – Resis-
Max.1
ness Min. 1 M
6 F01-3 – S14 (male) (1), – circuit branch end tance
cuit) Resis-
S14 (male) (2) – V01 (female) (1), – D01 Min. 1 M
tance
(female) (4)
40-400 18 PC200, 200LC-8E0 (Hybrid)

E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked SEN05252-00
Trouble (2) All work equipment, swing, and travel mechanism cannot be locked.
Related
information

Probable 1 S14 (female) Lock lever Resistance
causes and Lock Min. 1 M
Between (1) – (2)
standard Free Max.1
value in nor- a Prepare with starting switch OFF, then turn starting switch ON po-
mal condition Hot short sition and perform troubleshooting.
2 (Short circuit with 24 V circuit) Between ground and wiring harness between
in wiring harness S14 (male) (2) – V01 (female) (1), – D01 Voltage Max.1 V
(female) (4)
Circuit diagram related to PPC lock solenoid
PC200, 200LC-8E0 (Hybrid) 40-400 19

SEN05252-00 E-7 Caution monitor lights up while engine is running
E-7 Caution monitor lights up while engine is running

Trouble (1) Charge level monitor lights up red.
Related q Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge voltage)
information q Charge level monitor lights up red at 7.8 V and below.

Defective generation by alter- troubleshooting.
1 nator E12 (male) Engine speed Voltage
(when system is normal) Between (1) – chas-
Medium or higher 27.5 – 29.5 V
sis ground
Probable 2 (Disconnection in wiring or
Wiring harness between CM01 (female) (11) – Resis-
causes and defective contact in connec- Max.1
J02 – E12 (female) (1) tance
standard tor)
value in nor- a Prepare with starting switch OFF, then perform troubleshooting
mal condition Ground fault in wiring harness without turning starting switch to ON position.
3 (Short circuit with GND cir- Between ground and wiring harness between
Resis-
cuit) CM01 (female) (11) – J02 – E12 (female) (1) – Min. 1 M
tance
circuit branch end
troubleshooting.
4 Defective machine monitor CM02 Engine Voltage
Between (11) –
Running Min. 7.8 V
ground
40-400 20 PC200, 200LC-8E0 (Hybrid)

E-7 Caution monitor lights up while engine is running SEN05252-00
PC200, 200LC-8E0 (Hybrid) 40-400 21

Trouble (2) Fuel level monitor lights up red.

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

Probable
Low fuel level Fuel level may be low (below approximately 41 l). Check it and add
causes and 1
(when system is normal) fuel if necessary.
standard
If cause 1 is not detected, fuel level gauge system may be defective.
value in nor- Defective fuel level gauge
2 Perform troubleshooting for E-11 Fuel level gauge does not indicate
mal condition system
normally.
Trouble (3) Air cleaner clogging monitor lights up red.

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

Clogging of air cleaner Air cleaner may be clogged. Check it, then clean or replace if neces-
1
(when system is normal) sary.
troubleshooting.
P23 (male) Air cleaner Resistance
Defective air cleaner clog- When normal
2 ging switch (Internal discon- (Air intake resis- Max.1
nection) tance: *1)
Between (1) – (2)
When clogged
(Air intake resis- Min. 1 M
Probable tance: *2)
ness
value in nor- Wiring harness between CM02 (female) (4) – Resis-
3 (Disconnection in wiring or Max.1
mal condition P23 (female) (1) tance
tor) Max.1
troubleshooting.
CM02 Air cleaner Voltage
When normal
4 Defective machine monitor (Air intake resis- Max.1 V
Between (4) – chas- tance: *1)
sis ground When clogged
(Air intake resis- 20 – 30 V
tance:*2)
*1: Max. -3,430 Pa {Max. -350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
40-400 22 PC200, 200LC-8E0 (Hybrid)

E-7 Caution monitor lights up while engine is running SEN05252-00
Circuit diagram related to air cleaner clogging switch
PC200, 200LC-8E0 (Hybrid) 40-400 23

Trouble (4) Engine coolant temperature monitor lights up white.

q Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
Related machine monitor through communication system.
information q Engine coolant temperature can be checked by using monitoring function. (Code: 04107 Engine
coolant temperature)

If monitor lights up white, engine coolant temperature may be low
Probable Insufficient warm-up of
(below approximately 30 °C). Warm up engine.
causes and 1 machine
q Lighting up white: Engine coolant temperature is low.
standard (when system is normal)
q Lighting up blue: Engine coolant temperature is proper.
value in nor-
If cause 1 is not detected, engine coolant temperature gauge sys-
mal condition Defective engine coolant
2 tem may be defective. Perform troubleshooting for E-9 Engine
temperature gauge system
coolant temperature gauge does not indicate normally.
Trouble (5) Water separator monitor lights up red.

Related q Condition of signal from water-in-fuel sensor switch can be checked by using monitoring function.
information (Code: 18800 WIF sensor condition)

Probable
Water separator is full
causes and 1 Water separator may be full of water. Check it, then drain if full.
standard
If cause 1 is not detected, water-in-fuel sensor system may be
value in nor- Defective water-in-fuel sen-
2 defective. Perform troubleshooting for failure codes [CA428] and
mal condition sor system
[CA429].
Trouble (6) Hydraulic oil temperature monitor lights up white.

q Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to ma-
Related chine monitor through communication system.
information q Hydraulic oil temperature can be checked by using monitoring function. (Code: 04401 Hydraulic oil
temperature)

Probable If monitor lights up white, hydraulic oil temperature may be low
Insufficient warm-up of
causes and (below about 20 °C). Warm up engine.
1 machine
standard q Lighting up white: Hydraulic oil temperature is low.
value in nor- q Lighting up blue: Hydraulic oil temperature is proper.
mal condi- If cause 1 is not detected, hydraulic oil temperature gauge system
tion 2 may be defective. Perform troubleshooting for E-10 Hydraulic oil
perature gauge system
temperature gauge does not indicate normally.
40-400 24 PC200, 200LC-8E0 (Hybrid)

E-8 Emergency monitor lights up while engine is running SEN05252-00
E-8 Emergency monitor lights up while engine is running

Trouble (1) Engine coolant temperature monitor lights up red.
q Signals of engine coolant temperature sensor are input to engine controller and then transmitted to ma-
information q Engine coolant temperature can be checked by using monitoring function. (Code: 04107 Engine cool-
ant temperature)

If monitor lights up red, engine coolant temperature may be high
Probable (above approximately 102 °C). Cool down engine coolant (Run
Overheating of engine coolant
causes and 1 engine at low idle).
standard q Lighting up red:Engine coolant temperature is high (overheating).
value in nor- q Lighting up blue: Engine coolant temperature is proper.
mal condition If cause 1 is not detected, engine coolant temperature gauge system
Defective engine coolant tem-
2 may be defective. Perform troubleshooting for E-9 Engine coolant
temperature gauge does not indicate normally.
Trouble (2) Hydraulic oil temperature monitor lights up red.

Related infor- chine monitor through communication system.
mation q Hydraulic oil temperature can be checked by using monitoring function. (Code: 04401 Hydraulic oil
temperature)

If monitor lights up red, hydraulic oil temperature may be high (above
Probable approximately 102 °C). Cool down hydraulic oil (Run engine at low
Overheating of hydraulic oil
causes and 1 idle).
standard q Lighting up red: Hydraulic oil temperature is high (overheating).
value in nor- q Lighting up blue: Hydraulic oil temperature is proper.
mal condition If cause 1 is not detected, hydraulic oil temperature gauge system
2 may be defective. Perform troubleshooting for E-10 Hydraulic oil tem-
perature gauge does not indicate normally.
Trouble (3) Engine oil pressure monitor lights up red.

Related infor- q Engine oil pressure switch signal is input to engine controller and then transmitted to machine monitor
mation through communication system.

Probable
Lowering of engine oil pres-
causes and Engine oil pressure may be low. If it is low, perform troubleshooting
1 sure
standard for "S-12 Oil pressure lowers".
value in nor-
Defective engine oil pressure If cause 1 is not detected, engine oil pressure gauge system may be
mal condition 2
switch system defective. Perform troubleshooting for failure code [CA435].
PC200, 200LC-8E0 (Hybrid) 40-400 25

SEN05252-00 E-9 Engine coolant temperature gauge does not indicate normally
E-9 Engine coolant temperature gauge does not indicate normally

(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
information q Engine coolant temperature can be checked by using monitoring function. (Code: 04107 Engine cool-
ant temperature)

Probable
If cause 1 is not detected, engine coolant temperature sensor system
causes and Defective engine coolant tem-
1 may be defective. Perform troubleshooting for failure codes [CA144]
standard perature sensor system
and [CA145].
value in nor-
If cause 1 is not detected, machine monitor may be defective. (Since
mal condition 2 Defective machine monitor
(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.
information q Engine coolant temperature can be checked by using monitoring function.(Code:04107 Engine coolant
temperature)

a Turn starting switch to ON position or start engine and perform
troubleshooting.
Probable Engine coolant tem- Coolant temperature Color of monitor light
causes and perature level (a)
standard 105 °C 6
1 Defective machine monitor Red
value in nor- 102 °C 5
mal condition 100 °C 4
85 °C 3 Blue
60 °C 2
30 °C 1 White
Engine coolant temperature gauge and engine

coolant temperature monitor
40-400 26 PC200, 200LC-8E0 (Hybrid)

E-10 Hydraulic oil temperature gauge does not indicate normally SEN05252-00
E-10 Hydraulic oil temperature gauge does not indicate normally

(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range
Trouble (C).
(2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
temperature

without turning starting switch ON position.
perature sensor
Between (1) – (2) 3.5 – 90 k
short circuit)
ness
Wiring harness between C01 (female) (29) – Resis-
2 (Disconnection in wiring or Max.1
P22 (female) (2) tance
Probable tor) Max.1
causes and
a Ground fault in wiring harness
standard Ground fault in wiring harness
3 Between ground and wiring harness between Resis-
value in nor- (Short circuit with GND circuit) Min. 1 M
C01 (female) (29 – P22 (female) (2) tance
mal condition
Hot short
4 (Short circuit with 24 V circuit)
in wiring harness Voltage Max.1 V
C01 (female) (29) – P22 (female) (2)
Between (29) – (46) 3.5 – 90 k
If causes 1 – 5 are not detected, machine monitor may be defective.
Circuit diagram related to hydraulic oil temperature sensor
PC200, 200LC-8E0 (Hybrid) 40-400 27

SEN05252-00 E-10 Hydraulic oil temperature gauge does not indicate normally
(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 moni-
tor.
temperature

a Turn starting switch ON positiion or start engine and perform trou-
Probable bleshooting.
Hydraulic oil tempera- Hydraulic oil tempera- Color of monitor light
causes and
standard ture ture level (a)
105 °C 6
value in nor- 1 Defective machine monitor Red
102 °C 5
mal condi-
100 °C 4
tion
85 °C 3 Blue
40 °C 2
20 °C 1 White
Hydraulic oil temperature gauge and hydraulic

oil temperature monitor
40-400 28 PC200, 200LC-8E0 (Hybrid)

E-11 Fuel level gauge does not indicate normally SEN05252-00
E-11 Fuel level gauge does not indicate normally

(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 q Signal voltage of fuel level sensor can be checked by using monitoring function. (Code: 04200 Fuel
information sensor voltage)

Defective fuel level sensor without turning starting switch to ON position.
1 (Internal disconnection or P21 (male) Fuel level Resistance
short circuit) Between (1) – chassis FULL 7–11
ground EMPTY 85–95
Probable defective contact in connec- Max. 1
causes and tor)
standard Ground fault in wiring har- a Prepare with starting switch OFF, then perform troubleshooting
value in nor- ness without turning starting switch to ON position.
3
mal condi- (Short circuit with GND cir- Between ground and wiring harness between Resis-
Min. 1 M
tion cuit) CM01 (female) (9) – P21 (female) (1) tance
sition and perform troubleshooting.
4 24 V circuit) in wiring har-
CM01 (female) (9) – P21 (female) (1)
5 Defective machine monitor CM01 (female) Fuel level Resistance
FULL 7 – 11
EMPTY 85 – 95
Circuit diagram related to fuel level sensor
PC200, 200LC-8E0 (Hybrid) 40-400 29

SEN05252-00 E-11 Fuel level gauge does not indicate normally
(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 q Signal voltage of fuel level sensor can be checked by using monitoring function. (Code: 04200 Fuel
information sensor voltage)

a Turn starting switch to ON position or start engine and perform
troubleshooting.
Probable Reading of fuel level Color of monitor light
Quantity of fuel
causes and gauge (a)
standard 289 l 6
value in nor- 244.5 l 5
mal condition 200 l 4 Blue
100 l 3
60 l 2
41 l 1 Red
Fuel level gauge and fuel level monitor
40-400 30 PC200, 200LC-8E0 (Hybrid)

E-12 Contents of display by machine monitor are different from applicable machine SEN05252-00
E-12 Contents of display by machine monitor are different from appli-

cable machine
Trouble q Contents of display by machine monitor are different from applicable machine
Related infor-
mation

a Turn starting switch ON and perform troubleshooting (by using
Probable monitoring function).
causes and Monitoring code Normal display
1 Defective model code signal
standard 00200 Controller model code PC200-8
value in nor- If display of monitoring is abnormal, perform troubleshooting for failure
mal condition code [DA29KQ].
If causes 1 is not detected, machine monitor may be defective. (Since
PC200, 200LC-8E0 (Hybrid) 40-400 31

SEN05252-00 E-13 Some areas of the machine monitor screen are not displayed
E-13 Some areas of the machine monitor screen are not displayed
Trouble q Some areas of the machine monitor screen are not displayed
q The LCD panel sometimes has black points (points which are not lighted) and bright points (points
Related
which do not go off) for the reason of its characteristics. If the number of the bright points and black
information
points does not exceed 10, those points are not a failure or a defect.

Probable
a Turn starting switch ON and performed troubleshooting.
causes and
Defective machine monitor When following switches are operated, if all LCD panel is lighted up
standard 1
(LCD panel) (all surface becomes white), LCD panel is normal.
value in nor-
q Operation of switches: [4]+[F2] (Press switches simultaneously)
mal condi-
Defective machine moni- If cause 1 is not detected, machine monitor may be defective. (Since
tion 2
tor(body) trouble is in system, troubleshooting cannot be performed.)
40-400 32 PC200, 200LC-8E0 (Hybrid)

E-14 Function switch does not work SEN05252-00
E-14 Function switch does not work

Trouble q Function switch does not work
Related infor- q Condition of signal of function switch can be checked by using monitoring function.
mation (Code: 04503 Monitor function switch)

causes and
standard Machine monitor may be defective.(Since trouble is in system, trou-
value in nor- bleshooting cannot be performed.)
mal condition
PC200, 200LC-8E0 (Hybrid) 40-400 33

SEN05252-00 E-15 Auto-deceleration does not operate normally
E-15 Auto-deceleration does not operate normally

(1) When auto-deceleration switch is operated, auto-deceleration monitor does not light up or does not go
Trouble
off.
Related q Condition of signal of auto-deceleration switch can be checked by using monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)

causes and
standard Machine monitor may be defective.(Since trouble is in system, trou-
mal condition
Trouble (2) Auto-deceleration is not operated or released with lever.

Related q Set speed of auto-deceleration is 1,250 rpm. If fuel control dial is not set above this speed, autodecel-
information eration is not operated or released.

a Start engine and perform troubleshooting (by using monitoring
function).
Monitoring code Item Normal display
Swing
Travel When lever is oper-
01900 Boom LOWER ated: ON
Pressure Switch 1 Boom RAISE When lever is in neu-
Defective PPC pressure sig- Arm IN tral: OFF
1 Arm OUT
nal
Probable Bucket CURL When lever is oper-
causes and 01901 Bucket DUMP ated: ON
standard Pressure Switch 2 When lever is in neu-
Service
value in nor- tral: OFF
mal condition If display of monitoring is abnormal, perform troubleshooting for
"E-26 Monitoring function does not display lever control signal cor-
rectly".
If cause 1 is not detected, machine monitor may be defective.
(Since failure is in it, troubleshooting cannot be performed.)
If cause 1 is not detected, pump controller may be defective. (Since
If cause 1 is not detected, engine controller may be defective. (Since
If cause 1 is not detected, inverter may be defective. (Since trouble is
5 Defective inverter
in system, troubleshooting cannot be performed.)
40-400 34 PC200, 200LC-8E0 (Hybrid)

E-16 Working mode does not change SEN05252-00
E-16 Working mode does not change

Trouble (1) When working mode switch is operated, working mode selection screen is not displayed.
Related infor- q Condition of signal of working mode switch can be checked by using monitoring function.
mation (Code: 04504 Monitor 1st, 2nd line switches)

causes and
standard Machine monitor may be defective. (Since trouble is in system, trou-
mal condition
Trouble (2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related infor-
mation

causes and Machine monitor may be defective. (Since trouble is in system, trou-
standard bleshooting cannot be performed.)
value in nor- Pump controller may be defective
mal condition (Since trouble is in system, troubleshooting cannot be performed.)
PC200, 200LC-8E0 (Hybrid) 40-400 35

SEN05252-00 E-17 Travel speed does not change
E-17 Travel speed does not change

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

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

a Prepare with starting switch OFF, then turn starting switch ON po-
Hot short
Probable sition and perform troubleshooting.
1 (Short circuit with 24 V cir-
causes and Between ground and wiring harness between
cuit) in wiring harness Voltage Max. 1 V
standard C02 (female) (87) – V04 (female) (1)
value in nor- If cause 1 is not detected, machine monitor may be defective.
mal condition (Since trouble is in system, troubleshooting cannot be performed.)
If cause 1 is not detected, pump controller may be defective.
40-400 36 PC200, 200LC-8E0 (Hybrid)

E-18 Alarm buzzer cannot be stopped SEN05252-00
E-18 Alarm buzzer cannot be stopped

Trouble q Alarm buzzer cannot be stopped.
Related infor- q Condition of signal of alarm buzzer cancel switch can be checked by using monitoring function.

causes and
mal condition
PC200, 200LC-8E0 (Hybrid) 40-400 37

SEN05252-00 E-19 Windshield wiper and window washer do not operate
E-19 Windshield wiper and window washer do not operate

Trouble (1) When wiper switch is operated, wiper monitor does not light up or go off.
Related q Condition of wiper switch signal can be checked by using monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)

causes and
mal condition
Trouble (2) When wiper switch is operated, wiper does not operate.
Related q Condition of window rear limit switch signal can be checked by using monitoring function.
information (Code: 02204 Switch 5)

Defective window rear limit W03 (male) Front window Resistance
1 switch When installed to
Min. 1 M
(Internal short circuit) front
Between (1) – (2)
When retracted to
Max. 1
rear
Defective wiper motor without turning starting switch to ON position.
2
(Internal disconnection) M05 (female) Continuity
Between (1) – (3) Continuity
ness
Probable 3 (Disconnection in wiring or Max. 1
– M05 (male) (3) tance
causes and defective contact in connec-
standard tor) Max. 1
– M05 (male) (1) tance
value in nor-
mal condition Ground fault in wiring harness without turning starting switch to ON position.
4 (Short circuit with GND cir- Between ground and wiring harness
Resis-
cuit) between C01 (female) (57) – W03 (female) Min. 1 M
tance
(1)
C01 (female) Front window Resistance
Defective pump controller
When installed to
(Rear limit switch system) Min. 1 M
Between (57) – front
5 ground When retracted to
Max. 1
rear
Defective pump controller without turning starting switch to ON position.
(Wiper motor system) C02 (female) Continuity
40-400 38 PC200, 200LC-8E0 (Hybrid)

E-19 Windshield wiper and window washer do not operate SEN05252-00
Trouble (3) When window washer switch is operated, window washer does not operate.
Related infor- q Condition of window washer switch signal can be checked by using monitoring function.

causes and
standard value Machine monitor may be defective. (Since trouble is in system,
in normal condi- troubleshooting cannot be performed.)
tion
PC200, 200LC-8E0 (Hybrid) 40-400 39

SEN05252-00 E-20 One-touch power maximizing function does not operate normally
E-20 One-touch power maximizing function does not operate normally

(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.
q One-touch power maximizing function does not work when working mode is not power mode (P) or
Related infor- economy mode (E).
mation q Condition of left knob switch signal can be checked by using monitoring function. (Code: 02200 Switch
input 1)

Defective left knob switch
2 S11 (male) Left knob switch Resistance
Release Min. 1 M
Between (1) – (2)
Pressed Max. 1
ness
Wiring harness between F01-9 – S11 Resis-
(female)(1) tance
Probable defective contact in connec-
Wiring harness between S11 (female) (2) – Resis-
causes and tor) Max. 1
C01 (female) (41) tance
standard
value in nor- Ground fault in wiring har- without turning starting switch to ON position.
mal condition ness Between ground and wiring harness between Resis-
4 Min. 1 M
(Short circuit with GND cir- F01-9 – S11 (female) (1) tance
cuit) Between ground and wiring harness between Resis-
Min. 1 M
S11 (female) (2) – C01 (female) (41) tance
5 Defective pump controller C01 (female) Left knob switch Resistance
Between (41) – chas- Release Min. 1 M
sis ground Pressed Max. 1
Machine monitor may be defective. (Since trouble is in system, trou-
bleshooting cannot be performed.)
Circuit diagram related to left knob switch
40-400 40 PC200, 200LC-8E0 (Hybrid)

E-20 One-touch power maximizing function does not operate normally SEN05252-00
Trouble (3) When left knob switch is released, work equipment power does not return to normal level.
Related q Condition of left knob switch signal can be checked by using monitoring function. (Code: 02200 Switch
information input 1)

Probable a Prepare with starting switch OFF, then turn starting switch to ON
Hot short
causes and position and perform troubleshooting.
1 (Short circuit with 24V circuit)
standard Wiring harness between C02 (female) (109) –
in wiring harness Voltage Max. 1 V
value in nor- V02 (female) (1)
mal condition If cause 1 is not detected, pump controller may be defective. (Since
PC200, 200LC-8E0 (Hybrid) 40-400 41

SEN05252-00 E-20 One-touch power maximizing function does not operate normally
40-400 42 PC200, 200LC-8E0 (Hybrid)

E-21 Swing brake does not operate normally SEN05252-00
E-21 Swing brake does not operate normally

Trouble (1) When swing lock switch is operated, swing lock monitor does not light up or go off.
q Condition of swing lock switch signal can be checked by using monitoring function.
Related infor-
(Machine monitor system code: 04502 Monitor input 3)
mation
(Pump controller system code: 02200 Switch input 1)

a Prepare with starting switch OFF, then perform troubleshooting with-
Defective swing lock switch out turning starting switch to ON position.
1 (Internal disconnection or S04 (male) Swing lock switch Resistance
short circuit) OFF Min. 1 M
Between (5) – (6)
ON Max. 1
out turning starting switch to ON position.
ness
J02 – S04 (female) (5) tance
Wiring harness between S04 (female) (6) – Resis-
J05 – chassis ground (T07) tance
standard
value in nor-
out turning starting switch to ON position.
mal condition Ground fault in wiring harness
3 Between ground and wiring harness between
(Short circuit with GND circuit) Resis-
CM02 (female) (5) – J02 – S04 (female) (5), – Min. 1 M
tance
C01 (female) (19)
4 Defective machine monitor CM02 Swing lock switch Voltage
OFF 20 – 30 V
ON Max. 1 V
Defective emergency stop Resis-
5 D03(3)–H15(12) ON Max. 1
switch tance
(2) When swing lock switch is turned ON, swing lock does not operate.
Trouble
(Upper structure lowers by its own weight on slope.)
Related infor-
mation

Defective swing lock switch
1 S04 (male) Swing lock switch Resistance
OFF Min. 1 M
Between (3) – (4)
ON Max. 1
Probable Defective swing brake
Swing Brake
causes and 2 release switch (Internal short S25 (male) Resistance
release switch
standard circuit)
Normal Min. 1 M
value in nor- Between (13) – (14)
Release Max. 1
mal condition a Prepare with starting switch OFF, then turn starting switch to ON
Hot short (Short circuit with D01 (female) (3) – J02 – S04 (female) (3), – Voltage Max. 1 V
3
24V circuit) in wiring harness S25 (female) (14)
Between ground and wiring harness S04
(female) (4) – V03 (female) (1), – D03 Voltage Max. 1 V
(female) (3)
PC200, 200LC-8E0 (Hybrid) 40-400 43

SEN05252-00 E-21 Swing brake does not operate normally
Trouble (3) Even if swing lock switch is turned to OFF position, swing lock is not released.
Related infor-
mation

1 Defective swing lock switch S04 (male) Swing lock switch Resistance
Bucket DUMP Min. 1 M
Between (3) – (4)
Service Max. 1
Defective swing brake
Swing Brake
Probable 2 release switch (Internal short S25 (male) Resistance
release switch
causes and circuit)
Normal Min. 1 M
standard Between (13) – (14)
Release Max. 1
value in nor- a Prepare with starting switch OFF, then turn starting switch ON po-
mal condition sition and perform troubleshooting.
Hot short (Short circuit with D01 (female) (3) – J02 – S04 (female) (3), – Voltage Max. 1 V
3
24 V circuit) in wiring harness S25 (female) (14)
Between ground and wiring harness S04
(female)(4) – V03 (female) (1), – D03 Voltage Max. 1 V
(female) (3)
Defective swing emergency Resis-
4 D03(3) – H15(12) ON Max. 1
stop switch tance
40-400 44 PC200, 200LC-8E0 (Hybrid)

E-21 Swing brake does not operate normally SEN05252-00
Circuit diagram related to swing brake solenoid
PC200, 200LC-8E0 (Hybrid) 40-400 45

SEN05252-00 E-22 Travel alarm does not sound or does not stop sounding
E-22 Travel alarm does not sound or does not stop sounding
Trouble (1) Alarm does not sound during travel.
Related
information

If the fuse is broken, the circuit probably has a grounding fault, etc.
1 Defective fuse No.15
(See cause 4)
a Start the engine and perform troubleshooting.
When lever is oper-
Defective travel signal sys- 01900 ated: ON
2 Travel
tem Pressure Switch 1 When lever is in neu-
tral: OFF
Probable If display of monitoring is abnormal, perform troubleshooting for E-26
causes and Monitoring function does not display lever control signal normally.
ness
mal condi- Wiring harness between F01-15 – J03 – M14 Resis-
tion (female) (1) tance
Wiring harness between M14 (female) (2) – Resis-
tor Max. 1
J01(19) – P09 (female) (2) tance
ness
F01-15 – J03 – M14 (female) (1), – circuit Min. 1 M
cuit) tance
branch end
Defective travel alarm
5 If causes 1 – 4 are not detected, travel alarm is defective.
(Internal defect)
Trouble (2) Alarm does not stop sounding while machine is stopped.
Related
information

a Start the engine and perform troubleshooting.
When lever is oper-
Defective travel signal sys- 01900 ated: ON
1 Travel
tem Pressure Switch 1 When lever is in neu-
tral: OFF
If display of monitoring is abnormal, perform troubleshooting for "E-26
Probable
Monitoring function does not display lever control signal normally".
causes and
Defective assembled-type a Prepare with starting switch OFF, then perform troubleshooting
standard
diode D02 without turning starting switch to ON position.
value in nor- 2
(Short circuit with GND cir- D02(male) Continuity
mal condi- Between (4) – (8) Continuity
cuit)
tion
Defective travel hydraulic without turning starting switch to ON position.
3
pressure switch Resis-
Between P09 (male) (1) – (2) Min. 1 M
tance
4
(Short circuit with GND cir- Wiring harness between M14 (female) (2) – Resis-
Min. 1 M
cuit) J01 – P09 (female) (2), – D02 (female) (4) tance
40-400 46 PC200, 200LC-8E0 (Hybrid)

E-22 Travel alarm does not sound or does not stop sounding SEN05252-00
Circuit diagram related to travel alarm and travel PPC oil pressure switch
PC200, 200LC-8E0 (Hybrid) 40-400 47

SEN05252-00 E-23 Air conditioner does not operate normally (including air conditioner abnormality record)
E-23 Air conditioner does not operate normally (including air conditioner
abnormality record)
Trouble (1) When air conditioner switch is operated, air conditioner control screen is not displayed.
Related q Condition of air conditioner switch signal can be checked by using monitoring function.
information (Code: 04505 Monitor 3rd, 4th line switches, 04506 Monitor 5th line switch)
Possible Cause Standard value in normal condition/Remarks on troubleshooting

causes and
mal condition
Trouble (2) When air conditioner switch is operated, air conditioner does not operate at all.
Related
information

1 Defective fuse No.11 If fuse is broken, circuit probably has ground fault, etc. (See cause 4)
If fuse in unit is broken, circuit in unit probably has ground fault. (See
2 Defective fuse in unit
cause 4.)
ness
Wiring harness between F01-11 – fuse in unit
3 (Disconnection in wiring or Resistance Max. 1
– ACW (wiring side) (6)
Wiring harness between ACW (wiring side)
Probable tor) Resistance Max. 1
(16) – chassis ground (T07)
causes and
standard Ground fault in wiring har-
value in nor- ness
mal condition (Short circuit with GND cir-
F01-11 – fuse in unit – ACW (wiring side) (6), Resistance Min. 1 M
cuit)
– circuit branch end
Defective air conditioner
5 ACW (wiring side) Voltage
controller
Between (6) – (16) 20 – 30 V
If above voltage is normal, air conditioner controller may be defective.
40-400 48 PC200, 200LC-8E0 (Hybrid)

E-23 Air conditioner does not operate normally (including air conditioner abnormality record) SEN05252-00
Trouble (3) Air does not come out (Air flow is insufficient).
Related infor-
mation

without turning starting switch to ON position (coil side).
Between (1) – (3) 140 – 340
Defective blower relay
1 a Prepare with starting switch OFF, then turn starting switch to ON po-
sition and perform troubleshooting (contact side).
R20 Air conditioner switch Voltage
Between (4) – chas-
Air blow position 20 – 30 V
sis ground
a Prepare with starting switch OFF, then turn starting switch ON and
perform troubleshooting.
Defective power transistor
2 Fan switch If air flow changes according to
(Internal defect)
Operate in range of Low, operation of fan switch, power tran-
Medium, and High sistor is normal.
Defective blower motor MB (wiring side) Air conditioner switch Voltage
3
(Internal defect) Between (1) – (2) Air blow position 20 – 30 V
If the above voltage is normal and the blower motor does not rotate,
the blower motor is defective.
a Prepare with starting switch OFF, then performt troubleshooting
Wiring harness between F01-11 – fuse in unit
Resistance Max. 1
– R20 (female) (1)
Probable Wiring harness between R20 (female) (3) –
Resistance Max. 1
causes and ACW (wiring side) (36)
standard Wiring harness between F01-11 –R20
Disconnection in wiring har- Resistance Max. 1
value in nor- (female) (5)
ness
mal condition 4 Wiring harness between R20 (female) (4) –
(Disconnection in wiring or Resistance Max. 1
MB (wiring side) (1)
Wiring harness between MB (wiring side) (2) –
tor) Resistance Max. 1
PTR (wiring side) (3)
Wiring harness between PTR (wiring side) (1)
Resistance Max. 1
– chassis ground (T07)
Resistance Max. 1
Resistance Max. 1
Resistance Min. 1 M
Ground fault in wiring har- R20 (female) (3) – ACW (wiring side) (36)
ness Between ground and wiring harness between
(Short circuit with GND cir- R20 (female) (4) – MB (wiring side) (1)
cuit) Between ground and wiring harness between
Resistance Min. 1 M
MB (wiring side) (2) – PTR (wiring side) (3)
Resistance Min. 1 M
PTR (wiring side) (2) – ACW (wiring side) (8)
If causes 1 – 5 are not detected, air conditioner controller may be
6 defective. (Since trouble is in system, troubleshooting cannot be per-
controller
formed.)
If causes 1 – 5 are not detected, air conditioner system may be defec-
7 tive. See Machine Component Chapter of Shop Manual, Air condi-
system
tioner, Troubleshooting.
PC200, 200LC-8E0 (Hybrid) 40-400 49

Trouble (4) Air is not cooled (Cooling performance is insufficient).

Related infor-
mation

without turning starting switch to ON position (coil side).
Between (1) – (3) 140 – 340
Defective compressor relay
1 a Prepare with starting switch OFF, then turn starting switch to ON
position and perform troubleshooting (contact side).
R21 Air conditioner switch Voltage
Between (2) – chas-
Cooling position 20 – 30 V
sis ground
Internal air sensor may be defective. Perform 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. Perform trouble-
3
sure switches shooting for “Abnormality in refrigerant”.
Defective compressor clutch
4 Compressor clutch may be defective. Check it directly.
(Internal defect)
Defective compressor
5 Compressor may be defective. Check it directly.
(Internal defect)
Probable
causes and
standard Wiring harness between F01-11 – fuse in unit
value in nor- Disconnection in wiring har- Resistance Max. 1
– R21 (female) (1)
mal condition ness
Wiring harness between R21(female) (3) –
ACW (wiring side) (35)
Wiring harness between F01-11 – R21
(female)(4)
Wiring harness between R21 (female) (2) –
Resistance Max. 1
AC02 (female) (1)
ness Between ground and wiring harness between
(Short circuit with GND cir- R21 (female) (3) – ACW (wiring side) (35)
Resistance Min. 1 M
R21 (female) (2) – AC02 (female) (1)
controller
formed.)
If causes 1 – 7 are not detected, air conditioner system may be defec-
9 tive. See Machine Component Chapter of Shop Manual, Air condi-
system
tioner, Troubleshooting.
40-400 50 PC200, 200LC-8E0 (Hybrid)

(5) Air conditioner abnormality record: Communication condition “CAN disconnection”, Communication
Trouble
condition “Abnormal”
q While abnormality in communication is being detected, “CAN disconnection” is displayed.
q If abnormality in communication has been detected and reset, “Abnormality” is displayed.
Related infor-
q If “CAN disconnection” is displayed as communication condition, communication cannot be performed
mation
normally. Accordingly, condition of other monitor is not displayed.
q Method of reproducing abnormality record: Turn starting switch to ON position.

ness
Wiring harness between N10 (female) (2) –
CM02 (female) (8)(9)
Wiring harness between N10 (female) (1) –
CM02 (female) (10)
a Prepare with starting switch OFF, then performtroubleshooting
Ground fault in wiring har- N10 (male) (2) – CM02 (female) (8) (9) – C01
Resistance Min. 1 M
ness (female)(45), – CE02 (female) (46), – K02
2
(Short circuit with GND cir- (female) (A), – N08 (male) (3)
N10 (female) (1) – CM02 (female) (10), – C01
Resistance Min. 1 M
(female) (64), – CE02 (female) (47), – K02
Probable
(female) (B), – N08 (male) (10)
causes and
standard
value in nor- Between ground and wiring harness between
mal condition
N10(male) (2) – CM02 (female) (8) (9) – C01
Voltage Max. 5.5 V
Hot short(Short circuit with24 (female) (45), – CE02 (female) (46), – K02
3
V circuit) in wiring harness (female) (A), – N08(male) (3)
N10 (female) (1) – CM02 (female) (10), – C01
Voltage Max. 5.5 V
(female) (64), – CE02 (female) (47), – K02
(female) (B), – N08 (male) (10)
Defective CAN terminal a Prepare with starting switch OFF, then perform troubleshooting
resistance without turning starting switch to ON position.
4
(Internal short circuit or dis- K02 (male) Resistance
connection) Between (A) – (B) 47 – 67
controller
formed.)
PC200, 200LC-8E0 (Hybrid) 40-400 51

Trouble (6) Air conditioner abnormality record: Setting condition “Abnormality”

q If setting of air conditioner controller model is different from setting of machine monitor model,
“Abnormality” is displayed.
Related infor-
q If “CAN disconnection” is displayed as communication condition, communication cannot be carried
mation
out normally. Accordingly, this condition is not displayed.
q Method of reproducing abnormality record: Turn starting switch to ON position.

causes and Defective air conditioner con- Air conditioner controller may be defective. (Since trouble is in sys-
1
standard troller tem, troubleshooting cannot be performed.)
value in nor- Machine monitor may be defective. (Since trouble is in system, trou-
mal condition bleshooting cannot be performed.)
Trouble (7) Air conditioner abnormality record: Internal air sensor “Abnormality”
q If “CAN disconnection” is displayed as communication condition, communication cannot be per-
Related infor- formed normally. Accordingly, this condition is not displayed.
mation q Method of reproducing abnormality record: Turn starting switch to ON position + Turn air conditioner
(A/C) switch to ON position.

Defective recirculated air a Prepare with starting switch OFF, then perform troubleshooting
sensor without turning starting switch to ON position.
1
(Internal disconnection or THI (device side) Resistance
short circuit) Between (1) –(2) 300 –430
ness
Wiring harness between ACW (wiring side) Resis-
(11) – THI (wiring side) (2) tance
Wiring harness between ACW (wiring side) Resis-
(27) – THI (wiring side) (1) tance
standard
value in nor-
mal condition 3
(Short circuit with GND cir- Between ground and wiring harness between Resis-
Min. 1 M
cuit) ACW (wiring side) (11) – THI (wiring side) (2) tance
Hot short (Short circuit
4 with24 V circuit) in wiring
harness Voltage Max. 1 V
ACW (wiring side) (11) – THI (wiring side) (2)
controller
formed.)
40-400 52 PC200, 200LC-8E0 (Hybrid)

Trouble (8) Air conditioner abnormality record: External air sensor "Unused"
q External air sensor is not used in air conditioner system of this machine.
Related infor-
q If “CAN disconnection” is displayed as communication condition, communication cannot be performed
mation
normally. Accordingly, this condition is not displayed.

causes and
standard Since external air sensor is not used in air conditioner system of this
1 Normal display
value in nor- machine, above display is normal
mal condition
Trouble (9) Air conditioner abnormality record: Air flow sensor "Abnormality"
Related formed normally. Accordingly, this condition is not displayed.
information q Method of reproducing abnormality record: Turn starting switch to ON position + Turn air conditioner

Defective air flow sensor
THF (device side) Resistance
short circuit)
Between (1) – (2) 100 – 115 k
ness
(12) – THF (wiring side) (2)
Probable Wiring harness between ACW (wiring side)
causes and (27) – THF (wiring side) (1)
value in nor- 3 ness without turning starting switch to ON position.
mal condition (Short circuit with GND cir- Wiring harness between ACW (wiring side)
Resistance Min. 1 M
cuit) (12) – THF (wiring side) (2)
Hot short (Short circuit position and perform troubleshooting.
4 with24 V circuit) in wiring Between ground and wiring harness
harness between ACW (wiring side) (12) – THF (wir- Voltage Max. 1 V
ing side) (2)
Defective air conditioner con-
troller
formed.)
PC200, 200LC-8E0 (Hybrid) 40-400 53

Trouble (10) Air conditioner abnormality record: Daylight sensor "Abnormality"


Defective daylight sensor
1 Daylight sensor may be defective.
(Internal defect)
ness
(3) – P31 (female) (1)
(15) – P31 (female) (2)
Ground fault in wiring har- Between ground and wiring harness
Probable
ness between ACW (wiring side) (3) – P31 Resistance Min. 1 M
causes and 3
(Short circuit with GND cir- (female) (1), – circuit branch end
standard
cuit) Between ground and wiring harness
value in nor-
between ACW (wiring side) (15) – P31 Resistance Min. 1 M
mal condition
(female) (2)
Between ground and wiring harness
Hot short (Short circuit with between ACW (wiring side) (3) – P31 Voltage Max. 1 V
4
24V circuit) in wiring harness (female) (1), – circuit branch end
between ACW (wiring side) (15) – P31 Voltage Max. 1 V
(female) (2)
troller
formed.)
40-400 54 PC200, 200LC-8E0 (Hybrid)

Trouble (11) Air conditioner abnormality record: Air outlet damper “Abnormality”

Defective air outlet servo-
1 motor Air outlet servomotor may be defective.
(Internal defect)
Wiring harness between MV1 (wiring side)
Resistance Max. 1
(1) – ACW (wiring side) (3)
ness Resistance Max. 1
defective contact in connec- Resistance Max. 1
tor)
Resistance Max. 1
Resistance Max. 1
between MV1 (wiring side) (1) – ACW (wiring Resistance Min. 1 M
side) (3), – circuit branch end
Probable Ground fault in wiring har- Between ground and wiring harness
causes and ness between MV1 (wiring side) (5) – ACW (wiring Resistance Min. 1 M
3
standard (Short circuit with GND cir- side) (9)
value in nor- cuit) Between ground and wiring harness
mal condition between MV1 (wiring side) (6) – ACW (wiring Resistance Min. 1 M
side) (24)
between MV1 (wiring side) (7) – ACW (wiring Resistance Min. 1 M
side) (23)
between MV1 (wiring side) (1) – ACW (wiring Voltage Max. 1 V
4 with24 V circuit) in wiring
side) (9)
harness
side) (24)
side) (23)
troller
formed.)
PC200, 200LC-8E0 (Hybrid) 40-400 55

Trouble (12) Air conditioner abnormality record: A/M damper "Abnormality"


Defective air mix servomotor
1 Air mix servomotor may be defective.
(Internal defect)
Wiring harness between MAM (wiring
Resistance Max. 1
side)(1) – ACW (wiring side) (27)
Wiring harness between MAM (wiring side)
ness Resistance Max. 1
defective contact in connec- Resistance Max. 1
tor)
Resistance Max. 1
Resistance Max. 1
between MAM (wiring side) (3) – ACW (wiring Resistance Min. 1 M
Ground fault in wiring har- Between ground and wiring harness
Probable
ness between MAM (wiring side) (5) – ACW (wiring Resistance Min. 1 M
causes and 3
(Short circuit with GND cir- side) (2)
standard
value in nor-
mal condition side) (21)
side) (22)
between MAM (wiring side) (3) – ACW (wiring Voltage Max. 1 V
Hot short (Short circuit with between MAM (wiring side) (5) – ACW (wiring Voltage Max. 1 V
4
24V circuit) in wiring harness side) (2)
side) (21)
side) (22)
troller
formed.)
40-400 56 PC200, 200LC-8E0 (Hybrid)

Trouble (13) Air conditioner abnormality record: Refrigerant "Abnormality"


Insufficient refrigerant (gas)
1 Refrigerant (gas) may be insufficient. Check it directly.
Defective high and low pres-
2 sure switches (Internal dis-
P17 (male) Resistance
Probable connection)
Between (1) – (2) Max. 1
causes and
standard Disconnection in wiring har-
value in nor- ness
mal condition 3 (Disconnection in wiring or Resistance Max. 1
(4) – P17 (female) (1)
Wiring harness between P17 (female) (2) –
chassis ground (T06)
troller
formed)
PC200, 200LC-8E0 (Hybrid) 40-400 57

Circuit diagram related to air conditioner
40-400 58 PC200, 200LC-8E0 (Hybrid)

E-24 While starting switch is in OFF position, service meter is not displayed SEN05252-00
E-24 While starting switch is in OFF position, service meter is not

displayed
Trouble q While starting switch is in OFF position, service meter is not displayed
q While starting switch is in 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)

Probable When starting switch is turned to ON position, if machine monitor dis-
causes and Defective backup power sup- plays nothing, backup power supply system may be defective. In this
1
standard ply system case, carry out troubleshooting for E-1 When starting switch turned
value in nor- ON, machine monitor displays nothing”.
mal condition If cause 1 is not detected, machine monitor may be defective. (Since
PC200, 200LC-8E0 (Hybrid) 40-400 59

SEN05252-00 E-25 Machine monitor cannot be set in service mode
E-25 Machine monitor cannot be set in service mode

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

causes and
mal condition
40-400 60 PC200, 200LC-8E0 (Hybrid)

E-26 Monitoring function does not display lever control signal normally SEN05252-00
E-26 Monitoring function does not display lever control signal normally
Trouble (1) Monitoring function does not display boom RAISE correctly.
Related infor-
q Monitoring code: 01900 Pressure switch 1
mation

causes and
standard Defective boom RAISE PPC
1 Perform troubleshooting for failure code [DHS8MA].
value in nor- pressure sensor system
mal condition
Trouble (2) Monitoring function does not display arm IN correctly.

Related infor-
mation

causes and
standard Defective arm IN PPC pres-
1 Perform troubleshooting for failure code [DHS3MA].
value in nor- sure sensor system
mal condition
Trouble (3) Monitoring function does not display bucket CURL correctly.
Related infor-
mation

causes and
standard Defective bucket CURL PPC
1 Perform troubleshooting for failure code[ DHS4MA].
mal condition
Trouble (4) Monitoring function does not display bucket DUMP correctly.
Related infor- q Monitoring code: 01901 Pressure switch 2
mation
Probable Cause Standard value in normal state/Remarks on troubleshooting

causes and
standard Defective bucket DUMP PPC
1 Perform troubleshooting for failure code [DHSDMA].
mal condition
PC200, 200LC-8E0 (Hybrid) 40-400 61

SEN05252-00 E-26 Monitoring function does not display lever control signal normally
Trouble (5) Monitoring function does not display boom LOWER correctly.
Related infor-
mation

Defective boom LOWER troubleshooting.
PPC pressure switch (Inter- Right work equipment
nal disconnection or short control lever
circuit) Neutral Min. 1M
Between(1) –(2)
Boom RAISE Max. 1
ness
Probable Wiring harness between P02 (female) (2) – Resis-
tor) Max. 1
causes and chassis ground (T10) tance
value in nor- ness without turning starting switch to ON position.
3
mal condition (Short circuit with GND cir- Between ground and wiring harness between Resis-
Min. 1 M
cuit) C01 (female) (14) – P02 (female) (1) tance
4 with24 V circuit) in wiring har-
C01 (female) (14) – P02 (female) (1)
troubleshooting.
Right work equipment
control lever
Between (14) – Neutral Min. 1 M
ground Boom RAISE Max. 1
Circuit diagram related to boom LOWER PPC pressure switch
40-400 62 PC200, 200LC-8E0 (Hybrid)

Trouble (6) Monitoring function does not display arm OUT correctly.
Related
information

Defective arm OUT PPC troubleshooting.
pressure switch Left work equipment
(Internal disconnection or control lever
short circuit) Neutral Min. 1 M
Between (1) –(2)
Arm OUT Max. 1
a Prepare with starting switch OFF, then cperform troubleshooting
ness
P08 (female)(1) tance
tor) Max. 1
Probable chassis ground (T10) tance
ness
value in nor- 3 Between ground and wiring harness
mal condition between C01 (female) (15) – P08 (female) Min. 1 M
cuit) tance
harness between C01 (female) (15) – P08 (female) Voltage Max. 1 V
(1)
troubleshooting.
Left work equipment
control lever
Between (15) – Neutral Min. 1 M
ground Arm OUT Max. 1
Circuit diagram related to arm OUT PPC pressure switch
PC200, 200LC-8E0 (Hybrid) 40-400 63

Trouble (7) Monitoring function does not display swing correctly.

Related
information

causes and Defective swing RIGHT PPC
1 Perform troubleshooting for failure code [DHSAMA].
standard pressure sensor system
value in nor- Defective swing LEFT PPC
2 Perform troubleshooting for failure code [DHSBMA].
mal state pressure sensor system
Trouble (8) Monitoring function does not display travel normally.

Related infor-
mation

Defective travel PPC pres- troubleshooting.
sure switch P09 (male) Travel lever Resistance
1
(Internal disconnection or Neutral Min. 1 M
short circuit) Between (1) – (2) Travel forward or
Max. 1
reverse
2
(Internal disconnection) D02 (male) Continuity
Wiring harness between C01 female) (55) – Resis-
ness Max. 1
D02 (female)(8) tance
Wiring harness between D02 (female) (4) – Resis-
defective contact in connec- Max. 1
J01 – P09 (female) (2) tance
Probable tor)
causes and Max. 1
mal state Ground fault in wiring har- Between ground and wiring harness
Resis-
ness between C01 (female) (55) – D02 (female) Min. 1 M
4 tance
(Short circuit with GND cir- (8)
Resis-
between D02 (female) (4) – J01 – P09 Min. 1 M
tance
(female) (2) and circuit branch end
harness between C01 (female) (55) – D02 (female) Voltage Max. 1 V
troubleshooting.
C01 (female) Travel lever Continuity
Neutral No continuity
Between (55) –
Travel forward or
ground Continuity
reverse
40-400 64 PC200, 200LC-8E0 (Hybrid)

Circuit diagram related to travel PPC pressure switch and travel alarm
PC200, 200LC-8E0 (Hybrid) 40-400 65

Trouble (9) Monitoring function does not display "travel differential pressure" correctly.
Related infor-
mation

Defective travel steering
troubleshooting.
PPC pressure switch
1 P10 (male) Travel lever Resistance
Neutral Min. 1 M
short circuit) Between(1) – (2)
Only 1 side operated Max. 1
ness
tor) Max. 1
Probable
standard ness
3 Between ground and wiring harness
value in nor- (Short circuit with GND cir- Resis-
between C01 (female) (36) – P10 (female) Min. 1 M
mal condition cuit) tance
(2)
harness between C01 (female) (36) – P10 (female) Voltage Max. 1 V
(2)
troubleshooting.
C01 (female) Travel lever Resistance
Neutral Min. 1 M
Between(36) –
Only one side oper-
ground Max. 1
ated
Circuit diagram related to travel steering PPC pressure switch
40-400 66 PC200, 200LC-8E0 (Hybrid)

E-27 KOMTRAX system does not operate normally SEN05252-00
E-27 KOMTRAX system does not operate normally

Trouble q KOMTRAX system does not operate normally.
q If KOMTRAX system administrator makes request for checking system on machine side for trouble,
Related perform following troubleshooting.
information q Even if KOMTRAX system has trouble, it does not particularly appear on machine.
q Perform all troubleshooting on service menu screen of machine monitor.

a Turn starting switch to ON position and check “Setting condition
or terminal” screen.
1 Defective communication 1
Check item Normal display
Communication start check Completion
a Turn starting switch to ON position and check “Condition of po-
sitioning and communication” screen.
N ###.##.## (Latitude)
Probable 2 Defective GPS
Positioning E ###.##.## (Longitude)
causes and
In positioning
standard
If latitude and longitude are not displayed in 5 minutes on open
value in nor-
patch, notify KOMTRAX service hot line.
mal condi- a Turn starting switch to ON position and check “Condition of po-
tion
Defective communication envi- Check item Normal display
3
ronment 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.
a Turn starting switch to ON position and check “Condition of po-
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 service
machine monitor. menu of the machine monitor.
PC200, 200LC-8E0 (Hybrid) 40-400 67

SEN05252-00
©2009 KOMATSU
All Rights Reserved
40-400 68
SEN05253-00
SEN05253-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
500 Troubleshooting of hydraulic and
mechanical system (H-mode)
System diagram of hydraulic and mechanical system ................................................................................ 4

Information in troubleshooting table............................................................................................................ 6
H-1 Speed or power of all work equipment and travel is low ...................................................................... 7
H-2 Engine speed lowers significantly or engine stalls ............................................................................... 8
H-3 All work equipment and travel systems do not work ............................................................................ 9
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 ....................................................................................... 12
H-7 Speed or power of boom is low............................................................................................................ 13
H-8 Speed or power of arm is low............................................................................................................... 14
H-9 Speed or power of bucket is low .......................................................................................................... 15
H-10 Work equipment does not move in its single operation...................................................................... 16
H-11 Hydraulic drift of work equipment is large .......................................................................................... 17
H-12 Time lag of work equipment is large .................................................................................................. 18
H-13 When part of work equipment is relieved singly, other parts of work equipment move ..................... 19
H-14 Power maximizing function does not work ......................................................................................... 20
H-15 In compound operation of work equipment, speed of part loaded more is low .................................. 21
H-16 When machine swings and travels simultaneously, travel speed is low ............................................ 22
PC200, 200LC-8E0 (Hybrid) 40-500 1

500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-17 Machine deviates during travel........................................................................................................... 23

H-18 Travel speed is low............................................................................................................................. 24
H-19 Machine is not steered well or steering power is low ......................................................................... 25
H-20 Travel speed does not shift or travel speed is low or high ................................................................. 26
H-21 Travel system does not work (only one side) ..................................................................................... 27
H-22 Upper structure does not swing.......................................................................................................... 28
H-23 Swing acceleration or swing speed of upper structure is low............................................................. 29
H-24 Upper structure overruns remarkably when it stops swinging............................................................ 30
H-25 Large shock is made when upper structure stops swinging............................................................... 31
H-26 Large sound is made when upper structure stops swinging .............................................................. 32
H-27 Upper structure lowers largely by its own weight ............................................................................... 33
40-500 2 PC200, 200LC-8E0 (Hybrid)

Shop Manual SEN05253-00
PC200, 200LC-8E0 (Hybrid) 40-500 3

SEN05253-00 System diagram of hydraulic and mechanical system
System diagram of hydraulic and mechanical system
40-500 4 PC200, 200LC-8E0 (Hybrid)

System diagram of hydraulic and mechanical system SEN05253-00
a This system diagram is a rough general hydraulic circuit diagram made as reference material for trouble-
shooting of the hydraulic and mechanical systems.
PC200, 200LC-8E0 (Hybrid) 40-500 5

SEN05253-00 Information in troubleshooting table

a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting,
understand that information fully.
Trouble Trouble which occurred in machine
Related
Information related to detected trouble or troubleshooting
information
Cause Standard value/Remarks on troubleshooting
Possible 2
causes and Possible causes of trouble
standard <Contents of description>
(Given numbers are refer-
value for q Standard value to determine possible causes
ence numbers, which do not
judgment q Remarks on judgment
indicate priority)
3
40-500 6 PC200, 200LC-8E0 (Hybrid)

H-1 Speed or power of all work equipment and travel is low SEN05253-00
H-1 Speed or power of all work equipment and travel is low

Trouble q Speed or power of all work equipment and travel is low.
Related
q Carry out all troubleshooting in power mode (P) of working mode.
information

a Prepare with engine stopped, and then run engine at full speed and
carry out troubleshooting.
1 Malfunction of unload valve Control lever Unload pressure
3.5 ± 1.0 MPa
All levers in the neutral position
{36 ± 10 kg/cm2}
Defective adjustment or Left work equipment control lever Main relief pressure
2 malfunction of main relief 33.3 – 36.8 MPa
Arm IN 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 Control lever Control circuit source pressure
3
pressure valve 2.84 – 3.43 MPa
All levers in neutral position
{29 – 35 kg/cm2}
low speed and carry out troubleshooting at each speed.
PC-EPC valve output
Engine Control lever
Malfunction of PC-EPC pressure
4 2.9 MPa
valve Low speed
All levers in the neu- {30 kg/cm2}
tral position 0.52 – 0.91 MPa
High speed
Possible {5.3 – 9.3 kg/cm2}
causes and a Prepare with engine stopped, and then run engine at full speed and
standard carry out troubleshooting.
value for Measurement con-
Measured oil pressure Oil pressure ratio
judgment dition
Defective adjustment or
5 Pump discharge pressure Swing lock switch: 1
malfunction of PC valve
ON Approx. 0.6
PC valve output pressure
Arm IN relief (Approx. 3/5)
If oil pressure does not become normal after adjustment, PC valve may
have malfunction or internal defect. Check PC valve directly.
a Prepare with engine stopped, and then run engine at high idle and car-
ry out troubleshooting.
LS-EPC valve output
Travel speed Travel lever
Malfunction of LS-EPC pressure
6 2.9 MPa
valve Lo Neutral
{30 kg/cm2}
0 MPa
Hi Operated
{0 kg/cm2}
Operation of levers and oil pressure ratio
Measured oil pressure Run the track idle
All levers in neutral
Defective adjustment or (Lever operated halfway)
7
malfunction of LS valve Pump discharge pressure 1
Almost same pres-
Approx. 0.6
PC valve output pressure sure
(Approx. 3/5)
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 defect of
9 Defective piston pump
piston pump.
PC200, 200LC-8E0 (Hybrid) 40-500 7

SEN05253-00 H-2 Engine speed lowers significantly or engine stalls
H-2 Engine speed lowers significantly or engine stalls

Trouble q Engine speed lowers significantly or engine stalls.
Related
information

a Prepare with engine stopped, and then run engine at full speed
and carry out troubleshooting.
Left work equipment control lever Main relief pressure
Defective adjustment or mal- 33.3 – 36.8 MPa
1 Arm IN 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.
and low speed and carry out troubleshooting at each speed.
PC-EPC valve output
Engine Control lever
pressure
2 Malfunction of PC-EPC valve 2.9 MPa
Low speed
All levers in the neu- {30 kg/cm2}
tral position 0.52 – 0.91 MPa
High speed
{5.3 – 9.3 kg/cm2}
a Prepare with engine stopped, then run engine at high speed and
Possible carry out troubleshooting.
causes and Measurement condi-
Measured oil pressure Oil pressure ratio
standard tion
value for Defective adjustment or mal- Pump discharge pres-
3 1
judgment function of PC valve sure Swing lock switch: ON
PC valve output pres- Arm IN relief Approx. 0.6
sure (Approx. 3/5)
If oil pressure does not become normal after adjustment, PC valve
may have malfunction or internal defect. Check PC valve directly.
Measured oil pressure All levers in the neu- Run the track idle
(Lever operated half-
Defective adjustment or mal- tral position
4 way)
function of LS valve Pump discharge pres-
1
sure
Almost same pressure
PC valve output pres- Approx. 0.6
sure (Approx. 3/5)
If oil pressure does not become normal after adjustment, LS valve
may have malfunction or internal defect. Check LS valve directly.
Clogging of orifice or filter in Orifices or filters in pump servo devices may be clogged. Check them
5
serve device directly.
40-500 8 PC200, 200LC-8E0 (Hybrid)

H-3 All work equipment and travel systems do not work SEN05253-00
H-3 All work equipment and travel systems do not work

Trouble q All work equipment and travel systems do not work.
Related infor-
mation

PPC lock solenoid valve output
Lock lever
Malfunction of PPC lock sole- pressure
1 0 MPa
noid valve Lock
{0 kg/cm2}
2.9 MPa
Free
{30 kg/cm2}
Possible a Prepare with engine stopped, and then run engine at full speed
causes and and carry out troubleshooting.
standard Malfunction of self-pressure Control lever Control circuit source pressure
2
value for reducing valve
2.84 – 3.43 MPa
judgment All levers in the neutral position
{29 – 35 kg/cm2}
Piston pump may have malfunction or internal defect. Check it by fol-
lowing method.
1) Remove plugs from pump discharge pressure pickup ports (F and
3 Defective piston pump R).
2) Crank engine at flywheel (manually).
3) If oil flows out from pump discharge pressure pickup ports, piston
pump is normal.
a Pump shaft may not revolve because of defect in damper. Check
4 Defective damper
damper directly.
PC200, 200LC-8E0 (Hybrid) 40-500 9

SEN05253-00 H-4 Abnormal sound comes out from around hydraulic pump
H-4 Abnormal sound comes out from around hydraulic pump

Trouble q Abnormal sound comes out from around hydraulic pump.
Related
information

1 Lowering of hydraulic oil level Hydraulic oil level may be low. Check it directly.
Possible
causes and 2 Defective hydraulic oil Air may be mixed in hydraulic oil. Check oil directly.
standard Negative pressure may be generated in hydraulic tank because of
3 Clogging of hydraulic tank cap
value for clogged hydraulic tank cap. Check cap directly.
judgment 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.
40-500 10 PC200, 200LC-8E0 (Hybrid)

H-5 Auto-decelerator does not operate SEN05253-00
H-5 Auto-decelerator does not operate

Trouble q Auto-decelerator does not operate.
q Carry out this troubleshooting if auto-decelerator does not operate while travel lever is operated.
Related infor- Shuttle valve (in PPC valve) is installed between PPC valve and oil pressure switch of only in travel
mation circuit.

a Prepare with engine stopped, then run engine at high speed and
Possible carry out troubleshooting.
causes and
Travel lever PPC valve output pressure
standard Malfunction of travel PPC
value for 1 0 MPa
valve (shuttle valve) Neutral
judgment {0 kg/cm2}
Forward 2.84 – 3.43 MPa
Reverse {29 – 35 kg/cm2}
PC200, 200LC-8E0 (Hybrid) 40-500 11

SEN05253-00 H-6 Fine control performance or response is low
H-6 Fine control performance or response is low

Trouble q Fine control performance or response is low.
Related
information

LS-EPC valve output
pressure
1 Malfunction of LS-EPC valve Approx. 2.9 MPa
Lo Neutral
{Approx. 30 kg/cm2}
0 MPa
Hi Operated
{0 kg/cm2}
Orifice of LS circuit (pump – piping – control valve) may be clogged.
Possible 2 Clogging of LS circuit orifice
Check it directly.
causes and
standard
value for
judgment Operation of levers and oil pressure ratio
Measured oil pressure All levers in the neu- Run the track idle
3 way)
function of LS valve Pump discharge pres-
1
sure
Almost same pressure
PC valve output pres- Approx.0.6
sure (Approx. 3/5)
If oil pressure does not become normal after adjustment, LS valve
40-500 12 PC200, 200LC-8E0 (Hybrid)

H-7 Speed or power of boom is low SEN05253-00
H-7 Speed or power of boom is low

Trouble q Speed or power of boom is low.
Related infor-
mation

Right work equipment control
PPC valve output pressure
Malfunction of right PPC lever
1 0 MPa
valve (boom circuit) 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
3 Merge-divider LS-EPC valve may have malfunction. Check it directly.
LS-EPC valve
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
Possible 6 Spool of boom control valve may have malfunction. Check it directly.
valve (spool)
causes and Malfunction of boom control
standard Pressure compensation valve of boom control valve may have mal-
7 valve (pressure compensa-
value for function. Check it directly.
tion valve)
judgment 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 defec-
11 of boom control valve (suction
tive seal. Check it directly.
valve)
Safety-suction valve of boom control valve may have malfunction or
12 of boom control valve
defective seal. Check it directly.
(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.
a Prepare with engine stopped,and then run engine at full speed
14 Defective boom cylinder Right work equipment control
Leakage from boom cylinder
lever
Boom raise relief 20 cc/min
PC200, 200LC-8E0 (Hybrid) 40-500 13

SEN05253-00 H-8 Speed or power of arm is low
H-8 Speed or power of arm is low

Trouble q 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 IN 2.84 – 3.43 MPa
Arm OUT {29 – 35 kg/cm2}
2
LS-EPC valve
main valve
5 Merge-divider LS valve may have malfunction. Check it directly.
LS valve
Malfunction of arm control
6 Spool of arm control valve may have malfunction. Check it directly.
Possible valve (spool)
causes and Malfunction of arm control
Pressure compensation valve of arm control valve may have mal-
standard 7 valve (pressure compensation
function. Check it directly.
value for valve)
judgment 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. Check
9
valve (quick return valve) 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 defective
11 of arm control valve (suction
seal. Check it directly.
valve)
Safety-suction valve of arm control valve may have malfunction or
12 of arm control 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 may
valve (LS shuttle valve)
have malfunction. Check it directly.
14 Defective arm cylinder Left work equipment control lever Leakage from arm cylinder
Arm IN relief 20 cc/min
40-500 14 PC200, 200LC-8E0 (Hybrid)

H-9 Speed or power of bucket is low SEN05253-00
H-9 Speed or power of bucket is low

Trouble q Speed or power of bucket is low.
Related
information

Right work equipment control
Malfunction of right PPC valve lever
1 0 MPa
(bucket circuit) Neutral
{0 kg/cm2}
Bucket CURL 2.84 – 3.43 MPa
Bucket DUMP {29 – 35 kg/cm2}
Possible Malfunction of bucket control
2 Spool of bucket control valve may have malfunction. Check it directly.
causes and valve (spool)
standard Malfunction of bucket control
Pressure compensation valve of bucket control valve may have mal-
value for 3 valve (pressure compensation
judgment valve)
Safety-suction valve of bucket control valve may have malfunction or
4 of bucket control valve
Malfunction of service control LS shuttle valve of service control valve may have malfunction.
5
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
PC200, 200LC-8E0 (Hybrid) 40-500 15

SEN05253-00 H-10 Work equipment does not move in its single operation
H-10 Work equipment does not move in its single operation

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

Possible
causes and Work equipment control lever PPC valve output pressure
standard 1 Malfunction of PPC valve 0 MPa
Neutral
value for {0 kg/cm2}
judgment 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)
40-500 16 PC200, 200LC-8E0 (Hybrid)

H-11 Hydraulic drift of work equipment is large SEN05253-00
H-11 Hydraulic drift of work equipment is large

Trouble (1) Hydraulic drift of boom is large.
Related
information

Possible
1 Defective boom cylinder Right work equipment control
causes and Leakage from boom cylinder
lever
standard
value for Boom RAISE relief 20 cc/min
judgment Defective seal of boom con- Seal of lock valve of boom control valve may be defective. Check it
2
trol valve (lock valve) directly.
Defective seal of safety valve
3 Seal of safety valve for lock valve may be defective. Check it directly.
for lock valve
Trouble (2) Hydraulic drift of arm is large.

Related
information

1 Defective arm cylinder Left work equipment control lever Leakage from arm cylinder
Arm IN relief 20 cc/min
Possible Defective seal of arm control
causes and 2 Seal of arm control valve spool may be defective. Check it directly.
valve (spool)
standard Defective seal of arm control
value for Seal of pressure compensation valve of arm control valve may be
3 valve (pressure compensation
judgment defective. Check it directly.
valve)
Seal of suction valve of arm control valve may be defective. Check it
Defective seal of arm control directly.
4
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 valve
5 Seal of safety valve for lock valve may be defective. Check it directly.
for lock valve
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
causes and Defective seal of bucket con-
2 Seal of bucket control valve spool may be defective. Check it directly.
standard trol valve (spool)
value for Defective seal of bucket con-
Seal of pressure compensation valve of bucket control valve may be
judgment 3 trol valve (pressure compen-
defective. Check it directly.
sation valve)
Seal of safety-suction valve of bucket control valve may defective.
Defective seal of bucket con- Check it directly.
4 trol valve (safety-suction a You may replace the safety suction valves of the control valves on
valve) the bottom side and head side with each other and judge from the
change of the phenomenon.
PC200, 200LC-8E0 (Hybrid) 40-500 17

SEN05253-00 H-12 Time lag of work equipment is large
H-12 Time lag of work equipment is large

Trouble q Time lag of work equipment is large.
Related
information

LS-EPC valve output
pressure
1 Malfunction of LS-EPC valve Approx.2.9 MPa
Lo Neutral
{Approx. 30 kg/cm2}
0 MPa
Possible Hi Operated
{0 kg/cm2}
causes and
standard Regeneration valve of control valve may have malfunction. Check it
2 (regeneration valve) [Boom
value for directly.
and arm only]
judgment 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 cir-
cuit is different, however.)
Pressure compensation valve of control valve may have malfunction.
4 (pressure compensation
Check it directly.
valve)
40-500 18 PC200, 200LC-8E0 (Hybrid)

H-13 When part of work equipment is relieved singly, other parts of work equipment move SEN05253-00
H-13 When part of work equipment is relieved singly, other parts of work
equipment move
Trouble q When part of work equipment is relieved singly, other parts of work equipment move.
Related infor-
mation
Possible Cause Standard value/Remarks on troubleshooting

causes and
standard Defective seal of control valve
Seal of pressure compensation valve of control valve on moving side
value for 1 (pressure compensation
may be defective. Check it directly.
judgment valve) on moving side
PC200, 200LC-8E0 (Hybrid) 40-500 19

SEN05253-00 H-14 Power maximizing function does not work
H-14 Power maximizing function does not work

Trouble q Power maximizing function does not work.
Related
information

Possible 2-stage relief solenoid valve out-
causes and Swing lock switch
Malfunction of 2-stage relief put pressure
standard 1 0 MPa
solenoid valve OFF
value for {0 kg/cm2}
judgment 2.9 MPa
ON
{30 kg/cm2}
Malfunction of main relief
2 Main relief valve may have malfunction. Check it directly.
valve
40-500 20 PC200, 200LC-8E0 (Hybrid)

H-15 In compound operation of work equipment, speed of part loaded more is low SEN05253-00
H-15 In compound operation of work equipment, speed of part loaded

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

Pressure compensation valve of control valve on smaller load side
may have malfunction. Check it directly.
Compound operation Larger load side Smaller load side
Boom RAISE
+ Boom RAISE Arm IN
Possible Arm IN
Boom RAISE
causes and
Malfunction of control valve + Arm OUT Boom RAISE
standard
1 (pressure compensation Arm OUT
value for
valve) on smaller load side Boom RAISE
judgment
+ Boom RAISE Bucket CURL
Bucket CURL
Arm OUT
+ Arm OUT Bucket CURL
Bucket CURL
Boom LOWER
+ Arm OUT Boom LOWER
Arm OUT
PC200, 200LC-8E0 (Hybrid) 40-500 21

SEN05253-00 H-16 When machine swings and travels simultaneously, travel speed is low
H-16 When machine swings and travels simultaneously, travel speed is

low
Trouble q When machine swings and travels simultaneously, travel speed is low.
Related infor- q If speed of single travel operation is also low, carry out troubleshooting for "H-18 Travel speed is low"
mation first.
Possible Cause Standard value/Remarks on troubleshooting

causes and
standard Malfunction of each control LS shuttle valve of left travel control valve or swing control valve may
value for 1
valve (LS shuttle valve) have malfunction. Check it directly.
judgment
40-500 22 PC200, 200LC-8E0 (Hybrid)

H-17 Machine deviates during travel SEN05253-00
H-17 Machine deviates during travel

Trouble q Machine deviates during travel.
Related
information

Malfunction of travel PPC
1 0 MPa
valve Neutral
{0 kg/cm2}
Malfunction of self-pressure Control lever Control circuit source pressure
2
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Measured oil pres- Run the track idle.
sure All levers in the neu-
3 way)
Possible function of LS valve Pump discharge pres-
causes and 1
sure Almost same pres-
standard PC valve output pressure Approx. 0.6
value for sure (Approx. 3/5)
judgment If oil pressure does not become normal after adjustment, LS valve
Travel junction solenoid valve out-
Travel lever
Malfunction of travel junction put pressure
4 0 MPa
solenoid valve Both sides in the neutral position
{0 kg/cm2}
2.9 MPa
Either side operated
{30 kg/cm2}
Malfunction of travel junction
5 Travel junction valve may have malfunction. Check it directly.
valve
Malfunction of travel control
6 Spool of travel control valve may have malfunction. Check it directly.
valve (spool)
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.
PC200, 200LC-8E0 (Hybrid) 40-500 23

SEN05253-00 H-18 Travel speed is low
H-18 Travel speed is low

Trouble q Travel speed is low.
Related
information

Malfunction of travel PPC
1 0 MPa
valve Neutral
{0 kg/cm2}
Malfunction of self-pressure Control lever Control circuit source pressure
2
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Measured oil pres- LS-EPC valve output
Possible Travel lever
sure pressure
causes and 3 Malfunction of LS-EPC valve Approx. 2.9 MPa
standard Lo Neutral
value for {Approx. 30 kg/cm2}
0 MPa
judgment Hi Operated
{0 kg/cm2}
valve (spool)
Pressure compensation valve of control valve may have malfunction.
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
Travel relief 27.2 l/min
40-500 24 PC200, 200LC-8E0 (Hybrid)

H-19 Machine is not steered well or steering power is low SEN05253-00
H-19 Machine is not steered well or steering power is low

Trouble q Machine is not steered well or steering power is low.
Related
information

Travel lever
Malfunction of travel PPC (Steering)
1 0 MPa
valve (steering spool) Both sides in the neutral position
{0 kg/cm2}
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Travel junction solenoid valve out-
Travel lever
Malfunction of travel junction put pressure
2 0 MPa
solenoid valve Both sides in the neutral position
{0 kg/cm2}
2.9 MPa
{30 kg/cm2}
Malfunction of travel junction
3 Travel junction valve may have malfunction. Check it directly.
valve
4
Possible Malfunction of merge-divider
causes and LS-EPC valve
standard Malfunction of merge-divider
value for main valve
judgment 7 Merge-divider LS valve may have malfunction. Check it directly.
LS valve
valve (spool)
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
Malfunction of bucket control LS shuttle valve of bucket control valve may have malfunction.
11
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 motor
13 a You may replace the safety valves of forward and reverse sec-
(safety valve)
tions of the same motor or those of the right and left motors with
each other and judge from the change of the phenomenon.
Seal of check valve of travel motor may be defective. Check it
directly.
14 a You may replace the check valves of forward and reverse sections
(check valve)
of the same motor or those of the right and left motors with each
other and judge from the change of the phenomenon.
PC200, 200LC-8E0 (Hybrid) 40-500 25

SEN05253-00 H-20 Travel speed does not shift or travel speed is low or high
H-20 Travel speed does not shift or travel speed is low or high
Trouble q Travel speed does not shift or travel speed is low or high
Related
information

a Run engine at full speed and carry out troubleshooting (with mon-
itoring function).
Monitoring code:
01500
Lo *663 mA
Mi Operated 424 mA
Hi 0 mA
1 Malfunction of LS-EPC valve
LS-EPC valve output
Possible Travel speed Travel lever
pressure
causes and Approx. 2.9 MPa
standard Lo Neutral
value for {Approx. 30 kg/cm2}
0 MPa
judgment 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. Check
3
(speed shifting section) 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.
40-500 26 PC200, 200LC-8E0 (Hybrid)

H-21 Travel system does not work (only one side) SEN05253-00
H-21 Travel system does not work (only one side)

Trouble q Travel system does not work (only one side).
Related
information

Defective seal of travel control Seal of suction valve of travel motor may have malfunction. Check it
1
Seal of safety valve of travel motor may have malfunction. Check it
directly.
2 a You may replace the safety valves of forward and reverse sections
(safety valve)
other and judge from the change of the phenomenon.
Seal of check valve of travel motor may have malfunction. Check it
Possible directly.
causes and Defective seal of travel motor
3 a You may replace the check valves of forward and reverse sections
standard (check valve)
value for other and judge from the change of the phenomenon.
judgment Malfunction of travel motor
4 Parking brake of travel motor may have malfunction. Check it directly.
(parking brake)
Travel system relief 27.2 l/min
PC200, 200LC-8E0 (Hybrid) 40-500 27

SEN05253-00 H-22 Upper structure does not swing
H-22 Upper structure does not swing

Trouble (1) Upper structure does not swing in both right and left directions.
Related
q Perform all troubleshooting in power mode (P) of working mode.
information
See "Troubleshooting for hybrid system (Y mode)" and perform troubleshooting since this failure is related to hybrid
system.
Trouble (2) Upper structure swings only in one direction.

Related
information
See "Troubleshooting for hybrid system (Y mode)" and perform troubleshooting since this failure is related to the hybrid
system.
40-500 28 PC200, 200LC-8E0 (Hybrid)

H-23 Swing acceleration or swing speed of upper structure is low SEN05253-00
H-23 Swing acceleration or swing speed of upper structure is low

Trouble (1) Swing acceleration or swing speed of upper structure is low in both right and left directions.
Related
information
system.
Trouble (2) Swing acceleration or swing speed of upper structure is low only in one direction.
Related
information
system.
PC200, 200LC-8E0 (Hybrid) 40-500 29

SEN05253-00 H-24 Upper structure overruns remarkably when it stops swinging
H-24 Upper structure overruns remarkably when it stops swinging

Trouble (1) Upper structure overruns remarkably when it stops swinging in both right and left directions.
Related
information
system.
Trouble (2) Upper structure overruns remarkably when it stops swinging only in one direction.
Related
information
system.
40-500 30 PC200, 200LC-8E0 (Hybrid)

H-25 Large shock is made when upper structure stops swinging SEN05253-00
H-25 Large shock is made when upper structure stops swinging

Trouble q Large shock is made when upper structure stops swinging
Related
information
system.
PC200, 200LC-8E0 (Hybrid) 40-500 31

SEN05253-00 H-26 Large sound is made when upper structure stops swinging
H-26 Large sound is made when upper structure stops swinging

Trouble q Large sound is made when upper structure stops swinging
Related
information
system.
40-500 32 PC200, 200LC-8E0 (Hybrid)

H-27 Upper structure lowers largely by its own weight SEN05253-00
H-27 Upper structure lowers largely by its own weight

Trouble (1) Upper structure lowers largely by its own weight (when parking brake is applied)
q When swing lock switch is turned to ON position or when swing holding brake release switch is set to
Related normal position, swing holding brake is applied and swinging motion of upper structure is stopped with
information disc brake.
system.
Trouble (2) Upper structure lowers largely by its own weight (when parking brake is released).
q When swing holding brake release switch is set to RELEASE position, swing holding brake is released
Related and swinging motion of upper structure is held with swing electric motor. (However, this applies only
information while hybrid system is operating normally)
system.
PC200, 200LC-8E0 (Hybrid) 40-500 33

SEN05253-00
©2009 KOMATSU
All Rights Reserved
40-500 34
SEN05254-01
SEN05254-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
600 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart........................................................................................................ 2

S-1 Starting performance is poor ................................................................................................................ 6
S-2 Engine does not start ........................................................................................................................... 7
S-3 Engine does not pick up smoothly........................................................................................................ 10
S-4 Engine stops during operations ............................................................................................................ 11
S-5 Engine does not run smoothly.............................................................................................................. 12
S-6 Engine lacks output power ................................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion)................................................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 15
S-9 Oil becomes contaminated early .......................................................................................................... 16
S-10 Fuel consumption is excessive........................................................................................................... 17
S-11 Oil is in coolant (or coolant spurts or coolant level goes down).......................................................... 18
S-12 Oil pressure drops .............................................................................................................................. 19
S-13 Oil level rises (Entry of coolant/fuel)................................................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ....................................................................... 21
S-15 Abnormal noise is made..................................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................................... 23
PC200, 200LC-8E0 (Hybrid) 40-600 1

SEN05254-01 Method of using troubleshooting chart
Method of using troubleshooting chart
This troubleshooting chart is divided into four sections: Questions, Check items, Causes and Troubleshooting.
First, use the Questions and Check items to select highly probable causes among the Causes. The Questions
and Check items helps to narrows the extent of the probable causes based on the failure symptoms or simple
inspection results 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
Information items to be obtained from the customer or operator. They correspond to A and B in the chart on
the right.
The items in A are basic ones. The information items in B can be obtained from the customer or operator,
depending on their level of the attention to the machine condition.
Check items
Simple checks conducted by the technician to narrow the causes. They correspond to C in the chart on the
right.
Causes
List of items to be narrowed from the questions and checks.
The technician narrows down the probable causes from A, B, and C.
Troubleshooting
Work items to be conducted in order 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.
Among the items listed in the [Questions] and [Check items] sections, those related to the [Causes] are
marked withE, 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 mark
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.)
40-600 2 PC200, 200LC-8E0 (Hybrid)

Method of using troubleshooting chart SEN05254-01
PC200, 200LC-8E0 (Hybrid) 40-600 3

SEN05254-01 Method of using troubleshooting chart
Example of troubleshooting: Exhaust gas is black (incomplete combustion)

Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Questions] and [Check
items] and found the following three items to be the causal symptoms; [Exhaust gas slowly became black],
[Power slowly became weaker], and [Dust indicator is lighting red].
40-600 4 PC200, 200LC-8E0 (Hybrid)

Method of using troubleshooting chart SEN05254-01
There is a causal relationship between three items in the [Questions] and [Check items] sections and five
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, 200LC-8E0 (Hybrid) 40-600 5

SEN05254-01 S-1 Starting performance is poor
S-1 Starting performance is poor
General causes why starting performance is poor Causes

q Defective electrical system
Leaking or clogged fuel piping, entry of air

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

Defective contact of valve & valve seat
Defective alternator (regulator section)

Stuck or seized supply pump plunger
q Insufficient intake of air
q Improper selection of fuel
Defective intake air heater system
Defective or deteriorated battery

a The common rail fuel injection system (CRI) recognizes the fuel injection tim-
Worn piston ring and cylinder

ing electrically. Accordingly, even if the engine is cranked properly, the en-
Clogged air cleaner element
Clogged fuel filter element

gine may not start until the crankshaft rotates 2 turns in the case of the most
disadvantageous condition. This phenomenon does not indicate a trouble,
however.
Defective injector
Check recent repair history
Degree of use of
Operated for long period E E E
Questions temperature
machine
Starting perfor- Became worse gradually Q w w Q
mance Engine starts easily when warm w w
Non-specified fuel is being used Q Q Q
Replacement of filters has not been carried out according to Operation and
w w Q Q
Maintenance Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor
w
does not indicate normally
During operation, charge level monitor indicates abnormal charge w w
Dust indicator is red w
Air breather hole in 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 rotates engine slowly w
Check items
Even if air bleeding plug of fuel filter head is removed, fuel

While engine is w
does not flow out
cranked:
If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, tem-
w
perature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular Q Q w
Engine hunts Q w Q
Blowby gas is excessive w
Inspect air cleaner directly q
When compression pressure is measured, it is found to be low q q
When air bleeding operation for fuel system is performed, air comes out q
Inspect fuel filter, strainer directly q
Remedy
Perform troubleshooting for "Rail Press (Very) Low Error (*1) q

Even when a cylinder is cut out, engine speed does not change q
During pre-heating operation, intake air heater mount is cold q
Is voltage (20 – 30 V) between alternator terminal B and terminal Yes q
E detected with engine at low idle? No q
Specific gravity of electrolyte and voltage of battery are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
Remedy
*1: Displayed failure codes [CA559] and [CA2249]
40-600 6 PC200, 200LC-8E0 (Hybrid)

S-2 Engine does not start SEN05254-01
S-2 Engine does not start
a) Engine does not crank

General causes why engine does not crank
q Internal parts of engine seized Causes
o See “S-4 Engine stops during operations”
Defective starting motor (motor section)

q Defective electrical system
Defective connection of battery cable

q Defective hydraulic pump
Defective or deteriorated battery
Defective starting circuit wiring

Broken flywheel ring gear
Defective hydraulic pump

Defective starting switch
Defective battery relay
Defective safety relay

Questions temperature
Degree of use of
Operated for long period E E
machine
Horn does not sound. Q Q w
Condition of horn when
starting switch is turned
Horn volume is low. w
ON
Battery electrolyte level is low. w

Battery cable terminal is loose w
Q w
Check items
Starting switch is turned ON, but no battery relay operating sound is heard
Starting switch is turned to START, but pinion does not plunge Q Q w
When starting switch is Speed of rotation is low. w
turned to START, start- Abnormal noise is heard w w
ing pinion moves out, Pinion disengages soon w
but: Abnormal noise is heard and engine does not rotate Q Q Q Q
Inspect flywheel ring gear directly q
Carry out troubleshooting in H-mode

Carry out troubleshooting in E-mode
No voltage (20 - 30 V) is deteated between battery relay
q
terminal B and terminal E
When terminal B and termina C of starting switch are
q
connected, engine starts
Remedy
Turn starting switch

OFF, connect cable, When terminal B and terminal C at safety relay outlet are
q
and carry out trouble- connected, engine starts
shooting with starting Even if terminal B and terminal C at safety relay outlet q
switch at ON are connected, engine does not start
When safety switch terminal and terminal B of starting

q
motor are connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Rem-
-
-
edy
PC200, 200LC-8E0 (Hybrid) 40-600 7

SEN05254-01 S-2 Engine does not start
b) Engine cranks but no exhaust smoke comes out Causes

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

q Fuel is not being supplied.
q Supply of fuel is extremely small.
q Improper selection of fuel (particularly in winter)

Clogged air breather hole of fuel tank cap
Defective common rail pressure limiter

Seized, abnormally worn feed pump
Stuck, seized supply pump plunger

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

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Degree of use of
Questions
Operated for long period EE

machine
Exhaust smoke suddenly stopped coming out (when starting again). wQww E
Replacement of filters has not been carried out according to Operation and
w E Q
Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole in fuel tank cap is clogged Qw
Rust and water are found when fuel tank is drained QE EE
Check items
When fuel filter is removed, there is no fuel in it w w

Fuel is leaking from fuel piping w
When priming pump is operated, it makes no reaction or it is heavy wQ
Even if air bleeding plug of fuel filter head is removed, fuel
While engine is Q Q wQ
does not flow out
cranked:
If spill hose from injector is disconnected, little fuel spills Q www Q
Inspect fuel filter directly q
Inspect feed pump directly q
Remedy
Carry out troubleshooting for "Rail Press (Very) Low Error (*1)" qq
Carry out troubleshooting for "IMV/PCV1 Short (Open) Error (*2)" q
Inspect overflow valve directly. q
Engine can be started in reduced cylinder mode. q
If pressure limiter return pipe is disconnected, fuel flows out from limiter q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Add

40-600 8 PC200, 200LC-8E0 (Hybrid)

S-2 Engine does not start SEN05254-01
c) Exhaust smoke comes out but engine does not start (Fuel is being Causes
injected)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does not start
q Lack of cranking force due to defective electrical system
Worn valve system (valve, rocker arm, etc.)
Leaking or clogged fuel system, entry of air


Defective intake air heater system

Clogged injector, defective spray
Defective, deteriorated battery
Worn piston ring and cylinder
Use of improper fuel
Clogged fuel filter

Degree of use of
machine
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
w w
and Maintenance Manual
When engine is preheated or when temperature is low, preheating moni-
w
tor does not indicate proper preheating
Air breather hole in fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
When fuel filter is removed, there is no fuel in it w
When priming pump is operated, it makes no reaction or it is heavy w Q
Check items
Starting motor rotates engine slowly w

When engine is cranked, abnormal sound is generated around cylinder
w
head
Even if air bleeding plug of fuel filter head is removed,
Q w
While engine is fuel does not flow out
cranked: If spill hose from injector is disconnected, little fuel
w
spills
w
Inspect valve system directly q
When compression pressure is measured, it is found to be low q
Remedy
Inspect fuel filter directly q

Carry out troubleshooting for "Rail Press (Very) Low Error (*1)" q
Engine can be started in reduced cylinder mode. q
Coolant temperature gauge does not indicate normally q
During pre-heating operation, intake air heater mount is cold q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
PC200, 200LC-8E0 (Hybrid) 40-600 9

SEN05254-01 S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly
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 engine in derate mode (limiting injection rate (output) be-
cause of an error in electrical system)

Clogged injector, defective spray
Worn piston ring, cylinder

Improper valve clearance
Clogged fuel filter

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

Non-specified fuel is being used w w w
Replacement of filters has not been carried out according to Operation and Mainte-
w w
nance Manual
Oil must be added more frequently w
Check items
When exhaust manifold is touched immediately after starting engine, temperature

Q w
of some cylinders is low
Color of exhaust Blue under light load w
gas Black wQ w w
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed is normal, but speed suddenly drops when load is applied Q w
Engine hunts Q Q Q
Inspect valve clearance q
Remedy
When turbocharger is rotated by hand, it is found to be heavy q

A cylinder is cut out, but engine speed does not change q
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Remedy
40-600 10 PC200, 200LC-8E0 (Hybrid)

S-4 Engine stops during operations SEN05254-01
S-4 Engine stops during operations
General causes why engine stops during operations Causes

q Seized parts inside engine
Broken auxiliary equipment (pump, compressor, etc.)

q Engine overheating
Broken valve system (valve, rocker arm, etc.)

q Defective hydraulic pump

Broken, seized piston, connecting rod

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

Broken supply pump shaft
Defective hydraulic pump

Broken, seized gear train
Clogged fuel filter

Degree of use
Operated for long period E
of machine
Abnormal noise was heard, it stopped suddenly wwww QwQw w
Questions
Condition when Engine overheated and stopped wQ Q

engine stopped Engine stopped slowly w Q
Engine hunted, then stopped wQ QQ
Non-specified fuel is being used QQ Q
w
Fuel level monitor indicates low level (if monitor is installed) w
Check items

Metal particles are found when oil is drained www Q
Does not turn at all ww
When engine is Turns in opposite direction only w
rotated by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine operates, but stops when load is applied to machine w

Carry out troubleshoot-
Inspect piston, connecting rod directly q

Troubleshooting
q
ing in H-mode
Inspect crankshaft bearing directly

Inspect gear train directly q
Inspect feed pump directly q
Carry out troubleshooting for “Rail Press (Very) Low Error (*1)” qq
Engine operates when auxiliary equipment (hydraulic pump, compressor,
q
etc.) is removed
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy -
Add
PC200, 200LC-8E0 (Hybrid) 40-600 11

SEN05254-01 S-5 Engine does not run smoothly
S-5 Engine does not run smoothly
General causes why engine does not run smoothly Causes

q Air in fuel system
Clogged injector, defective spray (dirt in injector)

q Defective speed sensor (Error at degree that does not generate failure code)
Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness
Clogged fuel filter

Degree of use of
Operated for long period E
machine
Questions
Occurs at a certain speed range Q Q

Occurs at low idle QQQQ 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
w
Manual
Troubleshooting Check items

Rust and water are found when fuel tank is drained Q
Carry out troubleshooting for "Eng Ne Speed Sensor Error (*1)" q
Carry out troubleshooting for "Eng Bkup Speed Sensor Error (*2)" q
Replace
Replace
Replace
Replace
Replace
Clean
Remedy
Add
*1: Displayed failure codes [CA689]

*2: Displayed failure code [CA778]
40-600 12 PC200, 200LC-8E0 (Hybrid)

S-6 Engine lacks output power SEN05254-01
S-6 Engine lacks output power
General causes why engine lacks output power Causes

Clogged injector, defective spray (dirt in injector)

Defective command to injector (signal, solenoid)
Defective boost pressure sensor, wiring harness

Defective installation of boost pressure sensor

q Defective spray condition of fuel


q Engine is overheating
o See "S-14 Coolant temperature becomes too high (Overheating)".

q Controller is controlling engine in derate mode
Air leakage from air intake piping

(limiting injection rate (output) because of an error in electrical system)
Leaking, clogged fuel piping

Clogged spill piping

Clogged fuel filter
(air leakage)
Degree of use of machine Operated for long period E E E E
Suddenly Qw Q Q QQ
Questions
Power was lost

Gradually Q Q Q Q Q Q
Non-specified fuel is being used QQQ
w w
Engine oil must be added more frequently Q Q
Dust indicator is red ww
Air breather hole in fuel tank cap is clogged w w
Output power becomes insufficient after short stop of operation w
Color of exhaust gas
Black w w
Blue under light load w
Check items

ww
When engine is cranked, interference sound is generated around turbo-
w
charger
When engine is cranked, abnormal sound is generated around cylinder
w
head
High idle speed is too high Q
High idle speed is normal, but speed suddenly drops when load is applied Q wQQ
Engine does not pick up smoothly and combustion is irregular ww QQ w
Engine hunts QQQ QQ
Blowby gas is excessive w w
Inspect air intake piping directly q
When boost pressure is measured, it is found to be low qqq
q q
Troubleshooting
When compression pressure is measured, it is found to be low

Inspect fuel piping q
Inspect spill port check valve directly q
Carry out troubleshooting for "Rail Press (Very) Low Error(*1)" q
A cylinder is cut out, but engine speed does not change qq
Inspect boost pressure sensor mount directly q
Carry out troubleshooting for "Chg Air Press Sensor High (Low) Error (*2)" q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy

PC200, 200LC-8E0 (Hybrid) 40-600 13

SEN05254-01 S-7 Exhaust smoke is black (incomplete combustion)
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black Causes

Leakage of air between turbocharger and cylinder head

q Defective condition of fuel injection

q Engine is overheating
o See "S-14 Coolant temperature becomes too high (Overheating)".
q Controller is controlling engine 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
Degree of use of Operated for long period E E E E
Suddenly became black w w QQQ
Color of exhaust
Questions
Gradually became black w Q Q

gas
Non-specified fuel is being used QQ
Suddenly w Q QQ
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp worked loose w
Engine is operated in low-temperature mode at normal temperature QQQ
When exhaust manifold is touched immediately after starting engine, tempera-
Check items
Qw
ture of some cylinders is low
When engine is cranked, interference sound is generated around turbocharger w
When engine is cranked, abnormal sound is generated around cylinder head w
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 QQQ Qw
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 for "Rail Press (Very) Low Error (*1)" q q
Carry out troubleshooting for "Coolant Temp Sens High (Low) Error (*2)" q
Check by using monitoring function qq
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Clean
Remedy

40-600 14 PC200, 200LC-8E0 (Hybrid)

S-8 Oil consumption is excessive (or exhaust smoke is blue) SEN05254-01
S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive Causes

q Abnormal combustion of oil
q Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes continuously)
Turbocharger
q External leakage of oil
q Wear of parts in lubrication system
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
Dust sucked in from intake system
Clogged breather, breather hose

Worn seal on compressor side
Oil leakage from oil drain plug

Worn, damaged rear oil seal
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal on turbine side
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of use of
Questions
Operated for long period EEE E

machine
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 outlet pipe on compressor side is dirty with oil w
Check items
Inside of turbocharger outlet pipe on turbine side is dirty with oil Q w

Oil in coolant w
Oil level in damper chamber of applicable machine is high w
Exhaust smoke is blue under light load w w
Amount of blowby Excessive Q Q w w
gas None w
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is found to be dirty abnor-
q
Troubleshooting
mally
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 oil leakage q q
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, 200LC-8E0 (Hybrid) 40-600 15

SEN05254-01 S-9 Oil becomes contaminated early
S-9 Oil becomes contaminated early
General causes why oil becomes contaminated early Causes

q Entry of exhaust gas into oil due to internal wear
Clogged turbo lubrication oil drain tube

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

q Use of improper oil
Defective oil filter safety valve

q Operation under excessive load

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions
Degree of use of machine Operated for long period EEE

Non-specified fuel is being used Q Q
Metal particles are found when oil is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Check items
Engine oil temperature rises quickly w

Color of exhaust gas
Black w
Excessive Q Q w Q
Amount of blowby gas
None w
Excessive play of turbocharger shaft q
Troubleshooting

q
See S- 7
Check breather and breather hose directly
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is stuck or broken q
Inspect turbocharger lubrication oil drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy Clean -
40-600 16 PC200, 200LC-8E0 (Hybrid)

S-10 Fuel consumption is excessive SEN05254-01
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes

q Leakage of fuel

q Defective condition of fuel injection (improper fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage inside cylinder head cover

Fuel leakage from fuel filter, piping, etc
Defective common rail pressure

Defective supply pump plunger
Defective operation of injector

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

Degree of use of
Questions
Operated for long period EE E

machine
More than that on other machines of same model Q Q Q Q
Condition of fuel
Gradually increased Q Q
consumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of

w
some cylinders is low
Low idle speed is high Q
Pump relief speed is high Q
Exhaust smoke Black Q Q Q Q
color White Q
Remove and inspect cylinder head cover directly. q
Troubleshooting
Inspect feed pump oil seal directly q

If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting for "Coolant Temp Sens High (Low) Error (*2)" q
Check by using monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

PC200, 200LC-8E0 (Hybrid) 40-600 17

SEN05254-01 S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
General causes why oil is in coolant Cause

q Engine-internal leakage in lubrication system
q Engine-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
Degree of use of
Questions
Operated for long period E E

machine
Suddenly increased 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
Troubleshooting Check items
There are excessive air bubbles in radiator, coolant spurts w
Pressure-tightness test of cylinder head shows oil leakage q

Inspect cylinder block directly q q
Pressure-tightness test of oil cooler shows oil leakage Replace q

Replace
Replace
Remedy Replace
40-600 18 PC200, 200LC-8E0 (Hybrid)

S-12 Oil pressure drops SEN05254-01
S-12 Oil pressure drops
General causes why oil pressure drops Causes

q Leakage, clogging, wear of lubricating system
Defective oil level sensor, wiring harness

q Defective oil pressure control
Leaking, crushed, clogged oil piping

q Selection of oil according to the temperature etc. specified in the Operation and Main-
tenance Manual is not observed.
Clogged, broken pipe in oil pan

q Deterioration of oil due to overheating
Clogged strainer in oil pan
Defective regulator valve

Lack of oil in oil pan
Defective oil pump

Coolant/ fuel in oil
Clogged oil filter

Worn bearing
Degree of use of
Questions
machine
Oil pressure monitor indicates low oil pressure Qw
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Mainte-
w
nance Manual
Indicates pressure drop at low idle w
Oil pressure
Indicates pressure drop both at low and high idle Q wwwQ
monitor
Indicates pressure drop on slopes w
(if installed)
w Q
Check items
Sometimes indicates pressure drop

Oil level monitor indicates oil level drop w w
Oil level in oil pan is low w
External engine oil piping is leaking, crushed w
Oil is milky or smells of diesel oil w
Metal particles are found when oil pan is drained w
Metal particles are found in the oil drained from oil filter w Q
Metal particles are found in oil filter q
Troubleshooting
Inspect oil pan strainer, pipe directly qq

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 proper oil level q
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy -
Add
PC200, 200LC-8E0 (Hybrid) 40-600 19

SEN05254-01 S-13 Oil level rises (Entry of coolant/fuel)
S-13 Oil level rises (Entry of coolant/fuel)
General causes why oil level rises Causes

q Water in oil (cloudy white)
Defective seal of auxiliary equipment (pump, compressor)

q Fuel in oil (smells of 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
Degree of use of
Operated for long period E EE E
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
Oil in coolant Q QQ Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
Check items
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 bub-
w Q
bles appear, or coolant spurts
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
Troubleshooting
Remove injector and inspect O-ring q

Inspect cylinder block directly q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows oil 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
40-600 20 PC200, 200LC-8E0 (Hybrid)

S-14 Coolant temperature becomes too high (overheating) SEN05254-01
S-14 Coolant temperature becomes too high (overheating)
General causes why coolant temperature becomes too high Causes

q Lack of cooling air (deformation/damage of fan)
q Drop in heat dissipation efficiency
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

q Problem in coolant circulation system
Defective operation of thermostat
Slipping fan belt, worn fan pulley
Rise of hydraulic oil temperature

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

Broken water pump
Lack of coolant
Degree of use of
Operated for long period EE EE
machine
Questions
Condition of Suddenly occurred Q w Q

overheating Always tends to overheat Q w w Q
Coolant temper- Rises quickly Q w
ature gauge
Does not go down below red range w
(if installed)
Radiator coolant level monitor indicates drop of coolant level (if monitor is
w
installed)
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
Check items
There are excessive air bubbles in radiator, coolant spurts w

When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard on machine are clogged with dirt or
w w
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 temper-
w
ature
Carry out troubleshootinig in H-mode
Inspect cylinder directly q

Inspect oil cooler directly q
Temperature difference between upper and lower tanks of radiator is large q
Troubleshooting
When operation test of thermostat is carried out, it does not open at cracking
q
temperature
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, 200LC-8E0 (Hybrid) 40-600 21

SEN05254-01 S-15 Abnormal noise is made
S-15 Abnormal noise is made
General causes why abnormal noise is made Causes

q Abnormality due to defective parts
Improper fuel injection timing (abnormality in low coolant tem-

q Abnormal combustion
Deformed cooling fan, loose fan belt, interference of fan belt

q Air sucked in from intake system
Defective inside of muffler (partition board out of position)

a Judge if the noise is an internal noise or an external noise before starting
Leakage of air between turbocharger and cylinder head

troubleshooting.
a The engine is operated in the low-temperature mode while it is not warmed
Interference of turbocharger, seized turbocharger
perature sensor, charge air temperature sensor)

up sufficiently. Accordingly, the engine sound becomes a little larger. This
does not indicate abnormality, however.
a When the engine is accelerated, it is operated in the acceleration mode and
Broken valve system (valve, rocker arm)

its sound becomes a little larger for up to approximately 3 seconds.
Excessive wear of piston ring, cylinder

Improper gear train backlash
Dislocated, seized bushing
Clogged, seized injector

Dirt caught in injector
Degree of use Operated for long period E
Questions
Condition of Gradually occurred Q Q

abnormal 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, interference sound is heard from turbocharger w
When engine is cranked, abnormal sound is generated around cylinder w w
Check items
When engine is cranked, beat noise is generated around muffler w

w Q
Color of exhaust Blue under light load w
gas 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
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
A cylinder is cut out, but engine speed does not change q q
Abnormal noise is heard only when engine is cranked q
Perform checking by using monitoring function of machine monitor q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
40-600 22 PC200, 200LC-8E0 (Hybrid)

S-16 Vibration is excessive SEN05254-01
S-16 Vibration is excessive
General causes why vibration is excessive Causes

q Defective parts (abnormal wear, breakage, etc,)
Improper injection timing (Abnormality in coolant

q Misalignment between engine and chassis
Loose engine mounting bolts, broken cushions

Misalignment between engine and hydraulic
q Abnormal combustion
Worn main bearing, connecting rod bearing

a If abnormal noise is made and vibration is excessive, carry out troubleshooting
temper. sensor, charge air temp. sensor)

for "S-15 Abnormal noise is made", too.
Stiff valve system (valve, rocker arm)
Broken output shaft, parts in damper

Improper gear train backlash
Worn camshaft bushing
pump
Degree of use
Questions

of machine
Condition of Suddenly increased. Q Q
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
w w
Check items
Metal particles are found when oil pan is drained

Oil pressure is low at low idle Q Q
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, 200LC-8E0 (Hybrid) 40-600 23

SEN05254-01
©2010 KOMATSU
All Rights Reserved
40-600 24
SEN05270-03
SEN05270-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
700 Troubleshooting of Hybrid system
(Y-mode)
Precautions related to hybrid machine........................................................................................................ 2

Y-1 Hybrid monitor does not go off.............................................................................................................. 4
Y-2 Upper structure does not swing ............................................................................................................ 6
Y-3 Swing acceleration or swing speed is low ............................................................................................ 8
Y-4 Upper structure overruns largely after swinging ................................................................................... 9
Y-5 Large shock is made when upper structure stops swinging ................................................................. 10
Y-6 Large abnormal sound is made when upper structure stops swinging................................................. 11
Y-7 Upper structure lowers largely by its own weight.................................................................................. 12
Y-8 Swing electric motor temperature increases abnormally ...................................................................... 13
Y-9 Motor-generator temperature increases abnormally............................................................................. 15
Y-10 Inverter temperature increases abnormally ........................................................................................ 16
Y-11 Capacitor temperature increases abnormally ..................................................................................... 17
PC200, 200LC-8E0 (Hybrid) 40-700 1

700 Troubleshooting of Hybrid system (Y-mode)
SEN05270-03 Precautions related to hybrid machine
Precautions related to hybrid machine
k When testing or adjusting the hybrid machine, ensure that you fully understand the following mat-
ters.

(For details, see 00-200 Introduction, safety, and basic information, Handling of hybrid devices and
high-voltage wiring, "Discharge procedure for capacitor" or 30-102 Testing and adjusting (Part 2), Special
brid devices and high-voltage wiring" before beginning the work on them.
k After discharging the capacitor, confirm that both capacitor charge LEDs (1) are OFF.
k A voltage not exceeding 30V will still remain in the capacitor after the discharging process is com-
pleted. Do not work with bare hands. Always wear insulating gloves.
a For the monitoring items applied to troubleshooting for the hybrid devices, see the list in "Separate sheet
1".
a For the check sheet to record the inspection result when any hybrid device is abnormal, see "Separate
sheet 2".
(Use this check sheet to ask a question of a plant department)
q "Separate sheet 1" and "Separate sheet 2" are in "Troubleshooting by failure code (Part 5)".
40-700 2 PC200, 200LC-8E0 (Hybrid)

Precautions related to hybrid machine SEN05270-03
PC200, 200LC-8E0 (Hybrid) 40-700 3

SEN05270-03 Y-1 Hybrid monitor does not go off
Y-1 Hybrid monitor does not go off
Trouble Hybrid monitor does not go off but keeps lighting.

q Hybrid controller switch input can be checked by using monitoring function.
Related
(Code: 09702 Hybrid controller switch input)
information

If capacitor voltage is below 150 V, run engine at low speed for at
1 Capacitor voltage drop
least 5 minutes.
Swing emergency stop switch

2 Turn swing emergency stop switch OFF.
is ON
3 Defective hybrid system If error of user code E09 is displayed, troubleshoot it first.
Defective assembly of swing Operation section and contact section of swing emergency stop
4
emergency stop switch switch may be coupled defectively. Check them directly.
Swing emergency stop switch may have internal defect. Check it
directly.
Probable Defective swing emergency a Prepare with starting switch OFF, then troubleshoot without turn-
5
causes and stop switch ing starting switch to ON position.
standard Resis-
Between terminals HS01 (11) and HS01 (12) Max. 1 Ω
value in nor- tance
mal condition a Prepare with starting switch OFF, then troubleshoot without turn-
ing starting switch to ON position.
Wiring harness between terminals HS01 (11) Resis-
Max. 1 Ω
and HJ02 (female) (12) tance
Wiring harness between terminals HJ02 (11) Resis-
Max. 1 Ω
Disconnection in wiring har- and HC01 (female) (5)/(11) tance
ness Wiring harness between terminals HJ02 Resis-
6 Max. 1 Ω
(Disconnection or defective (female) (11) and HH07 (male) (2) tance
contact in connector) Wiring harness between terminals HH07 Resis-
Max. 1 Ω
(female) (2) and J06 (female) (7) tance
Wiring harness between terminals J06 Resis-
Max. 1 Ω
(female) (9) and F01-17 tance
Wiring harness between terminals HS01 (12) Resis-
Max. 1 Ω
and HC02 (female) (27) tance
If causes 1 – 6 are not the cause for the trouble, hybrid controller may
Defective inverter (hybrid con-
7 be defective. (Since trouble is in system, troubleshooting cannot be
troller)
performed.)
40-700 4 PC200, 200LC-8E0 (Hybrid)

Y-1 Hybrid monitor does not go off SEN05270-03
PC200, 200LC-8E0 (Hybrid) 40-700 5

SEN05270-03 Y-2 Upper structure does not swing
Y-2 Upper structure does not swing
Trouble (1) Upper structure swings neither to the right nor left
Related
q Perform all troubleshooting with working mode in power mode (P).
information
a Prepare with engine stopped, then troubleshoot with engine at full
speed.
Malfunction of swing brake Output pressure of swing brake
1 Left work equipment control lever
solenoid valve solenoid valve
Neutral 0 MPa {0 kg/cm2}
Swing LEFT/RIGHT 2.9 MPa {30 kg/cm2}
2 Malfunction of swing brake Swing brake may be malfunctioning. Check it directly.
a Troubleshoot with engine stopped and swing lock switch ON.
Wiring harness between emergency stop Resis-
Probable Defective emergency stop Max. 1 Ω
3 switch HS01 (11) and (12) tance
causes and switch
Wiring harness between emergency stop Resis-
standard Max. 1 Ω
switch HS01 (21) and (22) tance
value in nor- Swing machinery may have internal defect. Check it directly.
mal conditon 4 Defective swing machinery * You may judge by abnormal sound, abnormal heating, metallic dust
in drained oil, etc.
Disconnection or short circuit If failure code [DHVAKZ] is displayed, swing RIGHT PPC pressure
5 in swing RIGHT PPC pres- sensor for hybrid system may have disconnection or short circuit.
sure sensor for hybrid system Perform troubleshooting.
Disconnection or short circuit If failure code [DHVBKZ] is displayed, swing LEFT PPC pressure
6 in swing LEFT PPC pressure sensor for hybrid system may have disconnection or short circuit.
sensor for hybrid system Perform troubleshooting.
7 Defective inverter be defective. (Since trouble is in system, troubleshooting cannot be
performed.)
Trouble (2) Upper structure does not swing in only one direction.
Related
information
a Prepare with engine stopped, then troubleshoot with engine at
high idle.
Malfunction of swing PPC Left work equipment control lever PPC valve output pressure
1
Probable valve Neutral 0 MPa {0 kg/cm2}
causes and 2.84 – 3.43 MPa
Swing LEFT/RIGHT
standard {29 – 35 kg/cm2}
value in nor- Disconnection or short circuit If failure code [DHVAKZ] is displayed, swing RIGHT PPC pressure
mal conditon 2 in swing RIGHT PPC pres- sensor for hybrid system may have disconnection or short circuit.
sure sensor for hybrid system Perform troubleshooting.
Disconnection or short circuit If failure code [DHVBKZ] is displayed, swing LEFT PPC pressure
3 in swing LEFT PPC pressure sensor for hybrid system may have disconnection or short circuit.
sensor for hybrid system Perform troubleshooting.
40-700 6 PC200, 200LC-8E0 (Hybrid)

Y-2 Upper structure does not swing SEN05270-03
PC200, 200LC-8E0 (Hybrid) 40-700 7

SEN05270-03 Y-3 Swing acceleration or swing speed is low
Y-3 Swing acceleration or swing speed is low
Trouble (1) Swing acceleration or swing speed is low in both right and left directions
qCapacitor voltage can be checked by using monitoring function.
Related (Code: 09300 Capacitor voltage)
information q Method of reproducing failure code: Turn starting switch to ON position or start engine. Perform all trou-
bleshooting with working mode in power mode (P).
Malfunction of all control LS shuttle valves of all control valves may be malfunctioning. Check
2
valves (LS shuttle valves) them directly.
Swing machinery may have internal defect. Check it directly.
Probable
3 Defective swing machinery * You may judge by abnormal sound, abnormal heating, metallic dust
causes and
in drained oil, etc.
standard
If capacitor voltage decreases much below 200 V each time when
value in nor-
Lowering of capacitor perfor- machine starts normal swing operation (about 90 degrees), capacitor
mal conditon 4
mance function may be lowered. (Since trouble is in system, troubleshooting
5 Defective inverter be defective. (Since trouble is in system, troubleshooting cannot be
performed.)
Trouble (2) Swing acceleration or swing speed is low in only one direction.
Related
information
speed.
Probable Left work equipment control lever PPC valve output pressure
Malfunction of swing PPC
causes and 1
valve Neutral 0 MPa {0 kg/cm2}
standard
2.84 – 3.43 MPa
value in nor- Swing LEFT/RIGHT
mal conditon {29 – 35 kg/cm2}
If cause 1 is not the cause for the trouble, hybrid controller may be
2 Defective inverter defective. (Since trouble is in system, troubleshooting cannot be per-
formed.)
40-700 8 PC200, 200LC-8E0 (Hybrid)

Y-4 Upper structure overruns largely after swinging SEN05270-03
Y-4 Upper structure overruns largely after swinging
Trouble (1) Upper structure overruns largely after swinging in both directions.
Related
information
causes and
standard
value in nor- 1 Defective software Check the version No. of software.
mal conditon
Trouble (2) Upper structure overruns largely after swinging in only one direction.
Related
information

speed.
Output pressure of swing brake
Malfunction of swing PPC Left work equipment control lever
Probable 1 solenoid valve
valve
causes and Neutral 0 MPa {0 kg/cm2}
standard 2.84 – 3.43 MPa
value in nor- Swing LEFT/RIGHT
{29 – 35 kg/cm2}
mal conditon Swing PPC slow return valve may be malfunctioning. Check it
Clogged swing PPC slow directly.
2
return valve * You may judge by exchanging right and left valves and checking
change of phenomenon.
3 Defective software Check the version number of software.
PC200, 200LC-8E0 (Hybrid) 40-700 9

SEN05270-03 Y-5 Large shock is made when upper structure stops swinging
Y-5 Large shock is made when upper structure stops swinging
Trouble q Large shock is caused when upper structure stops swinging.

Related
information

speed.
Output pressure of swing brake
Probable Malfunction of swing PPC Left work equipment control lever
1 solenoid valve
causes and valve
standard Neutral 0 MPa {0 kg/cm2}
value in nor- 2.84 – 3.43 MPa
Swing LEFT/RIGHT
mal conditon {29 – 35 kg/cm2}
Swing PPC slow return valve may be malfunctioning. Check it
Clogged swing PPC slow directly.
2
return valve * You may judge by exchanging right and left valves and checking
change of phenomenon.
40-700 10 PC200, 200LC-8E0 (Hybrid)

Y-6 Large abnormal sound is made when upper structure stops swinging SEN05270-03
Y-6 Large abnormal sound is made when upper structure stops swinging
Trouble q Large abnormal sound is made when upper structure stops swinging in both directions.
Related
information
causes and
standard Swing machinery may have internal defect. Check it directly.
value in nor- 1 Defective swing machinery * You may judge by abnormal sound, abnormal heating, metallic dust
mal conditon in drained oil, etc.
PC200, 200LC-8E0 (Hybrid) 40-700 11

SEN05270-03 Y-7 Upper structure lowers largely by its own weight
Y-7 Upper structure lowers largely by its own weight
Trouble (1) Upper structure lowers largely by its own weight (when swing brake is being applied)
q If swing lock switch is ON or swing brake cancel switch is in normal position, swing brake operates and
Related
upper structure is fixed by disc brake.
information

Probable speed.
causes and Output pressure of swing brake
Malfunction of swing brake Left work equipment control lever
standard 1 solenoid valve
solenoid valve
value in nor- Neutral 0 MPa {0 kg/cm2}
mal conditon
Swing LEFT/RIGHT 2.9 MPa {30 kg/cm2}
Trouble (2) Upper structure lowers largely by its own weight (when swing brake is being released)
q If swing lock switch is ON or swing brake cancel switch is in normal position, swing brake operates
Related
and upper structure is fixed by disc brake.
information
causes and
standard 1 Defective swing motor Swing motor may be malfunctioning. Check it directly.
value in nor- Hybrid controller may be defective.
2 Defective inverter
mal conditon (Since trouble is in system, troubleshooting cannot be performed.)
40-700 12 PC200, 200LC-8E0 (Hybrid)

Y-8 Electric swing motor temperature increases abnormally SEN05270-03
Y-8 Electric swing motor temperature increases abnormally
Symptoms of
q Electric swing motor temperature increases abnormally and error code [GA70NS] is displayed.
failure
q Electric swing motor coil temperature can be checked with monitoring function.
Related
(Code: 09101 Electric swing motor coil temperature)
information
Cause Standard value in normal state and remarks on troubleshooting

Excessive charge and dis-
1 charge of capacitor Check if operator repeated only swing and swing stop operations.
a Prepare by setting starting switch to OFF position, and
Ground fault of wiring harness
troubleshoot without turning starting switch to ON position.
of electric swing motor coil
temperature sensor Resis- Min.
(female) (42) and PM01 (female) (7)) and
(contact with ground circuit) tance 1M
ground
Lowering of cooling (lubricat-
3 Check oil level with oil level gauge and add oil if oil level is low
ing) oil level
Low quality of cooling (lubri- Cooling (lubricating) oil may contain water, metal dust, etc. Check it
4
cating) oil directly.
a Prepare with engine stopped, then troubleshoot with engine at high
Defective lubricating oil pas- idle.
5 Max. 0.3 MPa
sage in electric swing motor Set all control levers in neutral and mea-
Pressure
sure by using pressure pickup plug. {3.1 kg/cm2}
Clogged cooling (lubricating)
6 Check directly. If clogged, clean.
oil filter
Lubrication pump may have malfunction or internal defect. Check it
according to following procedure.
Possible 1) Disconnect the cooling (lubricating) oil inlet hose of electric swing
causes and 7 Defective lubrication pump motor.
standard
2) Crank the engine with the flywheel (manually).
value in nor-
3) If oil flows out of the disconnected hose, the pump is normal.
mal state
Radiator coolant may have overheated. Perform troubleshooting of
8 Overheat of radiator coolant
"S-14 Coolant temperature is too high (overheat)" in S mode.
If radiator coolant level monitor indicates low level, add coolant
9 Low coolant level
directly to hybrid radiator.
a Prepare with starting switch OFF, then troubleshoot without turning
starting switch to ON position (Set tester in diode mode).
Defective wiring or disconnec-
10 Between CN-HK01 (male) (1) and (2).
tion of water pump
Connect (2) to positive pole, and (1) to Voltage Approx. 0.6 V
negative pole of tester.
Defective water pump impel-
11 Water pump makes unusual noise or vibration.
ler
Air may be accumulated on suction side of water pump. Check
1) Open the radiator cap of the hybrid radiator.
Air accumulated on suction
12 2) Turn the starting switch to the ON position to start the water
side of water pump
pump.
3) If water pump does not make unusual noise or vibration and if
coolant in radiator upper tank flows, pump is normal.
Clogged or crushed hybrid
13 Check hybrid radiator fins directly.
radiator fins
14 Clogged hybrid radiator core Check hybrid radiator core directly.
PC200, 200LC-8E0 (Hybrid) 40-700 13

SEN05270-03 Y-8 Electric swing motor temperature increases abnormally

Defective hybrid radiator cap If coolant flows out of hybrid radiator overflow hose, check hybrid radi-
Possible 15
(pressure valve) ator cap directly.
causes and
Slip of fan belt or wear of fan If dust or dirt is not accumulated in radiator shroud or of undercover,
standard 16
pulley check fan belt and fan pulley directly.
value in nor-
mal state 17 Defective swing electric motor
Since failure is in system, testing and troubleshooting cannot be per-
Defective inverter (hybrid con- formed.
18
troller)
40-700 14 PC200, 200LC-8E0 (Hybrid)

Y-9 Motor-generator temperature increases abnormally SEN05270-03
Y-9 Motor-generator temperature increases abnormally
Symptoms of
q Motor-generator temperature increases abnormally and error code [GA61NS] is displayed.
failure
q Motor-generator temperature can be checked with monitoring function.
Related
(Code: 09600 Motor-generator temperature)
information

1 charge of capacitor (when Check if operator repeated only swing and swing stop operations.
system is normal)
a Prepare by setting starting switch to OFF position, and
Ground fault of wiring harness
troubleshoot without turning starting switch to ON position.
of motor-generator tempera-
ture sensor (contact with Resis- Min.
(female) (52) and GM01 (female) (4)) and
ground circuit) tance 1M
ground
Lowering of cooling (lubricat-
3 Check oil level with oil level gauge and add oil if oil level is low
ing) oil level
Low quality of cooling (lubri- Cooling (lubricating) oil may contain water, metal dust, etc. Check it di-
4
cating) oil rectly.
Possible a Prepare with engine stopped, then troubleshoot with engine at high
causes and Defective lubricating oil pas- idle.
standard 5 Below 0.6 Mpa
sage in motor-generator Set all control levers in neutral and mea-
value in nor- Pressure
sure by using pressure pickup plug. {6.1 kg/cm2}
mal state Clogged cooling (lubricating)
6 Check directly. If clogged, clean.
oil filter
Lubrication pump may have malfunction or internal defect. Check it
1) Disconnect the cooling (lubricating) oil inlet hose of motor-gener-
7 Defective lubrication pump
ator.
2) Crank the engine with the flywheel (manually).
3) If oil flows out of the disconnected hose, the pump is normal.
Radiator coolant may have overheated. Perform troubleshooting of
8 Overheat of radiator coolant
"S-14 Coolant temperature is too high (overheat)" in S mode.
Since failure is in system, testing and troubleshooting cannot be per-
Defective inverter (hybrid con- formed.
10
troller)
PC200, 200LC-8E0 (Hybrid) 40-700 15

SEN05270-03 Y-10 Inverter temperature increases abnormally
Y-10 Inverter temperature increases abnormally
Symptoms of q Inverter temperature increases abnormally and either or both of error codes [GA1ZNS] and [GA1YNS]
failure are displayed.
q Temperature of booster IGBT and booster inductor of inverter can be checked with monitoring function.
Related
(Code: 09401 Booster IGBT temperature, Code: 09402 Booster inductor temperature)
information

1
charge of capacitor Check if operator repeated only swing and swing stop operations.
2
If radiator coolant level monitor indicates low level, add coolant directly
3 Low coolant level
to hybrid radiator.
a Prepare with starting switch OFF, then troubleshoot without turn-
ing starting switch to ON position (Set tester in diode mode).
4 Between CN-HK01 (male) (1) and (2). Con-
tion of water pump Approx.
nect (2) to positive pole, and (1) to negative Voltage
0.6 V
pole of tester.
Possible 5 Water pump makes unusual noise or vibration.
ler
causes and Air may be accumulated on suction side of water pump. Check
standard according to following procedure.
value in nor-
Air accumulated on suction 1) Open the radiator cap of the hybrid radiator.
mal state 6
side of water pump 2) Turn the key to the ON position to start the water pump.
radiator fins
9
10
Defective inverter (hybrid con- Since failure is in system, testing and troubleshooting cannot be per-
11
troller) formed.
40-700 16 PC200, 200LC-8E0 (Hybrid)

Y-11 Capacitor temperature increases abnormally SEN05270-03
Y-11 Capacitor temperature increases abnormally
Symptoms of
q Capacitor temperature increases abnormally and error code [GA1TNS] is displayed.
failure
Related
(Code: 09301 Capacitor temperature #1, Code: 09302 Capacitor temperature #2)
information

1 charge of capacitor (when Check if operator repeated only swing and swing stop operations.
system is normal)
Ground fault of wiring harness a Prepare with starting switch OFF, then troubleshoot without turn-
of capacitor temperature #1 ing starting switch to ON position.
2
sensor (contact with ground Between HC02 (female) (51) – HP01 (female) Resis-
Min. 1 MΩ
circuit) (4) wiring harness and ground tance
Ground fault of wiring harness a Prepare with starting switch OFF, then troubleshoot without turn-
of capacitor temperature #2 ing starting switch to ON position.
3
sensor (contact with ground Between HC02 (female) (61) – HP01 (female) Resis-
Min. 1 MΩ
circuit) (5) wiring harness and ground tance
If radiator coolant level monitor indicates low level, add coolant directly
4 Low coolant level
to hybrid radiator.
a Prepare with starting switch OFF, then troubleshoot without turn-
Possible ing starting switch to ON position (Set tester in diode mode).
5 Between CN-HK01 (male) (1) and (2). Con-
causes and tion of water pump Approx.
nect (2) to positive pole, and (1) to negative Voltage
standard 0.6 V
pole of tester.
value in nor-
mal state 6 Water pump makes unusual noise or vibration.
ler
Air may be accumulated on suction side of water pump. Check
Air accumulated on suction 1) Open the radiator cap of the hybrid radiator.
7
side of water pump 2) Turn the key to the ON position to start the water pump.
radiator fins
10
11
PC200, 200LC-8E0 (Hybrid) 40-700 17

SEN05270-03
©2012 KOMATSU
All Rights Reserved
40-700 18
SEN05256-01
SEN05256-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


100 General information on disassembly
and assembly
How to read this manual ............................................................................................................................. 2

Precautions related to hybrid machine........................................................................................................ 4
Coating materials list................................................................................................................................... 5
Special tools list .......................................................................................................................................... 8
Sketches of special tools ............................................................................................................................ 12
PC200, 200LC-8E0 (Hybrid) 50-100 1

100 General information on disassembly and assembly
SEN05256-01 How to read this manual
How to read this manual
1. Removal and installation of assemblies

Special tools
q Special tools which are necessary for removal or
: Precautions related to work safety for removal and
installation of parts are described as A1, ••• X1
installation of hybrid devices.
etc. and their part numbers, part names and
q The above mark is attached to each explanation
quantities are described in the special tool list.
peculiar to the hybrid model.
q Also the following information is described in the
special tool list.
Installation
1) Necessity
q Unless otherwise instructed, installation of parts
t :Special tools that cannot be substituted
is to be done in the reverse order to removal.
and should always be used
q Instructions and precautions for parts installation
q :Special tools that will be useful if avail-
is shown with the mark ([*1], [*2]...) which corre-
able and are substitutable with tools avail-
sponds to the mark in “Removal” section.
able on the market
q Common tools that are necessary for installation
2) Distinction of new and existing special tools are described as [1], [2]••• etc. and their part
N : Tools newly developed for this model. numbers, part names and quantities are not de-
They have a new part number respectively. scribed.
R : Tools made available by redesigning the q Marks shown in the “Installation” section stand
existing tools which were developed for other for the following.
models. Each of them has a new part number
k
assigned by setting forward the part number : Precautions related to work safety
of the existing tool. a : Guidance or precautions for the work
2 : Type of coating material
Blank : Tools already available for other
3 : Tightening torque
models. They can be used without any modi-
5 : Amount of oil or coolant to be replenished
fication.
3) Circle mark Qin sketch column:
q The sketch of the special tool is present- Sketches of special tools
ed in the section of “Sketches of special q Various special tools are illustrated for the local
tools”. manufacture.
q Part No. of special tools starting with
79*T-***-****:
means that they are not available from
Komatsu Ltd. (i.e. tools to be made
locally).
q General purpose tools that are necessary
for disassembly and assembly are de-
scribed as [1], [2]......etc, and their part
numbers, part names and quantities are
not described.
Removal
q In “Removal” section, the work procedures, pre-
cautions and know-how to do the work, and the
amount of oil and coolant to be drained are de-
scribed.
q Various symbols used in “Removal” section are
explained and listed below.
k : Precautions related to work safety

a : Guidance or precautions for the work
[*1]: This mark shows that instructions or precau-
tions for parts installation work are given in
“Installation” section.
6 : Amount of oil or coolant to be drained
4 : Weight of part or component
50-100 2 PC200, 200LC-8E0 (Hybrid)

How to read this manual SEN05256-01
2. Disassembly and assembly of assemblies

Special tools Disassembly
q Special tools which are necessary for disassem- q In “Disassembly” section, the work procedures,
bly and assembly of parts are described as A1, precautions and know-how to do the work, and
••• X1 etc. and their part numbers, part names the amount of oil and coolant to be drained are
and quantities are described in the special tool described.
list. q Common tools that are necessary for disassem-
q Also the following information is described in the bly are described as [1], [2]••• etc. and their part
special tool list. numbers, part names and quantities are not de-
1) Necessity scribed.
t: Special tools that cannot be substituted q The meanings of the symbols used in
and should always be used. “Disassembly” section are as follows.
q: Special tools that will be useful if available
and are substitutable with tools available k : Precautions related to work safety
on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special tools 6 : Amount of oil or coolant drained
N : Tools newly developed for this model.

They have a new part number respectively. Assembly
R : Tools made available by redesigning the q In “Assembly” section, the work procedures,
existing tools which were developed for other precautions and know-how to do the work, and
models. Each of them has a new part the amount of oil and coolant to be replenished
numberassigned by setting forward the part are described.
number of the existing tool. q Common tools that are necessary for assembly
Blank : Tools already available for other are described as [1], [2]••• etc. and their part
models. They can be used without any modi- numbers, part names and quantities are not de-
fication. scribed.
q The meanings of the symbols used in
3) Circle mark Q in sketch column:
q The sketch of the special tool is present-
“Assembly” section are as follows.
ed in the section of “Sketches of special
k : Precautions related to work safety
tools”.
q Part No. of special tools starting with
a : Guidance or precautions for the work
2 : Type of coating material
79*T-***-****:
3 : Tightening torque
means that they are not available from
5 : Amount of oil or coolant to be replenished
Komatsu Ltd. (i.e. tools to be made
locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
PC200, 200LC-8E0 (Hybrid) 50-100 3

SEN05256-01 Precautions related to hybrid machine
Precautions related to hybrid machine
k When removing or installing the hybrid de-

vices, ensure that you fully understand the
following matters.

2. The hybrid devices and high-voltage wirings
(covered by orange conduits) must be replaced
by the unit.
3. When removing and installing the hybrid
devices, handle them with extreme care not to
lose the safety or damage their quality.
4. When handling the hybrid devices, be sure to
discharge the capacitor completely first. (For
details, see 00-200 Introduction, safety, and
basic information, "Handling of hybrid devices
and high-voltage wirings", "Discharge procedure
for capacitor" or 30-102 Testing and adjusting
(Part 2), Special functions of machine monitor,
"Discharge of capacitor".)
The capacitor cannot be discharged with the
machine monitor, depending on the error that
occurred.
k Since the items having the above mark are

related to handling of the hybrid devices, en-
sure that you understand the descriptions of
00-200 Introduction, safety, and basic infor-
mation, "Precautions related to work safety
1. Precautions peculiar to hybrid machine"
and "Handling of hybrid devices and
high-voltage wirings", before biginning the
work on them.
50-100 4 PC200, 200LC-8E0 (Hybrid)

Coating materials list SEN05256-01
Coating materials list

(Rev. 2009. 02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassem-
bly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate
Komatsu code Part number Q'ty Container Main features and applications
gory
q Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
q Used for plastic (except polyethylene, polypro-
20 g Polyethylene pylene, tetrafluoroethylene and vinyl chloride),
LT-1B 790-129-9050
(2 pcs.) container rubber, metal, and non-metal parts which re-
quire immediate and strong adhesion.
Polyethylene q Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container q Used to fix and seal bolts and plugs.
Adhesive:
790-129-9060
1 kg q Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: tics.
and hardener)
500 g
Polyethylene
Adhesive
LT-4 790-129-9040 250 g q Use to seal plugs.

container
Holtz MH 705 790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
q Quick-setting adhesive.
Polyethylene q Setting time: Within 5 sec. to 3 min.
ThreeBond1735 790-129-9140 50 g
container q Used mainly to stick metals, rubbers, plastics,
and woods.
q Quick-setting adhesive.
q Quick-setting type. (max. strength is obtained
Polyethylene
Aron-alpha201 790-129-9130 2g after 30 minutes)
container
q Used mainly to stick rubbers, plastics, and met-
als.
q Features: Resistance to heat and chemicals.
Polyethylene
Loctite 648-50 79A-129-9110 50 cc q Used for fitted portions used at high tempera-
container
tures.
q Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container q Used to seal tapered plugs, elbows, and nipples
of hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube q Used to seal flange surfaces and threaded por-
tions.
q Used to seal oil pan, final drive case, etc.
q Features: Silicon-based quick-setting sealant.
Gasket sealant
LG-7 790-129-9170 1 kg Tube q Used to seal flywheel housing, intake manifold,

oil pan, thermostat housing, etc.
q Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
q Use to seal transfer case, etc.
q Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
q Can be coated with paint.
LG-10 q Used as lubricant/sealant when the radiator
ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E q Can be coated with paint.
PC200, 200LC-8E0 (Hybrid) 50-100 5

SEN05256-01 Coating materials list
Cate
gory
q Feature: Can be used together with gaskets.
Gasket sealant
LG-11
790-129-9330 200 g Tube q Used for covers of the transmission case and
ThreeBond1121
steering case etc.
ThreeBond1121 790-129-9090 100 g Tube q Gasket sealant used to repair engine.
q Used to prevent scuffing and seizure of

press-fitted portions, shrink-fitted portions, and
Molybdenum disulfide
LM-P 09940-00040 200 g Tube

threaded portions.
q Use to lubricate linkages, bearings, etc.
lubricant
q Spray type
q Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
― 09995-00250 190 g Can
ing each other.
q Applicable for the propeller shaft splines, nee-
dle bearings, pins and bolts of various links, etc.
prevention compound
q Feature: Seizure and scuffing prevention com-

pound with metallic super-fine-grain, etc.
Seizure
LC-G
― ― Can q Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI(*) q Feature: Lithium grease with extreme pressure
SYGA-160CNLI Various Various
*: For cold dis- lubrication performance.
SYG0-400LI-A
trict
(*)
SYG0-160CNLI
(*)
q Used for parts under heavy load.
Caution:
Molybdenumdis- SYG2-400M 400 g × 10 Bellows-type q Do not apply grease to rolling bearings like
ulfide grease SYG2-400M-A 400 g × 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can q The grease should be applied to work
equipment pins at their assembly only, not
applied for greasing afterwards.
Grease
Hyper White SYG2-400T-A

q Seizure resistance, heat resistance and water
Grease SYG2-16CNT
Bellows-type resistance higher than molybdenum disulfide
G2-T, SYG0-400T-A 400 g
container grease.
G0-T (*) (*) 16 kg
Can q Not conspicuous on machine since color is
*: For cold dis- SYG0-16CNT
white.
trict (*)
Biogrease
SYG2-400B
G2-B
SYGA-16CNB
G2-BT (*) Bellows-type q Since this grease is decomposed by natural
SYG2-400BT 400 g
*: For use at container bacteria in short period, it has less effects on mi-
(*) 16 kg
high tempera- Can croorganisms, animals, and plants.
SYGA-16CNBT
ture and under
(*)
high load
q Feature: Silicone grease with wide using tem-
perature range, high resistance to thermal-oxi-
G2-S
― 200 g Tube dative degradation and performance to prevent
ThreeBond1855
deterioration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
50-100 6 PC200, 200LC-8E0 (Hybrid)

Coating materials list SEN05256-01
Cate
gory
q Feature: Urea (organic system) grease with
Grease
G2-U-S heat resistance and long life. Enclosed type.

427-12-11871 2 kg Can
ENS grease q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR-
q Used as primer for cab side.
PAINT Glasscon-
20 ml (Using limit: 4 months after date of manu-
PRIMER580 tainer
facture)
SUPER 417-926-3910
SUNSTAR- q Used as primer for cab side.
Glasscon-
GLASSPRIMER 20 ml (Using limit: 4 months after date of manu-
Adhesive for cab glass

tainer
580SUPER facture)
q Used as primer for painted surface on cab
SUNSTAR-
Glasscon- side.
Primer
PAINT 22M-54-27230 20 ml
tainer (Using limit: 4 months after date of manu-
PRIMER435-95
facture)
q Used as primer for black ceramic-coated
SUNSTARGLAS surface on glass side and for hard polycar-
SPRIMER435-4 22M-54-27240 150 ml Can bonate-coated surface.
1 (Using limit: 4 months after date of manu-
facture)
SUNSTAR- q Used as primer for sash (Almite).
Glasscon-
SASH PRIM- 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
tainer
ERGP-402 facture)
q “S” is used for high-temperature season
SUNSTARPEN-
and “W” for low-temperature season as
GUINESEAL Polyethylene
417-926-3910 320 ml adhesive for glass.
580SUPER “S” container
(Using limit: 4 months after date of manu-
or “W”
Adhesive
facture)
Sika q Used as adhesive for glass.
Polyethylene
Japan,Sikaflex 20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Adhesive for cab glass
container
256HV facture)
SUNSTARPEN- q Used as adhesive for glass.
Ecocart(Spe-
GUINESUPER 22M-54-27210 320 ml (Using limit: 6 months after date of manu-
cialcontainer)
560 facture)
SUNSTARPEN- q Used to seal joints of glass parts.
Polyethylene
GUINESEAL 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
Caulking material
No. 2505 facture)

SEKISUISILI- q Used to seal front window.
Polyethylene
CONESEAL- 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
ANT facture)
q Used to seal joint of glasses.Translucent
GE TOSHIBA-
white seal.
SILICONES- 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
PC200, 200LC-8E0 (Hybrid) 50-100 7

SEN05256-01 Special tools list
Special tools list
a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity:
t............Special tools that cannot be substituted and should always be used
q............Special tools that will be useful if available and are substitutable with tools available on the
market
a New/Redesign:
N .............Tools newly developed for this model. They have a new part number respectively.
R .............Tools made available by redesigning the existing tools which were developed for other models.
Each of them has a new part number assigned by setting forward the part number of the existing tool.
Blank .............Tools already available for other models. They can be used without any modification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See "Sketch-
es of special tools").
Necessity
Sketch
Work item Symbol Part number Part name Work content
Q'ty
N/R
Installation of engine front
Cylinder head assem- 1 795-799-1131 Gear t 1
seal
bly, fuel injector assem-
2 795-799-8150 Remover q 1 Removal of inlet connector
bly
3 795-799-6700 Primer t 1 Removal of fuel injector
Installation of engine front
Engine front seal 4 795-799-6400 Seal puller t 1
seal
Installation of engine rear
Engine rear seal 5 795-799-6500 Seal puller t 1
seal
6 790-331-1120 Wrench (Angle) q 1 Angle tightening of bolt
Cylinder head assembly Judgment of cylinder head
7 795-790-4510 Gauge q 1
A bolt length
8 796T-401-1110 Plate q 1 Q Engine, motor-generator
Engine and hydraulic Removal and installation of
pump assembly 9 795-790-9300 Lifting tool q 1 engine and hydraulic pump
assembly
Hydraulic pump assem- 10 790-460-1210 Oil stopper q 1
Stopping oil
bly, Engine and hydrau- 11 796-770-1320 Adapter q 1
lic pump assembly,
Control valve assembly, Commercially Measurement of motor-gen-
12 Megaohm tester t 1 N
Center swivel joint available erator insulation
assembly
1 796T-401-1210 stand q 1 N Q
2 796T-401-1220 Plate q 1 N Q
1 3 01010-81690 Bolt q 2
4 01580-11613 Nut q 2
5 01643-31645 Washer q 4 Removal and installation of
Motor-generator hous-
B 1 796T-410-1000 Guide t 1 N motor-generator housing
ing assembly
2 796T-410-1040 Bar t 1 N assembly
3 796T-410-1050 Plate t 1 N
2
4 01010-81030 Bolt t 2
5 01643-31032 Washer t 6
6 01010-81035 Bolt t 4
Invertor capacitor Positioning of invertor
B 3 796T-426-1110 Assembly jig t 1 N Q
assembly capacitor assembly
50-100 8 PC200, 200LC-8E0 (Hybrid)

Special tools list SEN05256-01
Necessity
Sketch
Q'ty
N/R
796T-426-1130 Plate t 1 Q
1 790-101-5421 Grip t 1 Press-fitting of oil seal
01010-81240 Bolt t 1
2 796-426-1120 Push tool t 1 Press-fitting of sub bearing
Press-fitting of main bearing
3 796T-426-1410 Push tool t 1 Q
(PC200/210-8)
Swing electric motor Removal and installation of
and swing machinery F 4 796T-426-1510 Bolt t 3 N Q swing electric motor and
assembly swing machinery assembly
Removal and installation of
5 01124-51490 Guide bolt t 1 N swing electric motor assem-
bly
1 796-426-1710 Collet t 1 N Assembly of Spirolock in
6 2 796-426-1720 Tapered cone t 1 N swing machinery
3 796-426-1730 Collar t 1 N
796-427-1400 Wrench assembly t 1 N
796-427-1410 q Wrench 1 N Removal and installation of
Final drive assembly J 1
796-427-1140 q Pin 3 nut
01314-20612 q Screw 3
796T-427-1510 Push tool t 1 N Q
790-101-2510 Block t 1
790-101-3310 Block t 1
790-101-2610 Rod t 2
790-101-2730 Adapter t 2
2 Installation of bearing
01580-11613 Nut t 2
790-101-2570 Plate t 2
01643-31645 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
3 796-427-1520 Installer t 1 N Installation of floating seal
Final drive assembly J
4 796-427-1200 Wrench t 1
nut
5 791-545-1510 Installer t 1 Installation of floating seal
796T-427-1220 Push tool t 1 Q
790-101-2510 Block t 1
792-104-3940 Bolt t 1
6 05180-11610 Nut t 2 Installation of bearing
01613-31645 Washer t 2
790-105-2100 Jack t 2
790-101-1102 Hydraulic pump t 1
7 790-331-1110 Wrench t 1 Angle tightening of bolt
Carrier roller assembly 1 790-434-1660 Installer 1
Track roller assembly L 2 796-670-1020 Installer 1 Installation of floating seal
Idler assembly 3 791-530-1510 Installer
791-600-2001 Compressor (A) t 1
or
91-685-8006 Compressor (B) t 1
790-201-2780 Spacer
1 791-635-3160 Extension t 1
Cylinder
790-101-1600 t 1
(686 N {70 ton})
790-101-1102 Pump t 1
Recoil spring Disassembly and assem-
M 790-640-2180 Guide bolt t 1
assembly blyof recoil spring assembly
790-101-5201 Push tool kit (B) q 1
790-101-5241 q Plate 1
2
790-101-5221 q Grip 1
01010-51225 q Bolt 2
790-201-1500 Push tool kit q 1
790-201-1620 q Plate 1
3
790-101-5021 q Grip 1
01010-50816 q Bolt 1
PC200, 200LC-8E0 (Hybrid) 50-100 9

SEN05256-01 Special tools list
Necessity
Sketch
Q'ty
N/R
791-630-3000 Remover and installer t 1
Cylinder Separation and installation
Track shoe assembly R 790-101-1300 t 1
(980 kN {100 ton}) of track shoe assembly
790-101-1102 Pump t 1
Hydraulic pump assem- Press-fit of input shaft oil
S 796T-467-2410 Push tool t 1 N Q
bly seal
790-101-5201 Push puller q 1
790-101-2510 q Block 1
790-101-2520 q Screw 1
791-112-1180 q Nut 1 Disassembly and assembly
Center swivel joint
T 1 790-101-2540 q Washer 1 of center swivel joint assem-
assembly
790-101-2630 q Leg 2 bly
790-101-2570 q Plate 4
790-101-2560 q Nut 2
790-101-2650 q Adapter 2
796-946-1310 Guide f21.8
t 1
(For 723-46-40100)
796-946-1610 Guide f21.4
t 1
(For 723-46-41100)
796-946-1810 Guide f21.2
2 t 1
(For 723-46-43100 and 723-46-43400)
796-946-1910 Guide f21.0
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2210 Guide f20.6
t 1
(For 723-46-45100 and 723-46-45700)
796-946-1320 Guide f21.8
t 1
(For 723-46-40100)
796-946-1620 Guide f21.4
t 1
(For 723-46-41100)
796-946-1820 Guide f21.2
t 1
(For 723-46-43100 and 723-46-43400)
3
796-946-1920 Guide f21.0 Replacement of pressure
Control valve assembly T t 1
(For 723-46-46101 and 723-46-46300) compensation valve seal
796-946-2220 Guide f20.6
t 1
(For 723-46-45100)
796-946-1420 Guide f21.6
t 1
(For 723-46-42700)
796-946-1330 Sleeve
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
t 1
(For 723-46-43100 and 723-46-43400)
4
796-946-1930 Sleeve
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)
50-100 10 PC200, 200LC-8E0 (Hybrid)

Special tools list SEN05256-01
Necessity
Sketch
Q'ty
N/R
790-502-1003 Cylinder repair stand q 1 Disassembly and assembly
1 of hydraulic cylinder assem-
790-101-1102 Pump q 1
bly
790-102-4300 Wrench assembly t 1 Removal and installation of
2
790-102-4310 Pin t 2 piston assembly
3 790-720-1000 Expander q 1
Rubber band
796-720-1670 q 1
(for boom and arm)
07281-01279 Clamp q 1 Installation of piston ring
4
Rubber band
796-720-1660 q 1
(for bucket)
07281-01159 Clamp q 1
790-201-1702 Push tool kit t 1
q Push tool
790-201-1831 1
(for bucket)
Hydraulic cylinder q Push tool
U 790-201-1930 1
assembly 5 (for arm) Press fitting of bushing
q Push tool
790-201-1940 1
(for boom)
790-101-5021 q Grip 1
01010-50816 q Bolt 1
q Push tool kit
790-201-1500 q 1
(for bucket)
790-201-1640 q Push tool 1
790-101-5021 q Grip 1
01010-50816 q Bolt 1
6 Plate Press fitting of dust seal
790-201-1980 q 1
(for boom)
Plate
790-201-1990 q 1
(for arm)
790-101-5021 Grip q 1
01010-50816 Bolt q 1
796-900-1200 Remover t 1
796-900-1210 q Sleeve 1
792-900-1520 q Plate 1
799-900-1230 q Screw 1
Work equipment assem- 796-900-1240 q Adapter 1
V Removal of foot pin
bly 01643-33080 q Washer 1
01803-13034 q Nut 1
Puller
790-101-4000 t 1
(490 kN {50 ton} long)
790-101-1102 Pump (294 kN {30 t}) t 1
Operator’s cab glass 2 793–498–1210 Lifter (Suction cup) t 2 Installation of operator cab
X
(stuck glass) 3 20Y-54-13180 Stopper rubber t 2 glass (stuck glass)
Commercially
Impact wrench q 1
Counterweight assem- available Removal and installation of
Z
bly Commercially Socket wrench (Width counterweight mounting bolt
q 1
available across flats: 40 mm)
PC200, 200LC-8E0 (Hybrid) 50-100 11

SEN05256-01 Sketches of special tools
Sketches of special tools
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A8 Plate
B1-1 Stand
50-100 12 PC200, 200LC-8E0 (Hybrid)

Sketches of special tools SEN05256-01
B1-2 Plate
B3 Assembly jig
PC200, 200LC-8E0 (Hybrid) 50-100 13

F1 Plate
F3 Push tool
50-100 14 PC200, 200LC-8E0 (Hybrid)

F4 Bolt
J2 Push tool
PC200, 200LC-8E0 (Hybrid) 50-100 15

J6 Push tool
S Push tool
50-100 16 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 50-100 17

SEN05256-01
©2010 KOMATSU
All Rights Reserved
50-100 18
SEN05257-00
SEN05257-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


Removal and installation of fuel supply pump assembly ............................................................................ 2

Removal and installation of fuel injector assembly ..................................................................................... 6
Removal and installation of engine front seal ............................................................................................. 13
Removal and installation of engine rear seal .............................................................................................. 15
Removal and installation of cylinder head assembly .................................................................................. 18
Removal and installation of radiator assembly ........................................................................................... 35
Removal and installation of hydraulic oil cooler assembly .......................................................................... 37
Removal and installation of aftercooler assembly....................................................................................... 40
Removal and installation of fuel cooler assembly ....................................................................................... 43
Removal and installation of engine/motor-generator/hydraulic pump assembly......................................... 45
Removal and installation of fuel tank assembly .......................................................................................... 60
PC200, 200LC-8E0 (Hybrid) 50-200 1

SEN05257-00 Removal and installation of fuel supply pump assembly
Removal and installation of fuel 3. Remove the counterweight assembly. For

supply pump assembly details, see "Removal and installation of coun-
terweight assembly".
Removal 4. Disconnect the wiring harness and hoses from

k Park the machine on a level place, lower the
the supply pump assembly according to the
work equipment to the ground completely, following procedure. [*1]
and stop the engine. a Remove mud from the joints in advance.
k Disconnect the cable from the negative (-)
(since locks (L) may become hard because of
terminal of the battery. mud)
a While pressing lock (L) from both sides, pull
1. Close fuel stop valve (1). out each hose.
a When each hose is disconnected, fuel flows
out. Put a plug to the hose fitting to prevent
the fuel from leaking.
a Do not use a wooden plug since its chips may
enter the fuel line.
a Record the disconnected and clamped por-
tions of each hose.
a Cover the ends of the disconnected hoses
and high pressure fuel pipes with cloths.
1) Disconnect fuel hose clamp (6).
2) Disconnect connector PUMP (7).
3) Disconnect quick couplers (8) and (9) of the
fuel return tube. [*2]
4) Disconnect quick coupler (10) of the hose
2. If the fuel level is above the hose fitting (supply coming from the fuel filter. [*3]
pump portion) going to the fuel cooler, open right
inspection cover (2) and open fuel drain valve (3)
to drain the fuel until the fuel level lowers below
the hose fitting going to the fuel cooler.
50-200 2 PC200, 200LC-8E0 (Hybrid)

Removal and installation of fuel supply pump assembly SEN05257-00
5) Disconnect quick coupler (11) of the hose

going to the fuel filter. [*4]
6) Remove the joint bolt and disconnect hose
(12) coming from the prefilter. [*5]
6. Remove fuel spray prevention cap (21) from the

supply pump and common rail. [*9]
5. Remove the tandem pump according to the

1) Disconnect four lubrication hoses (13) - (16).
[*6]
(13) Hose to swing motor
(14) Hose from swing motor
(15) Hose to motor-generator
(16) Hose from motor-generator
a Record the disconnected position of each
hose.
a Cover the end of each disconnected hose
with cloth.
2) Remove elbows (15a) and (16a). 7. Remove high-pressure fuel pipe clamps (22)
a Do not remove elbows (13a) and (14a). and (23).
[*7] [*10]
a Record the installation direction of each
elbow.
3) Remove 2 tandem pump mounting bolts (17).
[*8]
4) Remove pump (18).
PC200, 200LC-8E0 (Hybrid) 50-200 3

SEN05257-00 Removal and installation of fuel supply pump assembly
8. Remove high-pressure fuel pipe mounting nuts Installation

(24) from the supply pump and common rail and q Carry out the installation in the reverse order to
remove high-pressure fuel pipe (25). [*11] the removal.
[*1]
a When installing the fuel hoses and hose clamps,
return them to the positions they were.
[*2], [*3], [*4]

q When installing a connector of quick coupler
type, observe the following points.
a The internal parts of the fitting may be dam-
aged when the hose or tube is removed. Ac-
cordingly, do not reuse the hose or tube.
When installing, replace with a new one.
a Ensure that mud or dirt is not sticking to the
hose joint portions in advance.
a Press and insert the connector straight (in di-
9. Remove three mounting nuts (26) (parts A) and rection (b)) without prying or bending it to the
remove supply pump assembly (27). [*12] right or left.
If it is difficult to insert the connector, do not
push it in forcibly but pull it out. Then, check
the convex and concave parts for abnor-
mality and sticking mud.
(Parts A: Indicate the pump mounting positions.)
[*5]
3 Joint bolt:19.6 – 29.4 Nm {2.0 – 3.0 kgm}
50-200 4 PC200, 200LC-8E0 (Hybrid)

Removal and installation of fuel supply pump assembly SEN05257-00
[*6] 3 Sleeve nut:

a Ensure that mud or dirt is not sticking to the hose 35 ± 3.5 Nm {3.6 ± 0.36 kgm}
fittings and inside of the hoses. 3. Install the high-pressure fuel pipe clamp.
3 Lubricating oil hose sleeve nuts: 3 High-pressure fuel pipe mounting bolt:
(12) Hose to swing motor: 24 ± 4 Nm {2.45 ± 0.4 kgm}
54 – 93 Nm {5.5 – 9.5 kgm}
(13) Hose from swing motor: [*12]
54 – 93 Nm {5.5 – 9.5 kgm} a If supply pump mounting stud bolt (29) on the
(14) Hose to motor-generator: gear housing is removed, apply adhesive to the
84 – 132 Nm {8.5 – 13.5 kgm} bolt hole before installing the stud bolt.
(15) Hose from motor-generator: a If grease is applied too much to O-ring (28) when
84 – 132 Nm {8.5 – 13.5 kgm} the supply pump is installed, it oozes out during
operation. Accordingly, do not apply grease too
[*7] much.
a If elbows (13a) – (16a) were removed, install (Apply grease to O-ring groove area (B).)
them in the directions recorded when they were 2 Stud bolt (29): Adhesive (LT-2)
removed. 3 Stud bolt (29): 12 ± 2 Nm {1.22 ± 0.2 kgm}
3 Hose mounting elbows: 3 Mounting bolt of fuel supply pump (27):
(13a) Swing motor discharge port: 24 ± 4 Nm {2.45 ± 0.4 kgm}
25 – 29 Nm {2.6 – 3.0 kgm}
(14a) Swing motor suction port:
25 – 29 Nm {2.6 – 3.0 kgm}
(15a) Generator discharge port:
35 – 63 Nm {3.6 – 6.4 kgm}
(16a) Generator suction port:
59 – 98 Nm {6.0 – 10 kgm}
[*8]
3 Flange mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*9]
a Install the fuel spray prevention caps with the
slits out and down.
a The fuel spray prevention cap are installed so
that fuel does not spurt over the hot parts of the
engine and catch fire when it leaks for some rea-
son.
3 High-pressure fuel pipe mounting bolt:
24 ± 4 Nm {2.45 ± 0.4 kgm}
[*10], [*11]
q Install the fuel high-pressure fuel pipe according
1. Tighten the sleeve nuts partially on the common
rail side and supply pump side.
2. Ensure that the high-pressure fuel pipe is not
installed forcibly and then alternately tighten the q Bleeding air
sleeve nuts on the common rail side and supply Bleed air from the fuel system. For details, see
pump side to the specified torque. Testing and adjusting, "Bleeding air from fuel
system".
PC200, 200LC-8E0 (Hybrid) 50-200 5

SEN05257-00 Removal and installation of fuel injector assembly
Removal and installation of fuel 3. Open engine hood (4).

injector assembly
Special tools
New/Remodel
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
1 795-799-1131 Gear t 1
A 2 795-799-8150 Remover q 1
3 795-799-6700 Puller t 1
Removal
4. Remove the fuel injection pipe according to the
work equipment to the ground completely,
following procedure. [*1]
and stop the engine.
1) Disconnect wiring harness connector (5).
(You do not need to disconnect this
terminal of the battery.
connector when removing only the No. 4
cylinder injector assembly.)
1. Close fuel stop valve (1).
a Since you cannot hold each connector,
disconnect it by using two flat-head
screwdrivers according to the following
procedure.
1] Keep pressing lock (a) of the connector
with flat-head screwdriver [1].
2] Insert flat-head screwdriver [2] in the
clearance between the connectors on the
right and left sides of lock (a) and move it
to the right and left to pry out the
connector gradually.
2. If the fuel level is above the hose fitting (supply

50-200 6 PC200, 200LC-8E0 (Hybrid)

Removal and installation of fuel injector assembly SEN05257-00
2) Remove fuel spray prevention caps (6) from 6. Remove mounting bolt (13) and blowby duct
the common rail and cylinder head. (14). [*2]
7. Remove cylinder head cover (15). [*3]
3) Loosen sleeve nuts (7) on the common rail

side and cylinder head side and remove fuel
injection pipe (8).
4) Disconnect wiring harness connector (10) of 8. Remove retaining nut (26) and inlet connector
fuel pressure sensor (9). (27).
a While pressing lock (b), pull out connector a Remove mud sticking around the inlet con-
(10) in the direction of the arrow. nector so that it does not enter the inlet con-
a Do not remove the fuel pressure sensor nector mounting hole.
for any other purpose than replacement. a Tool A2 is provided for removing inlet con-
nector (27). (See the special tools table)
5. Loosen bolt (11) and remove bracket (12).

(This procedure applies to the No. 1 cylinder
injector assembly removal.)
PC200, 200LC-8E0 (Hybrid) 50-200 7

9. Disconnect wiring harness (28). 13. Remove mounting bolts (34) of the fuel injector
assembly.
10. Loosen locknuts (29) and loosen adjustment
screws (30) thoroughly.
11. Remove rocker arm mounting bolts (31) and

rocker arms (32).
14. Using tool A3, remove fuel injector assembly

(35).
a After removing the fuel injector assembly,
cover the fuel injector mounting bore with
cloths to prevent dirt from entering it.
12. Remove crossheads (33).
a Record the installation position and direction
(shapes of holes (a) and (b)) of each cross-
head. (For reinstallation in the same direc-
tion)
50-200 8 PC200, 200LC-8E0 (Hybrid)

Installation 4) When installing, direct the fuel inlet hole (inlet

1. Fuel injector assembly connector mounting hole) toward the air
a When replacing the fuel injector assembly intake manifold.
with new one, be sure to replace the inlet 5) Install fuel injector assembly (35) into the fuel
connector, too. injector mounting bore and tighten mounting
a Check that fuel injector mounting bore (36) is bolts (34) at least three to four turns.
free from damage and dirt.
1) Fit O-ring (38) and gasket (39) to fuel injector

(37).
a Replace the O-ring and gasket with new
ones.
2) Apply engine oil to O-ring (38) of fuel injector
(37) and to the fuel injector mounting bore.
2 O-ring (38) and fuel injector mounting
bore: Engine oil (For details, see
"List of lubricant and water")
3) While matching concave and convex (A),
install holder (40) to fuel injector (37).
PC200, 200LC-8E0 (Hybrid) 50-200 9

6) Apply engine oil to O-ring (41) of inlet

connector (27) and to the inlet connector
mounting hole (hole in the cylinder head).
a Check the inlet connector visually for the
following defects. If it has any of these de-
fects, replace it and fuel injector assembly
with new ones.
q There is a bur or a worn part at front end
(a) or rear end (b) of the inlet connector.
q There is foreign matter in the edge filter at
rear end (c) of the inlet connector.
q The O-ring at upper part (d) of the inlet
connector is cracked or deteriorated.
q There is a worn part or an uneven seat
contact mark on sealing face (e) at the
8) Install the inlet connector and tighten
front end of the inlet connector.
retaining nut (26) partially.
3 Retaining nut:
a If high-pressure fuel leaks at the inlet
connector, the seal face has fine
15 ± 5 Nm {1.5 ± 0.5 kgm}
streaks or cracks.
7) Insert inlet connector (27) fully, while
matching its part (B) with the groove (upper)
in the head.
2 O-ring (41) and inlet connector mount-
ing hole: Engine oil (For details, see
"List of lubricant and water")
9) Tighten mounting bolts (34) of fuel injector

assembly (35) alternately.
3 Fuel injector mounting bolt (34):
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
10)Tighten retaining nut (26) to the specified
torque.
3 Retaining nut (26):
50 ± 5 Nm {5.1 ± 0.51 kgm}
50-200 10 PC200, 200LC-8E0 (Hybrid)

2. Rocker arm assembly 2) Install rocker arm assembly (32) and tighten
1) Install crossheads (33). mounting bolts (31).
a Install each crosshead in the position and a Ensure that adjustment screws (30) are
direction (the shape of parts (a) and (b)) thoroughly loosened.
recorded when removed. a Check that the ball of adjustment screw
(30) is fitted in the push rod socket se-
curely, and then tighten mounting bolts
(31).
3 Rocker arm mounting bolt (31):
36 ± 5 Nm {3.7 ± 0.51 kgm}
3) Adjust the valve clearance. For details, see
Testing and adjusting, "Adjusting valve clear-
ance".
a Use tool A1 to rotate the engine.
4) After adjusting the valve clearance, ensure
that locknuts (12) are tighten to the specified
torque.
q Locknut (29):
24 ± 4 Nm {2.4 ± 0.4 kgm}
5) Install wiring harness (28) and terminal nuts.
a Check that the wiring harness does not
interfere with the rocker arm.
a Installation position of wiring harness
Cable color Cylinder No.
White 1, 3
Black 2, 4
3 Terminal nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
PC200, 200LC-8E0 (Hybrid) 50-200 11

[*1]
a Precautions for installing fuel injection pipe
k Do not change the bending angle and di-
rection of the fuel injection pipe.
k Be sure to use genuine fuel injection pipe
clamps and tighten mounting bolts to the
specified torque.
k After installing the fuel injection pipe, be
sure to install the fuel spray prevention
cap to the sleeve nut.
k When installing the fuel spray prevention
cap, direct its slit out down.
a Before installing the fuel injection pipe, check the
following.
q If the fuel injection pipe has a fault, it may
leak the fuel. Accordingly, replace it with a
new one.
q There must not be visible longitudinal slits (k)
or pits (I) in taper seal portion (part (j): 2 mm
from the end) of the joint
q There must not be a level difference in part
(m) (taper seal end: part of 2 mm from the
end) which your finger nail feels.
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
[*2]
a When installing the blowby duct, check that the
O-ring is fitted.
3 Blowby duct mounting bolt:
7 ± 2 Nm {0.71 ± 0.2 kgm}
[*3]
3 Cylinder head cover mounting nut:
24 ± 4 Nm {2.4 ± 0.4 kgm}
a If the stud bolt is removed, install it and tighten to

the following torque.
3 Stud bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
q Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
50-200 12 PC200, 200LC-8E0 (Hybrid)

Removal and installation of engine front seal SEN05257-00
Removal and installation of engine Installation

front seal 1. Using tool A4, install front oil seal (3).
a Replace the engine front oil seal.
a Before installing the engine front oil seal,
Special tools check that crankshaft end corners and seal
lip sliding surface are free from flaw, burr, fin,
New/Remodel
Sym
rust, etc.
Necessity
bol
Part No. Part name a When installing the engine front oil seal, do
Sketch
not apply oil or grease to the crankshaft and
Q'ty
seal lip. Thoroughly wipe off oil and grease
4 795-799-6400 Seal puller t 1 from the crankshaft.
A
6 790-331-1120 Wrench (angle) q 1
Removal
1. Remove the radiator assembly referring to the
section of "Removal and installation of radiator
assembly".
2. Remove crank pulley mounting bolts (1) and

crank pulley (2).
a The projection and facial misalignment of en-

gine front oil seal (3) from cover (4) must be
as follows.
q Projection (x): Max. 0.38 mm
q Facial misalignment (y): Max. 0.25 mm
3. Remove engine front oil seal (3).
PC200, 200LC-8E0 (Hybrid) 50-200 13

SEN05257-00 Removal and installation of engine front seal
2. Crankshaft pulley (When not using angle tightening tool A6)

1) Check the dowel pin position on the reverse 5] After performing steps 1] – 3] above,
side of crankshaft pulley (2) and install the make marks on the crankshaft pulley and
crankshaft pulley to the crankshaft. bolts.
a If the dowel pin is removed, install it be- 6] Tighten the bolts in the diagonal order to
fore installing the crankshaft pulley. the following angle.
2) Install crankshaft pulley mounting bolts (1) Tightening angle: 90 ± 5°
according to the following procedure.
1] Tighten the bolts in the diagonal order to
3 Mounting bolt:
55 ± 5 Nm {5.6 ± 0.5 kgm}
2] Loosen all the bolts 180°.
3] Tighten the bolts in the diagonal order to
3 Mounting bolt:
55 ± 5 Nm {5.6 ± 0.5 kgm}
4] Using angle tightening tool A6, tighten the
bolts in the diagonal order to the following
angle. (See the special tools table)
Tightening angle: 90 ± 5°
q Carry out the following installation in the reverse
order to the removal.
50-200 14 PC200, 200LC-8E0 (Hybrid)

Removal and installation of engine rear seal SEN05257-00
Removal and installation of engine 5. Remove the flywheel according to the following
rear seal procedure.
1) Remove two of flywheel mounting bolts (3) in
the diagonal positions and install guide bolts
[1]. [*1]
2) Sling flywheel (4) and remove the remaining
Special tool mounting bolts.
3) Pull out flywheel (4) toward you.
New/Remodel
4) Remove guide bolts [1] and lift off flywheel
Sym-
Necessity
Part No. Part name (4).
4 Flywheel: 15 kg
bol
Sketch
Q'ty
A 5 795-799-6500 Seal puller t 1 N
Removal
1. Remove the "engine, motor-generator, and
hydraulic main pump assembly". For details, see
"Removal and installation of engine,
motor-generator, and hydraulic main pump
assembly".
2. Remove the hydraulic main pump assembly. For

details, see "Removal and installation of
hydraulic main pump assembly".
3. Remove the motor-generator housing assembly.

For details, see "Removal and installation of
motor-generator housing assembly".
4. Remove ten bolts (1) and coupling (2).
PC200, 200LC-8E0 (Hybrid) 50-200 15

SEN05257-00 Removal and installation of engine rear seal
6. Removal of engine rear oil seal

1) Install tool A5 to the crankshaft.
2) Screw tapping screws [2] of tool A5 into the
seal carrier of engine rear oil seal (5).
3) Rotate the handle clockwise to remove
engine rear oil seal (5).
50-200 16 PC200, 200LC-8E0 (Hybrid)

Removal and installation of engine rear seal SEN05257-00
Installation a Part (6) in the following figure is the crank-

1. Install the engine rear oil seal according to the shaft.
a Replace the engine rear oil seal with new
one.
a Do not remove pilot [3] which is attached to
oil seal (5) until oil seal (5) is installed to the
crankshaft.
a Before installing the oil seal, degrease, clean
and dry the seal sliding surface of the crank-
shaft and the seal lip face to prevent oil leak-
age.
2. Install pilot [3] to crankshaft (6) and push oil seal

(5) into flywheel housing (7).
q Carry out the following installation in the re-
3. Push in oil seal (5) further and pull out pilot [3]. verse order to the removal.
4. Position oil seal (5) in flywheel housing (7) to the

proper depth by using tool A5.
a Push in oil seal (5) taking care that there are
no bend etc. on it.
a Protrusion of oil seal (5) from flywheel hous-
ing (7)
(X): less than 0.38 mm
PC200, 200LC-8E0 (Hybrid) 50-200 17

SEN05257-00 Removal and installation of cylinder head assembly

cylinder head assembly
Special tools
New/Remodel
Necessity
Symbol Part No Part name
Sketch
Q'ty
1 795-799 -1131 Gear t 1
2 795-799-8150 Remover q 1
A 3 795-799-6700 Puller t 1
Wrench
6 790-331-1120 q 1
(Angle)
3. Open engine hood (4).
7 795-790-4510 Gauge q 1
Removal
4. Remove the counterweight assembly. For

details, see "Removal and installation of coun-
5. Disconnect and move the air conditioner

compressor so that it is not an obstacle
1) Remove fan guard (5).
2. If the fuel level is above the hose fitting (supply

50-200 18 PC200, 200LC-8E0 (Hybrid)

Removal and installation of cylinder head assembly SEN05257-00
2) Disconnect wiring harness connector AC02

(6).
3) Disconnect wiring harness clamps (7) and
(8).
4) Loosen air conditioner compressor fixing bolt
(9) and belt tension adjustment bolt (10) and
remove air conditioner compressor drive belt
(11). [*1]
a Do not loosen air conditioner compressor
mounting bolts (MB). [*2]
5) Remove air conditioner compressor fixing
bolt (9) and belt tension adjustment bolt (10)
and disconnect air conditioner compressor
assembly (12).
7. Remove the air conditioner compressor mount
bracket according to the following procedure.
1) Disconnect electric intake air heater wiring
harness E01 (14).
2) Disconnect wiring harness clamps (15) and
(16).
3) Remove three bolts (17).
4) Remove two bolts (18) and, brackets (19)

and (20) together.
6. Remove air hose (13). [*3]

a Make marks at the hose end and tube to indi-
cate the hose installation depth.
PC200, 200LC-8E0 (Hybrid) 50-200 19

8. Remove the fuel injection pipe and high-pres- 3) Remove fuel injection pipe mounting sleeve
sure fuel pipe according to the following proce- nuts (23) from the common rail and cylinder
dure. [*4] head and remove fuel injection pipe (24).[*5]
1) Disconnect wiring harness connector (21). 4) Disconnect wiring harness connector (26) for
a Since you cannot hold connector (21), fuel pressure sensor (25).
disconnect it by using two flat-head a While pressing lock portion (b), pull out
screwdrivers according to the following connector (26) in the direction of the ar-
procedure. row.
1] Keep pressing lock (a) of the connector a Do not remove fuel pressure sensor (25)
with flat-head screwdriver [1]. for any other purpose than replacement.
2] Insert flat-head screwdriver [2] in the
clearance between the connectors on the
right and left sides of lock (a) and move it
to the right and left to pry out the
connector gradually.
2) Remove fuel spray prevention caps (22) from
the common rail and cylinder head.
5) Similarly, remove fuel injection pipes (27),

(28) and (29) in the order of the No. 3, No. 2
and No. 1 cylinders.
50-200 20 PC200, 200LC-8E0 (Hybrid)

6) Disconnect quick couplers (30), (31) and (32) 9. Remove four mounting bolts (38) and common
of the fuel return tube. [*6] rail assembly (39). [*7]
7) Remove fuel spray prevention caps (33) from
the common rail and fuel supply pump.
1) Remove covers (40) and (41).
8) Remove high-pressure fuel pipe clamps (34)

and (35).
2) Disconnect turbocharger cooling hose

connector (42) from the turbocharger.
3) Disconnect turbocharger cooling tubes (43)
9) Remove high-pressure fuel pipe mounting and (44) from the turbocharger.
sleeve nuts (36) from the supply pump and 4) Disconnect hose (45) between the turbo-
common rail and remove high-pressure fuel charger and air cleaner from the turbo-
pipe (37). charger. [*8]
5) Disconnect hose (46) under the aftercooler
from the connector on the turbocharger. [*9]
6) Remove clamp (47).
PC200, 200LC-8E0 (Hybrid) 50-200 21

7) Remove heat insulation cover (48). 9) Loosen sleeve nut (51) and disconnect
supply hose (52) of the turbocharger lubri-
cating oil.
[*10]
a Fix connector (53) on the turbocharger by
using a wrench to prevent it from rotating.
10)Remove turbocharger mounting nut (54) and
place the turbocharger on stud bolt (55).
[*11]
11)Remove two hexagon socket head bolts (56)
and disconnect return tube (57) of the turbo-
charger lubricating oil. [*12]
12)Remove turbocharger (58).
8) Loosen the nuts of u-clamps (49) and tilt

muffler assembly (50) toward outside.
10. Remove heat insulation plate (59).
50-200 22 PC200, 200LC-8E0 (Hybrid)

11. Remove eight exhaust manifold mounting bolts 16. Remove fan guards (67) and (68).
(60a) and remove exhaust manifold assembly
(60). [*13]
17. Remove radiator fan (69).

a Lower the radiator fan.
12. Disconnect hose clamps (61) and (62).
13. Disconnect radiator upper hose (63) from the

water pump. [*14]
cate the hose installation depth.
14. Disconnect coolant bypass hoses (64) and (65).
15. Disconnect coolant temperature sensor

connector (66).
PC200, 200LC-8E0 (Hybrid) 50-200 23

18. Remove the alternator assembly according to 19. Remove turbocharger cooling tube (75).
the following procedure. [*15]
1) Disconnect wiring harness (70) and (71). 20. Remove two bolts (76) and blowby duct (77).
2) Insert wrench [1] into hole (A) (width across [*16]
flats: 12.7 mm) in tensioner assembly (72)
and rotate it counterclockwise (R), viewed 21. Remove joint bolt (78a) and disconnect fuel
from the front of the engine, to loosen fan belt return tube (78). [*17]
(73).
3) Remove fan belt (73) from alternator 22. Remove clamp (78b) of the fuel return tube.
assembly (74).
k Insert wrench [1] securely into hole (A) 23. Remove cylinder head cover (79). [*18]
in the tensioner assembly before rotat-
ing the tensioner assembly. (The
spring in the tensioner assembly is
strong. If wrench [1] is inserted incom-
pletely and rotated, it comes off and
that is very dangerous.)
k Rotate the tensioner assembly. While
rotating, take care that wrench [1] will
not come off.
k After removing fan belt (73), return
wrench [1] slowly and carefully.
k Take care not to catch your finger be-
tween the pulley and fan belt during
the work.
4) Remove the alternator mounting bolts and
24. Remove the fuel injectors and rocker arm hous-
remove alternator assembly (74).
ings according to the following procedure.
1) Disconnect wiring harness (80) from the fuel
injector.
2) Loosen retainer (81) and remove inlet
connector (82).
a Remove mud sticking around the inlet
connector so that it does not enter the in-
let connector mounting hole.
a Tool A2 is provided for removing the inlet
connector. (See the special tools table)
3) Remove rocker arm mounting bolts (83),
rocker arms (84), and seats.
a Loosen locknuts (85) and loosen adjust-
ment screw (86) thoroughly.
50-200 24 PC200, 200LC-8E0 (Hybrid)

4) Remove crossheads (87). 7) Using tool A3, remove fuel injector assembly
a Record the installation position and direc- (90).
tion (shapes of holes (a) and (b)) of each 8) Remove five mounting bolts (91) of the
crosshead. rocker arm housing and remove rocker arm
(For reinstallation in the same direction) housing assembly (92).
5) Remove push rods (88).
25. Remove eighteen mounting bolts (93) of the

cylinder head and lift off cylinder head assembly
(94).
4 Cylinder head assembly: 50 kg
26. Remove cylinder head gasket (95).
6) Remove two mounting bolts (89) of the fuel

injector assembly.
PC200, 200LC-8E0 (Hybrid) 50-200 25

Installation
1. Install the cylinder head assembly according to
the following procedure.
1) Using tool A7, measure stem length (a) of
each cylinder head mounting bolt and check
that it is shorter than the service limit. (See
the special tool table)
q Service limit length of bolt stem:
132.1 mm
a If the stem length of a bolt is longer than
the service limit, do not reuse that bolt but
replace it with new one.
2) Install cylinder head gasket (95).

a Check that the cylinder head mounting (When not using angle tightening tool
face and inside of the cylinders are free A6)
from dirt and foreign matter. 4] After performing steps 1] - 2] above,
a Use new cylinder head gasket (95). make marks on the cylinder head
3) Set cylinder head assembly (94). mounting bolts by a marker pen.
4 :Cylinder head assembly: 50 kg 5] Retighten 90 ± 5°.
a Check that the holes in cylinder head gas-
ket (95) are matched with those in the cyl-
inder head.
4) Tighten eighteen mounting bolts (93) at least
two to three turns with the fingers and then
tighten them in the following procedure.
a Apply engine oil to the threaded part and
seat of each bolt.
2 Threaded part and seat surface:
Engine oil (For details, see "List of
lubricant and water")
q Tightening procedure for mounting bolts

(93)
When using angle tightening tool A6 (See
Special tool table))
a Tighten the bolts in order of [1] – [18]
in three times.
3 Mounting bolt:
1] 90 ± 3 Nm {9.2 ± 0.3 kgm}
2] 90 ± 3 Nm {9.2 ± 0.3 kgm}
3] 90 ± 3° (Tighten by using tool A6)
50-200 26 PC200, 200LC-8E0 (Hybrid)

2. Install the rocker housing assembly according to 1) Fit O-ring (98) and gasket (99) to fuel injector
the following procedure. (97).
1) Install rocker housing assembly (92) and a Replace the O-ring and gasket with new
tighten five rocker housing mounting bolts ones.
(91). 2) Apply engine oil to O-ring (98) of fuel injector
a Replace the gasket with new one. (97) and to the fuel injector mounting bore.
3 Mounting bolt: 2 O-ring (98) and fuel injector mounting
24 ± 4 Nm {2.4 ± 0.4 kgm} bore: Engine oil (For details, see
2) Install push rods (88). "List of lubricant and water")
3) While matching concave and convex (A),
install holder (100) to fuel injector (97).
3. Install the fuel injectors according to the

a When replacing the fuel injector assembly 4) When installing, direct the fuel inlet hole (inlet
with new one, be sure to replace the inlet connector mounting hole) toward the air
connector, too. intake manifold.
a Check that fuel injector mounting bore (96) is 5) Install fuel injector assembly (90) into the fuel
free from damage and dirt. injector mounting bore and tighten mounting
bolts (89) at least three to four turns.
PC200, 200LC-8E0 (Hybrid) 50-200 27

6) Apply engine oil to O-ring (82a) of inlet

connector (82) and to the inlet connector
mounting hole (hole in the cylinder head).
a Check the inlet connector visually. If it
has any of the following faults, replace it
and fuel injector assembly together.
q There is a bur or a worn part at front end
(a) or rear end (b) of the inlet connector.
q There is foreign matter in the edge filter at
rear end (c) of the inlet connector.
q The O-ring at upper part (d) of the inlet
connector is cracked or deteriorated.
q There is a worn part or an uneven seat
contact mark on sealing face (e) at the
front end of the inlet connector.
8) Install retainer (81) and tighten it partially.
3 Retainer: 15 ± 5 Nm {1.5 ± 0.5 kgm}
a If high-pressure fuel leaks at the inlet con-
nector, the seal face has fine streaks or
cracks.
7) Insert inlet connector (82) fully, while
matching its part (b) with the groove (upper)
in the head.
2 O-ring (82a) and inlet connector
mounting hole: Engine oil (For de-
tails, see "List of lubricant and wa-
ter")
9) Tighten mounting bolts (89) of fuel injector

assembly (90) alternately.
3 Fuel injector mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
10)Tighten retainer (81) to the specified torque.
3 Retainer (81):
50 ± 5 Nm {5.1 ± 0.51 kgm}
50-200 28 PC200, 200LC-8E0 (Hybrid)

4. Install the rocker arm assembly according to the 3) Install rocker arms (84) and tighten mounting
following procedure. bolts (83).
1) Install push rods (88). a Ensure that adjustment screws (86) are
2) Install crossheads (87). thoroughly loosened.
a Install each crosshead in the position and 3 Rocker arm mounting bolt (83):
direction (the shape of parts (a) and (b)) 36 ± 5 Nm {3.7 ± 0.51 kgm}
recorded when removed. 4) Adjust the valve clearance. For details, see
Testing and adjusting, "Adjusting valve clear-
ance".
a Use tool A1 to rotate the engine.
5) After adjusting the valve clearance, ensure
that locknuts (85) are tighten to the specified
torque.
3 Locknut (85):
24 ± 4 Nm {2.4 ± 0.4 kgm}
6) Install the wiring harness and tighten the
terminal nuts.
a Check that the wiring harness does not
interfere with the rocker arm.
a Installation positions of wiring harness
Cable color Cylinder No.
White 1, 3
Black 2, 4
3 Terminal nut (80):
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
PC200, 200LC-8E0 (Hybrid) 50-200 29

q Carry out the following installation in the reverse q When reusing hose
order to the removal. 3) Install the clamp to the clamp mark made on
the hose.
[*1] 3 Clamp bolt: Min. 6 Nm {0.6 kgm}
a Adjust the tension of the air conditioner com-
pressor drive belt. For details, see Testing and q When using new hose
adjusting, "Adjusting belt tension". Tighten until dimension BDG becomes as
follows.
[*2] Parts (x), (y), (z): 7 – 10 mm
If mounting bolts (MB) of the air conditioner com-
pressor were loosened, tighten them to the following
torque.
a Excessive tightening can damage the internal
bearings. Observe the specified torque strictly.
3 Mounting bolt:
2.45 – 29.4 Nm {2.5 – 3.0 kgm}
[*3], [*9]
q If a hose is equipped with a MIKALOR clamp, in-
stall it according to the following procedure.
a Use a new MIKALOR clamp.
1) Set the hose to the original position (marked
when the hose was removed).
(Hose installation depth)
Hose (13) between aftercooler and air intake
manifold
Part (x): 80 mm
Part (y): 80 mm
Hose (46) between aftercooler and turbo-
charger
Part (z): 80 mm
2) Place bridge (BR) under the clamp bolt and
set overlap (b) between bridge (BR) and
band to the following dimension.
Dimension (b): Min. 5 mm
2 Threaded portion of clamp bolt (BC):
Lubricating oil (THREEBOND
PANDO 18B)
a Do not use an impact wrench.
50-200 30 PC200, 200LC-8E0 (Hybrid)

[*4], [*5], [*7] a Install the fuel injection pipe and high-pressure
a Precautions for installing fuel injection pipe and fuel pipe according to the following procedure.
high-pressure fuel pipe 1) Install the common rail assembly by tight-
k Do not change the bending angle and di- ening the mounting bolts partially.
rection of the fuel injection pipe and 3 Mounting bolt:
high-pressure fuel pipe. 0.2 – 0.8 Nm {0.02 – 0.08 kgm}
k Be sure to use genuine fuel injection pipe 2) Install the fuel injection pipes between the
clamps and tighten mounting bolts to the common rail and cylinder head by tightening
specified torque. the sleeve nuts partially.
k After installing the fuel injection pipe or 3 Sleeve nut:
fuel high-pressure pipe, be sure to install 0.2 – 0.8 Nm {0.02 – 0.08 kgm}
the fuel spray prevention caps to the 3) Install the fuel injection pipe and tighten the
sleeve nuts. sleeve nuts to the specified torque according
k When installing the fuel spray prevention
3 Sleeve nut:
caps, direct its slit out down.
a Before installing the fuel injection pipe or 35 ± 3.5 Nm {3.57 ± 0.36 kgm}
high-pressure fue pipe, check the following.
1] #1 cylinder head side
q If the fuel injection pipe has a fault, it may
2] #4 cylinder head side
leak the fuel. Accordingly, replace it with a
new one. 3] #4 common rail side
q There must not be visible longitudinal slits (k) 4] #1 common rail side
or pits (I) in taper seal portion (part (j): 2 mm 5] #2 cylinder head side
from the end) of the joint 6] #3 cylinder head side
q There must not be a level difference in part 7] #2 common rail side
(m) (taper seal end: part of 2 mm from the 8] #3 common rail side
end) which your finger nail feels. 4) Install the high-pressure fuel pipe between
the fuel supply pump and common rail and
tighten the sleeve nuts partially.
3 Sleeve nut:
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
5) Tighten the sleeve nut on the fuel supply
pump side first, and then tighten that on the
common rail side to the specified torque.
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}}
6) Install the two high-pressure fuel pipe
clamps.
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
7) Tighten the common rail assembly mounting
bolts to the specified torque.
a This procedure applies to the case where
the common rail assembly was removed.
3 Mounting bolt:
24 ± 4Nm {2.4 ± 0.4 kgm}
8) Install the fuel spray prevention caps to all
the high-pressure fuel pipes.
k Install the fuel spray prevention caps
with the slits out and down.
a The fuel spray prevention caps are in-
stalled so that fuel does not spurt over the
hot parts of the engine and catch fire
when it leaks for some reason.
PC200, 200LC-8E0 (Hybrid) 50-200 31

a Handling of fuel pressure sensor and fuel 2) Procedure for installing fuel pressure relief
relief valve valve (b)
1) Procedure for installing fuel pressure sensor 1] Before removing the fuel pressure relief
(a) valve, remove all mud from around it and
If fuel pressure sensor (a) is removed from clean thoroughly.
common rail assembly (39), be sure to 2] Remove the fuel pressure relief valve.
replace it with a new one. 3] If the leakage through the fuel pressure
1] Check the fuel pressure sensor connector for relief valve exceeds the specified value,
cracking/breakage, damage of seal, foreign do not reuse that relief valve.
matter at pin, corrosion/bend/breakage of pin, 4] Ensure that the fuel pressure relief valve
etc. and rail high-pressure fuel seal surface
2] Install a new fuel pressure sensor. (A) are free from damage.
a Apply clean gear oil (#90) to the 5] Install the fuel pressure relief valve.
2 Threaded portion of fuel pressure
threaded portion.
q Fuel pressure sensor:
relief valve: Gear oil (#90)
3 Fuel pressure relief valve:
70 ± 5 Nm {7.1 ± 0.5 kgm}
3] Connect the wiring harness connector. At 100 ± 4 Nm {10.2 ± 0.4 kgm}
this time, take care not to connect the a Excessive torquing can cause leak-
connector in reverse. age.
(After starting the engine, check for (After starting the engine, check for
leakage. For the checking procedure, see leakage. For the checking procedure,
Testing and adjusting, "Testing fuel see Testing and adjusting, "Testing
system for leakage".) fuel system for leakage".))
50-200 32 PC200, 200LC-8E0 (Hybrid)

[*6] [*11]
q When installing a connector of quick coupler 3 Turbocharger mounting nut:
type, observe the following points. 24 ± 4 Nm {2.4 ± 0.4kgm}
a The internal parts of the fitting may be dam- a If the stud bolt is removed, install it and tight-
aged when the hose is removed. According- en to the following torque.
ly, do not reuse the hose as a rule. 3 Stud bolt:
Replace the hose with a new one when 10 ± 2 Nm {1.0 ± 0.2 kgm}
assembling. [*12]
a Ensure that mud or dirt is not sticking to the q Mounting bolt of turbocharger lubricating oil re-
hose joint portions in advance. turn tube: 10 ± 2 Nm 1.0 ± 0.2 kgm}
a Press and insert the connector straight (in di- (Hexagonal head bolt M6×1.0)
rection (b)) without prying or bending it to the
right or left. [*13]
If it is difficult to insert the connector, do not a Tighten the exhaust manifold mounting bolts ac-
push it in forcibly but pull it out. Then, check cording to the following procedure.
the convex and concave parts for abnor- 1) Tighten the bolts to 24 ± 4 Nm {2.4 ± 0.4
mality and sticking mud. kgm} in the order shown in the figure.
2) Tighten the bolts to 53 ± 5 Nm {5.4 ± 0.51
kgm} in the order shown in the figure.
3) Tighten only [1] – [4] in the figure to again 53
± 5 Nm {5.4 ± 0.51 kgm} .
[*8]
3 Clamp mounting bolt:
10.0 – 11.0 Nm {1.02 – 1.12 kgm}
[*10] [*14]
3 Mounting nut of turbocharger lubricating oil (Radiator hose installation depth)
supply hose: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} Engine side: 49 mm
a When tightening the hose mounting nut, fix Radiator side: 45 mm
3 Radiator hose clamp bolt:
the connector on the turbocharger side se-
curely by using a wrench because its tighten- 10.8 – 11.8 Nm {1.1 – 1.2 kgm}
ing torque is low.
3 Connector on turbocharger:
a If the connector is loosened, tighten it to
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
PC200, 200LC-8E0 (Hybrid) 50-200 33

[*15] [*16]
q Install fan belt (73) to alternator (74) according to a When installing the blowby duct, check that the
the following procedure. two O-rings are fitted.
1) Set fan belt (73) to each pulley. 3 Blowby duct mounting bolt:
2) Insert wrench [1] into hole (A) (width across 7 ± 2 Nm {0.71 ± 0.2 kgm}
flats: 12.7 mm) in tensioner assembly (72)
and rotate it counterclockwise (R), viewed [*17]
from the front of the engine, to decrease the 3 Joint bolt: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
tension of the tensioner assembly, and install
the fan belt. [*18]
k Insert wrench [1] securely into hole (A) 3 Cylinder head cover mounting nut:
in the tensioner assembly before rotat- 24 ± 4 Nm {2.4 ± 0.4 kgm}
ing the tensioner assembly. (The a If the stud bolt is removed, install it and tight-
spring in the tensioner assembly is en to the following torque.
strong. If wrench [1] is inserted incom- 3 Stud bolt:
pletely and rotated, it comes off and 24 ± 4 Nm {2.4 ± 0.4 kgm}

that is very dangerous.))
k Rotate the tensioner assembly. While q Bleeding air
rotating, take care that wrench [1] will a Bleed air from the fuel system. For details,
not come off. see Testing and adjusting, "Bleeding air from
k After installing fan belt (73), return, fuel system".
wrench [1] slowly and carefully.
k Take care not to catch your finger be- q Refilling engine colling system with coolant
tween the pulley and fan belt during Supply engine coolant through the coolant filler
the work. to the specified level. Run the engine to circulate
the coolant through the system. Then, check the
coolant level again.
5 Engine cooling system (engine coolant):
17.3 l (For details, see "List of lubri-
cant and water")
50-200 34 PC200, 200LC-8E0 (Hybrid)

Removal and installation of radiator assembly SEN05257-00
Removal and installation of radi- 5. Open the engine hood.

ator assembly
6. Disconnect reservoir tank hose (8).
Removal
k Park the machine on a level place and swing
7. Disconnect turbocharger cooling hose (9).
the upper structure 90°, and then lower the
work equipment to the ground completely 8. Remove cover (10).
k Disconnect the cable from the negative (-) 9. Remove three bolts (11) and disconnect radiator
terminal of the battery. hose fixing bracket (12) from shroud (13).
a The three bolts are fixed to the bracket on the
1. Remove covers (1) and (2). back side of shroud (13). When removing
a Remove cover (1) first, and then remove cov- them, insert your hand through the hole of re-
er (2). moved cover (10) and support the bracket.
(If you remove fan guard (14) and support the
bracket through that portion, you can work
easily.)
10. Disconnect radiator upper hose (15). [*2]

cate the installation depth.
2. Open radiator drain valve (3) to drain the

coolant.
6 Radiator: 17.3 l
3. Loosen hose clamp (4) and disconnect radiator

lower hose (5). [*1]
4. Remove three bolts (6) and move cover (7).

a Perform this work to prevent the flange at the
lower hose mounting portion from interfering
with other parts when the radiator is lifted up.
PC200, 200LC-8E0 (Hybrid) 50-200 35

SEN05257-00 Removal and installation of radiator assembly
11. Remove two bolts (16). Installation

q Carry out installation in the reverse order to the
removal.
[*1], [*2]
q Install each hose over the tube to the position
marked when removed.
a Installation depth: 45 mm (both upper and
lower)
3 Radiator hose mounting clamp:
10.8 – 11.8 Nm {1.1 – 1.2 kgm}
a Install the clamp to the original position.
[*3]
a Ensure that the heat insulation (sponge) around
the radiator is not damaged.
12. Lift off radiator assembly (17). [*3] If the heat insulation (sponge) is damaged,
4 Radiator assembly: 15 kg
replace it.
a Check that convex parts (A) at the radiator bot-
tom are matched with concave parts (B), by ob-
serving them from the undercover side.
q Refilling cooling system with coolant

5 Radiator: 17.3 l
a Run the engine to circulate the coolant
through the system and then check the cool-
ant level again. If the coolant level is low, add
coolant.
50-200 36 PC200, 200LC-8E0 (Hybrid)

Removal and installation of hydraulic oil cooler assembly SEN05257-00

hydraulic oil cooler assembly
k Never disconnect the high-voltage wiring

(power cable) during the removal and instal-
lation work described in this section.
Removal
work equipment to the ground completely
and stop the engine. 4. Remove the hybrid radiator assembly. For
k Loosen the hydraulic tank oil filler cap grad- details, see "Removal and installation of hybrid
ually to release the pressure inside the tank radiator assembly".
and then set the lock lever to the LOCK posi-
tion. 5. Remove three bolts (6) and bracket (7).
k If the radiator coolant temperature is high,
wait until it decreases to avoid getting scald-
ed and then drain the coolant.
1. Remove covers (1) - (3).

a Remove cover (1) first, and then remove cov-
er (2).
6. Disconnect air conditioner hose (8).
7. Remove frame (9).
2. Open hybrid radiator drain valve (4) to drain the

coolant.
6 Hybrid radiator: 3.5 l
3. Remove drain plug (5) to drain the oil from the

hydraulic oil cooler. [*1]
6 Hydraulic oil cooler: 9 l
PC200, 200LC-8E0 (Hybrid) 50-200 37

SEN05257-00 Removal and installation of hydraulic oil cooler assembly
8. Remove two bolts (10) and disconnect hose

(11).
9. Remove two bolts (12) and block (13).
16. Remove two bolts (16) and install eyebolts [1].
17. Lift off hydraulic oil cooler assembly (17).

4 Hydraulic oil cooler assembly: 25 kg
10. Open the engine hood.
11. Remove the mounting bolts of cover (18) and

move the cover.
12. Disconnect radiator overflow hose (18a) from

the radiator.
14. Disconnect hydraulic tank return tube (14).
15. Remove two bolts (15).
50-200 38 PC200, 200LC-8E0 (Hybrid)

Removal and installation of hydraulic oil cooler assembly SEN05257-00
Installation
removal.
[*1]
the hydraulic oil cooler is not damaged.
If the heat insulation (sponge) is damaged,
replace it.
a Check that convex parts (A) at the oil cooler bot-

tom is matched with concave parts (B), by ob-
q Refilling hydraulic tank with oil

Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the piping. Then, check the oil level again.
5 Hydraulic oil cooler: 9 l
q Refilling cooling system with coolant

Supply coolant and bleed air. For details, see
"Draining/adding coolant and bleeding air for
hybrid system".
PC200, 200LC-8E0 (Hybrid) 50-200 39

SEN05257-00 Removal and installation of aftercooler assembly
Removal and installation of after- 4. Open the engine hood.

cooler assembly
Removal
6. Remove four bolts (8) and disconnect after-
cooler hose fixing bracket (9) from shroud (10).
a The four bolts are fixed to the bracket on the
back side of shroud (10). When removing
them, insert your hand through the hole of re-
moved cover (7) and support the bracket.
(If you remove fan guard (11) and support the
bracket through that portion, you can work
1. Remove covers (1) and (2). easily.)
a Do not loosen U-clamp (12). [*2]
7. Disconnect aftercooler upper hose (13). [*3]

cate the installation depth.
2. Remove bolts (3) and aftercooler lower tube (4).

[*1]
3. Remove three bolts (5) and move cover (6).

a Perform this work to prevent the flange at the
lower tube mounting portion from interfering
with other parts when the aftercooler is lifted
up.
50-200 40 PC200, 200LC-8E0 (Hybrid)

Removal and installation of aftercooler assembly SEN05257-00
8. Remove two bolts (14).
9. Lift off aftercooler assembly (15). [*4]

4 Aftercooler assembly: 10 kg
PC200, 200LC-8E0 (Hybrid) 50-200 41

SEN05257-00 Removal and installation of aftercooler assembly
Installation
removal.
[*1]
a Replace the O-ring with a new one.
[*2]
q If the U-clamp (12) is loosened or removed, in-
stall it and tighten to the following torque.
3 Mounting nut:
10.8 – 19.6 Nm {1.1 – 2.0 kgm}
[*4]
the aftercooler is not damaged.
If the heat insulation (sponge) is damaged,
replace it.
a Check that convex parts (A) at the aftercooler
bottom is matched with concave parts (B), by ob-
[*3]
q Install hose (13) according to the following pro-
cedure.
1) Install each hose over the tube to the position
marked when removed.
(Hose installation depth)
Aftercooler side: 60 mm
Removed tube side: 67 mm
2) MIKALOR clamp at 30 mm from the marked
position.
2 Threaded portion of clamp bolt (part
BC):
PANDO 18B)
4) Tighten the clamp bolt to the following
torque.
(when reusing hose)
a Install the clamp to the clamp mark made
on the hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}
(when using new hose)

Tighten until dimension (BDG) becomes as
follows.
Dimension (BDG): 7 – 10 mm
50-200 42 PC200, 200LC-8E0 (Hybrid)

Removal and installation of fuel cooler assembly SEN05257-00
Removal and installation of fuel 3. Remove two mounting bolts (6) of the fuel cooler
cooler assembly mounting bracket.
4. Remove fuel cooler assembly (7) and bracket (8)

Removal together.
(Position of fuel cooler assembly (7) after counter-

weight is removed)
2. Disconnect fuel hoses (2) and (3). [*1]

a Prepare an oil container to receive the fuel
flowing out of the fuel hoses.
a When loosening each fuel hose fitting, hold
elbows (4) or (5) on the fuel cooler side by us-
ing the wrench.
PC200, 200LC-8E0 (Hybrid) 50-200 43

SEN05257-00 Removal and installation of fuel cooler assembly
Installation
removal.
[*1]
a When tightening each fuel hose fitting, hold el-
bows on the fuel cooler side by using the
wrench.
q Bleeding air
After adding fuel, bleed air from the fuel system.
For details, see Testing and adjusting, "Bleeding
air from fuel system".
50-200 44 PC200, 200LC-8E0 (Hybrid)

Removal and installation of engine/motor-generator/hydraulic pump assembly SEN05257-00
Removal and installation of k While draining the coolant, take care that the
engine/motor-gener- coolant does not stick to your skin or enter
your eyes.
ator/hydraulic pump assembly Super Coolant mixed in the coolant is toxic. If the
coolant splashes on your skin or enters your eye,
wash it away thoroughly with water and then
consult a doctor.
a Record the installed positions, connector Nos.,
or hose band colors of the disconnected wires
k Understand the descriptions of 00-200 Introduc- and pipes so that you do not make a mistake in
tion, safety, and basic information, "Precautions their connection positions.
related to work safety 1. Precautions peculiar to
hybrid machine" and "Handling of hybrid devic-
1. Open left inspection cover (1).
es and high-voltage wirings", before starting
work.
Special tools
New/Remodel
Necessity
Sym-
Q'ty
Part No. Part name

bol
8 796T-401-1110 Plate q 1
9 795-790-9300 Lifting tool q 1
A
10 790-460-1210 Oil stopper q 1
11 796-770-1320 Adapter q 1
Commercially Insulation resistance
12 t 1
available tester
2. Remove rubber cover (2) above the inverter.
Removal
k Discharge the capacitor. For details, see

mation, "Handling of hybrid devices and
high-voltage wirings", "Discharge procedure
for capacitor" .
k Disconnect two one-touch connectors (cable
terminals of (+) and (-)) from the capacitor
(See step 3).
k Referring to Testing and adjusting, "Releas-

ing residual pressure in hydraulic circuit", re-
lease the pressure inside the hydraulic
circuit and then set the lock lever to the
LOCK position.
k When opening the coolant filler cap or drain-
ing the coolant, ensure that coolant tempera-
ture is low and it does not scald you.
PC200, 200LC-8E0 (Hybrid) 50-200 45

SEN05257-00 Removal and installation of engine/motor-generator/hydraulic pump assembly
3. Disconnect two one-touch wiring connectors

HB01 (CC) (cable terminals of (+) and (-)) from
the capacitor.
a While pressing the lock portion of the con-
nector with your thumb to unlock the connec-
tor, pull out the connectors.
4. Remove the counterweight assembly. For

details, see "Removal and installation of coun-
5. Remove lower covers (3a) - (5b).

a Remove cover (5a) first, and then remove
cover (5b).
k Since each cover is heavy, remove them 6. Close fuel stop valve (6).
carefully.
(Reference)
4 Cover (3a): 14.3 kg
Cover (3b): 14.0 kg
Cover (4): 7.5 kg
Cover (5a): 15.1 kg
Cover (5b): 22.3 kg
50-200 46 PC200, 200LC-8E0 (Hybrid)

7. If the fuel level is above the pre-filter fitting

portion, drain some fuel through fuel drain valve
(7) so that it does not flow out when the hose is
disconnected.
9. Remove the engine hood according to the

1) Open engine hood (111) and sling it.
2) Remove pins (112) and (113) and disconnect
8. Loose drain plug (8) to drain the oil from the two gas springs (114) on the right and left
hydraulic tank. sides.
6 Hydraulic tank: 232l (specified oil quan-
tity)
:135 l (refill capacity)
3) Remove four bolts (116) from hinge (115)

and lift off engine hood (111).
a Make marks of (x) and (y) to indicate the
a If you do not drain the oil from the tank, skip installed positions of hinges (115).
steps 1, 2, and 4, and install the stopper by 4 Engine hood: 30 kg
using tool A10 according to the following pro-
cedure.
2) Remove the strainer.
3) Install tool A10 (oil stopper) and tool A11
(adapter).
4) Install tools A10 and A11 together to the
position of the removed strainer.
5) Install cover (9).
a Tighten with several bolts temporarily.
PC200, 200LC-8E0 (Hybrid) 50-200 47

10. Remove the covers and frames according to the 6) Remove frame (18).
following procedure. 7) Remove heat insulation plate (19).
1) Remove cover (10). a Remove rubber partitions (19a) and (19b)
2) Remove partitions (11) and (12). together.
a To remove partition (11), remove cover
(10) and remove bolt (11a), and the re-
move two bolts (11b) from the control
valve side.
a Remove bolt (13) to remove partition (12).
3) Remove two bolts (14) and partition (15).
a Remove bolt (14) from the control valve
side.
a Remove partition (15) by pulling it up.
5) Remove frame (17).
11. Disconnect pre-filter (20) and bracket (21)

together from frame (22).
50-200 48 PC200, 200LC-8E0 (Hybrid)

12. Disconnect fuel filter (23) and bracket (24)

together from frame (25).
a Place fuel filter (23) and bracket (24) together
on the engine.
13. Disconnect lubricating oil filter (26) of the gener-

ator motor from bracket (24).
a Tie lubricating oil filter (26) of the motor-gen-
erator to the engine/ motor-generator/ hy-
draulic main pump assembly.
14. Disconnect the following seven hoses connected to

the hydraulic main pump.
(27) Rear load pressure input port hose
(Collar band color: No band)
(28) EPC source pressure port hose
(Band color: Yellow)
(29) Front load pressure input port hose
(Band color: Red)
(30) Pump pressure input port hose
(Band color: Blue)
(31) Drain port hose
(32) Pump discharge port hose (2 pieces)
(32a) Branch hoses (2 pieces)
15. Remove four bolts (33) and disconnect suction

tube (34).
PC200, 200LC-8E0 (Hybrid) 50-200 49

16. Disconnect the air conditioner compressor and 17. Remove hose (46) returning from the after-
reposition it out of the way according to the cooler. [*2]
following procedure. a Do not loosen clamp (47).
1) Remove fan guard (35). a Make marks at the hose end and tube to indi-
2) Disconnect wiring connector AC02 (36). cate their installed positions.
18. Remove radiator upper hose (48). [*3]

cate their installed positions.
19. Disconnect turbocharger cooling hose (49).

a Disconnect clip (54a).
20. Disconnect bypass hose (50) and heater hose

(51).
21. Disconnect hose (52) between the turbocharger

and air cleaner from the turbocharger. [*4]
3) Disconnect wiring clamps (37) and (38). 22. Remove covers (53), (54), and (55).
4) Loosen air conditioner compressor fixing bolt
(39) and belt tension adjustment bolt (40)
and remove air conditioner compressor drive
belt (41).
a Do not loosen air conditioner compressor
mounting bolts (MB). [*1]
5) Remove air conditioner compressor fixing
bolt (39) and belt tension adjustment bolt (40)
and remove air conditioner compressor
assembly (42).
50-200 50 PC200, 200LC-8E0 (Hybrid)

23. Disconnect electrical intake air heater wiring 29. Remove the alternator assembly according to
(43). the following procedure. [*8]
1) Disconnect wirings (62) and (63).
24. Disconnect wiring clamps (44) and (45). 2) Insert wrench [1] in hole (A) (width across
flats: 12.7 mm) of tension pulley (64) and
rotate it counterclockwise (R), when you face
the front of the engine, to loosen fan belt (65).
3) Remove fan belt (65) from alternator (66).
k Set wrench [1] securely to hole (A) of
tensioner assembly (64) before rotat-
ing the tensioner assembly. (The
spring of the tensioner assembly is
strong. If wrench [1] is set incomplete-
ly and rotated, it comes off and that is
very dangerous.))
k While rotating the tensioner assembly
, take care that wrench [1] will not
come off.
25. Remove radiator fan (56). [*5] k After removing the fan belt, return
a Lower the radiator fan out of the way. wrench [1] slowly and carefully.
k Take care not to catch your finger be-
tween the pulley and fan belt during
the work.
4) Remove the alternator mounting bolts and
remove alternator assembly (66).
26. Disconnect hose (59) going to the aftercooler

from elbow (59a) on the engine side. [*6]
27. Disconnect radiator lower hose (60) from the

water pump. [*7]
28. Disconnect heater hose (61) from the water

pump.
PC200, 200LC-8E0 (Hybrid) 50-200 51

30. Remove hose connectors (67) and (68). 34. Disconnect wiring connector GM01 (76).
a Remove these connectors so that the re-
moved mounting bolts do not interfere with or 35. Disconnect wiring clamp (77).
break them.
36. Disconnect ground strap (78).
31. Disconnect starting motor wiring (70) and wiring

connector E10 (71) 37. Disconnect all the hose and wiring clamps from
frame (79) and remove frame (79).
38. Disconnect hose clamps (80) and (81).
32. Disconnect wiring clamps (72) and (73).

a Work from underside of the engine.
33. Disconnect wiring connectors E08 (74) and P44

(75).
a Work from underside of the engine.
50-200 52 PC200, 200LC-8E0 (Hybrid)

39. Remove connector cover (82) of the 44. Disconnect wiring connectors CE02 (90) and
high-voltage wiring (power cable). CE03 (91) from the engine controller.
40. Remove clamp (83) of the high-voltage wiring

(power cable).
41. Disconnect connectors (84) and (85) of the

high-voltage wiring (power cable). [*9]
(Connector No.) (Wiring color)
(84): CM03 A2 (white)
(85): CM02 A1 (red)
45. Disconnect fuel return hose (92). [*10]
46. Disconnect fuel hoses (93) and (94) between the

supply pump and fuel filter. [*11]
a After disconnecting the hose, plug its both
ends.
47. Disconnect fuel hose (95) between the supply

pump and pre-filter.
42. Disconnect clamps (86) and (87) of the a After disconnecting the hose, plug its both
high-voltage wiring (power cable). ends.
43. Disconnect all the hose and wiring clamps from 48. Disconnect fuel hose clamp (96).
frames (88) and (89) and remove frames (88)
and (89). 49. Disconnect swing electric motor lubrication
hoses (97) - (99). [*12]
PC200, 200LC-8E0 (Hybrid) 50-200 53

50. Disconnect wiring connector K02 (100).
51. Disconnect engine controller ground strap T12

(101).
52. Remove wiring clamp (102).
55. Lift off engine/ motor-generator / hydraulic main

pump assembly (107).
a As a sling for this work, tool A9 is a recom-
mended.
(See tool table)
a Check that all the wiring and hoses are dis-
connected before lifting off the assembly.
4 Engine/ generator motor/ hydraulic
main pump assembly: 850 kg
54. Remove four engine mounting bolts (103).
[*13]
a When removing three engine mounting bolts
(103) other than the one at the right front of
the engine (engine grounding portion), hold
nut (N) with nut lock tool A8 and bolt (B).
(Since the nuts for the three bolts other than
the one at the right front of the engine are not
welded to the frame, they are dragged by the
bolts if they are not held.)
50-200 54 PC200, 200LC-8E0 (Hybrid)

Installation
q Perform installation in the reverse order to re-
moval.
[*1]
q If mounting bolts (MB) of the air conditioner com-
pressor are loosened, tighten them to the follow-
ing torque.
a Tightening the bolts to too high torque can
damage the internal bearings. Observe the
specified torque strictly.
3 Mounting bolt:
24.5 to 29.4 Nm {2.5 to 3.0 kgm}
[*2], [*6]
q If a hose is clamped with a MIKALOR clamp, in-
stall it according to the following procedure.
1) Set the hose to the original position (marked
(Hose litting length over tube)
q Aftercooler side (46)
Aftercooler side: 60 mm
Tube side: (z) 67 mm
q Air intake manifold side (13)
Tube side: (x) 80 mm
Manifold side (y): 80 mm
q Hose (46) between aftercooler and turbo-
charger
Both sides: 80 mm a If air intake connector (108) is removed, replace
the gasket with a new one.
3 Air intake connector mounting bolt:
8.8 to 10.8 Nm {1.1 to 1.2 kgm}
PANDO 18B)
q When reusing hose

1) Install the clamp at the clamp mark left on the
hose.
3 Clamp bolt: Min. 6 Nm {0.6 kgm}
q When using new hose

1) Tighten until dimension BDG becomes as
follows.
(Dimension BDG)
q Aftercooler side (46)
Aftercooler side: 7 to 10 mm
Tube side: (z) 7 to 10 mm
q Air intake manifold side (13)
Tube side: (x) 7 to 10 mm
Manifold side (y): 9 to 13 mm
PC200, 200LC-8E0 (Hybrid) 50-200 55

a When using two MIKALOR clamps at a place, [*3]

set their clamp portions (A) and (B) at 180 de- a Put each hose over a tube until it reaches the po-
grees reparated each other. sition marked when removed.
(Reference)
Hose fitting length (engine side): 49 mm
(Three places on radiator side): 45 mm
3 Hose clamp bolt:
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
[*4]
3 Air hose clamp bolt:
10.0 to 11.0 Nm {1.02 to 1.12 kgm}
[*5]
3 Fan mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kg}
[*7]
a Put each hose over a tube until it reaches the po-
sition marked when removed.
(Reference) Hose fitting length over tube: 45
mm
3 Hose clamp bolt:
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
a Reference
Radiator hose fitting length over tube
50-200 56 PC200, 200LC-8E0 (Hybrid)

[*8] [*9]
q Install fan belt (65) to alternator (66) according to q Install the connector to the high-voltage wiring
the following procedure. (power cable) according to the following proce-
1) Set fan belt (65) to each pulley. dure.
2) Put wrench [1] in hole (A) of tensioner a Before installing the connector to the
assembly (64) and rotate it counterclockwise high-voltage wiring (power cable), measure
(R), seeing from the front of the engine, to the insulation resistance of the motor-gener-
decrease the tension of tensioner assembly ator according to the following procedure.
(64). 1. Precautions for measuring
3) With the tension of tensioner assembly (64) k Since high voltage (DC 500 V) is applied
decreased, install fan belt (65) to the alter- for measurement of the insulation resis-
nator pulley. tance, observe the followings.
k Put wrench [1] securely in hole (A) of 1) Connection of test plugs
the tension pulley (64) before rotating a Check that the test plugs P (+) and P (-)
the tension pulley. (The spring of the are connected to the objective portions to
tension pulley is strong. If wrench [1] be measured.
is put incompletely in and rotated, it a Use extreme care so that the test plugs
comes off and that is very dangerous.) do not come off and touch another part or
k While rotating the tension pulley, take a human body during measurement
care that wrench [1] does not come off. (while high voltage is applied).
k After installing the fan belt, loosen 2) Do not touch the motor-generator assembly
wrench [1] slowly and carefully. during measurement.
k Take care of your finger not to be Do not touch the object (MOTOR A) of
caught between the pulley and fan belt measurement during measurement (while
during the work. high voltage is applied).
During measurement, the measurer must
alert around.
2. Measurement
1) Measurement of insulation
Connect the following items as shown in the
figure below.
Between lines A and B
Between lines A and C
Between lines B and C
(Criteria)
a Insulation resistance between line A and
B: Min. 5 MΩ
C: Min. 5 MΩ
a Insulation resistance between line B and
C: Min. 5 MΩ
PC200, 200LC-8E0 (Hybrid) 50-200 57

2) Measurement of insulation between each

line and motor case
Connect the following items as shown in the
figure.
Between line A and motor case
Between line B and motor case
Between line C and motor case
(Criteria)
case: Min. 5 MΩ
a Insulation resistance between line B and
case: Min. 5 MΩ
a Insulation resistance between line C and
case: Min. 5 MΩ [*10], [*11]
q When installing a connector of quick coupler
type, observe the following points.
a The internal parts of the adapter may be dam-
aged when the hose is removed. Accordingly,
do not reuse the hose. When installing, replace
it with a new one.
a Check that mud or dirt is not sticking to the hose
joint portions in advance.
a Press and insert the connector straight (in direc-
tion (b)) without prying or bending it to the right
or left.
If it is difficult to insert the connector, do not push
it in forcibly but pull it out. Then, check the
convex and concave parts for abnormal coudi-
a Match the color of each high-voltage wiring tion and sticking mud.
(power cable) with that on the motor-generator
side.
1) Check that there are no dirt and flaw on plug
(P) on the cable side.
2) Thinly apply grease to sealing portion (R) of
the flange when it is inserted.
2 Sealing portion of flange:
Grease (G2-LI )
3) Install connectors (84) and (85).
a Install connector (84) (white) to upper
sockets and (85) (red) to lower sockets,
with their white and red marks on the right
side.
a Insert plug (P) on the cable side straight
into power feed terminal socket (S) on the
motor side.
3 High-voltage wiring connector bolt:
8.8 to 10.8 Nm {0.9 to 1.1 kgm}
50-200 58 PC200, 200LC-8E0 (Hybrid)

[*12] (Reference)
a Check that mud or dirt is not sticking to the hose 2 Threaded portion of mounting bolt of engine
fittings and inside of the hoses. mount bracket: Liquid adhesive (LT-2)
3 Lubricating oil hose sleeve nuts: 3 Mounting bolt (B) of engine mount bracket (4
(97) Hose to swing motor: places): 122.5 to 147 Nm { 12.5 to 25 kgm}
54 to 93 Nm {5.5 to 9.5 kgm}
(98) Hose from swing motor:
54 to 93 Nm {5.5 to 9.5 kgm}
(99) Hose from motor-generator:
84 to 132 Nm {8.5 to 13.5 kgm}
a If the elbows of hybrid swing motor lubrication

hoses (97) to (99) on the pump side are re-
moved, install and tighten them to the following
torque.
3 Hose mounting elbows:
(97) Swing motor discharge port:
25 to 29 Nm {2.6 to 3.0 kgm}
(98) Swing motor suction port:
25 to 29 Nm {2.6 to 3.0 kgm} q Refilling of coolant
(99) Generator suction port: Add engine coolant through the coolant filler to
59 to 98 Nm {6.0 to 10 kgm} the specified level. Run the engine to circulate
the coolant through the system. Then, check the
[*13] coolant level again and add coolant if it is low.
5 Coolant: 17.3 l
a When installing the bolts, use care since their
lengths are different. a For the precautions for mixing proportion of
(The bolts on the engine front side are longer water and Super Coolant, see "Removal and
than those on the engine rear side) installation of radiator assembly" on page
500-200 page 38.
a When installing the engine mount rubbers, use
care since their sizes are different. q Refilling of oil (Hydraulic tank)
(The mount rubbers on the engine front side are Add oil through the oil filler to the specified level.
smaller than those on the engine rear side) Run the engine to circulate the oil through the
piping. Then, check the oil level again.
5 Hydraulic tank: 232 l
3 Hydraulic oil drain plug:
58.8 to 78.5 Nm {6.0 to 8.0 kgm}
q Bleeding air
See Testing and adjusting, "Bleeding air from
each part".
2 Threaded portion of engine mounting bolt:

Liquid adhesive (LT-2)
3 Engine mount mounting bolt:
245 to 308.9 Nm {25 to 31.5 kgm}
PC200, 200LC-8E0 (Hybrid) 50-200 59

SEN05257-00 Removal and installation of fuel tank assembly
Removal and installation of fuel

tank assembly
Removal
1. Open right inspection cover.
2. Open fuel drain valve (1) to drain the fuel.

5. Remove four bolts (6) and move battery box (4)
forward.
3. Remove six bolts (2) and handrail (3).

a Two bolts (2) are installed at the left front side
of battery box (4).
6. Disconnect wiring connector (7) of the fuel level
sensor.
4. Remove mirror (5).
7. Remove two lower mounting bolts (9) of cover
(8).
50-200 60 PC200, 200LC-8E0 (Hybrid)

Removal and installation of fuel tank assembly SEN05257-00
8. Remove two upper mounting bolts (10) of cover 10. Remove lower cover (13).
(8) and remove cover (8).
11. Disconnect fuel supply hose (14), return hose

9. Remove four mounting bolts (11) and cover (12). (15), and drain hose (16).
12. Remove six fuel tank mounting bolts (17).

[*1]
13. Lift off fuel tank (18).

4 Fuel tank assembly: 140 kg
PC200, 200LC-8E0 (Hybrid) 50-200 61

2 0 0 E n g i n e a n d c o o l i n g s y s t e m
SEN05257-00 R e m o v a l a n d i n s t a l l a t i o n o f f u e l t a n k a s s e m b l y
Installation
q Perform out installation in the reverse order to
removal.
[*1]
3 Fuel tank mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
q Bleeding air
After adding fuel, bleed air from the fuel system.
For details, see Testing and adjusting, "Bleeding
air from fuel system".
50-200 62 PC200, 200LC-8E0 (Hybrid)

Removal and installation of fuel tank assembly SEN05257-00
PC200, 200LC-8E0 (Hybrid) 50-200 63

SEN05257-00
©2009 KOMATSU
All Rights Reserved
50-200 64
SEN05258-02
SEN05258-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


300 Hyblid Relation
Draining and adding coolant and bleeding air for hybrid system ................................................................ 2
Removal and installation of hybrid radiator assembly................................................................................. 7
Removal and installation of water pump assembly for hybrid system ........................................................ 10
Removal and installation of inverter assembly............................................................................................ 13
Removal and installation of inverter and capacitor assembly ..................................................................... 17
Draining and adding generator lubricating oil ............................................................................................. 23
Removal and installation of tandem pump assembly.................................................................................. 25
Removal and installation of motor-generator and housing assembly ......................................................... 28
Removal and installation of swing electric motor assembly ........................................................................ 37
PC200, 200LC-8E0 (Hybrid) 50-300 1

300 Hyblid Relation
SEN05258-02 Draining and adding coolant and bleeding air for hybrid system
Draining and adding coolant and Draining

bleeding air for hybrid system

a Since the hybrid system coolant temperature
k While draining the coolant, take care that the
does not increase high like the engine coolant
coolant does not stick to your skin or enter
(about 100 °C), it does not need to be replaced
your eye.
unless a particular trouble occurs.
Super Coolant mixed in the coolant is toxic.
If the coolant needs to be drained or added
If the coolant splashes on your skin or enters
because of leakage, etc., perform the following
your eye, wash it away thoroughly with water
procedure.
and then consult a doctor.
(power cable) during the removal and instal- 1. Open left inspection window cover (1).
lation work in this section.
SM: Swing electric motor 2. Check that radiator cap (2) of hybrid radiator
HR: Hybrid radiator (HR) is at a temperature that you can touch with
WP: Water pump for hybrid system your bare hand and then open radiator cap (2)
HI: Inverter slowly.
HC: Capacitor
(2): Radiator cap
(4): Drain valve
(5): Swing motor elbow plug (IN)
(6): Swing motor elbow plug (OUT)
(7): Coolant filler
(8): Overflow hose
(9): Swing motor air bleeding plug
50-300 2 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Draining and adding coolant and bleeding air for hybrid system SEN05258-02
3. Remove cover (3). Refilling of coolant and bleeding air

a As coolant, use Komatsu genuine Super Coolant
(AF-NAC).
a Use city water to dilute.
k Undiluted Super Coolant is flammable. So
keep it away from open flame.
1. Close hybrid radiator drain valve (4).
4. Place a container to receive the coolant under

the drain hose and open hybrid radiator drain
valve (4) to drain the coolant.
2. Install cover (3).
3. Remove swing motor air bleeding plug (9).
PC200, 200LC-8E0 (Hybrid) 50-300 3

300 Hyblid Relation
4. Add coolant through coolant filler (7) of the

hybrid radiator slowly (taking approximately 5
minutes). (5.3 l)
a Add coolant through the coolant filler of the
hybrid radiator, taking care not to spill it.
a The minimum necessary volumetric percent-
age of Super Coolant is 30%.
a Decide the mixing proportion of the coolant to
the water according to the past lowest tem-
perature and the following mixing proportion
table.
Actually, set the proportion for a temperature
approximately 10 °C lower than the past
lowest temperature.
Mixing proportion between city water and 5. Tighten air bleeding valve (9) partially. (Until the
Super Coolant O-ring is seated)
(Refill capacity of hybrid system radiator: 3.5
l)
Lowest temperature(°C)
Above-
-15 -20 -25 -30 (-35) (-40)
10
Quan-
tity of
Super 1.05 1.26 1.44 1.61 1.75 (1.89) (2.03)
Mixing proportion(l)
Cool-
ant
Quan-
tity of 2.45 2.24 2.06 1.89 1.75 (1.61) (1.47)
water
Volu-
metric
30 36 41 46 52 (54) (58)
ratio
6. With the radiator cap open, turn the key switch to
(%)
the ON position to rotate the water pump.
k Never start the engine.
(Standard capacity of hybrid system radi- a If too long time passes before the starting
ator: 6.4l) switch is turned to the ON position after the
Lowest temperature(°C) coolant is added, air may be trapped on the
Above- suction side of the water pump and the water
-15 -20 -25 -30 (-35) (-40) pump may have a suction trouble. According-
10
Quan- ly, turn the starting switch to the ON position
tity of immediately after adding the coolant.
Super 1.92 2.31 2.63 2.95 3.2 (3.46) (3.72)
Mixing proportion(l)
Cool-
ant
Quan-
tity of 4.48 4.09 3.77 3.45 3.2 (2.94) (2.68)
water
Volu-
metric
30 36 41 46 50 (54) (58)
ratio
(%)
50-300 4 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Draining and adding coolant and bleeding air for hybrid system SEN05258-02
a Judge if hybrid system water pump (WP) is 11. Check that bubbles do not come out of radiator
running by directly touching water pump coolant filler (7) any more and the coolant level
(WP) with your hand. (Since the drive sound does not lower any more.
of the pump is low, it is difficult to judge by the a Continue to run the water pump for at least
drive sound.) 10 minutes after turning the starting switch to
the ON position in step 6 to bleed air com-
pletely.
12. Close the radiator cap and turn the key switch to
the OFF position to complete the air bleeding
work.
7. Check that the coolant is flowing in radiator tank

by looking into radiator coolant filler (7).
q If the coolant flow is not ensured, air may be
trapped on the suction side of the water
pump and the water pump may not be dis-
charging. In this case, drain the coolant ac-
cording to "Replacement of complete hybrid
coolant" and then perform steps 4 to 6 again.
8. If the water pump runs, the coolant level lowers.

Add coolant repeatedly until the system is filled.
(Total quantity of additional coolant: 1.1 l)
a If no coolant is seen in the radiator upper
tank, the water pump draws in air and mal-
functions. Accordingly, add coolant while
there is still some coolant in the upper tank.
9. Loosen air bleeding plug (9) a little to bleed air.

a If air or bubbles come out of the plug portion,
continue bleeding until they do not come out
any more.
10. Tighten air bleeding plug (9) to the specified

torque.
3 Plug: 9.8 to 12.7 Nm {1.0 to 1.3 kgm}
PC200, 200LC-8E0 (Hybrid) 50-300 5

300 Hyblid Relation
Complete replacement of hybrid coolant 9. Supply the specified quantity of coolant

a When changing the mixing proportion of Super according to "Refilling coolant and bleeding air",
Coolant or replacing the coolant completely be- steps 3 to 12 described above, and bleed air.
cause of entry of swing motor lubricating oil into
it, replace the coolant according to the following
procedure.
1. Open coolant filler cap (2) of the hybrid radiator.
2. Loosen clamp (10) for the hose for the coolant

returning from the swing motor and disconnect
hose (11).
a Before disconnecting hose (11), prepare a
container to receive the drained coolant un-
der the disconnecting point of the hose.
3. Install a thick vinyl bag, etc. to the tube discon-

nected to prevent the coolant from splashing
around.
4. Close coolant filler cap (2) and supply

compressed air (for an impact wrench, etc.) into
the disconnected hose to discharge all the
coolant forcibly. (For prevention of splashing of
coolant)
a Be sure to close the radiator cap before sup-
plying compressed air.
5 Quantity of discharged coolant: 6.4 l
5. Connect the disconnected hose and tighten the

clamp temporarily.
6. Supply the specified quantity of coolant

according to "Refilling coolant and bleeding air",
steps 3 to 12, described above and wash the
circuit.
7. Perform above steps 2 to 4 (Washing inside and

discharge).
Repeat steps 6 and 7 (Washing inside and
discharge) if necessary, depending on the dirti-
ness of the inside.
8. Install the disconnected hose to the original posi-

tion and tighten the clamp to the specified
torque.
3 Tightening torque:
3.9 to 4.9 Nm {0.4 to 0.5 kgm}
50-300 6 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Removal and installation of hybrid radiator assembly SEN05258-02
Removal and installation of hybrid 2) Open coolant filler cap (2) of the hybrid radi-
radiator assembly ator.


ture is low and it does not scald you. 3) Remove lower cover (3).
your eye.
1. Drain the coolant from the hybrid radiator

1) Open left inspection window cover (1).
4) Open hybrid radiator drain valve (4) to drain

the coolant.
PC200, 200LC-8E0 (Hybrid) 50-300 7

300 Hyblid Relation
SEN05258-02 Removal and installation of hybrid radiator assembly
2. Remove rubber cover (5) above the inverter. 7. Disconnect overflow hose (21).
8. Disconnect radiator upper hose (22) from the

radiator. [*1]
9. Remove hose clamp (23). [*2]
3. Loosen wiring clamp (6). (Remove as neces-

sary)
10. Remove two bolts (25) and hybrid radiator

assembly (26). [*3]
5. Disconnect radiator lower hose (19) from the

radiator.
6. Disconnect drain hose (20) from the radiator.
50-300 8 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Removal and installation of hybrid radiator assembly SEN05258-02
Installation
moval.
[*1], [*2]
3 Connector mounting bolt:
3.9 to 4.9 Nm {0.4 to 0.5 kgm}
[*3]
3 Hybrid radiator mounting bolt:
3.9 to 4.9 Nm {0.4 to 0.5 kgm}
q Refilling of coolant and bleeding air

a Add coolant and bleed air. For details, see
"Draining and adding coolant, and bleeding
air for hybrid system".
PC200, 200LC-8E0 (Hybrid) 50-300 9

300 Hyblid Relation
SEN05258-02 Removal and installation of water pump assembly for hybrid system
Removal and installation of water 1. Drain the coolant from the hybrid radiator
pump assembly for hybrid system according to the following procedure.
k Understand the descriptions in 00-200 Intro-

duction, safety, and basic information, "Safe-
ty precautions 1. Precautions peculiar to
hybrid machine" and "Handling of hybrid de-
vices and high-voltage wirings" before start-
ing work.
Removal
k Discharge the capacitor. For details, see 2) Open coolant filler cap (2) of the hybrid radi-
00-200 Introduction, safety, and basic infor- ator.
high-voltage wirings-Discharge procedure
for capacitor" .
(See step 3).

ing remaining pressure in hydraulic circuit",
release the pressure inside the hydraulic cir-
cuit and then set the lock lever to the LOCK
position. 3) Remove lower cover (3).
ing the coolant, check that coolant tempera-
your eye.
50-300 10 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Removal and installation of water pump assembly for hybrid system SEN05258-02
4) Open hybrid radiator drain valve (4) to drain

the coolant.
9. Disconnect wiring connector HC02 (11).

(Connector No.)
(11): HC01
2. Remove rubber cover (5) above the inverter.

3. Disconnect one-touch wiring connectors HB01
(6a) and (6b) from the capacitor.
4. Loosen clamp (6). (Remove if necessary)
5. Disconnect coolant level sensor wiring

connector P24 (7).
6. Loosen overflow hose clamp (8).
7. Remove overflow tank (9).
PC200, 200LC-8E0 (Hybrid) 50-300 11

300 Hyblid Relation
SEN05258-02 Removal and installation of water pump assembly for hybrid system
11. Remove hose clamp (19) between the water 16. Disconnect hose (25) from water pump (24).
pump and radiator.
13. Disconnect hose clamp (21) between the water

pump and inverter.
Installation
moval.
[*1], [*2]
3 Mounting bolt of coolant hose clamp:
14. Disconnect hose (22). [*1] 3.9 to 4.9 Nm {0.4 to 0.5 kgm}

"Draining and adding coolant and bleeding
15. Loosen hose clamp (25a), remove four bolts

(23), and remove water pump assembly (24).
[*2]
50-300 12 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Removal and installation of inverter assembly SEN05258-02
Removal and installation of 1. Drain the coolant from the hybrid radiator
inverter assembly according to the following procedure.
k Understand the contents of 00-200 Introduc-

tion, safety, and basic information, "Safety
precautions 1. Precautions peculiar to hybrid
machine" and "Handling of hybrid devices
and high-voltage wirings" before starting
work.
Removal
k Discharge the capacitor. For details, see 2) Open coolant filler cap (2) of the hybrid radi-
00-200 Introduction, safety, and basic infor- ator.
for capacitor" .
(See step 5).
a When replacing the inverter assembly, replace it
and swing motor assembly as a set.

release the pressure inside the hydraulic cir- 3) Remove lower cover (3).
position.
your eye.
PC200, 200LC-8E0 (Hybrid) 50-300 13

300 Hyblid Relation
SEN05258-02 Removal and installation of inverter assembly
4) Open hybrid radiator drain valve (4) to drain 4. Remove rubber cover (8).
the coolant.
6 Coolant: 3.5 l
5. Disconnect one-touch wiring connectors HB01

(9) and (10) from the capacitor.
2. Remove cover (5) and net (6) together. a While pressing the lock portion of the con-
6. Remove clamps (11) and (12) for the

high-voltage wiring (power cable).
7. Disconnect connectors (13) to (15) for the

(Connector No.): (From the left)
(13): HC05
(14): HC04
(15): HC03

50-300 14 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Removal and installation of inverter assembly SEN05258-02
9. Disconnect wiring connectors (17) to (20). 12. Remove four mounting bolts (25).
(Connector No.)
(17): HP01 13. Install the eyebolt to the rubber cover mounting
(18): HK01 portion (P).
(19): HC02
(20): HC01
14. Lift off inverter assembly (26).

4 Inverter assembly: 45 kg
11. Disconnect hoses (22) and (23) from inverter

(24). [*2]
PC200, 200LC-8E0 (Hybrid) 50-300 15

300 Hyblid Relation
SEN05258-02 Removal and installation of inverter assembly
Installation
moval.
[*1]
q Install the connector for the high-voltage wiring
(power cable) according to the following proce-
dure.
1) Check plug (P) on the cable side for dirt and
flaw.
2) Thinly apply grease (G2-LI) to insertion
sealing portion (R) of the flange.
(For protection of the seal from damage at
insertion)
3) Insert plug (P) on the cable side straight into
power feed terminal socket (S) on the motor
side.
a Face the black mark up.
a When inserting the plug, set disconnec-
tion detection contact (Q) of the power ca-
ble under the cable.
3 Mounting bolt for high-voltage wiring
(power cable) plug :
8.8 to 10.8 Nm {0.9 to 1.1 kgm}
[*2]
3 Tightening torque of coolant hose clamp
screw: 3.9 to 4.9 Nm {0.4 to 0.5 kgm}

50-300 16 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Removal and installation of inverter and capacitor assembly SEN05258-02
Removal and installation of 1. Drain the coolant from the hybrid radiator
inverter and capacitor assembly according to the following procedure.
6 Coolant: 3.5 l
1) Open left inspection cover (1).
k Understand the description in 00-200 Intro-

duction, safety, and basic information, "Safe-
ty precautions 1. Precautions peculiar to
hybrid machine" and "Handling of hybrid de-
vices and high-voltage wirings" before start-
ing work.
Special tools
New/Remodel
Necessity
Sym Sketch
Q'ty
Part No. Part name

bol
2) Open coolant filler cap (2) of the hybrid radi-
ator.
B 3 796T-426-1110 Assembling jig t 1 N Q
Removal

for capacitor" .
(See step 7).
a When replacing the inverter assembly, replace it
3) Remove lower cover (3).
and swing motor assembly as a set.

position.
your eye.
PC200, 200LC-8E0 (Hybrid) 50-300 17

300 Hyblid Relation
SEN05258-02 Removal and installation of inverter and capacitor assembly
4) Open hybrid radiator drain valve (4) to drain 4. Remove door (8).
the coolant. a If you sling the door temporarily, you can re-
move it easily.
5. Remove frames (9) and (10).
2. Remove cover (5) and net (6) together.
6. Remove rubber cover (11).
50-300 18 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
7. Disconnect one-touch wiring connectors HB01 14. Disconnect wiring connectors (23) to (26).
(12) and (13) from the capacitor. (Connector No.)
a While pressing the lock portion of the con- (23): HP01
nector with your thumb to unlock the connec- (24): HK01
tor, pull out the connectors. (25): HC02
(26): HC01
8. Remove hybrid wiring clamps (14) and (15).
9. Disconnect connectors (16) to (18) for the

(Connector No.): (From the left)
(16): HC05
(17): HC04
(18): HC03
11. Loosen overflow hose clamp (20).
12. Disconnect coolant level sensor wiring

connector P24 (21).
13. Remove overflow tank (22).
PC200, 200LC-8E0 (Hybrid) 50-300 19

300 Hyblid Relation
16. Remove hose clamp (28). 23. Remove two mounting bolts (37) for the hybrid
radiator lower bracket and remove bracket (38).
17. Disconnect hose (29) from inverter (30).
18. Disconnect radiator lower hose (31). [*2]
19. Disconnect drain hose (32).
20. Disconnect overflow hose (33).
21. Disconnect radiator upper hose (34). [*3]
25. Remove two rear mounting nuts (42). [*4]
22. Remove two radiator mounting bolts (35) and

remove hybrid radiator (36) by pulling it up.
50-300 20 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
26. Disconnect ground strap (43). Installation

27. Remove two front mounting nuts (44). [*4] moval.
[*1]
3 Connector mounting bolt:
8.8 to 10.8 Nm {0.9 to 1.1 kgm}
[*2]
3 Tightening torque of coolant hose clamp
screw: 3.9 to 4.9 Nm {0.4 to 0.5 kgm}
[*3]
3 Tightening torque of clamp screws of upper
and lower hoses of hybrid radiator:
3.9 to 4.9 Nm {0.4 to 0.5 kgm}
a Do not loosen mounting bolts (46) for four [*4]
rubber mounts (45). [*5] a Replace four mounting nuts (01596-01211) for
the "capacitor and inverter assembly" with new
ones.
(Replace the nuts once they are used since they
are loosened and the torque decreases.)
3 Tightening torque:
35 to 44 Nm{3.5 to 4.5 kgm}
[*5]
a If the mounting bolts for the rubber mounts are
loosened, position the rubber mounts according
1) Install rubber mount (45) and finger-tighten
mounting bolts (46).
28. Using the eyebolts at the four capacitor lower

corners, lift off "inverter and capacitor assembly"
(47).
a Put cloths, etc. between the "inverter and ca-
pacitor assembly" and sling to protect the "in-
verter and capacitor assembly".
4 "Inverter and capacitor assembly":
160 kg
PC200, 200LC-8E0 (Hybrid) 50-300 21

300 Hyblid Relation
2) Install tool B3.
3) Tighten the mounting bolts.

50-300 22 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Draining and adding generator lubricating oil SEN05258-02
Draining and adding generator Refilling of oil

lubricating oil 1. Tighten oil drain plug (3).
3 Oil drain plug:
58.8 to 78.4 Nm {6.0 to 8.0 kgm}
Target value: 68.6 Nm {7.0 kgm}

Draining
1. Remove motor-generator lower cover (1).

2. Install motor-generator lower cover (1).
2. Place a container to receive the oil under oil

drain plug (3) of generator housing (2). 3. Open right inspection window cover (4).
3. Loosen oil drain plug (3) to drain the oil.

6 Generator housing: 5.5 to 6 l
PC200, 200LC-8E0 (Hybrid) 50-300 23

300 Hyblid Relation
SEN05258-02 Draining and adding generator lubricating oil
4. Remove plug (6) of oil supply port (5) and add oil
to the specified level.
5 Generator housing: 5.5 to 6 l (TO10)
a Check the oil level with oil level gauge (7).
a Run the engine to circulate the oil in the lubri-
cation circuit, and then check the oil level and
add oil if necessary.
5. Install plug (6).

3 Plug: 58.8 to 78.4 Nm {6.0 to 8.0 kgm}
Target value: 68.6 Nm{7.0 kgm}
50-300 24 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Removal and installation of tandem pump assembly SEN05258-02
Removal and installation of 3. Remove lower cover (4).

tandem pump assembly

Removal
k Disconnect the cable from the negative (-) 4. Referring to "Draining and adding lubricating oil",
terminal of the battery. loosen oil drain plug (5) to drain the oil.
[*1]
1. Close fuel stop valve (1). 6 Generator oil tank: 6 l
2. If the fuel level is higher than the place of the 5. Remove the counterweight assembly. For
return hose, open right inspection window cover details, see "Removal and installation of coun-
(2) and open fuel drain valve (3) to drain the fuel. terweight assembly".
6. Disconnect the winings and hoses from the fuel

supply pump assembly according to the
a Record the disconnected and clamped por-
tions of each hose.
with cloth.
1) Remove fuel hose clamp (6). [*2]
PC200, 200LC-8E0 (Hybrid) 50-300 25

300 Hyblid Relation
SEN05258-02 Removal and installation of tandem pump assembly
7. Disconnect four lubrication hoses (11) to (14).

[*6]
(11): Hose to swing motor
(12): Hose from swing motor
(13): Hose to motor-generator
(14): Hose from motor-generator
a Record the disconnected position of each
hose.
with cloth.
a Do not remove elbows (11a) to (14a). [*7]
When loosening or removing an elbow to
replace it, record its installed direction.
2) Disconnect connector PUMP (7). 8. Remove two bolts (15) and tandem pump
3) Disconnect hose (8) coming from the fuel assembly (16). [*8]
filter. [*3]
4) Disconnect hose (9) to the fuel filter.

[*4]
5) Disconnect hose (10) from the pre-filter. [*5]
50-300 26 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Removal and installation of tandem pump assembly SEN05258-02
Installation [*6]
q Perform installation in the reverse order to re- a Check that mud or dirt is not sticking to the hose
moval. adapters and inside of the hoses.
3 Lubricating oil hose sleeve nuts:
[*1] (11)Hose to swing motor:
3 Oil drain plug: 54 to 93 Nm {5.5 to 9.5 kgm}
58.8 to 78.4 Nm {6.0 to 8.0 kgm} (12)Hose from swing motor:
Target value: 68.6 Nm {7.0 kgm} 54 to 93 Nm {5.5 to 9.5 kgm}
5 Generator oil tank: 6 l (13)Hose to motor-generator:
84 to 132 Nm {8.5 to 13.5 kgm}
[*2] (14)Hose from motor-generator:
a Clamp the fuel hose to the portion from which it 84 to 132 Nm {8.5 to 13.5 kgm}
was removed.
[*7]
[*3], [*4] a If elbows (11a) to (14a) are removed, install
q When installing a connector of quick coupler them in the directions recorded when they are
type, observe the following points. removed.
a The internal parts of the adapter may be 3 Hose mounting elbows:
damaged when the hose is removed. Ac- (11a) Swing motor discharge port:
cordingly, do not reuse the hose. 25 to 29 Nm {2.6 to 3.0 kgm}
When assembling, replace with a new one. (12a) Swing motor suction port:
a Check that mud or dirt is not sticking to the 25 to 29 Nm {2.6 to 3.0 kgm}
hose joint portions in advance. (13a) Generator discharge port:
a Press and connect the connector straight (in 35 to 63 Nm {3.6 to 6.4 kgm}
direction (b)) without prying or bending it to (14a) Generator suction port:
the right or left. 59 to 98 Nm {6 to10 kgm}
If it is difficult to connect the connector, do not
push it forcibly but pull it out. Then, check the [*8]
convex and concave parts for abnormal a When installing the pump assembly, install
condition and sticking mud. O-ring (17) and shaft (18) to the pump first.
a Take care not to mistake the installing direction
of the pump assembly.
3 Tandem pump assembly mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
[*5]
3 Hose clamp bolt:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
PC200, 200LC-8E0 (Hybrid) 50-300 27

300 Hyblid Relation
SEN05258-02 Removal and installation of motor-generator and housing assembly
Removal and installation of 3. Loosen the drain plug to drain the oil from the
motor-generator and housing motor-generator housing. [*1]
assembly
4. Remove the hydraulic pump according to the
1) Remove the parts.
q Muffler assemblyAss'y (1)
q Oil level gauge (2)
q Oil filter assembly (3)
Special tools
a Bind the oil filter assembly and hose
New/Remodel
Necessity together to the engine
Sketch
Part
Symbol Part No.
name Q'ty
1 796T-401-1210 Stand q 1 N Q
2 796T-401-1220 Plate q 1 N Q
1 3 01010-81690 Bolt q 2
4 01580-11613 Nut q 2
5 01643-31645 Washer q 4
B 1 796-410-1000 Guide t 1 N
2 796-410-1040 Bar t 1 N
3 796-410-1050 Plate t 1 N
2
4 01010-81030 Bolt t 2
5 01643-31032 Washer t 6
6 01010-81035 Bolt t 4
a When removing the motor-generator and hous-
ing assembly, set the engine upright.
Removal
1. Remove the "engine, motor-generator , and
hydraulic main pump assembly". For details, see
"Removal and installation of engine, motor-gener-
ator , and hydraulic main pump assembly".
2. Using tool B1, set the "engine, motor-generator

and hydraulic pump assembly" upright.
a When not using tool B1, set the "engine, mo-
tor-generator and hydraulic pump assembly"
upright according to the following procedure.
1) Place blocks [1] under the right and left
mounts on the front side of the engine.
a Adjust height (L1) of blocks [1] to the fol-
lowing dimension.
L1 = 332.5
2) Put block [2] to the horizontal part at the rear
of the oil pan.
3) Using two jacks [3], support block [2] at the
corners on the rear side of the oil pan.
a Adjust height (L2) of block[2] and jack [3]
to the following dimension.
L2 = 325
50-300 28 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Removal and installation of motor-generator and housing assembly SEN05258-02
2) Sling hydraulic pump assembly (4) and

remove mounting bolts (5).
3) Lift off hydraulic pump assembly (4).
a If the hydraulic pump assembly is not
separated easily because of the liquid
gasket applied to its mounting face, hit
the cover surface lightly with a plastic
hammer.
4 Hydraulic pump assembly: 165 kg
8. Remove clamp bracket (11) from generator

motor housing (12).
5. Disconnect blow-by hose clamp (7).
(Removal of rotor and flange assembly)

9. Disconnect speed sensor wiring connector (13)
a Do not remove speed sensor (14).
1) Disconnect speed sensor wiring clamp (15).
2) Disconnect mounting plate (16) of the speed
sensor connector. [*2]
3) Disconnect speed sensor wiring connector
6. Disconnect oil supply hose (8). (13).
4) Disconnect wiring (17) from plate (16).
7. Disconnect lubrication hose (9) from hybrid
system oil cooler (10).
PC200, 200LC-8E0 (Hybrid) 50-300 29

300 Hyblid Relation
5) Install plate (16) to the flange temporarily. 2) Insert tool B2-2 (bar) in the guide hole of tool
10. Remove seven mounting bolts (19b) of the rotor B2-1 (guide).
and flange assembly, leaving two mounting bolts 3) Tighten tools B2- 4 (bolts).
(19a). a Press tool B2-2 (bar) against crank shaft
center (C) securely and align it, and then
fix B2-1 (guide) with tools B2-4 (bolts).
11. Set tool B2 according to the following procedure.

1) Install tool B2-1 (guide) to the motor-gener-
ator housing (12) by using two tools B2-4
(bolts) and two B2-5 (washers).
a Finger-tighten the two bolts.
a When installing tool B2-1 (guide), take
care not to damage the sensor wiring har-
ness.
4) Install tool B2-3 (bar fixing plate) and fix it

with tools B2-6 (plate mounting bolts).
12. Remove remaining two mounting bolts (19a) of

rotor and flange assembly (18).
50-300 30 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
13. Install forcing screws [4] (M8 x 1.25) to forcing

tap holes (p) of the flange to disconnect rotor and
flange assembly (18) from motor-generator
housing (12).
a Tighten two forcing screw [4] on the right and
left evenly to pull out rotor and flange assem-
bly (18) approximately 20 mm.
15. Install sling [5] to rotor assembly (20) and lift up

temporarily.
a Be sure to use a nylon sling so that the rotor
is not damaged. (Never use a wire or chain
sling which damages the rotor.)
a Shift sling [5] toward the flange and install it
around the rotor assembly.
14. Pull out rotor and flange assembly (18) toward (Apply the sling in this way so that the flange
you. does not lower and come off down when the
a Pull out rotor assembly (20) and flange (21) rotor assembly is lifted up.)
together so that rotor assembly (20) is not
separated and left from flange (21) and does 16. Remove tool B2-3 (bar fixing plate) and pull out
not come off. tool B2-2 (bar).
a When pulling out rotor and flange assembly
(18), take care not to damage the following
portions.
q Coil insulation portion (D) on housing side
q Core end portion (E) on housing side
q Core portion (F) on rotor side
PC200, 200LC-8E0 (Hybrid) 50-300 31

300 Hyblid Relation
17. Lift off rotor and flange assembly (18).

a When lifting up, take care that the end of rotor
assembly (20) is not damaged by touching
motor-generator housing (12).
a Keep the end (part R) of the rotor assembly
at the bottom during the work from lifting of
rotor and flange assembly (18) to removal of
it.
(Observe this to prevent the flange from
coming off.)
a When lowering rotor and flange assembly
(18) to the ground, spread soft cloths thickly
under it.
a When lowering the rotor and flange assembly
to the ground, slant it carefully so that end (Removal of motor-generator housing assembly)
(part R) of the rotor assembly (20) lowers first a After removing the rotor and flange assem-
and flange (21) faces up. bly, check again that the engine assembly is
4 Rotor and flange assembly: 45 kg in an upright posture.
18. Remove tool B2-1 from the motor-generator 19. Remove the motor-generator housing assembly
housing. (12) according to the following procedure.
1) Remove two starting motor mounting bolts
(22) and nut (23) to remove starting motor
assembly (24). [*3]
50-300 32 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
2) Install eyebolts [J] (M10 x 1.5) to two eyebolt 6) Lift off motor-generator housing assembly
holes (G) of the housing, and sling (12).
motor-generator housing assembly (12). 4 Motor-generator housing assembly:
3) Remove the following mounting bolts and 120 kg
mounting nuts from the portions shown in the
following figure.
q Mounting bolts [1] to [15]
q Mounting nuts [16] to [18]
4) Install two guide pins [H] to the places of
guide bolts [3] and [5].
5) Using two forcing screws [L], disconnect

motor-generator housing (12) from rear
housing (25).
a Tighten two forcing screws [L] on the right
and left evenly to disconnect the mo-
tor-generator housing.
a When disconnecting motor-generator
housing (12), take care not to damage the
coil portion of the housing and gear por-
tion (Q) of the rear housing.
a Since the stud bolts for nuts [16], [17] and
[18] are left installed to motor-generator
housing (12) and rear housing (25), re-
move generator motor housing assembly
(12) straight until those stud bolts come
out completely.
PC200, 200LC-8E0 (Hybrid) 50-300 33

300 Hyblid Relation
Installation
(Installation of motor-generator housing assembly)
1. Set the "engine, generator motor and hydraulic

pump assembly" upright according to the
removal procedure
2. Install the motor-generator housing assembly
1) Clean the mounting faces of the rear housing
and motor-generator housing (R) and apply a
string of liguid gasket (diameter t: 1 to 2 mm)
on those faces.
2 Rear housing end face:
Liquit gasket (LG-7)
5) Tighten bolts [1] to [15] and nuts [16] to [18]
in the order of [1] to [18] shown in the
following figure.
3 Housing mounting bolt and nut:
98 to 123 Nm {10.0 to 12.5 kgm}
2) Install guide pins [H] (two places ) to rear

housing (25).
3) Install eyebolts [J] (M10 x 1.5) to
motor-generator housing assembly (12) and
sling it.
4) Install motor-generator housing assembly to
rear housing (25) along the guide pins.
a When installing the motor-generator
housing, take care not to damage the coil
portion of the housing and gear portion
(Q) of the rear housing.
50-300 34 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
(Installation of rotor and flange assembly) 3) Pass tool B2-2 (bar) through the shaft hole
of rotor and flange assembly (18) and insert
1. Install the rotor and flange assembly to the it until it reaches center (C) of the crankshaft.
housing according to the following procedure. 4) While tool B2-2 (bar) is aligned, tighten tool
1) Install tool B2-1 (guide) to housing (12) and B2-4 (bolts) completely to fix tool B2-1
finger-tighten two tools B2-4 (bolts) and B2-5 (guide) to housing (12).
(washers). 5) Install tool B2-3 (bar fixing plate) and fix it
with tools B2-6 (bolts).
6) Remove sling [5].
2) Sling rotor and flange assembly (18) and

align it with the crankshaft before
motor-generator housing assembly (12).
a Be sure to use a nylon sling so that the ro-
tor is not damaged. (Never use a wire or
chain sling which damages the rotor.)
a Shift sling [5] toward the flange and install
it around the rotor assembly. (Apply the
sling in this way so that the flange does
not lower and come off down when the ro-
tor assembly is lifted up.)
a While slinging rotor and flange assembly
(18), take care that flange (21) does not
come off rotor (20) and fall.
PC200, 200LC-8E0 (Hybrid) 50-300 35

300 Hyblid Relation
7) Insert rotor and flange assembly (18) in the q Perform the following installation in the reverse
motor-generator housing along tool B2-2 order to removal.
(bar).
a When inserting rotor and flange assembly [*1]
(18), take care not to damage the follow- 3 Drain plug: 58.8 to 78.4 Nm {6.0 to 8.0 kgm}
ing portions.
q Coil insulation portion (D) on housing [*2]
side 3 Bracket mounting bolt:
q Core end portion (E) on housing side 5.8 to 8 Nm {0.6 to 0.8 kgm}
q Core portion (F) on rotor side
[*3]
a Clean the mounting face of the starting motor as-
sembly and apply liquid gasket to it.
(R: Periphery L = 4mm apart from end face)
2 Starting motor assembly mounting face:
Gasket sealant (LG-7)
q Refilling of oil
Refill the motor-generator housing with oil.
5 Motor-generator housing: 6.5 l
(Power train oil TO10)
8) Install flange mounting bolts (19).

9) Remove tool B2.
50-300 36 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
Removal and installation of swing electric motor assembly SEN05258-02
Removal and installation of swing 1. Open left inspection window cover (1).
electric motor assembly
Special tool
New/Remodel
Necessity
Sketch
Q'ty
F 5 01124-51490 Guide bolt t 1
a When replacing the swing electric motor assem- 2. Remove rubber cover (2) above the inverter.
bly, replace it and inverter assembly in a set.
Removal

for capacitor" .
(See step 3).
3. Disconnect two one-touch wiring connectors
HB01 (CC) (cable terminals of (+) and (-)) from
k
the capacitor.
Referring to Testing and adjusting, "Releas-
tor, pull out the connector.
position.
your eye.
PC200, 200LC-8E0 (Hybrid) 50-300 37

300 Hyblid Relation
SEN05258-02 Removal and installation of swing electric motor assembly
4. Remove lower cover (30). [*1]
9. Disconnect clip (8) and disconnect wiring

5. Loosen oil drain plug (31) to drain the oil. [*2] connector CN-P01 (9).
6 Swing electric motor (in case): 1.9 to 2.1 l
(Quantity of drain): 1.7 l 10. Remove mounting bolts (10) and disconnect
power cable plug (11). [*6]
11. Disconnect power cable fixing clamp (12) from

bracket (13).
12. Disconnect delivery hose (lubricating oil inlet)

(14). [*7]
13. Disconnect delivery hose clamp (15) from

bracket (13).
14. Remove two mounting bolts (16) and bracket

(13). [*8]
6. Remove mounting bolts (3) and plate (4). 15. Disconnect drain hose (17) from oil supply pipe
[*3] (18)
7. Remove six mounting bolts (5) and cover (6).

[*4]
8. Remove hose mounting bracket (7) from the

swing electric motor. [*5]
50-300 38 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
16. Loosen clamp (19) and disconnect two coolant 20. Sling swing electric motor and remove six
hoses (20). [*9] mounting bolts (28). [*13]
a Put marks on the hoses so that you do not a Before removing the bolts, put a match mark
confuse them for each other. (X) between the swing electric motor and
swing machinery
17. Disconnect lubricating oil outlet hose (21). [*10]
18. Disconnect lubricating oil drain hose (22). [*11]
21. Install eyebolt(s) [1] to eyebolt(s) holes (P) (two

places on a diagonal line).
a Eyebolt(s) thread diameter: 8 mm
19. Remove oil supply pipe (18) according to the
following procedure. 22. Lift off swing electric motor assembly (29).
1) Remove two mounting bolts (23) and bracket k When removing the swing electric motor
(24). assembly, the springs may jump out.

2) Remove two mounting bolts (25) and bracket Sling carefully and slowly.
4 Swing electric motor assembly: 70 kg
(26).
3) Remove four mounting bolts (27) and oil
supply pipe (18). [*12]
PC200, 200LC-8E0 (Hybrid) 50-300 39

300 Hyblid Relation
Installation [*7]
q Perform installation in the reverse order to re- 3 Delivery hose sleeve nut:
moval. 54 to 93 Nm {5.5 to 9.5 kgm}
[*1] [*8]
3 Cover mounting bolt: 3 Bracket mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm} 59.7 to 74 Nm {6.0 to 7.5 kgm}
[*2] [*9]
3 Oil drain plug: a When connecting the coolant hoses, check their
58.8 to 78.4 Nm {6.0 to 8.0 kgm} marks made when they were removed.
Target value: 68.6 Nm {7.0 kgm} (Left side): Outlet hose from swing electric motor
(Right side): Inlet hose to swing electric motor
[*3]
3 Plate fixing bolt: [*10]
27 to 34 Nm {2.8 to 3.5 kgm} 3 Sleeve nut of lubricating oil outlet hose:
54 to 93 Nm {5.5 to 9.5 kgm}
[*4]
3 Cover mounting bolt: [*11]
27 to 34 Nm {2.8 to 3.5 kgm} 3 Sleeve nut of lubricating oil outlet hose:
84 to 132 Nm {8.5 to 13.5 kgm}
[*5]
3 Mounting bolt of travel hose bracket: [*12]
27 to 34 Nm {2.8 to 3.5 kgm} 3 Mounting bolt of oil supply pipe:
27 to 34 Nm {2.8 to 3.5 kgm}
[*6]
q Install the connector of the high-voltage wiring
dure.
1) Check plug (P) on the cable side for dirt and
flaw.
2) Thinly apply grease (G2-LI) to insertion
sealing portion (R) of the flange.
(For protection of the seal from the inserted
flange)
power feed terminal socket (S) on the motor
side.
a Face the black mark up.
a When inserting the plug, set disconnec-
ble to the lower side of the cable.
3 Mounting bolt of high-voltage wiring
(power cable) plug :
8.8 – 10.8 Nm {0.9 – 1.1 kgm}
50-300 40 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
[*13]
q Install the swing motor assembly to the swing
machinery according to the following procedure.
1) Check that six springs (31) are set correctly.
2) Degrease mating faces (Q) of the swing elec-
tric motor and No. 1 ring gear (30).
a When installing a new swing electric mo-

tor assembly (29), match mounting face
(S) of the oil supply pipe with piping port
face (T) of the swing electric motor and
use tool F5 to install.
3) Install three tools F5 (guide bolts) to three

places of swing electric motor mounting face
(R) of No. 1 ring gear (30).
a While checking that the springs are set to

the spring mounting face of the swing
electric motor, sling the swing electric mo-
tor assembly slowly.
k When positioning the springs, never
4) Install swing electric motor assembly (29) to
put your finger between the swing
the swing machinery assembly, matching the
electric motor and No. 1 ring gear.
match marks put on at removal.
(If you are required to position the
springs, use a screwdriver, etc.)
4 Swing electric motor assembly:
70 kg
5) Install three mounting bolts (28) of the swing
electric motor and tighten them partially.
6) Remove tool F5 and evenly tighten the six
bolts, including the remaining three mounting
bolts.
3 Swing electric motor mounting bolt:
157 to 196 Nm {16 to 20 kgm}
PC200, 200LC-8E0 (Hybrid) 50-300 41

300 Hyblid Relation
q Refilling of oil
Supply the cases with oil through the oil filler to
the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil
level again.
5 Swing machinery case: 6 l (TO30)
5 Swing electric motor case:
1.9 – 2.1 l (TO10)
(Refill capacity): 1.7 l (TO10)

50-300 42 PC200, 200LC-8E0 (Hybrid)

300 Hyblid Relation
PC200, 200LC-8E0 (Hybrid) 50-300 43

SEN05258-02
©2012 KOMATSU
All Rights Reserved
50-300 44
SEN05259-01
SEN05259-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


400 Power train
Removal and installation of final drive assembly ........................................................................................ 2

Disassembly and assembly of final drive assembly.................................................................................... 3
Removal and installation of "swing electric motor and swing machinery assembly"................................... 11
Disassembly and assembly of swing machinery assembly ........................................................................ 15
Removal and installation of swing circle assembly ..................................................................................... 29
PC200, 200LC-8E0 (Hybrid) 50-400 1

400 Power train
SEN05259-01 Removal and installation of final drive assembly
Removal and installation of final 4. Sling the final drive assembly (6).
drive assembly
5. Remove 18 mounting bolts (7) and sling final
drive assembly (6) to remove it. [*1]
Removal a Be careful so that the nipple sealing surface
1. Remove the sprocket, referring to the section on the hose mounting block may not be dam-
“Removal and installation of sprocket”. aged.
k Completely lower the work equipment to 4 Final drive assembly: 300 kg
the ground and stop the engine. Then
loosen the oil filler cap for the hydraulic
tank to release the pressure inside the
tank.
Installation
moval.
[*1]
3 Mounting bolt :
3. Disconnect the travel speed selector hose (2), 245 – 309 Nm {25 – 31.5 kgm}
the motor hoses (3) and (4), and the drain hose q Refilling
(5). Supply the power train oil (TO30) via the oil filler
port to the specified level. Start the engine to
circulate the oil through the pipings and check
the oil level again.
q Air bleeding
Refer to the “Bleeding air from each part” in the
Testing and adjusting chapter of this manual.
50-400 2 PC200, 200LC-8E0 (Hybrid)

400 Power train
Disassembly and assembly of final drive assembly SEN05259-01
Disassembly and assembly of 4. Remove washer (2).

final drive assembly
5. No.1 carrier assembly
1) Remove No. 1 carrier assembly (3).
Special tools
Necessity
Sketch
Q'ty
N/R
Wrench
796-427-1400 t 1 N
assembly
1 796-427-1410 q Wrench 1 N
796-427-1140 q Pin 3
01314-20612 q Screw 3
796T-427-1510 Push tool t 1 N Q
790-101-2510 Block t 1
790-101-3310 Block t 1
J 790-101-2610 Rod t 2
790-101-2730 Adapter t 2
2 01580-11613 Nut t 2 2) Disassemble No. 1 carrier assembly as
790-101-2570 Plate t 2 follows.
01643-31645 Washer t 2 1] Push in pin (4) to remove shaft (5) out of
Puller carrier (6).
790-101-2102 t 1
(294 kN 30 ton) a After removing the shaft, remove pin
790-101-1102 Pump t 1 (4).
3 796-427-1520 Installer t 1 N 2] Remove thrust washer (7), gear (8),
bearing (9), and thrust washer (10) from
carrier (6).
Disassembly
1. Oil draining
Remove the drain plug to drain the oil from the
final drive case.
6 Final drive case: 3.5 l
2. Set the final drive assembly on the block [1].
3. Remove mounting bolts to remove cover (1).

a When cover (1) is difficult to be separated,
tap the cover (1) with a plastic hammer.
PC200, 200LC-8E0 (Hybrid) 50-400 3

400 Power train
SEN05259-01 Disassembly and assembly of final drive assembly
6. Remove No. 1 sun gear shaft (11).
7. Remove thrust washer (12).
8. Remove No. 2 sun gear (13).
9. No. 2 carrier assembly

4 No. 2 carrier assembly: 35 kg
2) Remove thrust washer (15).
10. Nut
1) Remove lock plate (23).
2) Use the tool J1 to remove nut (24).
a Use bar [2] to hold.
3) Disassemble No. 2 carrier assembly as

follows.
1] Push in pin (16) to remove shaft (17) out
of carrier (18).
a After removing the shaft, remove pin
(16).
2] Remove thrust washer (19), gear (20),
bearing (21), and thrust washer (22).
50-400 4 PC200, 200LC-8E0 (Hybrid)

400 Power train
11. Hub assembly 13. Use the puller [3] and push tool [4] to remove
1) Sling hub assembly (25) and remove it from bearing (32).
the travel motor. a Bearing may come off without using the pull-
2) Remove bearing (26). er.
3) Remove bearing outer races (27) and (28).
12. Remove floating seals (30) and (31) from travel

motor (29).
a The floating seal (30) may be on the hub as-
sembly (25).
PC200, 200LC-8E0 (Hybrid) 50-400 5

400 Power train
Assembly 3. Use the tool J3 to install floating seal (31) to

a Clean the parts completely and inspect them for travel motor (29).
any foreign material or damage. Apply power a Install floating seal with the O-ring and O-ring
train oil (TO30) on the sliding surfaces before in- contact surface degreased and dried com-
stalling. pletely.
1. Hub assembly a After installing the floating seal, check that
1) Use push tool to press fit bearing outer races the leaning of the floating seal is within 1 mm.
(27) and (28) into hub (32). a After floating seal installation, apply a thin
film of power train oil (TO30) on the sliding
surfaces.
2) Use the tool J3 to install floating seal (30).

a Install floating seal with the O-ring and
O-ring contact surface degreased and 4. Set hub assembly (25) to the travel motor.
dried completely.
a After installing the floating seal, check
that the leaning of the floating seal is with-
in 1 mm.
a After floating seal installation, apply a thin
film of power train oil (TO30) on the slid-
ing surfaces.
5. Install bearing (26) by tapping it lightly with the

push tool.
2. Install bearing (32) to travel motor (29).

a Warm the inner race of the bearing (32) to 50
- 70 °C with a heater.
a Cool the bearing (32) down. Tap the bearing
(32) with a drift and listen to the sound to
check that it is fully seated.
50-400 6 PC200, 200LC-8E0 (Hybrid)

400 Power train
6. Nut
1) Install nut as follows.
1] Rotate the hub 2 - 3 turns.
2] Use the tool J2 and the push tool [5] to
press fit the inner race of the bearing (26).
a Press-fitting force:
29.4 – 38.2 kN {3.0 – 3.9 ton}
3] Rotate the hub to the both directions at
least 5 turns in total with the bearing inner
race pressed.
4] Release the pressing force.
5] Press the bearing again.
a Press-fitting force:
17.7 – 21.6 kN {1.8 – 2.2 ton}
6] Rotate the hub 2 - 3 turns. 2) Measure the tangential force of the hub
against the motor case in the rotation direc-
tion using the push scale [6].
a Tangential force:
490 N or less {50 kg or less}
a The tangential force denotes the maxi-
mum force at start of the rotation.
7] Measure the size (a) under the condition

described in 6] above.
3) Install lock plate (23).

a Install the lock plate so that the splines A
of the lock plate and the motor are in full
contact.
2 Mounting bolt thread:
Adhesive (LT-2)
a Do no apply the adhesive (LT-2) to the
tapped portion of the nut.
8] Measure thickness (b) off the indepen-

dent nut (24).
9] (a) - (b) = (c)
10] Use the tool J1 to tighten nut (24) until the
following condition is met:
size (d): (c) + 0.06/- 0.04
PC200, 200LC-8E0 (Hybrid) 50-400 7

400 Power train
7. No.2 carrier assembly

1) Assemble No. 2 carrier assembly as follows.
a Replace thrust washers (19) and (22) as
well as pin (16) with new ones.
a There are traces of expansion on the end
surface of carrier side hole (e) which were
originally caused when the pin was insert-
ed. Make such the end surfaces are
smooth enough before reassembly.
1] Install bearing (21) to gear (20), fit top and
bottom thrust washers (19) and (22) and
then set the gear assembly on carrier
(18).
2] Align the pin holes in the shaft (17) and
the carrier, and install the shaft (17) by
tapping it lightly with a plastic hammer.
a Install the shaft, rotating planetary
gear (20). Take care so the thrust
washers are not damaged.
2) Install No.2 carrier assembly (14).

a Align the 4 gear shaft ends of the carrier
assembly (14) with the 4 dimples on the
motor case end surface to install.
8. Thrust washer
3] Insert pin (16). Install thrust washer (15).
a When inserting the pin, take care so
that any of the three pawls on the cir-
cumference (Portion (f)) may not
touch the thin-walled portion on the
carrier (Portion (g)). Take note, how-
ever, that the thin-walled portion is
likely to be on the opposite side of the
carrier, depending on actual individual
items. Pay attention so that a pin pawl
will not come to the slender side of the
carrier any way. And when traces of
the groove are present, assembly
must be done avoiding such locations.
a After assembling the carrier assem-
bly, check that gear (20) rotates
smoothly.
a After the pin is inserted, stake the pin
(B) on the carrier.
50-400 8 PC200, 200LC-8E0 (Hybrid)

400 Power train
9. No. 2 sun gear 2] Align the pin holes on the shaft (5) and the
Install No. 2 sun gear (13). carrier, and install the shaft (5) by tapping
10. No. 1 sun gear it lightly with a plastic hammer.
Install No. 1 sun gear (11). a Install the shaft, rotating the planetary
11. Thrust washer gear (8). Take care so the thrust
Install thrust washer (12). washer is not damaged.
3] Insert pin (4).
a When inserting the pin, take care so
that any of the three pawls on the cir-
cumference (Portion (f)) may not
touch the thin-walled portion on the
carrier (Portion (g)). Take note, how-
ever, that the thin-walled portion is
likely to be on the opposite side of the
carrier, depending on actual individual
items. Pay attention so that a pin pawl
will not come to the slender side of the
carrier any way. And when traces of
the groove are present, assembly
must be done avoiding such locations.
a After assembling the carrier assem-
12. No.1 carrier assembly bly, check that gear (8) rotates
1) Assemble No. 1 carrier assembly as follows. smoothly.
a Replace thrust washers (7) and (10) and a After the pin is inserted, stake the pins
pin (4) with new ones. (Refer to Pin (4): (C) on the carrier at 2 locations.
3].)
a There are remains of caulking when the
pin is inserted at the end face of hole h at
the side of the carrier. Remove the
caulked metal from the inside diameter of
the hole before starting to assemble.
1] Assemble bearings (8) and (9), fit top and
bottom thrust washers (7) and (10) and
then set the gear assembly on carrier (6).
PC200, 200LC-8E0 (Hybrid) 50-400 9

400 Power train
2) Install No. 1 carrier assembly (3).
13. Washer
Install washer (2).
a After installing washer (2), measure distance
(i) from the top of planetary gear (8) to the top
of ring gear (25) and check the assembly
condition.
a If the distance (i) is not within 0.1 ± 0.4, it
can not be assembled properly. Confirm the
condition again.
15. Oil refill

Tighten drain plug and supply power train oil
(TO30) through the oil filler port.
5 Final drive case: 3.5 l
a Do a final check of the oil level at the deter-
mined position after installing the final drive
assembly to the chassis.
14. Cover
Install cover (1).
2 Cover mounting face:
Liquid gasket (LG-6)
3 Mounting bolts:
98 – 123 Nm {10 – 12.5 kgm}
50-400 10 PC200, 200LC-8E0 (Hybrid)

400 Power train
Removal and installation of "swing electric motor and swing machinery assembly" SEN05259-01
Removal and installation of 1. Open left inspection cover (1).

"swing electric motor and swing
machinery assembly"
k Since the items with the above mark are relat-

ed to handling of the hybrid devices, ensure
that you understand the descriptions of
mation, "Safety precautions 1. Precautions
peculiar to hybrid machine" and "Handling of
hybrid devices and high-voltage wirings" be-
fore beginning the work on them. 2. Remove rubber cover (2) above the inverter.
Special tool
New/Remodel
Necessity
Sketch
Q'ty
F 4 796T-426-1510 Bolt t 3 N Q
Removal
k Discharge the capacitor completely first. For

details, see 00-200 Introduction, safety, and 3. Disconnect two one-touch wiring harness
basic information, "Handling of hybrid devic- connectors HB01 (CC) (cable terminals of (+)
es and high-voltage wirings", "Discharge and (-)) from the capacitor.
procedure for capacitor" . a While pressing the lock portion of the con-
k Disconnect two one-touch connectors (cable nector with your thumb to unlock the connec-
terminals of (+) and (-)) from the capacitor tor, pull out the connectors.
(See step 3).
LOCK position.
PC200, 200LC-8E0 (Hybrid) 50-400 11

400 Power train
SEN05259-01 Removal and installation of "swing electric motor and swing machinery assembly"
4. Remove lower cover (37). [*1] 8. Remove mounting bolts (3) and plate (4). [*3]
9. Remove six mounting bolts (5) and cover (6).

[*4]
10. Disconnect travel hose mounting bracket (7)

from the swing electric motor. [*5]
5. Loosen oil drain plug (34a) to drain the oil. [*2]

6 Swing electric motor case: 1.5 – 2.1 l
Quantity of drain: 1.7 l
6. Remove drain block mounting bolts (33) and
disconnect swing electric motor drain block (34)
and swing machinery drain block (35).
11. Disconnect clip (8) and disconnect wiring
7. Pull out swing machinery drain block (35) and harness connector CN-P01 (9).
drain hose (36) from the hole of the revolving
frame. 12. Remove mounting bolts (10) and disconnect
power cable connector (11). [*6]
13. Disconnect power cable fixing clamp (12) from

bracket (13).
14. Disconnect delivery hose (lubricating oil inlet)

(14). [*7]
15. Disconnect delivery hose clamp (15) from

bracket (13).
16. Remove two mounting bolts (16) and bracket

(13). [*8]
50-400 12 PC200, 200LC-8E0 (Hybrid)

400 Power train
Removal and installation of "swing electric motor and swing machinery assembly" SEN05259-01
17. Loosen clamps (19) and disconnect two coolant 22. Remove twelve mounting bolts (31). [*12]
hoses (20). [*9]
a Make marks on the hoses so that you do not
mistake them for each other.
18. Disconnect lubricating oil outlet hose (21). [*10]
19. Disconnect lubricating oil drain hose (22). [*11]
23. Install tools F4 to three tool mounting tap holes

(P) on the periphery of the swing machinery.
24. Install eyebolts [1] to tools F4.
25. Install lifting tools [2].
20. Disconnect swing brake hose (28) from the

swing machinery.
21. Disconnect hose clamp (29) from the swing

machinery.
26. Lift off swing electric motor and swing machinery

assembly (32).
4 Swing electric motor and swing machin-
ery assembly: 300 kg
PC200, 200LC-8E0 (Hybrid) 50-400 13

400 Power train
SEN05259-01 Removal and installation of "swing electric motor and swing machinery assembly"
Installation [*7]
q Perform installation in the reverse order to re- 3 Delivery hose sleeve nut:
moval. 54 – 93 Nm {5.5 – 9.5 kgm}
[*1] [*8]
3 Cover mounting bolt: 3 Bracket mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm} 59.7 – 74 Nm {6.0 – 7.5 kgm}
[*2] [*9]
3 Oil drain plug: a When connecting the coolant hoses, check their
19.6 – 24.5 Nm {2.0 – 2.5 kgm} marks made when they were removed.
(Left side): Outlet hose from swing electric motor
[*3] (Right side): Inlet hose to swing electric motor
3 Plate fixing bolt: 27 – 34 Nm {2.8 – 3.5 kgm}
[*10]
[*4] 3 Sleeve nut of lubricating oil outlet hose:
3 Cover mounting bolt: 54 – 93 Nm {5.5 – 9.5 kgm}
27 – 34 Nm {2.8 – 3.5 kgm}
[*11]
[*5] 3 Sleeve nut of lubricating oil drain hose:
3 Mounting bolt of travel hose bracket: 84 – 132 Nm {8.5 – 13.5 kgm}
27 – 34 Nm {2.8 – 3.5 kgm}
[*12]
[*6] 3 Swing machinery assembly mounting bolt:
q Connect the connector of the high-voltage wiring 490 – 608 Nm {50 – 62 kgm}
dure. q Refilling of oil
1) Check plug (P) on the cable side for dirt and Supply oil through the oil filler of the swing elec-
flaw. tric motor to the specified level. Run the engine
2) Thinly apply grease (G2-LI) to insertion to circulate the oil through the piping. Then,
sealing portion (R) of the flange. check the oil level again.
(For protection of the seal from the inserted 5 Swing electric motor case: 1.9 – 2.1l
flange) (TO10)
power feed terminal socket (S) on the motor q Refilling of coolant and bleeding air
side. a Supply coolant and bleed air. For details, see
a Insert the plug with the black mark up. "Draining and adding coolant and bleeding
a When inserting the plug, set disconnec- air for hybrid system".
ble under the cable.
3 Mounting bolt of high-voltage wir-
ing (power cable) plug:
8.8 – 10.8 Nm {0.9 – 1.1 kgm}
50-400 14 PC200, 200LC-8E0 (Hybrid)

400 Power train
Disassembly and assembly of swing machinery assembly SEN05259-01
Disassembly and assembly of 3. Accessories

swing machinery assembly 1) Remove machinery drain hose (62) and
swing electric motor drain hose (63).
2) Remove the oil level gauge according to the
Special tools
New/Remodel
1] Remove two mounting bolts (63) and
Necessity
Sketch
bracket (64).
Q'ty
2] Remove two mounting bolts (65) and
bracket (66).
796T-426-1130 Plate t 1 Q 3] Remove four mounting bolts (2a) and oil
supply pipe (2).
1 790-101-5421 Grip t 1
01010-81240 Bolt t 1
4. Swing electric motor
2 796-426-1120 Push tool t 1
1) Remove six mounting bolts (3a) (size: M14).
3 796T-426-1410 Plate t 1 Q
F a Make match marks (P) on the case of the
4 796T-426-1510 Bolt t 3 N Q
swing electric motor assembly (3) and
5 01124-51490 Guide bolt t 3
swing machinery assembly (4).
1 796-426-1710 Collet t 1
6 2 796-426-1720 Tapered cone t 1
3 796-426-1730 Collar t 1
Disassembly
1. Set the swing electric motor and swing
machinery assembly on a block.
a Use tools F4 to sling the swing electric motor
and swing machinery assembly.
2. Draining oil from swing machinery

Loosen oil drain plug (61) of the swing
machinery to drain the oil from the swing
machinery case.
6 Swing machinery case: 6.9 – 7.1 l
PC200, 200LC-8E0 (Hybrid) 50-400 15

400 Power train
SEN05259-01 Disassembly and assembly of swing machinery assembly
2) Lift off swing electric motor assembly (3). 9. No. 1 carrier assembly
k When removing the swing electric mo- 1) Remove No. 1 carrier assembly (9).
tor assembly, the springs may jump
out. Sling carefully and slowly.
2) Disassemble the No. 1 carrier assembly

1] Reverse carrier assembly (9).
5. Remove springs (5). 2] Remove Spirolock (10).
a While lifting up the abutment joint of
6. Remove No. 1 sun gear (6). Spirolock (10) with a thin flat-head
screwdriver, move the screwdriver
7. Remove six mounting bolts (7) of the No. 1 ring around clockwise to remove Spirolock
gear. (10).
3] Remove ring (11).
4] Remove the shaft from the carrier
assembly by using the push tool.
q Shaft press-fitting force (reference):
12.2 – 30.0 N {1,240 – 3,050 kg}
5] Remove plate (13), planetary gear (14),
bearing (15), plate (16), and ring (17).
6] Reverse carrier assembly (9).
7] Remove holder (18).
a Take care not to lose ball (19).
8. Lift off No. 1 ring gear (8).
50-400 16 PC200, 200LC-8E0 (Hybrid)

400 Power train
11. No. 2 sun gear assembly

1) Remove No. 2 sun gear assembly (22).
10. Using air pump [3], apply air pressure through

swing brake port (Q) to remove piston (21).
k Use air pressure of 5 – 6 kg/cm .
2 2) Disassemble the No. 2 sun gear assembly
k When applying air pressure, hold piston according to the following procedure.
(21) to prevent it from jumping out. 1] Remove snap ring (23) and plate (24)
from No. 2 sun gear (22).
2] Remove swing brake gear (25) from No.
2 sun gear (22).
12. Remove three plates (26) and two discs (27) in

order.
PC200, 200LC-8E0 (Hybrid) 50-400 17

400 Power train
13. Remove six mounting bolts (28) and lift off case 3) Using push tool [1], remove shaft (39) from
(29). carrier (38).
q Shaft press-fitting force (reference):
11.2 – 25.8 kN {1,140 – 2,630 kg}

15. Remove No. 3 sun gear (40).
16. Remove the mounting bolts and No. 2 ring gear

(41).
2) Disassemble the No. 2 carrier assembly

1] Remove snap ring (31), thrust washer
(32), planetary gear (33) bearing (34),
and thrust washer (35) in order. 17. Remove holder mounting bolt (42).
2] Remove plate (36).
3] Reverse carrier (30) and remove snap 18. No. 3 carrier assembly
ring (37). 1) Remove No. 3 carrier assembly (43).
50-400 18 PC200, 200LC-8E0 (Hybrid)

400 Power train
2) Disassemble the No. 3 carrier assembly 3) Reverse shaft and case assembly (51) again
according to the following procedure. and set it to the press.
1] Push in pin (44) and drive out shaft (45) 4) Using push tool [2], remove shaft assembly
from carrier (46). (53) from shaft and case assembly (51).
a After removing the shaft, remove pin
(44).
2] Remove thrust washers (47), planetary
gear (48), and bearing (49).
3] Remove plate (50).
19. Shaft and case assembly

1) Reverse shaft and case assembly (51).
2) Remove cover mounting bolts (52).
PC200, 200LC-8E0 (Hybrid) 50-400 19

400 Power train
20. Shaft assembly Assembly

1) Using push tools [3] and [4], remove shaft a Clean all the parts thoroughly, check them for
(54). dirt and damage, and apply power train oil to the
2) Remove bearing (55) and oil seal (57) from sliding parts before installing.
cover (56). a Do not reuse the removed bearings and oil seals
but replace them with new ones.
1. Oil seal
Using tool F1, install oil seal (57) to cover (56).
a Take care not to install the oil seal with wrong
direction (top and bottom).
2 Periphery of oil seal: Liquid gasket
(LG-6)
a When press fitting the oil seal, take care that
liquid gasket (LG-6) does not stick to the lip
of the oil seal.
a When not using tool F1, use a push tool that

can press periphery (A) of oil seal (57) even-
ly.
21. Remove bearing (59) from case (58). a Take care not to slant oil seal (57).
a Apply a proper tool to the periphery (thick
line: part Q) of the outer race and hit the tool
lightly with a hammer around the periphery
evenly to remove the bearing gradually.
a If the outer race is slanted, the bearing be-
comes hard to be removed. Keep the bearing
horizontal during removal.
50-400 20 PC200, 200LC-8E0 (Hybrid)

400 Power train
2. Using push tool [5], press fit bearing (55) to case

(58).
a Use a new bearing.
3) Set the assembly to the press.

4) Using tool F2 and push tools [9] and [10],
press fit the inner race of bearing (55).
3. Install cover assembly (61) to case assembly a Put in push tool [10] against large slant of
(60). the case assembly.
2 Cover mounting face: Liquid gasket a If case assembly (60) slants, correct it by
(LG-6) hitting the flange lightly.
a Take care that liquid gasket (LG-6) does not a Just before oil seal (57) fits shaft (B), ad-
stick to drain port (DP). just case assembly (60) horizontal and
a Match the drain portion of the cover with align it with shaft (54), taking care not to
drain port (DP). damage the oil seal lip.
4. Shaft and case assembly

1) Set case assembly (60) to shaft (54).
2 Oil seal lip: Grease (G2-LI)
a Put the case assembly over the shaft
without contacting the oil seal with the
shaft.
2) Using tool F2, push tool [6], and hammer [7],
hit the inner race of bearing (55) to press fit.
a Sag sling [8].
k Press fit it to a degree that shaft (54)
does not drop when the case is lifted
up.
PC200, 200LC-8E0 (Hybrid) 50-400 21

400 Power train
5. Bearing 4] Matching the pin holes in shaft (45)

Using tool F3 and push tool [11], press fit bearing and the carrier with each other, install
(59). shaft (45) by tapping the shaft with a
a Press the inner race and outer race of the plastic hammer.
bearing simultaneously. Do not press only a When installing the shaft, rotate the
the inner race. planetary gear taking care not to dam-
q Bearing press-fitting force (reference): age the thrust washers.
9.4 – 35.5 kN {960 – 3,620 kg} 5] Insert pin (44).
a After press fitting the bearing, check that the a Insert so that three pawls (a) on its pe-
case rotates smoothly. riphery are not located on thin part (b)
of the carrier. The thin part may be on
the opposite side, however. Check
each carrier and avoid locating a claw
on the thin part.
a After inserting the pin, punch two plac-
es (c) around the pin hole in the carri-
er.

1) Assemble the No. 3 carrier assembly
a Side hole (h) in carrier (46) has punching
marks on its edge made when the pin was
inserted and the inside wall of the hole is
swelled at that marks. Remove the
swelled part in advance. (See 5]) 2) Install No. 3 carrier assembly (43) by using
1] Install plate (50) to carrier (46). bolt (42).
2] Install bearing (49) and two thrust 2 Threaded portion of mounting bolt:
washers (47) at the top and bottom to Adhesive (LT-2)
planetary gear (48). 3 Mounting bolt:
3] Set the planetary gear assembly to 157 – 196 Nm {16 – 20 kgm}

carrier (46).
3) Install O-ring (61) to case (58).
50-400 22 PC200, 200LC-8E0 (Hybrid)

400 Power train
7. No. 3 sun gear 10. No. 2 carrier assembly

Install No. 3 sun gear (40). 1) Assemble the No. 2 carrier assembly
8. No. 2 ring gear 1] Press fit shaft (39) to carrier (30) in the
Using eyebolts (M10 x 1.5), install No. 2 ring direction of arrow (1st) until the snap ring
gear (41). groove is seen under the carrier.
a Degrease mating faces of No. 2 ring gear 2] After installing snap ring (37), push it back
(41) and case (58). from the opposite side (in the 2nd direc-
a Do not stick liquid gasket sealant to the mat- tion) until the snap ring is fitted tightly to
ing faces of the No. 2 ring gear and case. face P of the carrier. At this time, take
a When installing the No. 2 ring gear, align its care not to push too much.
match mark (c) with convex part (d) of the q Shaft press-fitting force (reference):
flange as shown in the figure. 11.2 – 25.8 kN {1,140 – 2,630 kg}
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
9. Install O-ring (62).
3] Install plate (36) to carrier (30).

4] Install thrust washer (35), bearing (34),
planetary gear (33), thrust washer (32),
and snap ring (31) in order.
PC200, 200LC-8E0 (Hybrid) 50-400 23

400 Power train
2) Install No. 2 carrier assembly (30). 12. Install three plates (26) and two discs (27).
a Do not clean the discs with trichloroethylene
or Drysol or blow air strongly against it.
a When installing the discs, apply clean lubri-
cating oil (TO30) to their surfaces.
a Install the plates and discs in the order shown
in the figure.
11. Case
Install case (29) according to the following
procedure.
1) When installing case (29), match its notch (a)
with bolt (c) next to convex part (b) of the
flange as shown in the figure.
a Degrease mating faces of No. 2 ring gear
(41) and case (29).
a Do not stick liquid gasket to the mating
faces of No. 2 ring gear (41) and case
(29).
2) Install six mounting bolts (28).
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
50-400 24 PC200, 200LC-8E0 (Hybrid)

400 Power train
13. No. 2 sun gear 14. Install piston (21).

1) Assemble No. 2 sun gear (22) according to a When installing piston (21), match its notch
the following procedure. (e) with notch (d) of case (29) as shown in the
1] Install swing brake gear (25) to No. 2 sun figure.
gear (22). a When installing, take care not to damage the
2] Install plate (24) to No. 2 sun gear (22) O-ring.
and install snap ring (23).
a Take care not to install swing brake
gear (25) upside down.
a Take care not to install plate (24) up-
side down.
2) Install No. 2 sun gear assembly (22).
PC200, 200LC-8E0 (Hybrid) 50-400 25

400 Power train
15. No. 1 carrier assembly 4] Reverse carrier assembly (9).

1) Assemble the No. 1 carrier assembly 5] Install ring (11).
according to the following procedure. 6] Install the Spirolock according to the
1] Install holder (18) and ball (19) as a unit. following procedure.
2] Install ring (17), plate (16), bearing (15), a Do not reuse the removed Spirolock
planetary gear (14), and plate (13) to but replace it with a new one.
shaft (12) in order. 1) Set Spirolock (10) to tool F6-2 (tapered
3] Reverse the shaft and planetary gear cone)
assembly and press fit it to carrier (9). 2) Install tool F6-1 (collet) to tool F6-2 and
a Install each shaft with its groove (g) set them so that the end of tool F6-2 is
facing carrier center (h) as shown in fitted tightly to the end of shaft (12).
the figure. 3) Press tool F6-1 until its end touches the
a Press fit the assembly so that distance Spirolock.
(j) between the carrier end and shaft 4) Set tool F6-3 to the end of tool F6-1.
end is 5.2 – 6.1 mm. 5) Hit tool F6-3 lightly with a plastic
q Shaft press-fitting force (reference): hammer to insert Spirolock (10) in the
12.2 – 30.0 kN {1,240 – 3,050 kg} groove of the shaft.
a When inserting the Spirolock, take
care not to press ring (11) too much.
a Ensure that the Spirolock is fitted to
the ring tightly.
a After installing, check that dimensions (i)

and (j) are as follows.
(i): 7.9 – 8.5 mm
(j): 5.2 – 6.1 mm
50-400 26 PC200, 200LC-8E0 (Hybrid)

400 Power train
2) Install No. 1 carrier assembly (9). 18. Install No. 1 sun gear (6).
a Before installing No. 1 sun gear (6), check
that the plate is installed.
a If the plate is not installed, install it before in-
stalling No. 1 sun gear (6).
a When installing No. 1 sun gear (6), apply oil
(TO30) to the plate.
a When installing the plate, do not bruise or
scratch its face to be in contact with the ball.
19. Install springs (5).
16. Sling and install No. 1 ring gear (8).
17. Tighten the mounting bolts.

2 Threads of mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
20. Install the swing electric motor assembly

a Degrease the mating faces of the swing elec-
tric motor assembly and swing machinery as-
sembly (4).
a Do not stick liquid gasket to the mating faces
of the swing electric motor assembly and
swing machinery assembly (4).
1) Install tools F5 (guide bolts) (M14 x 2 x 90
mm) to three places of swing electric motor
mounting bolt holes (Q) in No. 1 ring gear (8).
PC200, 200LC-8E0 (Hybrid) 50-400 27

400 Power train
2) Sling swing electric motor assembly (3) while 3) Install three mounting bolts (3a) of the swing
matching the match marks that were made electric motor and tighten them partially.
on the swing electric motor and No. 1 ring 4) Remove tool F5 and evenly tighten the six
gear at disassembly. bolts to the specified torque, including the
remaining three mounting bolts.
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
a When installing a new swing electric mo-

tor assembly or a new No. 1 ring gear,
match mounting face (S) of the oil supply
pipe with piping port face (T) of the swing
electric motor and use tool F5 to install. 21. Install oil supply pipe (2) with four mounting bolts
a While checking that the springs are set to (2a).
the spring mounting holes in the swing 3 Mounting bolt:
electric motor, lift down the swing electric 27 – 34 Nm {2.8 – 3.5 kgm}
motor assembly slowly. Never align the
spring holes by inserting your finger. 22. Install brackets (64) and (66).
3 Bracket mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}
q Refilling
Supply oil to the swing machinery case.
2 Swing machinery case: 6.9 – 7.1l
50-400 28 PC200, 200LC-8E0 (Hybrid)

400 Power train
Removal and installation of swing circle assembly SEN05259-01
Removal and installation of swing Installation

circle assembly
moval.
Removal [*1]
1. Disassemble the revolving frame assembly a Place the swing circle assembly with the soft
referring to the section “Disassembly and zone mark (S), (a) on an inner race and the soft
assembly of revolving frame assembly”. zone (S) (6) on the outer race facing right side of
the machine body as shown below and install it
2. Sling swing circle assembly (1) at three points to the track frames.
and remove the mounting bolts to remove the 2 Amount of filled grease:
assembly. [*1] Grease (G2-L1) 14.6 l
4 Swing circle assembly: 270 kg 2 Swing circle mounting bolt threaded portion:
Adhesive compound (LT-2)
q Perform angle tightening.
3 Swing circle mounting bolt:
1) Initial torque:
191.3 ± 19.6 Nm {19.5 ± 2 kgm}
2) After that, retighten the bolt 48 ± 5 °
PC200, 200LC-8E0 (Hybrid) 50-400 29

SEN05259-01
©2010 KOMATSU
All Rights Reserved
50-400 30
SEN05260-01
SEN05260-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


Disassembly and assembly of carrier roller assembly ................................................................................ 2

Disassembly and assembly of track roller assembly .................................................................................. 5
Disassembly and assembly of idler assembly ............................................................................................ 7
Disassembly and assembly of recoil spring assembly................................................................................ 10
Removal and installation of sprocket .......................................................................................................... 12
Expansion and installation of track shoe assembly..................................................................................... 13
Removal and installation of revolving frame assembly ............................................................................... 16
Removal and installation of counterweight assembly ................................................................................. 18
PC200, 200LC-8E0 (Hybrid) 50-500 1

SEN05260-01 Disassembly and assembly of carrier roller assembly
Disassembly and assembly of a Cover (3) is placed under shaft (2).

carrier roller assembly
Special tools
Necessity
Sketch
Sym-
Q'ty
N/R
Part number Part name
bol
L 1 790-434-1660 Installer t 1
q Sectional view
a A number shows the number in the text.
3. Remove ring (5) from roller (4).

4. Remove floating seal (6) from ring (5).
a Take care not to damage the sealing surface.
Disassembly
1. Remove plug (9) and drain the oil from carrier
roller (1).
6 Carrier roller: 75 – 85 cc
5. Remove floating seal (7) from roller (4).

a Take care not to damage the sealing surface.
2. Using push tool [1], push the end surface of a

shaft (2) and remove followings from carrier
roller (1).
q Roller (4), ring (5) assembly, shaft (2) and
cover (3).
q Press fitting force (reference): 59 kN{6,000
kg} min.
a The press fitted shaft (2) and ring (5), and
also roller (4) and cover (3) will be both dis-
assembled together.
50-500 2 PC200, 200LC-8E0 (Hybrid)

Disassembly and assembly of carrier roller assembly SEN05260-01
6. Using push tools [2] and [3], remove bushing (8)

from roller (4).
Assembly
1. Using push tools [3] and [4] , press fit bushing (8)
to roller (4).
a Press it from the side of cover (3) .
2. Floating seal
1) Using tool L1, install floating seal (7) to roller
(4).
2) Using tool L1, install floating seal (6) to roller
(5)
a When installing the floating seal, com-
pletely wash, degrease and dry both
O-ring and the surfaces where the O-ring
and the floating seal will contact each oth-
er (hatched area in the sketch). And take
care that there is no dust sticking on the
contact surface of floating seal.
a When fitting the floating seal, use tool L1
and be sure that the O-ring is pushed dur-
ing the insertion.
a After inserting the floating seal, verify that
the inclination of the seal is less than 1
mm per its diameter and that the protru-
sion height of the seal shown as (a) in the
illustration falls within the range of 7 - 11
mm.
PC200, 200LC-8E0 (Hybrid) 50-500 3

SEN05260-01 Disassembly and assembly of carrier roller assembly
3. Install roller (4) and ring (5) to shaft (2) .

a On the sliding surfaces of floating seals, ap-
ply some oil and take care not to have any
dirt stuck on them.
6. Fill carrier roller assembly (1) with oil and tighten

plug (9).
5 Carrier roller : 75 – 85 cc (E030-CD)
3 Plug: 15 ± 5 Nm {1.5 ± 0.5 kgm}
4. To make the height gap between roller (4) and
ring (5) 1.8 ± 0.2 mm, put washer [7] between
push tool [6] and roller (4) , then press fit ring (5)
to shaft (2).
a The thickness of washer [7] is 1.8 ± 0.2 mm.
a Use push tool [5] to support shaft (2) on it.
5. Using push tool [8], press fit cover (3) to roller

(4).
a Degrease, wash and dry the surfaces where
roller (4) and cover (3) fit tight.
q Press fitting force (reference): 59 kN {6,000
kg}
50-500 4 PC200, 200LC-8E0 (Hybrid)

Disassembly and assembly of track roller assembly SEN05260-01
Disassembly and assembly of Assembly

track roller assembly 1. Using push tool [1], press fit bushings (9) and
(10) to roller (4).
Special tools 2. Fit an O-ring and install collar (8) to shaft (5), and
Necessity
insert pin (7).
Sketch
Sym-
Q'ty
N/R
bol
L 2 796-670-1020 Installer t 1
Disassembly
1. Remove pin (1) and then collar (2).
2. Remove floating seal (3) from collar (2) and roller

(4).
3. Pull out rollert (4) from shaf (5) and collar (8)
assembly.
a Since 195 cc of oil is filled in, drain it at this
timing, or underlay some cloth to prevent any 3. Using tool L2, install floating seal (6a) to collar
careless smearing. (8).
a When installing the floating seal, completely
wash, degrease and dry both O-ring and the
4. Pull out other side floating seal (6) from roller (4),
surfaces where the O-ring and the floating
shaft (5) and collar (8) assembly.
seal will contact each other (hatched area in
the sketch). And take care that there is no
5. Remove pin (7) and then collar (8) from shaft (5).
dust sticking on the contact surface of float-
ing seal.
6. Remove bushings (9) and (10) from roller (4). a After inserting the floating seal, verify that the
inclination of the seal is less than 1 mm per
its diameter and that the protrusion height
shown as (a) in the illustration falls within the
range of 7 – 11 mm.
PC200, 200LC-8E0 (Hybrid) 50-500 5

SEN05260-01 Disassembly and assembly of track roller assembly
4. Using tool L2, install floating seals (6b) and (3b) 7. Using tool L2, install floating seal (3a) to collar
to roller (4). (2).
a As to notes for installation of floating seals a As to notes for installation of floating seal
(6b) and (3b), refer to a marked comments (3a), refer to a marked comments in the sec-
in the section 3. tion 3.
a On the sliding surfaces of the floating seals,
apply some oil and take care not to have any
dust stuck on them.
8. Fit an O-ring and install collar (2) to the shaft with

pin (1).
9. Add oil and tighten the plug.

5 Amount of oil: 190 – 200 cc (E030-CD)
3 Plug: 1.5 ± 5 Nm{1.5 ± 0.5 kgm}
5. Install shaft (5) to roller (4).
6. Put roller (4) and shaft (5) assembly upside

down.
50-500 6 PC200, 200LC-8E0 (Hybrid)

Disassembly and assembly of idler assembly SEN05260-01
Disassembly and assembly of 3. Detach idler (4) from shaft (5) and support
idler assembly assembly (7) .
a Since 250 cc of oil is filled in, drain it at this
timing, or underlay some cloth to prevent any
Special tools careless smearing.
Necessity
Sketch
Sym-
Q'ty
N/R
Part number Part name 4. Remove floating seal (6) on opposite side from
bol
idler (4), and shaft (5) and support assembly (7).
L 3 791-530-1510 Installer t 1
Disassembly
q Structural illustration
5. Remove dowel pin (8) and remove support (7)

from shaft (5).
6. Remove bushings (9) and (10) from idler (4).
1. Remove dowel pin (1) and dismount support (2).
2. Remove floating seal (3) from support (2) and

idler (4).
PC200, 200LC-8E0 (Hybrid) 50-500 7

SEN05260-01 Disassembly and assembly of idler assembly
Assembly
3. Using tool L3, install floating seals (6) to idler (4)

and to shaft (5) and support (7) assembly.
a Completely wash, degrease and dry both
O-rings and the surfaces (shown hatched
area in the illustration) of floating seals where
they contact each other.
a On the sliding surfaces of the floating seals,
apply some oil and take care not to have any
dust stuck on them.
a After inserting the floating seal, verify that the
1. Press fit bushings (9) and (10) to idler (4).
2. Fit an O-ring and install support (7) to shaft (5)

with dowel pin (8).
50-500 8 PC200, 200LC-8E0 (Hybrid)

Disassembly and assembly of idler assembly SEN05260-01
4. Install the assembly of shaft (5) and support (7) 6. Fit an O-ring and install support (2) to the shaft
to idler (4). with dowel pin (1).
a See structural illustration.
7. Add oil and tighten the plug.

5 Amount of oil: 245 – 255 cc (EO30-CD)
3 Plug: 205.8 ± 49 Nm {21 ± 5 kgm}
5. Using tool L3, install floating seals (3) to idler (4)

and to support (2).
a Completely wash, degrease and dry both
O-rings and the surfaces (shown hatched
area in the illustration) of floating seals where
they contact each other.
a Coat the sliding surface of the floating seal
with oil, and be careful not to let any dirt or
dust get stuck to it.
a After inserting the floating seal, verify that the
PC200, 200LC-8E0 (Hybrid) 50-500 9

SEN05260-01 Disassembly and assembly of recoil spring assembly
Disassembly and assembly of 1. Remove piston assembly (2) from recoil spring
recoil spring assembly assembly (1).
2. Disassembly of recoil spring assembly

Special tools
1) Set tool M1(1) to recoil spring assembly.
k Since the recoil spring will be pressed
Necessity
Sketch
Sym-
Q'ty
N/R
Part number Part name to a high installation load, be very sure
bol
to set the tool properly to prevent any
791-600-2001 risk.
Compressor (A)
or t 1 a Installation load
Compressor (B)
791-685-8006
790-201-2780 Spacer
1 791-635-3160 Extension t 1
Cylinder
790-101-1600
(686 kN {70 ton})
790-101-1102 Pump t 1
M 790-640-2180 Guide bolt t 1
790-101-5201 Push tool kit (B) q 1
790-101-5241 q Plate 1
2
790-101-5221 q Grip 1
01010-51225 q Bolt 2
790-201-1500 Push tool kit q 1
790-201-1620 q Plate 1
3
790-101-5021 q Grip 1
01010-50816 q Bolt 1
Disassembly 2) Apply oil pressure gradually to compress the

q Structural illustration spring and remove lock plate (3) and nut (4).
a Compress the spring up to the point
where the nut gets loose.
a Release the hydraulic pressure slowly
and release the tension of the spring.
a Free length of spring: 531 mm
3) Remove yoke (5) and cylinder (7) from spring
(6).
4) Remove snap ring (8), dust seal (9) and
bushing (10), one after the other, from
cylinder (7).
3. Further disassembly of piston assembly (2)

1) Remove lock plate (12) from piston (11), and
then remove valve (13).
2) Remove snap ring (14), and then U-packing
(15), and ring (16).
50-500 10 PC200, 200LC-8E0 (Hybrid)

Disassembly and assembly of recoil spring assembly SEN05260-01
Assembly
1. Assembly of piston assembly (2) 5) Apply hydraulic pressure slowly to compress

1) Assemble ring (16) and U-packing (15) to the spring, and then tighten nut (4) so that the
piston 11, and secure them with snap ring installed length of the spring is dimension (a)
(14). and secure it with lock plate (3)
2) Tighten valve (13) temporarily, and secure it a Installed length of spring (a): 417 mm
with lock plate (12).
2. Disassembly of recoil spring assembly

1) Using tool M2, press fit bushing (10) to
cylinder (7).
2) Using tool M3, assemble dust seal (9) to
cylinder (7).
3) Secure them with snap ring (8).
6) Remove recoil spring assembly (1) from tool

M1.
3. Assemble piston assembly (2) to recoil spring

assembly (1).
2 Sliding portion of cylinder :
Grease (G2-LI)
2 Wear ring : Grease (G2-LI)
a Install the piston assembly so the valve in-
stalling position is on the outside.
4) Assemble cylinder (7) and yoke (6) to spring a Fill the cylinder with 300 cc of grease (G2-LI),
(5), and set them to tool M1. purging air, and see the grease comes out of
2 Sliding portion of cylinder: the grease hole.
Grease (G2-LI)
PC200, 200LC-8E0 (Hybrid) 50-500 11

SEN05260-01 Removal and installation of sprocket
Removal and installation of Installation

q Installation is done in the reverse order of remov-
sprocket
al.
Removal [*1]
1. Expand the track shoe assembly referring to 2 Threads of sprocket mounting bolt:
"Expansion and installation of track shoe Adhesive compound (LT-2)
assembly". 3 Sprocket mounting bolt:
441 – 490 Nm {45 – 50 kgm}
2. Swing work equipment 90°, push up chassis with
work equipment and place block [1] between
track frame and track shoe.
3. Remove sprocket (2), hanging as follows.

1) Remove fixing bolt (1) [*1]
a Before removing the final fixing bolt, place
block [2] under sprocket (2).
2) Put sprocket (2) on block [2], make a clear-
ance from final drive (FD), and lead sling [3]
in between.
4 Sprocket: 40kg
50-500 12 PC200, 200LC-8E0 (Hybrid)

Expansion and installation of track shoe assembly SEN05260-01
Expansion and installation of

track shoe assembly
Special tools
Necessity
Sketch
Sym
Q'ty
N/R
bol
791-630-3000 Remover and installer t 1

Cylinder
R 790-101-1300 t 1
(980 kN {100 ton})
790-101-1102 Pump t 1
Expansion of track shoe 4. Using tool R, remove master pin (2) [*2]
1. Turn the upper structure by 90 °. a Press fit guide pin (GP), so that master pin
2. Loosening lubricator (1), slacken the tension of (2) will be pushed out.
track shoes. [*1]
k Since the inner pressure of adjusting cyl-
inder is extremely high, never loosen the
lubricator more than one turn. If the
grease does not come out smoothly,
move the machine forward and reverse.
3. Set the location of master pin (2).

1) Pushing against ground with the work equip-
ment, lift the track shoes.
2) Locate master pin (2) at around the center of
lower track shoes and between 2 track
rollers.
3) Set blocks [1] under both track shoes at the
idler and the sprocket 5. Set the location of guide pin (GP).
1) Pushing against ground with the work equip-
ment, lift the track shoes.
2) Take away blocks [1] under both track shoes
at idler and sprocket.
3) Bring guide pin (GP) at the front of the idler.
PC200, 200LC-8E0 (Hybrid) 50-500 13

SEN05260-01 Expansion and installation of track shoe assembly
4) Relieve the work equipment, and lower the a When replacing dust seals, apply some
machine. grease on the end surfaces of bushing and
5) Set block (3) under track shoe [1] at front of the contact surface (B) of dust seals.
the idler. 2 Contact surface (B portion) between
bushing and dust seal:
Grease
Nigutaite LYK-2 from nihon grease co.,
ltd. : part no. 44392708 or epuivalent.
a Press fit master pin (2) and push guide pin

(GP) out.
a Using tool R, press fit the master pin, so that
the protrusion amount (a) of master pin (2)
will be the dimension designated below.
Protruding amount of the master pin (a):
2.5 ± 1 mm
6. Pull out guide pin (GP), and move the machine

back slowly to lay track shoes down. (3) [*3]
a Put some blocks between upper track shoes
and the track frame to prevent damages.
Installation of track shoe

al.
[*1]
a Refer to the “Checking and adjusting track shoe
tension” section in the Testing and adjusting
chapter of this manual.
[*3]
[*2] 1. Using bar [2], roll up track shoes (3) while the
1. Apply grease on master pin (2). (At the area machine moves forward slowly.
where bushing (4) and master pin (2) come
contact: shown hatched)
2 Between the bushing and the master pin
(shown as hatched area):
Grease
Nigutaite LYK-2 from nihon grease co.,
ltd. : part no. 44392708 or epuivalent.
50-500 14 PC200, 200LC-8E0 (Hybrid)

Expansion and installation of track shoe assembly SEN05260-01
2. As for latter half of the operation, use a forklift or

the work equipment, to pull wire [3] to fix the
track shoes.
PC200, 200LC-8E0 (Hybrid) 50-500 15

SEN05260-01 Removal and installation of revolving frame assembly

revolving frame assembly
Removal
k Safely lower the work equipment to the
ground by extending the arm and the bucket
completely. Set the lock lever in the lock po-
sition.
1. Disassemble the work equipment assembly,

referring to the "Removal and installation of work
equipment assembly" section in this manual.
2. Disassemble the counterweight assembly, refer-

ring to the "Removal and installation of counter-
weight assembly" section in this manual.
3. Disconnect 4 boom cylinder hoses (1).

a Plug the hose to stop oil flow-out.
4. Sling boom cylinder assembly (2) .
5. Remove plate (3) and pin (4) and then lift off
boom cylinder assembly (2) to remove.
a Remove the boom cylinder on the opposite
side in the same manner.
4 Boom cylinder assembly: 180 kg
50-500 16 PC200, 200LC-8E0 (Hybrid)

Removal and installation of revolving frame assembly SEN05260-01
6. From center swivel joint assembly, disconnect 6

hoses (8) – (13).
q (8): Center swivel joint (D port) –
Swing motor (T port)
q (9): Center swivel joint (E port) –
Solenoid valve
q (10): Center swivel joint (B port) –
L.H. travel control valve (A2 port)
q (11): Center swivel joint (D port) –
R.H. travel control valve (B5 port)
q (12): Center swivel joint (A port) –
L.H. travel control valve (B2 port)
q (13): Center swivel joint (C port) –
R.H. travel control valve (A5 port)
7. Put out pin (14) on the center swivel joint, and Installation
detach jam plate (15) from the center swivel q Installation is done in the reverse order of remov-
joint. al.
[*1]
2 Swivel circle mating surface:
Gasket sealant (LG-1)
2 Threads of revolving frame mounting bolt:
q Tighten the revolving frame mounting bolt with
torque plus angle method in the following proce-
dure.
1) Tighten the bolts in the following order so that
the pressure to bolt seat surface becomes
equal.
1] 6 each front and rear
2] 6 each right and left
8. Remove the 32 mounting bolts and dismount 3] All the remaining bolts
revolving frame assembly (16) of slinging it up. 3 Tightening torque (Initial torque):
[*1] 294.2 ± 29.4 Nm {30 ± 3 kgm}
a Using levers and blocks, hold the balance of 2) Then tighten the bolts turning by 6 0 ± 6°
revolving frame assembly front and rear, and
left and right. q Refilling with oil (Hydraulic tank)
k When dismounting the revolving frame Refill hydraulic oil through the oil filler port to the
assembly, take care so that it does not hit specified level. Let the oil circulate in the
the center swivel joint assembly. hydraulic system by starting the engine. Then
4 Revolving frame assembly: 5,100 kg check the oil level again.
q Air bleeding
Bleed air from the travel motor referencing the
"Bleeding air from each part" section in the
Testing and adjusting chapter of this manual.
PC200, 200LC-8E0 (Hybrid) 50-500 17

SEN05260-01 Removal and installation of counterweight assembly
Removal and installation of coun- 3. Remove rear camera (2) according to the
terweight assembly following procedure.
a Insert thin flat blade screwdriver [1] in
Special tools hole (a) of cover (3) and pull it toward you
New/Remodel
to remove cover (3).
Necessity
2) Remove cover mounting bolts (4) and cover
Sketch
Sym
Q'ty
Part No. Part name (5).
bol
3) Loosen wiring connector (6) and disconnect
it from the camera.
Commercially
Impact wrench q 1 a To disconnect wiring connector (6), rotate
available
Z Socket wrench it counterclockwise to loosen.
Commercially a Tie the wirings to the machine by using
(Width across q 1
available
flats: 46mm) strings.
4) Remove rear camera mounting bolts (7) and
a Select an impact wrench and a socket wrench remove rear camera assembly (2).
for the tightening torque of the counterweight
mounting bolt.
3 Counterweight mounting bolt:
1.52 – 1.91 kNm {155 – 195 kgm}
Removal
2. Remove rear view mirror (1).
50-500 18 PC200, 200LC-8E0 (Hybrid)

Removal and installation of counterweight assembly SEN05260-01
4. Disconnect wiring connector (8) for the rear Installation

camera. q Installation is done in the reverse order of remov-
al.
[*1]
2 Mounting bolt threaded section:
3 mounting bolts:
1.52 – 1.91 Nm {155 – 195 kgm}
[*2]
a Installing and adjusting counterweight
1) Using shims, adjust the differences in level or
gaps between the counterweight and the
exterior of machine body.
a Shims: 1 mm (205-46-25150)
5. Using impact wrench Z and socket wrench Z, 2) Fix the counterweight so that the clearances
remove counterweight mounting bolts (9). [*1] in the direction of front and rear are even and
within the limit of 10 ± 5 mm for both from the
doors and from the revolving frame.
3) The difference in level in left to right direction
between the exterior of door (D) and counter-
weight (C)
(a): 10 ± 4 mm
The difference in level in left to right direction
between revolving frame (R) and counter-
weight (C)
(b): 5 mm or less
The difference in level in up and down direc-
tion between exterior upper cover (UC) and
counterweight (C)
(c): 0 ± 5 mm
are the respective limits for the mounting
6. Using 2 sling bolts (M48 × 3 mm), lift off coun- adjustment.
terweight assembly (10). [*2] a Rear view (Enlarged drawing for right
q Counterweight assembly: 3,450 kg hand side)
PC200, 200LC-8E0 (Hybrid) 50-500 19

SEN05260-01
©2011 KOMATSU
All Rights Reserved
50-500 20
SEN05261-01
SEN05261-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


600 Hydraulic system
Removal and installation of center swivel joint assembly ........................................................................... 2

Disassembly and assembly of center swivel joint assembly ....................................................................... 4
Removal and installation of hydraulic tank assembly.................................................................................. 5
Removal and installation of control valve assembly ................................................................................... 10
Disassembly and assembly of control valve assembly ............................................................................... 14
Removal and installation of hydraulic pump assembly ............................................................................... 18
Removal and installation of oil seal in hydraulic pump input shaft .............................................................. 22
Disassembly and assembly of work equipment PPC valve assembly ........................................................ 23
Disassembly and assembly of travel PPC valve assembly......................................................................... 25
Disassembly and assembly of hydraulic cylinder assembly ....................................................................... 28
PC200, 200LC-8E0 (Hybrid) 50-600 1

SEN05261-01 Removal and installation of center swivel joint assembly
Removal and installation of center 4. Disconnect eight hoses (7) to (14).

swivel joint assembly q (7): Center swivel joint (port E) –
Left travel motor (port P)
q (8): Center swivel joint (port E) –
Removal Right travel motor (port P)
k Lower the work equipment to the ground q (9): Center swivel joint (port D) –
completely, stop the engine, and then loosen Hydraulic tank drain
the hydraulic tank cap gradually to release q (10): Center swivel joint (port E) –
the pressure inside the tank and set the lock Solenoid valve
lever to the LOCK position. q (11): Center swivel joint (port B) –
a Fit the pipes with tags to show their installed po- Control valve left travel (port B2)
sitions to prevent any mistake at installation. q (12): Center swivel joint (port D) –
Control valve right travel (port B5)
1. Swing the upper structure 45 degrees to the q (13): Center swivel joint (port A) –
right. (For draining of the oil in the hydraulic tank) Control valve left travel (port A2)
a For the method of using the oil stopper with- q (14): Center swivel joint (port C) –
out draining the oil from the hydraulic tank, Control valve right travel (port A5)
see "Removal of hydraulic pump assembly".
2. Drain the oil from the hydraulic tank. 5. Pull out pin (15) on the center swivel joint side
6 Hydraulic tank: and disconnect the lock plate from the center
232 l (specified capacity) swivel joint.
135 l (refill capacity)
3. Disconnect six hoses (1) to (6) between the

travel motor and center swivel joint.
q (1): Center swivel joint (port T) –
Left travel motor (port T)
q (2): Center swivel joint (port T) –
Right travel motor (port T)
q (3): Center swivel joint (port B) –
Left travel motor (port PA)
q (4): Center swivel joint (port D) –
Right travel motor (port PB)
q (5): Center swivel joint (port A) –
Left travel motor (port PB)
q (6): Center swivel joint (port C) –
Right travel motor (port PA)
50-600 2 PC200, 200LC-8E0 (Hybrid)

Removal and installation of center swivel joint assembly SEN05261-01
6. Remove four mounting bolt (16). Installation

al.
[*1]
Install the center swivel joint (CSJ) facing in the di-
rection shown in the figure. (The figure shows the
machine body as seen from above.)
a S: Sprocket
A – D: Port name
7. Lift off center swivel joint assembly (17). [*1]

4 Center swivel joint assembly: 40 kg
q Refilling with oil (hydraulic tank)

Refill hydraulic oil through the oil filler port to the
specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
5 Hydraulic tank::
232 l (specified oil quantity)
3 Hydraulic tank drain plug:
58.8 – 78.5 Nm {6.0 – 8.0 kgm}
q Air bleeding
Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see
Testing and adjusting, "Bleeding air from each
part".
PC200, 200LC-8E0 (Hybrid) 50-600 3

SEN05261-01 Disassembly and assembly of center swivel joint assembly
Disassembly and assembly of 4. Using tool T1, pull out swivel shaft (7) from swivel
center swivel joint assembly shaft (8).
Special tools
Necessity
Sketch
Q'ty
N/R
790-101-2501 Push puller q 1
790-101-2510 q Block 1
790-101-2520 q Screw 1
791-112-1180 q Nut 1
A 790-101-2540 q Washer 1
790-101-2630 q Leg 2
790-101-2570 q Plate 4
790-101-2560 q Nut 2
790-101-2650 q Adapter 2
5. Remove seal (9) and O-ring (10) from swivel
rotor (7).
6. Remove dust seal (11) from cover (12).
Disassembly
Assembly
a See figure at left.
1. Install seal (9) and O-ring (10) to swivel rotor (7).

2. Install dust seal (11) to cover (12).
3. install cover (12) to swivel shaft (8).
4. Set swivel shaft (8) to block, then using push
tool, tap swivel rotor (7) with a plastic hammer to
install.
2 Contact surface of rotor, shaft:
Grease (G2-LI)
a When installing rotor, be extremely careful
not to damage the dust seal and O-ring.
5. Install ring (6) and fix with snap ring (5).
1. Remove elbows (1), (2) and tee (3). 6. Fit O-ring and install cover (4).
2. Remove cover (4). 3 mounting bolts:
3. Remove snap ring (5) and ring (6). 31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
7. Install elbows (1), (2) and tee (3).
3 Elbow (1): 128 – 186 Nm {13 – 19 kgm}
3 Elbow (2), tee (3):
35 – 63 Nm {3.5 – 6.5 kgm}
8. Install plug (13) according to the following proce-

dure.
1) Clean, degrease, and dry the threaded
portion of the plug, and install the plug.
2) After installing the plug, ensure that it is lower
than the shaft end.
q Plug: 33.3 ± 3.9 Nm {3.4 ± 0.2 kgm}
50-600 4 PC200, 200LC-8E0 (Hybrid)

Removal and installation of hydraulic tank assembly SEN05261-01
Removal and installation of 4. Remove side cover (4) according to the following
hydraulic tank assembly procedure.
1) Remove four mounting bolts (6) of battery
box (5) and move battery box (5) forward.
Removal
k Loosen the hydraulic tank cap gradually to
release the pressure inside the tank and then
set the lock lever to the LOCK position.
k Disconnect the cable from the negative (–)
a Fit the pipes with tags to show their installed po-
sitions to prevent any mistake at installation.
1. Swing the upper structure 45 degrees to the

right. (For draining of the oil in the hydraulic tank)
2. Remove covers (1) and (2).
2) Remove two lower mounting bolts (8) of

cover (7).
3. Loose drain plug (3) to drain the oil from the
hydraulic oil tank. [*1]
6 Hydraulic tank:
232l (specified capacity)
PC200, 200LC-8E0 (Hybrid) 50-600 5

SEN05261-01 Removal and installation of hydraulic tank assembly
3) Remove two upper mounting bolts (9) of 2) Remove four bolts (15) from hinge (14) and
cover (7) and remove cover (7). lift off engine hood (12).
a Make marks of (x) and (y) to indicate the
installed positions of hinges (14).
4) Remove two each of mounting bolts (10) and

(11) and remove side cover (4).
5. Remove engine hood (12) according to the

following procedure. 7. Remove the covers on the engine side
1) Disconnect right and left gas springs (13). according to the following procedure.
50-600 6 PC200, 200LC-8E0 (Hybrid)

2) Remove frames (18) and (19). 8. Disconnect pre-filter (23) and bracket (24) as a
3) Remove partition (20). unit from frame (25).
4) Remove partition (21).
9. Disconnect drain hoses (26) to (28).
10. Disconnect clamp (29).
5) Remove frame (22).
11. Disconnect drain hoses (30) to (34).

q (30): Solenoid valve drain
q (31): Main valve drain
q (32): PPC drain
q (33): Travel motor drain
q (34): Pump drain
PC200, 200LC-8E0 (Hybrid) 50-600 7

SEN05261-01 Removal and installation of hydraulic tank assembly
12. Disconnect suction hose (35). [*2] 14. Remove six mounting bolts (37). [*3]
a Make a mark of the hose end on the tube to
indicate the inserted position.
13. Disconnect hose clamp (36).
15. Lift off hydraulic tank assembly (38).
50-600 8 PC200, 200LC-8E0 (Hybrid)

Installation [*3]
q Perform installation in the reverse order to re- 3 Mounting bolts:
moval. 245 – 309 Nm {25 – 31.5 kgm}
[*1] q Refilling (hydraulic tank)

3 Hydraulic tank drain plug: Supply oil through the oil filler to the specified
58.8 – 78.5 Nm {6.0 – 8.0 kgm} level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
[*2] 5 Hydraulic tank:
a Use a new MIKALOR clamp. 232 l (specified capacity)
2 Apply evenly over the tube side: 135 l (refill capacity)
Adhesive (ThreeBond No.4314) q Air bleeding
a Set the hose to the original position. See Testing and adjusting, "Bleeding air from
1) Set the hose to the original position (marked each part".
a Reference
Hose installation length:
85 mm (Left and right)
2) Set bridge (BR) under the clamp bolt and
secure at least Min. 5mm of overlap (b)
between the bridge (BR) and band.
Demension (b): Min. 5 mm
Lubricating oil (ThreeBond
PANDO18B)
q If hoses are to be reused

Install the clamp to the clamp mark made on the
hose.
3 Clamp tightening bolts:
Min. 6 Nm {0.6 kgm}
q When using a new hose

Tighten until dimension (BDG) is as follows.
BDG: 7 – 10 mm
PC200, 200LC-8E0 (Hybrid) 50-600 9

SEN05261-01 Removal and installation of control valve assembly
Removal and installation of 4. Remove the following cover and partitions.

control valve assembly q Control valve top cover (4)
q Partition (5) between control valve and en-
gine
Removal
LOCK position.
and pipes so that you do not make a mistake in
their connection positions.
q Partition (6) between control valve and en-
gine
5. Disconnect hose (7) going to the left travel

motor.
6. Disconnect port PLS1 hose (8).

3. Loose drain plug (3) to drain the oil from the
a Hose band color: None
hydraulic oil tank. [*1]
6 Hydraulic tank:
232 l (specified capacity) 7. Disconnect port PLS2 hose (9).
135 l (refill capacity) a Hose band color: None
8. Disconnect hoses and tubes on the front side of

the control valve.
q Line A: In order from top
Port A1 (bucket cylinder head side) (hose)
Port A2 (left travel motor, reverse) (tube and
hose)
Port A3 (boom cylinder bottom side) (tube)
Port A5 (right travel motor reverse) (hose)
Port A6 (arm cylinder head side) (hose)
q Line B: In order from top
Port B1 (bucket cylinder bottom side) (tube
and hose)
Port B2 (left travel motor, forward) (tube and
hose)
50-600 10 PC200, 200LC-8E0 (Hybrid)

Removal and installation of control valve assembly SEN05261-01
Port B3 (boom cylinder head side) (tube)

Port B5 (right travel motor, forward) (tube and
hose)
Port B6 (arm cylinder bottom side) (hose)
a For port A2 (left travel motor, reverse),
port B1 (bucket cylinder bottom side), and
port B5 (right travel motor, forward), dis-
connect the tube from the hose, and then
disconnect the tube from the control
valve.
a For port B2 (right travel motor, forward),
remove tube (10) according to the follow-
ing procedure.
1] Disconnect hose (11) from tube (10). q (20): Port B6 (arm cylinder bottom hose) (de-
2] Remove two clamps (12) and bracket scribed above)
(13). q (21): Port T1 (drain hose)
3] Remove tube (10).
a Remove tube (14) of port A3 (boom cylin-

der bottom side) and tube (15) of port B3
(boom cylinder head side) according to
the following procedure.
1] Remove tube mounting clamp (16).
2] Disconnect two horns (17) from the
bracket.
3] Disconnect four hoses (18).
4] Remove boom tube mounting clamps
(19).
5] Remove tubes (14) and (15).
9. Disconnect wiring connectors and hoses at the

rear (engine side) of the control valve according
1) Disconnect connectors (22) and (23) on the
sensor side from the clip.
2) Disconnect wiring connectors V23 (22) and
V24 (23).
3) Disconnect clamp (24).
4) Disconnect brackets (25) and (26) from the
control valve.
PC200, 200LC-8E0 (Hybrid) 50-600 11

SEN05261-01 Removal and installation of control valve assembly
5) Disconnect wiring connectors P25 (27) and 11. Disconnect the hoses on the left side of the
P26 (28). control valve according to the following proce-
6) Disconnect hoses (29) to (33). dure.
q (29): Port PP1 hose (from rear pump) 1) Disconnect PPC hoses (41) to (48).
q (30): Port PP2 hose (from front pump) q (41): (Attachment)
q (31): Port T hose (to hydraulic tank) q (42): Port P2 hose (bucket CURL PPC)
q (32): Port PPS2 hose (to front pump con- q (43): Port P4 hose (left travel PPC)
trol) q (44): Port P6 hose (boom LOWER PPC)
q (33): Port PR hose (to solenoid valve) q (45): Port P10 hose (right travel PPC)
q (46): Port P12 hose (arm IN PPC)
q (47): (Attachment)
q (48): Port P2 hose (bucket CURL PPC)
2) Disconnect port PST hose (solenoid valve)
(49).
10. Disconnect the hoses on the right side of the

control valve according to the following proce-
dure.
1) Disconnect PPC hoses (34) to (39).
q (34): (Attachment)
q (35): Port P2 hose (bucket CURL PPC) 12. Remove cover (50).
q (36): Port P4 hose (left travel PPC)
q (37): Port P6 hose (boom LOWER PPC)
q (38): Port P10 hose (right travel PPC)
q (39): Port P12 hose (arm IN PPC)
2) Disconnect port PST hose (solenoid valve)
(40).
50-600 12 PC200, 200LC-8E0 (Hybrid)

Removal and installation of control valve assembly SEN05261-01
13. Remove hoses (51) to (57). Installation

(Hose band color:) q Perform installation in the reverse order to re-
q (51): None moval.
q (52): Red
q (53): None [*1]
q (54): None 3 Hydraulic tank drain plug:
q (55): Red/Yellow 58.8 – 78.5 Nm {6.0 – 8.0 kgm}
q (56): Brown
q (57): None q Refilling with oil (hydraulic tank)
14. Disconnect following six connectors (58). level. Run the engine to circulate the oil through
(From top) the system. Then, check the oil level again.
q V06 6 Hydraulic tank:
q V05 232l (specified capacity)

q V04 135 l (refill capacity)
q V03
q V02 q Bleeding air
q V01
See Testing and adjusting, "Bleeding air from
each part".
16. Keep solenoid valve assembly (60) away from

control valve bracket (61).
17. Remove four mounting bolts (62) of the control

valve.
18. Lift off control valve assembly (63).
PC200, 200LC-8E0 (Hybrid) 50-600 13

SEN05261-01 Disassembly and assembly of control valve assembly
Disassembly and assembly of Procedures for replacing pressure compensa-

control valve assembly tion valve seal
a Since there are many types of pressure compen-
sation valve, mark the positions when removing
a This section deals with only precautions to be to correspond to the original.
followed when reassembling the control valve 1. Remove piston (2), plug (3) and spring (4) from
assembly. pressure compensation valve (1).
Special tools 2. Remove piston (2) from seals (5) and (6).
Necessity
Sketch
Q'ty
N/R
796-946-1310 Guide f21.8
t 1
(For 723-46-40100)
796-946-1610 Guide f21.4
t 1
(For 723-46-41100)
796-946-1810 Guide f21.2
(723-46-43100 and t 1
2 723-46-43400)
796-946-1910 Guide f21.0
(723-46-46101 and t 1
723-46-46300)
796-946-2210 Guide f20.6
(723-46-45100 and t 1 a There are many types of piston.
723-46-45700)
796-946-1320 Guide f21.8 3. Set tool T2 to piston (2) and push it in slowly by
t 1
For 723-46-40100) hand so that seal (5) may spread out evenly.
796-946-1620 Guide f21.4
t 1
(For 723-46-41100) a The seal may be also fitted by pushing it
796-946-1820 Guide f21.2 down to the flat surface of the tool and then
(723-46-43100 and t 1 pushing it in with the tool fitted to the piston.
723-46-43400)
3
T 796-946-1920 Guide f21.0
(723-46-46101 and t 1
723-46-46300)
796-946-2220 Guide f20.6
t 1
(For 723-46-45100)
796-946-1420 Guide f21.6
t 1
(For 723-46-42700)
796-946-1330 Sleeve
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
(723-46-43100 and t 1
723-46-43400)
4
796-946-1930 Sleeve
(723-46-46101 and t 1
723-46-46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)
50-600 14 PC200, 200LC-8E0 (Hybrid)

Disassembly and assembly of control valve assembly SEN05261-01
4. Likewise, set tool T3 to piston (2) in the same 6. Fit plug (3) and spring (4) to piston (2), then
direction and push it slowly by hand so that assemble pressure compensation valve (1).
another seal (6) may be spread out evenly. a After the installation, push the piston by hand
a The seal may be also fitted by pushing it and check that the piston reacts only with
down to the flat surface of the tool and then spring force.
pushing it in with the tool fitted to the piston.
5. Keep compensation tool T4 fitted to piston (2) for

about 1 minute so that seals (5) and (6) are
adapted well.
a Check that there is no protrusion or cut on the
seal.
PC200, 200LC-8E0 (Hybrid) 50-600 15

SEN05261-01 Disassembly and assembly of control valve assembly
Assembly of control valve assembly
q Apply engine oil to the sliding parts before as-

sembling.
q When installing spools (7) and (8) to the valve
chamber, direct holes (H1) and (H2) as shown in
the figure.
a Apply this to sections H-H, K-K, L-L, and M-M,
too.
q Install filters (13) to the bottoms of PLS1PORT

and PLS2PORT in the directions shown in the
figure (Take care of caulked points *).
TRUE: Correct
ERROR: Wrong
50-600 16 PC200, 200LC-8E0 (Hybrid)

Disassembly and assembly of control valve assembly SEN05261-01
q Upper and lower control valve covers

2 Mating face of upper and lower control valve
cover blocks (SE):
SEALEND 242 or equivalent
q Tighten the mounting bolts for the upper and
lower control valve covers in order of figure.
(AoDoCoB)
3 Mounting bolt for upper and lower control
covers:
156.9 – 176.5 Nm {16 – 18 kgm}
q Pump merge-divider valve

2 Mating faces of merge-divider valve (SE2):
SEALEND 242 or equivalent
q Tighten the mounting bolts for the mergedivider
valve in the same sequence as that for the con-
trol valve cover mounting bolts.
3 Merge-divider valve mounting bolt:
156.9 – 176.5 Nm {16 – 18 kgm}
q Tighten back pressure valve, boom lock valve,
arm quick return valve, arm check valve and
mounting bolts in the same order as that for the
control valve cover.
3 Back pressure valve, boom lock valve, arm
quick return valve, arm check valve and
mounting bolt:
58.8 – 73.6 Nm {6 – 7 kgm}
q After assembling, put a stopper (CAP) so as not
to flow into oil and detergent liquid from f12
hole.
q Pressure compensation valve

a Install each pressure compensation valve,
paying attention to the counter mark that was
put when removing it. Especially, do not in-
stall BKC1 and BKC2 adversely.
q Main relief valve assembly
After assembling the main relief valve assembly
in the control valve, refer to the section of
"Measuring and adjusting oil pressure in work
equipment, swing and travel circuits", Testing
and adjusting, in this manual.
PC200, 200LC-8E0 (Hybrid) 50-600 17

SEN05261-01 Removal and installation of hydraulic pump assembly
Removal and installation of 3. Remove lower covers (2) and (3).

hydraulic pump assembly
Special tools
New/Remodel
Necessity
Sketch
Q'ty
10 796-460-1210 Oil stopper q 1
A
11 796-770-1320 Adapter q 1
Removal
work equipment to the ground completely, 4. Loose drain plug (4) to drain the oil from the
and stop the engine. hydraulic oil tank. [*1]
k Referring to Testing and adjusting, "Releas- 6 Hydraulic tank:
ing residual pressure in hydraulic circuit", re- 232 l (specified capacity)
lease the pressure inside the hydraulic 135 l (refill capacity)
LOCK position.
and pipes so that you do not make a mistake in
their connection positions.

2. Remove lower cover (1).
50-600 18 PC200, 200LC-8E0 (Hybrid)

Removal and installation of hydraulic pump assembly SEN05261-01
a If you prefer not to drain the oil from the tank, 3) Remove four bolts (11) from hinges (10) and
skip steps 1, 2, and 4, and install the oil stop- lift off engine hood (6).
per according to the following procedure. a Make marks of (x) and (y) to indicate the
1) Remove cover (5). installed positions of hinges (10).
2) Remove the strainer. 4 Engine hood: 30 kg
3) Put tool A10 (oil stopper) and tool A11

(adapter) together.
4) Install tools A10 and A11 as a unit to the
position of the removed strainer.
5) Install cover (5).
a Use several bolts to fix the cover tempo-
rarily.
5. Remove the engine hood according to the

1) Open engine hood (6) and sling it.
2) Remove pins (7) and (8) and disconnect two
gas springs (9) on the right and left sides.
7. Remove frames (13) and (14).
8. Remove partition (15).
PC200, 200LC-8E0 (Hybrid) 50-600 19

9. Remove clamp (16). [*2] 17. Disconnect fuel filter (26) and bracket as a unit
from frame (27).
10. Remove two muffler mounting U-clamps (17).
18. Disconnect hybrid system lubricating oil filter
11. Lift off muffler assembly (18). (28) and bracket as a unit from frame (27).
4 Muffler assembly: 30 kg
19. Disconnect the following seven hoses

12. Remove lubricating oil supply hose (19) of the connected to the hydraulic pump.
motor-generator. (29): Rear load pressure input port hose
(Collar band color: None)
13. Disconnect lubricating oil gauge hose (20) of the (30): EPC source pressure port hose
motor-generator from bracket (21). (Collar band color: Yellow)
(31): Front load pressure input port hose
14. Disconnect engine oil filter assembly (22) from (Collar band color: Red)
bracket (23). (32): Pump pressure input port hose
(Collar band color: Blue)
(33): Drain port hose
15. Remove bracket (23).
a When tool A10 is installed without draining
the oil from the hydraulic tank, if the oil level
16. Disconnect pre-filter (24) and bracket as a unit
in the tank is above the drain port of the hy-
from frame (25).
draulic pump, prepare a rather large contain-
er to receive the oil.
(When the drain hose is disconnected, oil
flows out of the hose.)
(34): Branch hoses
50-600 20 PC200, 200LC-8E0 (Hybrid)

Removal and installation of hydraulic pump assembly SEN05261-01
20. Remove four bolts (35) and disconnect suction Installation

tube (36) from the hydraulic pump assembly. q Perform installation in the reverse order to re-
moval.
[*1]
3 Hydraulic tank drain plug:
58.8 – 78.5 Nm {6.0 – 8.0 kgm}
[*2]
3 Mounting bolt:
27.4 – 34.3 Nm {2.8 – 3.5 kgm})
q Refilling (Hydraulic tank)

level. Run the engine to circulate the oil through
the piping. Then, check the oil level again.
6 Hydraulic tank:
21. Sling hydraulic pump assembly (37). 232l (specified capacity)
135l (refill capacity)
22. Remove twelve mounting bolts (38).
23. Lift off hydraulic pump assembly (37).

4 Hydraulic pump assembly: 165 kg
PC200, 200LC-8E0 (Hybrid) 50-600 21

Removal and installation of oil Installation

seal in hydraulic pump input shaft
al.
Special tools [*1]

2 Oil seal lip portion: Grease (G2-LI)
Necessity
Symbol Part 2 Oil seal outer circumference: Grease (G2-LI)
Sketch
Symbol Part name
number a Coat the oil seal outer circumference thinly with
Q'ty
N/R
grease.
S 796T-467-2410 Push tool t 1 N
a Press fit oil seal (3) with tool S, [1], [2].
Removal
1. Remove the hydraulic pump assembly referring
to the section of "Removal and installation of
hydraulic pump assembly.
2. Remove snap ring (1) and then remove spacer
(2).
3. Pry off oil seal (3) with a screwdriver. [*1]
a Take care in removing the oil seal so that the
shaft may not be damaged.
50-600 22 PC200, 200LC-8E0 (Hybrid)

Disassembly and assembly of work equipment PPC valve assembly SEN05261-01
Disassembly and assembly of work equipment PPC valve assembly
a Only precautions for assembling the work equip- Assembly

ment PPC valve assembly are explained below. a When assembling, clean and inspect the parts
closely and take care fully so that dirt, rust, flaw,
Disassembly etc. will not cause a trouble.
a Spring (6) and spring (7) consist of each one of
two types of springs with different installed loads a The head of plug (2) must not be projected from
in four places, so check the mounting position the body (1) surface.
(oil pressure port) and mark with tags to prevent 3 Plug (2): 6 – 11 Nm {0.6 – 1.1 kgm}
mistakes when installing. a When installing plug (3) to body (1), check the in-
sertion depth so that the tip of plug does not en-
ter the inside f20 hole of the body.
3 Plug (3): 4 – 9 Nm {0.4 – 0.9 kgm}
a Install spring (5) with its small diameter side on

the shim (4) side.
q Diameter of spring (Inside diameter)
Small diameter side: f4.9 mm
Large diameter side: f5.55 mm
PC200, 200LC-8E0 (Hybrid) 50-600 23

SEN05261-01 Disassembly and assembly of work equipment PPC valve assembly
a When installing springs (6) and (7), note that a Apply grease (G2-LI) to the sliding parts of joint
they are different and they must be installed to (12) and contact surfaces of disc (13) and piston
different hydraulic ports. (8).
q Installed height: 31.9 mm (Common to both 2 Quantity of grease (G2-LI)
springs) 1) Sliding parts of joint: 2 – 4 cc/periphery
q Installed load: 2) Contact surfaces of disc and piston:
Spring (6) (P1, P2): 35.3 N {3.6 kg} 0.3 – 0.8 cc/place
Spring (7) (P3, P4): 21.6 N {2.2 kg}
a When assembling disc (13), adjust it so that the
a When installing piston (8), apply grease (G2-LI) end play of the lever will be 0.5 – 3 mm at 200
to its outside and the inside of the body (1) hole. mm from the center of revolution.
3 Bolt (11):11.8 – 14.7 Nm {1.2 – 1.5 kgm} a See Testing and adjusting, "Adjusting play of
a When installing joint (12) to body (1), apply LOC- work equipment and swing PPC valve".
TITE as shown below. a Tighten nut (14) to the following tightening
1) When installing the joint, apply 1 drop torque.
(approx. 0.02 g) of LOCTITE (No. 648) each 3 Nut (14): 69 – 88 Nm {7 – 9 kgm}
to 2 places of the female screw (A) of the
body. Before installing the joint, thoroughly
degrease and dry its male screw and the
female screw of the body with DRYSOL.
2) Drop LOCTITE to the following positions.
2 Female screw (A) of body:
LOCTITE No. 262
3 Joint (12): 39 – 49 Nm {4 – 5 kgm}
50-600 24 PC200, 200LC-8E0 (Hybrid)

Disassembly and assembly of travel PPC valve assembly SEN05261-01
Disassembly and assembly of travel PPC valve assembly
Special tool 5. Remove mounting bolt (19) to remove plate (22).

a Check the thickness and the mounting posi-
New/Remodel
Necessity
tion of washer (18).

Sketch
a Remove pin (23) from body (1).

Q'ty
6. Remove seal (9) and collar (8).

4 796T-416-1010 Push tool t 1 Q
M 5 796T-416-1030 Push tool t 1 Q 7. Remove piston (7) to remove retainer (6),
6 796T-416-1020 Push tool t 1 Q springs (5) and (4) and shim (3).
a Store shim (3) after checking the thickness
and the number of shims at each mounting
Disassembly
position.
1. Remove screw (20) and damper assembly (16).
8. Remove valve (2) from body (1).
2. Remove mounting bolt (21) to remove case (12),
shaft (14) and lever (15) assembly.
3. Remove pin (13).
4. Remove lever (15), bushing (10), (11) and shaft

(14) from the case.
PC200, 200LC-8E0 (Hybrid) 50-600 25

SEN05261-01 Disassembly and assembly of travel PPC valve assembly
Assembly 2) Using tool P2, insert busing (11) in case.

Only the precautions for assembling the travel PPC a Insert the bushing (11) from the 10 °
valve assembly are described. chamfered side.
a Insert bushing (11) so that dimension (b)
a When assembling, clean and inspect the parts will be as follows. (End surface of bushing
closely and take care fully so that dirt, rust, flaw, will tightly fit to the end surface of case.)
etc. will not cause a trouble. q Dimension (b): 0 mm
a When installing piston (7), apply grease (G2- LI) a Do not drive the pin with direct impact
to its outside and the inside of the body hole. loads of a hammer etc.
a Install spring (4) with its small diameter side on

the shim (3) side.
q Diameter of spring (4) (inside diameter)
Small diameter side: 4.9 mm
Large diameter side: 5.55 mm
a Assemble shaft (14) in the following procedure.

1) Using tool M4, insert bushing (10) in case.
a Insert the bushing (10) from the 10 °
chamfered side.
a Insert bushing (10) so that dimension (a)
will be as follows.
q Dimension (a): 20.4 ± 0.3 mm
a Do not drive the bushing with direct im- 3) Insert lever (15).
pact loads of a hammer etc.
4) Insert shaft (14).
5) Using tool P3, insert pin (13).
a Insert pin (13) so that dimension (c) will
be as follows.
q Dimension (c): 0 – 0.5 mm
a Do not drive the pin with direct impact
loads of a hammer etc.
50-600 26 PC200, 200LC-8E0 (Hybrid)

Disassembly and assembly of travel PPC valve assembly SEN05261-01
a Apply grease (G2-LI) to the rocking part

of shaft (14) and the contact surfaces of
lever (15) and piston (7) and the contact
surfaces of damper (16) and pin (17).
2 Quantity of grease (G2-LI)
Rocking part of shaft (16):
4 – 8 cc/periphery
Contact surfaces of lever (15) and
piston (7):
0.3 – 0.8 cc/place
Contact surfaces of damper (16) and
pin (17) :
0.3 – 0.8 cc/place
a Install washer (18)1.6 mm thick first. If the
difference between both sides at the
stroke end of the lever exceeds 0.7 °,
change the washer thickness to reduce
the difference to below 0.7 °. (If the wash-
er thickness is reduced by 0.3 mm, the
stroke end angle is increased by 0.39 °.)
q Thickness and varieties of washer
(18): 1.0, 1.3, 1.6, 1.9 and 2.2 mm
a Tighten each part to the following torque.

q Bolt (19): 27 – 34 Nm {2.8 – 3.5 kgm}
q Screw (20):
0.441 – 0.588 Nm {0.045 – 0.06 kgm}
q Bolt (21): 25 – 31 Nm {2.5 – 3.2 kgm}
q Bolt (24): 19.6 – 27.4 Nm {2.0 – 2.8 kgm}
q Plug (25): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
q Plug (26): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
q Plug (27): 9.8 – 14.7 Nm {1.0 – 1.5 kgm}
q Plug (28): 4 – 9 Nm {0.4 – 0.9 kgm}
q Plug (29): 6 – 11 Nm {0.6 – 1.1 kgm}
q Plug (30):
1.47 ± 0.2 Nm {0.15 ± 0.02 kgm}
PC200, 200LC-8E0 (Hybrid) 50-600 27

SEN05261-01 Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of

hydraulic cylinder assembly
Special tools
Necessity
Sketch
Q'ty
N/R
Cylinder repair
790-502-1003 q 1
1 stand
790-101-1102 Pump q 1
Wrench
790-102-4300 t 1
2 assembly
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1 4) Disassemble the piston rod assembly as
Rubber band follows.
796-720-1670 (for boom and q 1
arm) 1] Set piston rod assembly (2) in tool U1.
4 07281-01279 Clamp q 1
Rubber band
796-720-1660 q 1
(for bucket)
07281-01159 Clamp q 1
790-201-1702 Push tool kit t 1
q Push tool
790-201-1831 1
(for bucket)
U q Push tool
790-201-1930 1
5 (for arm)
q Push tool
790-201-1940 1
(for boom)
790-101-5021 q Grip 1
01010-50816 q Bolt 1
Push tool kit
790-201-1500 q 1
(for bucket)
790-201-1640 q Push tool 1 2] Remove stopper screw (3) of piston
790-101-5021 q Grip 1 assembly.
01010-50816 q Bolt 1 a Common to the boom, arm and bucket
6 Plate cylinder.
790-201-1980 q 1 Screw size: M12 x Pitch 1.75
(for boom)
Plate
790-201-1990 q 1
(for arm)
790-101-5021 Grip q 1
01010-50816 Bolt q 1
Disassembly
1. Piston rod assembly
1) Remove piping from the cylinder assembly.
2) Remove the mounting bolts and then discon-
nect head assembly (1).
3) Pull out piston rod assembly (2).
a Place a container under the cylinder to
catch the oil.
50-600 28 PC200, 200LC-8E0 (Hybrid)

Disassembly and assembly of hydraulic cylinder assembly SEN05261-01
a If the caulking of screw (3) is too 7] Remove cap (8), and pull 12 balls (9),
strong and it cannot be removed, then remove plunger (10).
tighten the screw fully, then fit tap (T) q Arm cylinder only
to the thread and remove the screw.
2. Disassembly of piston assembly

3] Using tool U2, remove piston assembly 1) Remove ring (11).
(4). 2) Remove wear ring (12).
q When not using tool U2, use the drill
3) Remove piston ring (13).
holes (H) (f10: 2 places) and loosen
4) Remove O-ring and backup ring (14).
piston assembly.
4] Remove plunger (5).

q Boom and arm cylinder only
5] Remove collar (6).
6] Remove head assembly(7).
PC200, 200LC-8E0 (Hybrid) 50-600 29

3. Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (15).
2) Remove snap ring (16) and then remove dust
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
2. Assembly of piston assembly

1) Using tool U3, expand piston ring (13).
a Set the piston ring on tool U3, and turn the
handle 8 – 10 times to expand the ring.
2) Set tool U4, and compress piston ring (13).
Assembly
a Be careful not to damage the packing, dust
seals, and O-rings.
a Clean each part, then cover the piping ports and
pin-inserting hole to prevent dust from entering
them.
a Do not try to force the backup ring into position.
Warm it in warm water (50 – 60 °C) before in-
stalling it.
1. Assembly of recoil spring assembly
1) Using tool U5, press fit bushing (20).
2) Assemble buffer ring U5.
3) Assemble rod packing (18). 3) Install the backup ring and O-ring (14).
4) Using tool U6, install dust seal (17). 4) Assemble wear ring (12).
5) Install snap ring (16). 5) Assemble ring (11).
a Be careful not to open the end gap of the
ring too wide.
2 Ring groove: Grease (G2-LI)
50-600 30 PC200, 200LC-8E0 (Hybrid)

3. Piston rod assembly a Put a mark on the end face of the rod so
1) Set piston rod assembly (2) in tool U1. that the processing hole position of cap
(8) is visual from outside.
q Arm cylinder only
2) Assemble head assembly (7).

3) Fit O-ring and backup ring to collar (6), then
assemble. 6) Assemble piston assembly (4) as follows.
q When using piston rod assembly (2)
and piston assembly (4) again
4) Assemble plunger (5).
a Wash thoroughly and remove all metal
particles and dirt.
1] Screw in piston assembly (4) by using tool
U2, and tighten piston assembly (4) until
the position of the screw thread hole (H1)
which is in piston rod assembly (2)
halfway matches.
a Remove all burrs and flashes on the
threaded portion with a file.
5) Set plunger (10) on the piston rod, assemble

12 balls (9) to it and secure with cap (8).
a Check that there is a small amount of play
at the tip of the plunger.
PC200, 200LC-8E0 (Hybrid) 50-600 31

2] Tighten screw (3). 2] Machine one of the hole used to install

2 Screw part female screw side: screw (3).
Loctite No.262 a Align a drill horizontal with the
3 Screw: Vgroove of the thread of piston rod as-
58.9 – 73.6 Nm {6 – 7.5 kgm} sembly (2) and piston assembly (4),
3] Caulk thread at 4 places (a) of screw (3) then carry out machining.
with punch. a For the arm cylinder, avoid the cap
machining holes position when ma-
chining. (See step 3. 5))
q Screw machining dimension (mm)
Bottom hole Bottom hole

Tap used Tap depth
drill diameter depth
10.3 24 12×1.75 20
3] After machining, wash thoroughly to

remove all metal particles and dust.
4] Tighten screw (3).
2 Screw part female screw side:
Loctite No. 262
3 Screw:
58.9 – 73.6 Nm {6 – 7.5 kgm}
5] Caulk thread at 4 places (a) of screw
q When using a new part for either or (3) with punch.
both of piston rod assembly (2) and
piston assembly (4)
a For the rod with bottom cushion, mark

the cap position on the end surface of
rod. (See step 3. 5))
q Arm cylinder only
1] Screw in until piston assembly (4)
contacts end surface (B) of rod, then
use tool to tighten.
3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
a After tightening the piston, check that
there is play in plunger (5).
q Boom, arm cylinder only
7) Set piston rod assembly (2) on tool U1.
50-600 32 PC200, 200LC-8E0 (Hybrid)

8) Assemble the cylinder tube to piston rod

assembly (2).
a Align axial center of the cylinder tube,
then insert.
a Check that the ring is not broken and has
not come out, then push in fully.
9) Tighten head assembly (1) with mounting

bolts.
3 Mounting bolt:
Cylinder name Tightening torque
Bucket 270 ± 39 Nm {27.5 ± 4.0 kgm}
Arm 373 ± 54 Nm {38.0 ± 5.5 kgm}
Boom 270 ± 39 Nm {27.5 ± 4.0 kgm}
q Adjust cylin-
892 ± 137 Nm {91.0 ± 14.0 kgm}
der
10)Install piping.
PC200, 200LC-8E0 (Hybrid) 50-600 33

SEN05261-01
©2010 KOMATSU
All Rights Reserved
50-600 34
SEN05262-00
SEN05262-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


700 Work equipment Body
Removal and installation of work equipment assembly .............................................................................. 2
PC200, 200LC-8E0 (Hybrid) 50-700 1

SEN05262-00 Removal and installation of work equipment assembly
Removal and installation of work 5. Start the engine and then retract the piston rod.
equipment assembly a Bind the piston rod with wire etc. and put it
down on the blocking tools so that the piston
rod does not slip out, or allot a support so that
Special tools the cylinder doesn't fall down to the bottom
side. If a support is allotted, remove the
Necessity
Sym-
Sketch
Part number Part name grease fitting at the bottom side.
bol
a Remove the boom cylinder on the other side
Q'ty
N/R
796-900-1200 Remover t 1
in the same manner.
a If bumping of the lifting hook against the work
796-900-1210 q Sleeve 1
equipment lamp is anticipated in lifting the
792-900-1520 q Plate 1
work equipment, the lamp must be removed.
799-900-1230 q Screw 1
6. Disconnect 2 pieces of bucket cylinder hose (6)
796-900-1240 q Adapter 1
V and 2 pieces of arm cylinder hose (7).
01643-33080 q Washer 1
a Apply the oil restraining plug and then fix the
01803-13034 q Nut 1 hoses to the valve side by use of ropes.
Puller
790-101-4000 t 1 7. Disconnect intermediate connector for working
(490 kN {50 ton} long)
Pump lamp A13 (8).
790-101-1102 t 1
(294 kN {30 ton})
Removal
k Safely lower the work equipment to the
ground by extending the arm and the bucket
completely. Set the lock lever in the lock po-
sition.
k Release the residual pressure in the hydrau-
lic circuit. Refer to the "Releasing residual
pressure from hydraulic circuit" section in
the Testing and adjusting chapter of this
manual.
1. Disconnect grease hose (1).

2. Sling the boom cylinder assembly (2).
3. Remove lock bolt (3).
4. Remove plate (4) and remove the head pin. [*1]
a Check the number as well as locations of the
shims used.
50-700 2 PC200, 200LC-8E0 (Hybrid)

Removal and installation of work equipment assembly SEN05262-00
8. Lift the work equipment assembly, remove plate Installation

(9) and pin (10) at the foot. [*2] q Installation is done in the reverse order of remov-
al.
[*1]
2 Inside surface of bushing when assembling
pin: Antifriction agent (LM-P)
2 Greasing after assembling the pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers into the pin hole.
a st1: resin shim (thickness 1.0 mm)
a Adjust the clearance (b) between cylinder rod
(12) and plate (4) to 1.5 mm or less using shims:
1.0 and 2.0 mm
q In case to remove using tool V

Remove plate (9) and remove pin (10) at the
foot using tool V.
a Check the number as well as locations of the
shims used.
[*2]
2 Inner surface of bushing as assembling the
pin: Anti-friction compound (LM-P)
2 Feed grease after assembling pin:
Grease (LM-G)
a Adjust the clearance (c) between the foot's end
9. Remove work equipment assembly (11). face of boom (13) and bracket (14) to 1 mm or
4 Work equipment assembly: 3,300 kg
less by use of shims. Thickness of standard
shim: 2.0, 2.5, 3.0 and 3.5 mm
PC200, 200LC-8E0 (Hybrid) 50-700 3

SEN05262-00 Removal and installation of work equipment assembly
q Air bleeding
Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see
Testing and adjusting, "Bleeding air from each
part".
q Refilling with oil (hydraulic tank)

Refill hydraulic oil through the oil filler port to the
specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
50-700 4 PC200, 200LC-8E0 (Hybrid)

Removal and installation of work equipment assembly SEN05262-00
PC200, 200LC-8E0 (Hybrid) 50-700 5

SEN05262-00
©2009 KOMATSU
All Rights Reserved
50-700 6
SEN05263-00
SEN05263-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


Removal and installation of operator's cab assembly ................................................................................. 2

Removal and installation of operator cab glass (stuck glass) ..................................................................... 6
Removal and installation of front window assembly ................................................................................... 15
Removal and installation of floor frame assembly ...................................................................................... 22
Removal and installation of air conditioner unit assembly .......................................................................... 27
PC200, 200LC-8E0 (Hybrid) 50-800 1

SEN05263-00 Removal and installation of operator's cab assembly
Removal and installation of oper- 9. Remove rear covers (10) to (13).

ator's cab assembly
Removal
1. Remove front window (1).

2. Remove step plate (2).
3. Remove floor mat (3).
4. Refer to “Removal and installation of monitor
assembly”, and remove monitor assembly (4).
6. Remove cover duct assembly (7).
10. Remove duct (14).
a Disconnect connector H15 fixed on the back
from the clip.
7. Insert key (8), turn it right, and open the

outside-air filter cover.
8. Remove outside-air filter (9).
12. Remove plate (16).

13. Remove lock pin (17) and remove duct (18).
50-800 2 PC200, 200LC-8E0 (Hybrid)

Removal and installation of operator's cab assembly SEN05263-00
14. Remove duct (19) to (22).
17. Disconnect wiring (28) clamps (29).

15. Disconnect connector (23) from the operator's
cab. 18. Remove plate (30).
a Connector R10 (24) is tighten together with
the mounting bolt. 19. Disconnect connector L03 (31).
16. Disconnect connector R05 (25) and pump

controller connector C01(26), C02(27).
a Remove pump controller connectors (26)
and (27) in the following procedure.
1) While pressing lock (L1), push lever (L2) in
the direction of the arrow.
(Bar (B) pushes the lock to release.)
2) Pull down and disconnect the connector.
PC200, 200LC-8E0 (Hybrid) 50-800 3

SEN05263-00 Removal and installation of operator's cab assembly
20. Disconnect antenna cable (32) from the 26. Disconnect window washer hose (43).
KOMTRAX terminal (K).
21. Disconnect connectors CK01 (33) and CK02 27. Disconnect harness clamp (44).
(34) from the KOMTRAX terminal (K).
22. Disconnect cab wiring intermediate connectors 28. Haul in antenna (42).
H09 (36), H08 (37), and H16 (38).
a Cut tie-wrap (T).
23. Disconnect radio antenna (39).

a (23) is a removed plate.
29. Detach harness clamp (43) from the right back

side of cab.
24. Disconnect wiper motor connector M05 (40).
25. Remove harness (41) and antenna (42) from the

cab wall.
a Cut 2 points of tie-wrap.
30. Remove bolt (44) under the cab and remove lock
plate (45). [*1]
31. Remove bolt (46). [*2]
50-800 4 PC200, 200LC-8E0 (Hybrid)

Removal and installation of operator's cab assembly SEN05263-00
32. Dismount 6 mounting bolts (47) and and 4 Installation

mounting nuts (48). q Installation is done in the reverse order of remov-
a Check the bolt length beforehand. al.
[*1]
3 Mounting bolt (45) of lock plate (44):
98 – 123 Nm {10 – 12.5 kgm}
[*2]
3 Bolt (46): 245 – 309 Nm {25 – 31.5 kgm}
33. Lift off and remove operator's cab assembly

(49).
4 Operator's cab assembly: 470 kg
PC200, 200LC-8E0 (Hybrid) 50-800 5

SEN05263-00 Removal and installation of operator cab glass (stuck glass)
Removal and installation of operator cab glass (stuck glass)
a Among the panes of window glass on the 4 sides (1): Right side window glass
of the operator's cab, 5 panes (1) to (4) and (18) (2): Left side rear window glass
are stuck. (3): Door lower window glass
a In this section, the procedure for replacing the (4): Front window glass
stuck glasses is explained. (5): Front window assembly
a When replacing front window glass (4), remove (Front window glass + Front frame)
front window assembly (5). (It is impossible to re- (6): Dam rubber
place only the front window glass while the front (17): Center trim seal
window assembly is installed to the operator's (18): Rear glass
cab.)
a For the procedure for replacing the front window
assembly, see “Removal and installation of front
window assembly”.
50-800 6 PC200, 200LC-8E0 (Hybrid)

Removal and installation of operator cab glass (stuck glass) SEN05263-00
Special tools Installation

1. Using a knife and scraper [5], remove the
Necessity
Sketch
Sym- remaining adhesive and dam rubber from the
Q'ty
N/R
Part No. Part name
bol metal sheets (glass sticking surfaces) of the
operator's cab.
2 793-498-1210 Lifter (Suction cup) t 2
X
3 20Y-54-13180 Stopper rubber t 2 a Remove the adhesive and dam rubber to a
degree that they will not affect adhesion of
the new adhesive. Take care not to scratch
Removal the painted surfaces.
a Remove the window glass to be replaced ac- (If the painted surfaces are scratched, adhe-
cording to the following procedure. sion will be lowered.)
1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator's cab
(metal sheet) (8).
2. Remove oil, dust, and dirt, etc. form the sticking

surfaces of cab (8) and window glass (9) with
a If the window glass is broken finely, it may be white gasoline.
removed with a knife [4] and a screwdriver. a If the sticking surfaces are not cleaned well,
a Widening the cut with a flat blade screw- the glass may not be stuck perfectly.
driver, cut the dam rubber and adhesive with a Clean the all black part on the back side of
knife [4]. the window glass.
a After cleaning the sticking surfaces, leave
them for at lease 5 minutes to dry.
2. Remove the window glass.
PC200, 200LC-8E0 (Hybrid) 50-800 7

3. Apply primer (10).

a The using limit of primer is 4 months after the
date of manufacture. Do not use the primer
after this limit.
a Use the primer within 2 hours after unpacking
it.
a Even if the primer is packed again just after it
is unpacked, use it within 24 hours after it is
unpacked for the first time.
(Discard the primer 24 hours after it is
unpacked.)
1) Stir the primers for both of paint and glass
sufficiently before using them.
a If the primer has been stored in a refriger- a Parts to be coated with primer; Apply the
ator, leave it at the room temperature for primer all over dimension (a).
at least half a day before stirring it. q Dimension to apply primer (a): 25 mm
(If the primer is unpacked just after taken
out of the refrigerator, water will be
condensed. Accordingly, leave the primer
at the room temperature for a sufficient
time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again for
dirt and foreign matter.
a Prepare respective brushes for the paint
primer and glass primer.
a In addition to the above parts, additionally

apply the primer to right side window
glass (1) and door lower window glass
(3).
q Range to apply primer additionally for
right side window glass (1): (b)
q Range to apply primer additionally for
door lower window glass (3): (c)
a After applying the primer, leave it for at
least 5 minutes (within 8 hours ) to dry.
3) Evenly apply the paint primer to the surfaces

to stick dam rubber and its outside surfaces
to apply adhesive on operator's cab (8).
2 Paint primer:
Sunstar primer for painting plane 580
super or equivalent
a Do not apply the primer more than 2
times.
(If it is applied more than 2 times, its
performance will be lowered.)
50-800 8 PC200, 200LC-8E0 (Hybrid)

a Never apply the wrong primer. 4. Stick dam rubber (both-sided adhesive tape) (6)
If the glass primer, etc. is applied by along the inside edge of the glass sticking
mistake, wipe it off with white gasoline. section.
a Do not remove the release tape of dam rub-
4) Apply the glass primer to the sticking ber on the glass sticking side before sticking
surfaces of window glass (9). the glass.
2 Glass primer: a When sticking the dam rubber, do not touch
Sunstar primer for glass 580 super or the cleaned surface to the utmost.
equivalent a Care should be taken not to float the dam
a Do not apply the primer more than 2 rubber of each sticking corner.
times.
(If it is applied more than 2 times, its
performance will be lowered.)
a When sticking dam rubber (6) around a

frame, do not lap its finishing end over the
starting end. Or, make clearance of about 5
a Parts to be coated with primer; Apply the mm between them (a).
primer to all around of sticking surface (d) 1) Stick dam rubber(6) for right side window
of window glass (9) for dam rubber (6) in- glass (1) to the position (e) as shown in the
stallation position and operator's cab (8). figure.
a Do not apply the primer to the boarder
about 5 mm wide between the black part
and transparent part of the glass.
a After applying the primer, leave it for at
least 5 minutes (within 8 hours ) to dry.
a Never apply the wrong primer.
If the paint primer, etc. is applied by
mistake, wipe it off with white gasoline.
PC200, 200LC-8E0 (Hybrid) 50-800 9

a Stick dam rubber (6a) additionally to right a Stick dam rubber (6b) additionally to door
side window glass (1). lower window glass (3).
q Positions to stick additional dam rubber to q Positions to stick additional dam rub-
the right side window glass: ber to the door lower window class:
(f): 50 mm (j): 110 mm
(g): 90 mm (k): 90 mm
(h): 250 mm (m): 200 mm
2) Stick dam rubber (6) for left side window 4) Stick dam rubber (6) for front window glass
glass (2) to the position as shown in the (4) to the position as shown in the figure.
figure.
a Stick dam rubber (6c) of the lower side of

3) Stick dam rubber (6) for door lower window the front window glass along the outside
glass (3) to the position as shown in the edge of the lower line, differently from
figure. other dam rubbers (6). (If it is stuck along
the inside, it will be seen through the
transparent part of the glass.)
50-800 10 PC200, 200LC-8E0 (Hybrid)

5. Position the new window glass. a When positioning front window glass (4),
1) Check the clearance between the window set its horizontal position to the frame
glass and the operator's cab on the right, left, width.
upper, and lower sides, and then position the And set its vertical position to make the
window glass to be the clearances evenly. height difference (p) between the frame
2) Stick tapes [6] between window glass (9) and top and the front window glass (4) 3 mm.
operator's cab (8) and draw positioning line
(n).
a Stick tapes [6] for positioning to 3 points,
that is, right, left and lower parts of the
right side window glass, left side rear win-
dow glass, and door lower window glass
for accurate positioning.
3) Cut the tape between window glass (9) and
operator's cab (8) with a knife, etc. and then
remove the window glass.
a Do not remove the tapes left on the win-
dow glass and the operator's cab before
installing the window glass.
6. Apply adhesive.
a Use either of two types of adhesives accord-
ing to the season.
2 Adhesive (Apr.to Oct.):
Sunstar penguine seal 580 super “S”
or equivalent
2 Adhesive (Oct. to Apr.):
Sunstar penguine seal 580 super “W”
or equivalent
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use the
adhesive after this limit.
a Keep the adhesive in a dark place where the
temperature is below 25 °C.
a Never heat the adhesive higher than 30 °C.
a When reusing the adhesive, remove the all
hardened part form the nozzle tip.
1) Break aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
PC200, 200LC-8E0 (Hybrid) 50-800 11

2) Cut the tip of the adhesive nozzle (14) so that a Apply adhesive (15) with dimensions (s)
dimensions (q) and (r) will be as follows. and (t) for dam rubber (6) of operator's
q Dimension (q): 10 mm cab (8).
q Dimension (r): 15 mm q Dimension (s): 10 mm
q Dimension (t): 15 mm
a Apply adhesive (15) higher than dam rub-
ber (6).
a Apply the adhesive evenly with same
height level.
3) Set adhesive cartridge (12) to caulking gun

[7].
a An electric caulking gun is more efficient.
a Apply adhesive (15) additionally to addi-

tional dam rubber (6a) of right side win-
dow glass and additional dam rubber (6b)
of door lower window glass.
4) Remove the release tape of dam rubber on

the glass adhesive side.
5) Apply adhesive (15) to the outside of dam
rubber (6) of the operator's cab.
50-800 12 PC200, 200LC-8E0 (Hybrid)

7. Install the window glass. a After installing front window glass (4) fill
1) Install window class (9), matching it to the the clearances between it and center trim
lines of the positioning tapes drawn in step 5. seal (16) with caulking material in range
a Since the window glass cannot be re- (s) with dimensions (t) and (u).
moved and stuck again, stick it with ut- After applying the primer to glass (4) of
most caution. section A-A, apply the adhesive as
a Stick the glass within 5 minutes after ap- caulking material.
plying the adhesive. q Caulking dimension (t): 2 mm
q Caulking dimension (u): 5 mm
2) After sticking window glass (9), press all
around of it until it sticks to the dam rubber a When caulking, mask the glass side and
closely. form the adhesive with a rubber spatula
a Press the corners of the window glass as shown in the figure.
firmly. a Wipe off the projected adhesive.
2 Glass primer:
Sunstar primer for glass 580 super
or equivalent
2 Adhesive:
SUNSTAR penguine seal 580 super
“S” or “W” or equivalent
a You can perform this work efficiently by

pulling window glass (9) from inside of the
operator's cab with suction cup X2.
PC200, 200LC-8E0 (Hybrid) 50-800 13

8. Fix the window glass. 9. After installing the window glass, remove any
1) After installing right window glass (1) to the excess of the primer and adhesive from the
operator's cab, insert stopper rubbers X3 to 2 operator's cab and window glass.
places (v) at the bottom of the glass to fix the a By using the white gasoline, wipe off the ad-
glass. hesive before it is dried up.
a When cleaning the glass, do not give an im-
pact on it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours.
(at temperature of 20 °C and humidity of
60 %)
2) After removing the stopper rubbers, styrene
foam blokes, and rubber bands, wait at least
14 hours, that is, at least 24 hours in total,
before operating the machine actually.
2) By using styrene foam blocks [9] and rubber

bands [10], fix the window glass and the dam
rubber to fit them completely.
50-800 14 PC200, 200LC-8E0 (Hybrid)

Removal and installation of front window assembly SEN05263-00
Removal and installation of front

window assembly
k Lower the work equipment completely to the

ground and stop the engine.
a To replace the front window glass, the front win-
dow assembly must be removed from the opera-
tor's cab. The procedure for removing and
installing the front window assembly (front frame
and front window glass) is explained below.
Removal
1. Raise the front window assembly to the ceiling
and fix it with the rear locks ( on both sides).
2. Remove left corner block (1) and right corner
block (2). [*1]
a Mounting bolt (4) and washer (3) for left cor-
ner block are used to hang the pull-up assist
cable in the following step 6.
6. Remove left lower pin (7). [*2]

a By removing left lower pin (7), plate (8) at the
end of pull-up assist cable (9) comes off.
a Hang plate (8) on the mounting bolt for the
left corner block (use washer) and set in
place.
3. Release the rear lock of the cab. k The return load of 58.8 N {6kg} is applied
to the rear of the operator's cab. Accord-
4. Lower the front window assembly carefully a ingly, take care when removing left lower
little. Put out rollers (5) and (6) under the both pin (7) to disconnect pull-up assist cable
sides of the front window through the portion (9).
from which the corner blocks were removed in
the above step 2. (the portion where the rail is
open) and hold them.
5. Remove rollers (5) and (6) under the both sides

of the front window.
PC200, 200LC-8E0 (Hybrid) 50-800 15

SEN05263-00 Removal and installation of front window assembly
9. Twist front window assembly (10) to the right and

left to remove both upper rollers (11) and (12)
from the rails, and then remove front window
assembly (10).
7. Pull out the bottom of front window assembly

(10) though the rail opening portion and lower it
gradually.
8. Lower front window assembly (10) completely.

a Do not let the front window assembly touch
the monitor.
50-800 16 PC200, 200LC-8E0 (Hybrid)

Installation a Install the right corner block so that clearance

q Carry out installation in the reverse order to re- (a) between the rail and right corner block (2)
moval. becomes 0 - 2.0 mm.
a Install the right corner block so that there is
[*1] no level difference at the rolling surface (R) of
q Adjust opening and closing of the front window the roller.
assembly according to the following procedure.
1. Open and close the front window to check that it
does not interfere with the rails and that the
rollers are not hitched.
2. If there is any problem in opening and closing of
the front window, loosen the mounting bolt of
roller adjustment bracket (13) and adjust the
condition of the front window, and then tighten
the mounting bolt again.
a Make sure that bracket (13) is not mounted
on the angle.
3 Mounting bolt: 34.3 Nm {3.5 kgm}
5. Install left corner block (1).

a Fully tighten the block after adjusting the
"Close" position in the following step 6.
a Install the left corner block so that clearance
(b) between the rail and left corner block (1)
becomes 0 - 2.0 mm.
a Install the left corner block so that there is no
level difference at the rolling surface (R) of
the roller. (Refer to the above figure.)
3. Raise the front window assembly and fix it with

the rear locks (on both sides).
a Check that the locks in the rear of the opera-
tor's cab are securely fastened.
4. Install right corner block (2).

a Fully tighten the block after adjusting the
"Close" position in the following step 6.
PC200, 200LC-8E0 (Hybrid) 50-800 17

6. Adjust the "Close" position of the front window

assembly lock according to the following proce-
dure.
1) Tighten left and right corner blocks (1) and
(2) at roughly right positions so that front
window glass (14) is attached firmly to
cab-side trim seal (15).
7. After the adjustment, splash water heavily over

the front window glass and check that the water
does not leak into the cab.
8. Adjust the "Open" position of the front window
assembly lock.
1) After adjusting the "Close" position of the
front window assembly lock in steps 6 and 7,
2) Check the working condition of right and left raise the front window assembly to the
locks (16) and (17) when opening and ceiling.
closing the front window assembly. 2) Set the front window assembly locks at the
q If right and left locks (16) and (17) do not both sides of rear of the operator's cab to the
work normally. “Open" position, and then check the following
1] Loosen lock fitting bolt (18), move lock items.
(16) forward, and then tighten the bolt q Check the working condition of right and
again. left locks (16) and (17) (as explained
a The same applies to the right side. above).
2] After moving the lock, recheck the fitness q Front window assembly must be in con-
of front window glass (14) and cab-side tact with the right and left rubber stoppers
trim seal (15) which was checked in step (18) and furthermore, must be pushing
1). them (18) backward for 1.5 - 3.0 mm.
3] Repeat the work in 1] and 2] until the q The front window assembly must be
fitness of the front window glass and the pushing the limit switch (19) backward for
working condition of locks (16) and (17) 4 - 7 mm.
are both acceptable, and then tighten the a The position of limit switch (19) cannot be
mounting bolts of the right and left corner adjusted. Therefore, the "Open" position
blocks. of the front window assembly is decided
within the range where this switch works.
50-800 18 PC200, 200LC-8E0 (Hybrid)

a Limit switch (19) is used to prevent the 5) Loosen both sides of locknuts (22), and
windshield wiper from moving when turn- adjust the position of striker bolt (21).
ing the wiper switch on by mistake when a Striker bolt (21): M10.Inner diameter of
the front window assembly is in "Open" plate (23): f14.5 mm
position. If the wiper operates when there
is no glass in the front, the wiper falls
down inside the cab and causes trouble.
To check whether limit switch (19) is
working, turn the key switch on and see
that, even if the wiper switch is turned on,
the wiper does not operate when the front
window assembly is in "Open" position.
1] Front window assembly (10) must be

pushing the limit switch (19) backward for
4 - 7 mm (at "Open" position).
2] Working condition of lock (17).
q When adjustment is necessary after the

above checking
3) Close front window assembly (10).
4) Loosen locknut (20) of right and left side of
rubber stoppers (18), and then pull back both
rubber stoppers (18) so that they won't
contact with (18) the front window assembly
when it is in "Open" position.
PC200, 200LC-8E0 (Hybrid) 50-800 19

6) Adjustment of right and left rubber stoppers 4] Tighten locknuts (20) of the both sides of
(18). rubber stopper (18).
1] Bring front window assembly (10) (the
lock should be in "Open" position) into
contact with right and left rubber stoppers
(18).
9. Adjust stopper (24) of the front window

assembly.
1) Adjust and lock both sides of stopper (24) so
2] Close front window assembly (10). that when pulling up the front window
3] Turn right and left rubber stoppers (18) to assembly, surface d of stopper (D) of front
the left for one and a half rotation. window assembly (10) is in contact with
a One turn of rubber stopper (18) to the surface (10) of stopper (24).
left is equivalent t o squashing the rub-
ber for approximately 1.5 mm.
a When the front window assembly is in
“Open“ position, the front window as-
sembly must be pushing right and left
rubber stoppers (18) for 1.5 - 3.0 mm.
50-800 20 PC200, 200LC-8E0 (Hybrid)

10. Check the operating effort of the lock of the front

window assembly.
1) After finishing the adjustment of steps 6 – 9,
check that latching efforts of both right and
left locks (16) and (17) are even.
a Check the latching efforts on both "Close"
side (in the front of the operator's cab)
and "Open" side (in the rear of the opera-
tor's cab).
[*2]
3 Left lower pin:
27 – 34 Nm {2.75 – 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
PC200, 200LC-8E0 (Hybrid) 50-800 21

SEN05263-00 Removal and installation of floor frame assembly
Removal and installation of floor 6. Disconnect ground (2).

frame assembly
Removal
k If you drain the coolant or disconnect the
heater hose when the coolant temperature in
the radiator is high, you may be scalded. In
this case, wait until the coolant temperature
lowers and then disconnect the heater hose.
1. Collect the air conditioner refrigerant (refrigerant

gas: R134a) from air conditioner circuit. [*1]
a Ask a qualified shop for collecting, adding
and filling operation of refrigerant (R134a). 7. Disconnect the following PPC hoses from the
a Never release the refrigerant (R134a) to the travel PPC valve. The color of the band is;
q (3): Red
atmosphere.
k If refrigerant gets in your eyes, you may
q (4): No band
q (5): Green
lose your sight. And if it touches your
q (6): Blue
skins, you may suffer from frostbite. Ac-
cordingly, put on protective goggles, a Prepare an oil sump.
gloves and working suits with long
sleeves while you are collecting the re- 8. Disconnect top and bottom of connector (7)
frigerant or filling the air conditioner cir- Top: P09
cuit with the refrigerant. Collecting and f Bottom: P10
illing work must be conducted by a quali- q Step 8 – 10 is optional (for breaker).
fied person.
q Quantity of collected refrigerant: 870 ± 50 g 9. Disconnect the following PPC hoses from the
PPC valve. The color of the band is:
2. Turn the upper structure by 90°. q (8): Yellow
q (9): No band
3. Drain the engine coolant. a Plug the hose to stop oil flow-out.
6 Coolant: 17.3 l
4. Remove the operator's cab assembly by refer-

ring to “Removal and installation of operator's
cab assembly”.
a Refrigerant
50-800 22 PC200, 200LC-8E0 (Hybrid)

Removal and installation of floor frame assembly SEN05263-00
10. Disconnect ground strap (11). 16. Disconnect hose (17).

From left, T04, T05, T06, T07, T09, T10 a Check the destination.
a Put an oil stopper to the hose.
17. Disconnect heater hose (18).
12. Disconnect connector A08 (13) from the clip. a Check the destination
13. Disconnect connector P17 (14) from the air 18. Remove mounting bolt (19) and disconnect air
conditioner tube. conditioner tube (20). [*1]
14. Remove the clamp and spacer (15). 19. Remove clamps (21) and (22). [*2]
15. Disconnect hose (16). 20. Disconnect clamp (23). (If equipped)
a Check the destination.
a Put an oil stopper to the hose.
a Disconnect work equipment PPC hose (P)
from the joint box. (See step 33)
21. Disconnect clamp (25) of wiring (24).
22. Disconnect air conditioner controller (ACCNT)

and plate (26) together.
PC200, 200LC-8E0 (Hybrid) 50-800 23

23. Disconnect connectors N10(27) and AC01(28). 30. Disconnect the clamp of wiring harness (35).
24. Disconnect connectors ECU10 and ECU11(29) 31. Move plates (36) and (37) together with wiring
from the air conditioner controller (ACCONT). harness (35) to the boom side.
25. Cut tie-wrap (30) and draw in wiring harness

(31).
26. Disconnect the clamp of wiring harness (32).
32. Open the engine hood and remove cover (38).
27. Disconnect connector H15(33).
28. Remove grommet (34).
29. Move wiring harness (35) to the outside of the

floor frame.
a (SP) is made of sponge.
50-800 24 PC200, 200LC-8E0 (Hybrid)

Removal and installation of floor frame assembly SEN05263-00
33. Disconnect clamp (39). 36. Sling floor frame assembly (42) and remove it.
a Make sure that the hoses, connectors,
34. Disconnect the work equipment PPC hose (40). clamps, and so on are disconnected without
From the top, the color of the band is: fail.
White 4 Floor frame assembly: 250 kg
Brown
None
Blue
Black
Green
Red
Yellow
a Prepare an oil sump.
35. Pull out the work equipment PPC hose assembly

(41).
PC200, 200LC-8E0 (Hybrid) 50-800 25

Installation
al.
[*1]
a When installing the air conditioner circuit hoses,
take care so that dirt, water, may not enter.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat the
O-ring with compressor oil for new refrigerant
(R134a) (Denso: ND-OIL8, VALEO THERMAL
SYSTEMS: ZXL100PGZXL100PG (PAG 46 or
equivalent)).
3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm}
[*2]
a Make sure that the hoses do not lap over.
q Refilling refrigerent
Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 870 ± 50 g
q Refilling with coolant

Add coolant through the coolant filler to the spec-
ified level. Run the engine to circulate the
coolant through the system. Then, check the
5 Coolant: 17.3 l
50-800 26 PC200, 200LC-8E0 (Hybrid)

Removal and installation of air conditioner unit assembly SEN05263-00
Removal and installation of air 8. Pull down opening and closing lever (8) of the
conditioner unit assembly outside air filter cover.
9. Remove outside-air filter (9).

Removal
k If you drain the coolant or disconnect the
heater hose when the coolant temperature in
the radiator is high, you may be scalded. In
this case, wait until the coolant temperature
lowers and then disconnect the heater hose.
1. Collect the air conditioner refrigerant (refrigerant

gas: R134a) from air conditioner circuit. [*1]
a Ask a qualified shop for collecting, adding
and filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gets in your eyes, you may 10. Remove rear covers (10) to (13).
lose your sight. And if it touches your
skins, you may suffer from frostbite. Ac-
cordingly, put on protective goggles,
gloves and working suits with long
sleeves while you are collecting the re-
frigerant or filling the air conditioner cir-
cuit with the refrigerant. Collecting and f
illing work must be conducted by a quali-
fied person.
q Quantity of collected refrigerant: 870 ± 50 g
2. Turn the upper structure by 90 °
3. Drain the engine coolant.

6 Coolant: 21 l 11. Remove duct (14).
4. Remove front window (1). 12. Remove cover (15).

a Disconnect connector H15 fixed on the back
5. Remove step plate (2). from the clip.
6. Remove floor mat (3).
7. Remove covers (5) and (6)
PC200, 200LC-8E0 (Hybrid) 50-800 27

SEN05263-00 Removal and installation of air conditioner unit assembly
13. Remove plate (16). 18. Disconnect connectors N10(27) and AC01(28).
14. Remove lock pin (17) and remove duct (18). 19. Disconnect connectors ECU10 and ECU11(29)
from the air conditioner controller (ACCONT).
20. Loosen tie-wrap (30) and draw in wiring harness

(31).
15. Remove ducts (19) and (23).

a Cut tie-wrap.
16. Disconnect clamp (25) of wiring (24).
17. Disconnect air conditioner controller (ACCONT)

and plate together.
50-800 28 PC200, 200LC-8E0 (Hybrid)

Removal and installation of air conditioner unit assembly SEN05263-00
22. Remove mounting bolt (33) and disconnect air Installation

conditioner tube (34). [*1] q Installation is done in the reverse order of remov-
al.
23. Disconnect heater hose (35).
a Check the connecting point. [*1]
a When installing the air conditioner circuit hoses,
take care so that dirt, water, may not enter.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat the
O-ring with compressor oil for new refrigerant
(R134a) (Denso: ND-OIL8, VALEO THERMAL
SYSTEMS: ZXL100PG (PAG 46 or equivalent)).
3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm}
q Refilling refrigerent
Fill the air conditioner circuit with refrigerant
24. Remove the seven mounting bolts and remove (R134a).
air conditioner unit assembly (36). a Filling quantity: 870 ± 50 g
q Refilling with coolant

Add coolant through the coolant filler to the spec-
ified level. Run the engine to circulate the
coolant through the system. Then, check the
5 Coolant: 17.3 l
PC200, 200LC-8E0 (Hybrid) 50-800 29

SEN05263-00
©2009 KOMATSU
All Rights Reserved
50-800 30
SEN05264-01
SEN05264-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


900 Electric system
Removal and installation of KOMTRAX terminal ........................................................................................ 2

Removal and installation of machine monitor assembly ............................................................................. 3
Removal and installation of pump controller assembly ............................................................................... 5
Removal and installation of engine controller assembly ............................................................................. 8
PC200, 200LC-8E0 (Hybrid) 50-900 1

900 Electric system
SEN05264-01 Removal and installation of KOMTRAX terminal

KOMTRAX terminal
Removal
k Disconnect the negative terminal (–) of the
battery before starting the work.
1. Remove covers (1) – (4).
2. Twist antenna wire (5) and disconnect it.

3. Disconnect connectors CK01(6) and CK02(7).
4. Remove the 4 mounting bolts and KOMTRAX
communication modem assembly (8).
Installation
al.
50-900 2 PC200, 200LC-8E0 (Hybrid)

900 Electric system
Removal and installation of machine monitor assembly SEN05264-01
Removal and installation of a Separate the swing emergency stop switch

machine monitor assembly (8) into the body and operation portion ac-
cording to the following procedure.
1] While pressing right and left knobs (A),
Removal pull lock part (B) toward the wiring
k Park the machine on a level place, lower the harness.
work equipment to the ground completely, 2] Rotate lock part (B) by 45° in the direc-
and stop the engine. tion of arrow (a).
1. Remove cover (1) according to the following

procedure.
1) Remove cap (2) and bolt.
2) Remove mounting bolts (3) and (4).
4) While removing the cover, disconnect
connector P31 (5) of the sunlight sensor.
2. Remove cover (6) according to the following

procedure.
1) Insert a flat-head screwdriver in slit (SL) and
pull it up to unlock. 3. Remove the one mounting bolt and remove duct
2) Pull up cover (6) to remove. (9).
a The cover is fixed by using clip (7).
3) While removing the cover, separate swing
emergency stop switch (8) into body and
operation portion.
PC200, 200LC-8E0 (Hybrid) 50-900 3

900 Electric system
SEN05264-01 Removal and installation of machine monitor assembly
4. Disconnect connectors CM01 (10), CM02 (11), Installation

and CM03 (12). q Carry out the following installation in the reverse
order to the removal.
5. Disconnect wiring harness connector CM05 (13)
for the rear camera.
6. Disconnect wiring harness connector GT5 (14)

for GPS.
7. Remove mounting bolts (15) and remove

machine monitor assembly (16).
50-900 4 PC200, 200LC-8E0 (Hybrid)

900 Electric system
Removal and installation of pump controller assembly SEN05264-01
Removal and installation of pump 3. Disconnect wiring harness connectors C014 (5)
controller assembly and C02 (6) according to the following proce-
dure.
q While pressing lock (L1), tilt in lock (L2).
Removal a Bar (B) comes out and connector is un-
k Disconnect the cable from the negative (–) locked.
4. Remove four mounting bolts (7) and pump
1. Remove cover (1). controller assembly (8).
2. Disconnect bracket (2) and move it toward the

right.
a Bracket mounting bolt (3) is fixing connector
R10 (4), too.
PC200, 200LC-8E0 (Hybrid) 50-900 5

900 Electric system
SEN05264-01 Removal and installation of pump controller assembly
Installation a Connector without connector cover (1).

al.
a Reference
1. Procedure for removing connector cover (1)
1) Cut and remove cable tie (2).
2) Move lever (3) up.
2. Procedure for installing connector cover

1) Push in right and left sliders (4) as far as
possible.
3) Lightly push part (A) of connector cover (1)

from both sides to unfasten claw (B).
4) Remove connector cover (1) around claw
(C).
a Right and left sliders (4) pushed in as far

as possible (Left figure)
2) Move lever (3) of connector cover (1) from
the upper position to the left position (lock
position) in the figure.
a (B), (C): Claws
a If the sliders and lever are not set as
shown in the following figure, the connec-
tor is not disconnected or locked securely
with the lever. Accordingly, check their
positions again.
50-900 6 PC200, 200LC-8E0 (Hybrid)

900 Electric system
Removal and installation of pump controller assembly SEN05264-01
3) Set claw (C) to the connector and place

connector cover (1).
a Take care that wiring harness (5) will not
be caught.
4) Set claw (B) and install connector cover (1).
5) Bind connector cover (1) and wiring harness

with a new cable tie. (See 1. 1))
PC200, 200LC-8E0 (Hybrid) 50-900 7

900 Electric system
SEN05264-01 Removal and installation of engine controller assembly

engine controller assembly
Removal
k Disconnect the negative terminal (–) of the
battery before starting with the work.
1. Turn the upper structure by 90 °.
4. Disconnect connectors CE02(2) and (3) from the

engine controller. [*1]
a The connector is locked with the inside hex-
agonal head bolt (L6)(4 mm).
5. Disconnect connector (4) from the engine

controller by pushing the lock. [*1]
6. Remove the mounting bolt and engine controller

(5).
a Ground (E) and harness clamp are tightened
together with.
50-900 8 PC200, 200LC-8E0 (Hybrid)

900 Electric system
Removal and installation of engine controller assembly SEN05264-01
Installation
q Carry out installation in the reverse order to re-
moval
[*1]
q Check that there is no sand, dust or water inside
the controller connecter (especially on the bot-
tom). If any of them is found, completely remove
them using a blower, etc. (Sand, dust or water
may cause defective contact in connectors or
defects by entering water.)
a Reference
q How to replace the O-ring seal of power source
connector (4).
Seal of O-ring:
1010-074-0406 (NIHON-DEUTSCH Ltd.) or
equivalent
1. Remove cover [1] by nipping the tab with twee-

zers (6).
2. Remove O-ring [1] with tweezers (7).
PC200, 200LC-8E0 (Hybrid) 50-900 9

SEN05264-01
©2010 KOMATSU
All Rights Reserved
50-900 10
SEN05266-01
SEN05266-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


100 Hydraulic diagrams and drawings
Hydraulic circuit diagram............................................................................................................................. 3
PC200, 200LC-8E0 (Hybrid) 90-100 1

SEN05266-01
90-4 2 PC200-8E0 (Hybrid), PC200LC-8E0 (Hybrid)

SEN05266-01
PC200-8E0 (Hybrid), PC200LC-8E0 (Hybrid) 90-4 5

SEN05266-01
©2010 KOMATSU
All Rights Reserved
90-100 6
SEN05267-01
SEN05267-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)


200 Electrical diagrams and drawings
Electrical circuit diagram ............................................................................................................................. 3

Connector list and sterogram...................................................................................................................... 17
PC200, 200LC-8E0 (Hybrid) 90-200 1

SEN05267-01
90-200 2 PC200, 200LC-8E0 (Hybrid)

SEN05267-01
PC200, 200LC-8E0 (Hybrid) 90-200 19

SEN05267-01
PC200, PC200LC-8E0 (Hybrid)
©2010 KOMATSU
All Rights Reserved
90-200 20

SEN05221-05 - Hydraulic Excavator PC200-8E0 (Hybrid), PC200LC-8E0 (Hybrid) Shop Manual

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SEN05221-05 - Hydraulic Excavator PC200-8E0 (Hybrid), PC200LC-8E0 (Hybrid) Shop Manual

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Machine model Serial number

00 Index and Foreword

Composition of shop manual ...................................................................................................................... 2

PC200, 200LC-8E0 (Hybrid) 00-100 1

Composition of shop manual

next to each Section Name shown in the table below:

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN05221-05

00 Index and foreword SEN05222-05

10 Structure, function and maintenance standard SEN05227-03

20 Standard value table SEN05238-00

30 Testing and adjusting SEN05240-02

00-100 2 PC200, 200LC-8E0 (Hybrid)

600 Troubleshooting of engine (S-mode) SEN05254-01

50 Disassembly and assembly SEN05255-03

90 Diagrams and drawings SEN05265-01

PC200, 200LC-8E0 (Hybrid) 00-100 3

00 Index and Foreword

10 Structure,function and maintenance standard

00-100 4 PC200, 200LC-8E0 (Hybrid)

Hydraulic tank and filter ..................................................................................................................... 4

20 Standard value table

30 Testing and adjusting

PC200, 200LC-8E0 (Hybrid) 00-100 5

00-100 6 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 00-100 7

Troubleshooting by failure code, Part 3 SEN05249-00

00-100 8 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 00-100 9

00-100 10 PC200, 200LC-8E0 (Hybrid)

E-14 Function switch does not work .................................................................................................. 33

PC200, 200LC-8E0 (Hybrid) 00-100 11

S-9 Oil becomes contaminated early ................................................................................................. 16

50 Disassembly and assembly

00-100 12 PC200, 200LC-8E0 (Hybrid)

90 Diagrams and Drawings

PC200, 200LC-8E0 (Hybrid) 00-100 13

PC200, 200LC-8E0 (Hybrid) Hydraulic excavator

Form No. SEN05223-05

Machine model Serial number

00 Index and Foreword

Safety notice ............................................................................................................................................... 2

PC200, 200LC-8E0 (Hybrid) 00-200 1

1. Precautions peculiar to hybrid machine 00-200).

00-200 2 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 00-200 3

00-200 4 PC200, 200LC-8E0 (Hybrid)

q When lowering a load, stop it temporarily

6. Precautions for using mobile crane

PC200, 200LC-8E0 (Hybrid) 00-200 5

15)After finishing the work, stop the hoist at the

a The allowable load is one-sixth of the

9. Precautions for disconnecting and

00-200 6 PC200, 200LC-8E0 (Hybrid)

How to read the shop manual

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

PC200, 200LC-8E0 (Hybrid) 00-200 7