Hydraulic Excavator PC200-8 PC200LC-8 PC220-8 PC220LC-8: 40 Troubleshooting

SE N00 231- 01
HYDRAULIC EXCAVATOR 1SH OP MA NU AL
PC200-8
PC200LC-8
PC220-8
PC220LC-8
Machine model Serial number

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
PC220LC-8 70001 and up
40 Troubleshooting 1
General information on troubleshooting
Ge neral information on trou bleshoo ting .......................................................................................................... 2
Po ints to reme mb er wh en tro ublesho oti ng........................................................................................... 2
Se quence of e ve nts in tro ublesho otin g ................................................................................................ 3
Check b efo re tro ublesho otin g .............................................................................................................. 4
Classification an d p rocedur es for tro ublesho otin g ............................................................................... 5
How to read e lectric wire cod e ............................................................................................................. 9
Conne ction table for co nnector pin numbe rs ..................................................................................... 12
T-b oxes an d T-adap te rs ta ble ............................................................................................................ 35
PC20 0, 220 -8 1
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SE N0 0231- 01 40 Trouble shooting
General information on troubleshooting 1

Points to remember when troubleshooting 1
k Stop the m achine in a lev el ground, and check that the lock pin, blocks, and pa rk ing brak e are
sec urely fitted.
k When carry ing out the operation with tw o or more w orkers, ke ep stric tly to the agreed signa ls ,
and do not allow any unauthorized person to come near.
k If the radiat or ca p is rem ove d w hen the engine is hot, hot coola nt may spurt out and cause
burns, s o wait for the engine to cool dow n before start ing troubleshooting.
k Be extreme ly ca ref ul not to touch a ny hot parts or to get caught in any rotat ing parts .
k When disconnec ting wiring, a lw ays disc onnect the ne gativ e () termina l of the batte ry firs t.
k When removing t he plug or c ap from a location which is under pressure from oil, w ater, or air,
alway s releas e the interna l pres sure first. When installing mea suring equipme nt , be s ure to c on-
nect it properly.
The aim o f tro ubleshoo tin g i s to pin point the basic cau se of the fa ilure, to carry ou t repair s swiftl y, and to pr e-
vent r eoccu rrence of the failure .
When carrying out trou bleshoo ting , and important po int is o f cou rse to u nderstand th e structur e an d function.
However, a short cu t to effective trou bleshoo ting i s to ask the op erator various que stions to fo rm some ide a
of p ossib le ca uses of the failur e that wo uld prod uce the rep orted symptoms.
1. When carrying out tro uble sho oti ng, do n ot 3) Check the tr ave l o f th e con tro l le ve rs.
hur ry to disassembl e the compone nts. 4) Check the stroke of the co ntr ol valve
If compo ne nts are disa ssembl ed immed iatel y spool .
any fa ilure occurs: 5) Other main te nance items ca n be che cked
q Pa rts that h ave no conne ction with the fail- exter nal ly, so check an y item that is con -
ure o r oth er unne ce ssary parts will be d is- sidere d to be necessary.
assembled.
4. Confirming fa ilure
q It will b ecome impossib le to find th e cau se
q Confirm the e xtent of the failure yoursel f,
of the failur e.
a nd jud ge whe ther to h an dle it a s a r ea l
It wi ll al so cause a waste of man hou rs, parts,
failur e or as a pro blem with the me tho d of
or oil or gr ease, an d at the sa me time, will al so
ope ration, e tc.
lose th e co nfid ence of the user or opera tor.
a When opera ting the ma ch ine to reen -
Fo r thi s r ea so n, whe n ca rr yin g ou t tr ou b le -
act the troub leshooting symp to ms, d o
shoo ti ng, it i s n ecessary to ca rry out thoro ugh
n o t c ar r y o ut a n y i n ve st ig a ti o n o r
p ri or i nve stig a tio n an d to car ry o ut tr o ub le -
me a s ur e m en t th a t ma y m a ke th e
sho otin g i n a ccord an ce wi th the fixed pr oce-
pro blem wo rse .
dur e.
5. Tro ubleshoo tin g
2. Poin ts to ask user or op erator
q Use th e results of th e investi gation an d
1) Have any other prob lems occur red ap art
in spection in Items 2 4 to n arr ow do wn
from the pro blem th at has been re ported?
the ca uses of fa ilure, the n u se the trouble -
2) Wa s th ere anyth ing stran ge a bout the
shooting flowchart to locate the position of
machine be fore the failure occurre d?
the fa ilure exactl y.
3) Did the failu re o ccur su ddenl y, o r were
a The basic procedur e for troubl esh oot-
there prob lems with the machine condi tion
ing is as follows.
before this?
1) Start fro m the si mp le points.
4) Under what condition s did the fa ilure
2) Start fro m the most likely p oints.
occur?
3) In ve stigate oth er r elated pa rts o r
5) Had an y repair s b een ca rried out before
information.
the fai lure?
When were these repair s carried ou t? 6. Measures to re mo ve roo t cause of failure
6) Has the same kind of failu re occurred q Even if the fai lure is re paired , i f the r oot
before ? ca use o f the fa il ur e is n ot re pa ir ed , th e
same fai lure will occur aga in.
3. Check be for e trou bleshoo ting
To pr eve n t thi s, al ways in vesti ga te w hy
1) Check the oil level
the pro ble m occu rre d. The n, re move th e
2) Check for an y e xtern al leakage of o il fro m
roo t cause.
the pipin g o r h ydr aulic equip me nt.
2 PC200 , 220 -8
40 Trouble shooting SE N00 231- 01
Sequence of events in troubleshooting 1
PC20 0, 220 -8 3
Check before troubleshooting 1
Item Criterion Remedy

1. Check of level and type of fuel Add fuel
2. Check of fuel for foreign matter Clean and drain
3. Check of hydraulic oil level Between H L Add oil
4. Check of hydraulic oil s trainer Clean and drain
Lubricating
5. Check of s wing machinery oil level Betw een H L Add oil
oil/Coolant
6. Check of level and type of engine oil (in oil pan) Betw een H L Add oil
7. Check of c oolant level (in s ub tank) Betw een H L Add c oolant
8. Check of dust indicator for clogging No red part C lean or replac e
9. Check of hydraulic oil filter Replace
1. Check for abnormal noise/s mell Repair
Hydraulic/
Mechanical 2. Check for oil leakage Repair
equipment 3. Bleeding air Bleed air
1. Check of battery term inals and wiring for loose-
Retighten or replac e
nes s and corrosion
2. Check of alternator terminals and wiring for
looseness and corrosion
3. Check of s tarting motor terminals and wiring for
looseness and corrosion
4. Check of battery voltage (with engine stopped) 20 30 V C harge or replace
5. Check of electrolyte level Betw een H L Add or replace
Electric ,
6. Check of wires for dis coloration, burn, and
electric al Repair or replace
removal of cover
equipment
7. Check for released wire clamp and drooping wire Repair
8. Check of wires for wetness (Chec k connectors
Dry
and terminals for wetness, in particular)
9. Check of fus e for disconnection and c orrosion Replace
10. C heck of alternator voltage After operating for several
Replace
(while engine speed is at middle or higher) minutes : 27.5 29.5 V
11. Check of battery relay for operating sound
Replace
(when s tarting s witch is turned ON or OF F)
4 PC200 , 220 -8
Classification and procedures for troubleshooting 1

Classification for troubleshooting
Mode Contents
Display of code Troubleshooting by failure code
E-m ode Troubles hooting of elec trical system
H-mo de Troubles hooting of hydraulic and mec hanical system
S-m ode Troubles hooting of engine
Procedure for troubleshooting

If a phen omenon lo oki ng like a troub le o ccur s in th e ma ch ine, sele ct a p roper troubl esh ooting No. accordin g
to the followin g p rocedure , and then go to the corre sp ondin g trou bleshoo tin g section.
1. Proc edure for troubleshooting to be tak en when us er code and failure code a re display ed on
ma chine monitor:
If a u se r code an d a failure code are displ aye d o n the machine monitor, carry o ut th e trou bleshooting for
the co rrespond ing "Dis play of code" according to th e d isp layed fa ilure code.
2. When elect rical s ystem e rror code or mechanical s ystem e rror code is recorded in abnormality
record:
If a user cod e and a fai lure code are no t displayed on the machine monitor, check a mechan ica l system
failu re code and a n ele ctrica l system fa ilur e code with the ab norma lity r ecord fun ctio n of th e machin e
monitor.
If a co de is re co rde d, car ry out tr oub leshoo ti ng for the co rrespo ndin g "Dis pla y of code" a ccor ding to
the recorded cod e.
a If an e lectrical system failur e co de is recorde d, d elete all the code s an d repro duce them, a nd then
see if the tro uble is still detecte d.
a An err or co de of the me ch anical system cann ot be de leted.
a If a troub le i s displayed in th e ai r cond itio ner abnorma lity record or heater abno rmality record by the
abn ormality recor d function, car ry out th e corr espondi ng tro ubleshoo tin g in E-m ode.
3. Whe n user code a nd failure code is not displaye d and no failure c ode is recorded in abnorm ality
record:
If a user code and fa ilure co de are not displa yed on the ma ch ine mo nito r an d no failur e code is record ed
in the ab normality record, a trouble tha t the machine cann ot find out b y itself may ha ve occurre d in the
ele ctrical syste m or hydra ulic a nd me ch anical syste m.
In this case, ch eck th e p henomen on looking like a trou ble agai n a nd se lect th e same phe nomenon from
the tab le o f "Phe nome na l ookin g like tr oub les an d trou blesh ootin g Nos.", an d then ca rry ou t tro ubl e-
shooting corre sp onding to th at phe nomeno n in the "E-m ode ", "H-mode", or "S-m ode ".
PC20 0, 220 -8 5
Phenomena looking like troubles and troubleshooting Nos.
Troubles hooting
No. Phenomena looking like troubles Display
E-m ode H-mo de S-m ode
of code
Phen omena r elated to user code/failur e co de
User code and failure c ode are dis played on ordinary screen of machine
1
monitor Accord-
When abnormality record is checked, failure code is displayed in ing to dis -
2
mechanical sys tem abnormality record played
code
When abnormality record is checked, failure code is displayed in
3
electric al system abnormality rec ord
When abnormality record is checked, failure code is dis played in air
4 E-23
conditioner or heater abnormality rec ord
Phen omena r elated to eng ine
5 Starting performance is poor S-1
6 Engine does not start E-3 S-2
7 Engine does not pic k up smoothly S-3
8 Engine stops during operations S-4
9 Engine does not rotate smoothly S-5
10 Engine lacks output (or lack s pow er) S-6
11 Exhaust smoke is black (inc omplete combus tion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Oil becomes contaminated quick ly S-9
14 Fuel c onsumption is excessiv e S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
16 Oil pres sure drops S-12
17 Oil level rises (Entry of coolant/fuel) S-13
18 Coolant temperature bec omes too high (overheating) S-14
19 Abnormal nois e is made S-15
20 Vibration is ex cessive S-16
21 Preheater does not operate E-4
22 Automatic warm-up system does not operate (in cold s eason) E-5
23 Auto-decelerator does not operate normally E-15 H-5
Phenomena r elated to wor k equipm ent/swin g/travel
Work equipment, swing, and travel mechanism do not move or cannot
24 E-6 H-3
be loc ked
25 Speed or power of whole work equipment, s wing, and travel is low H-1
26 Engine s peed lowers extremely or engine stalls H-2 S-6
27 Working mode does not change E-16
28 Abnormal sound comes out from around hy draulic pump H-4
29 Fine c ontrol performance or res ponse is low H-6
Phen omena r elated to wor k equipm ent
30 Speed or power of boom is low H-7
31 Speed or power of arm is low H-8
32 Speed or power of bucket is low H-9
33 Work equipment does not move singly H-10
34 Hydraulic drift of work equipment is large H-11
6 PC200 , 220 -8
Troubles hooting
of code
35 Time lag of work equipment is large H-12
When part of work equipment is relieved singly, other parts of work
36 H-13
equipment move
37 Power maximizing function does not work E20 H-14
38 Attac hment circ uit is not c hanged (when attachment is installed) H-29
Oil flow in attachment circuit c annot be controlled (when attachment is
39 H-30
installed)
Phen omena r elated to co mpoun d oper atio n
In compound operation of work equipment, speed of part loaded more is
40 H-15
low
When machine swings and raises boom simultaneously, boom rising
41 H-16
speed is low
When machine swings and travels simultaneously, trav el s peed lowers
42 H-17
largely
Phenomena r elated to travel
43 Machine deviates during trav el H-18
44 Travel speed is low H-19
45 Machine is not s teered well or steering pow er is low H-20
46 Travel speed does not change or travel speed is low /high E-17 H-21
47 Travel sy stem does not move (only one side) H-22
48 Travel alarm does not sound or does not s top sounding E-22
Phen omena r elated to swing
49 Upper structure does not swing H-23
50 Swing acceleration or swing speed is low H-24
51 Upper structure overruns remark ably when it stops swinging H-25
52 Large shock is made when upper s tructure stops swinging H-26
53 Large s ound is made when upper struc ture stops swinging H-27
Swing holding brake does not operate normally
54 E-21 H-28
Hydraulic drift of sw ing is large
Phen omena related to machine m onitor
55 When starting switc h turned ON, machine monitor display s nothing E-1
When s tarting s witch turned ON (before starting engine), basic check
56 E-2
item lights up
57 Precaution lights up while engine is running E-7
58 Emergency stop item lights up while engine is running E-8
59 Engine coolant temperature gauge does not indic ate normally E-9
60 Hydraulic oil temperature gauge does not indicate normally E-10
61 Fuel level gauge does not indicate normally E-11
Contents of display by machine monitor are different from applicable
62 E-12
machine
63 Machine monitor does not display some items E-13
64 Function s witch does not work E-14
65 Alarm buz zer cannot be stopped E-18
66 Windshield wiper and window was her do not operate E-19
67 Air conditioner does not operate normally E-23
68 When starting switc h is turned OFF, service meter is not dis played E-24
PC20 0, 220 -8 7
Troubles hooting
of code
69 Mac hine monitor c annot be set in servic e mode E-25
70 Monitoring function does not display lev er c ontrol signal normally E-26
Oth er phenom ena
71 KOMTRAX sys tem does not operate normally E-27
8 PC200 , 220 -8
How to read electric wire code 1

a In this se ction, electric wire codes sp ecific to PC20 0/2 00LC-8 an d P C2 20/220L C- 8 a re exp laine d.
In the ele ctric circuit diagr am, the materi al, thi ckne ss, and colo r of each ele ctric wire ar e indi ca ted by sym-
bol s. The electric wire code is helpful in unde rstand ing th e e lectric cir cu it diag ram.
Example: AEX 0.85 L - - - Indic ates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by c olor code.

Color codes are shown in Table 4.
Indicates size of wire by nominal No.

Size (Nom inal No.) is shown in Table 2 and Table 3.
Indicates ty pe of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV, AVS, AVSS, and CAVS are c lass ified by size (nominal No.), they are not
indicated.)
1. Type, s ymbol, a nd mat erial

AV, AVS , an d AVS S are d ifferent in on ly thickness a nd outsi de diame ter o f the cover. AEX is similar to
AV in thickness and outside d iameter of AE X an d differe nt fro m AV, AVS , an d AVSS in materia l of th e
cover. CAV S has circularly compressed cond ucto r and is diffe rent fro m AV an d AV S in ou tside di ame-
ter.
(Table 1)
Using tem-
Type Symbol Material perature Example of us e for reference
range (°C)
Annealed copper for
Conductor
Low-v oltage wire for elec tric applianc e General wiring
AV
automobile (Nominal No. 8 and abov e)
Insulator Soft polyvinyl c hloride
30 to +60
Annealed copper for AVS: General w iring
Conductor
Thin-cover, low-voltage AVS elec tric applianc e (Nominal No. 3 5)
wire for automobile AVSS AVSS: General wiring
Insulator Soft polyvinyl c hloride (Nominal No. 2)
Annealed copper for

Conductor General wiring in extremely cold
Heat-res is tant, low-volt- elec tric applianc e
AEX 50 to +110 district, wiring at high-
age w ire for automobile Heat-resistant
Insulator temperature place
crosslinked polyethylene
Annealed copper for
Thin-c over, low-voltage, Conductor
elec tric applianc e General wiring
circularly compressed CAVS 30 to +60
(Nominal No. 0.5 1.25)
wire for automobile Insulator Soft polyvinyl c hloride
PC20 0, 220 -8 9
2. Dim ensions
AVS, AV, A EX, AVSS

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of strands/
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
Diameter of s trand
Conductor Sectional area
2 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm )
d (Approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 3.5 3.6 4.4
Cover D
AV Standard
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/ 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
Diameter of s trand
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm 2)
d (Approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard
Cover D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AVSS Standard
CAVS
(Table 3)
Nominal No. 0.5 0.85 1.25
Number of strands/
7/Compressed circularly 11/Compressed circularly 16/Compressed circularly
Diameter of strand
0.56 0.88 1.29
(mm 2)
d (Approx.) 0.9 1.1 1.4
Cover D CAVS Standard 1.7 1.9 2.2
"f" of n ominal No. de notes "fle xibl e".
10 PC200 , 220 -8
3. Color codes table
(Table 4)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brow n LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brow n & Red LW Blue & White
BrW Brow n & 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 Sk y Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Blac k
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Blac k YR Yellow & Red
LgR Light green & R ed YW Yellow & White
Remarks: In a color cod e consisti ng o f 2 colors, the first color is th e color of the backg round and the
second color is the color of the marking .
Example : GW means th at the backgroun d i s Gree n and marking is White.
4. Types of c ircuits and color codes
(Table 5)
Type of wire AVS or AV AEX
Charge R WG R
Ground B B
Start R R
Light RW RB RY RG RL D
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB L
Type of
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW
O
Others Gr
P
Sb
Dg
Ch
PC20 0, 220 -8 11
Connection table for connector pin numbers 1

a The terms male a nd fe ma le refer to the p ins, while the terms male h ousing an d femal e housing re fer to
the ma tin g p ortion of the hou sin g.
X ty pe c onnec tor
No.of
pins T-adapter
Male (female hous ing) F emale (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
Electric wire s iz e: 0.85 Electric w ire siz e: 0.85

Grommet: Black Grom met: Black
Qty: 20 Qty : 20
Terminal part No.: 79A-222-3380 Terminal part No.: 79A-222-3410

Grommet: Red Grom met: Red
Qty: 20 Qty: 20
12 PC200 , 220 -8
SWP type connector

No.of
pins T-adapter
Male (female hous ing) F emale (male hous ing)
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
PC20 0, 220 -8 13
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:

Grommet: Black Grom met: Black
Qty: 20 Qty: 20
Terminal part No.: Terminal part No.:

Grommet: Red Grom met: Red
Qty: 20 Qty: 20
14 PC200 , 220 -8
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
PC20 0, 220 -8 15
S ty pe c onnec tor
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
16 PC200 , 220 -8
S ty pe c onnec tor
No.of
pins T-adapter
Part No.
10

(Blue)

12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
PC20 0, 220 -8 17
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Qty : 5) Body part No.: 79A-222-2630 (Qty : 5)
11 Body part No.: 79A-222-2680 (Qty: 5) Body part No.: 79A-222-2670 (Qty : 5)
5 799-601-2710
Body part No.: 79A-222-2620 (Qty: 5) Body part No.: 79A-222-2610 (Qty: 5)
9 799-601-2950
13 799-601-2720
18 PC200 , 220 -8
MIC type connector

No.of
pins T-adapter Part
No.
17 799-601-2730
21 799-601-2740
Body part No.: 79A-222-2770 Body part No.: 79A-222-2760

(Qty: 50) (Qty: 50)
PC20 0, 220 -8 19
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
Housing part No.: 79A-222-3430 (Qty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
a Terminal par t No.: 79A-2 22-3 470 (No relation with n umber of p ins)
20 PC200 , 220 -8
AMP070 type connector

No.of
pins T-adapter Part
No.
10 799-601-7510
Part No.: 7821-92-7330
12 799-601-7520
Part No.: 7821-92-7340
14 799-601-7530
Part No.: 7821-92-7350
18 799-601-7540
Part No.: 7821-92-7360
20 799-601-7550
Part No.: 7821-92-7310
PC20 0, 220 -8 21
L ty pe c onnec tor
No.of
pins T-adapter Part
No.
2

Connector for PA
No.of
T-adapter Part
pins Male (female hous ing) F emale (male housing)
No.
9

Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460

22 PC200 , 220 -8
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
2
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black ) 08027-10270 (Black )
3
Part No.:08027-10310 Part No.:08027-10360
4
08027-10420 (Black ) 08027-10470 (Black )
6
08027-10620 (Black ) 08027-10670 (Black )
PC20 0, 220 -8 23
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
8
08027-10820 (Black ) 08027-10870 (Black )
Connector for relay (Soc ket type)

No.of
pins T-adapter Part
No.
5 799-601-7360

6 799-601-7370

24 PC200 , 220 -8
F type connector
No.of
pins T-adapter
Part No.
4

PC20 0, 220 -8 25
[Th e p in No . is also marked on the co nnector (electric wire insertion en d)]

Type HD30 Series connec tor
(shell
size T-adapter
Body (plug) Body (rec eptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
26 PC200 , 220 -8

(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
PC20 0, 220 -8 27

(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
28 PC200 , 220 -8

(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
PC20 0, 220 -8 29

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
30 PC200 , 220 -8

DT Series connector
No.of
pins T-adapter
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
PC20 0, 220 -8 31

No.of DT Series connector
pins Body (plug) Body (receptacle) T-adapter Part No.
Body color (Gray):

799-601-9060
Body color (Blac k):
799-601-9070
8
Body color (Green):
799-601-9080
Body color (Brown):
799-601-9090
08192-2820 (fine wire ty pe) 08192-2810 (fine wire ty pe)
Body color (Gray):

799-601-9110
Body color (Blac k):
799-601-9120
12
Body color (Green):
799-601-9130
Body color (Brown):
799-601-9140
08192-2920 (fine wire ty pe) 08192-2910 (fine wire ty pe)
32 PC200 , 220 -8

DTM Series connector
No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100

DTHD Series connector
No.of
pins T-adapter Part
No.
1
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contac t s iz e #8) 08192-41100 (Contact size #8)
08192-51200 (Contac t s iz e #4) 08192-51100 (Contact size #4)
PC20 0, 220 -8 33

DRC26 Series c onnec tor
No.of
pins T-adapter Part
No.
24 799-601-9360
Part No.:7821-93-3110
40
799-601-9350
(A)
Part No.:7821-93-3120
40
799-601-9350
(B)
Part No.:7821-93-3130
34 PC200 , 220 -8
T-boxes and T-adapters table 1

a The Nos. in the columns are the part Nos. of the T-boxes, T-a dapters, a nd other par ts. The Nos. in the
line s are the kit Nos. of the T-a dapter kits.
T-adapte r kit
Nu mber of pins
799 -601 -250 0

799 -601 -270 0
799 -601 -280 0
799 -601 -290 0
799 -601 -300 0
799 -601 -550 0
799 -601 -600 0
799 -601 -650 0
799 -601 -700 0
799 -601 -710 0
799 -601 -740 0
799 -601 -750 0
799 -601 -800 0
799 -601 -900 0
799 -601 -910 0
799 -601 -920 0
799 -601 -930 0
Out of kit
Iden tif ica-
Part No . Pa rt n ame
tion symbol
799 -601 -260 0 T -box (for ECONO) 21 q q q q q q

799-601 -310 0 T-box (for MS) 37 q
799-601 -320 0 T-box (for MS) 37 q
799 -601 -330 0 T -box (for ECONO) 24 q

799 -601 -336 0 Plate for MS (24-pin) q
799 -601 -337 0 Plate for MS (17-pin) q
799 -601 -338 0 Plate for MS (14-pin) q
799-601 -341 0 Ada pter for BENDI X (MS) 24 M S-24 P q q

799-601 -345 0 Ada pter for BENDIX (MS) 5 MS-5P q q
799-601 -351 0 Ada pter for BENDIX (MS) 5 MS-5S q q

799 -601 -347 0 C ase q
799-601 -271 0 Ada pter for MIC 5 M IC-5P q q q q
799-601 -272 0 Ada pter for MIC 13 MI C-13P q q q q
799-601 -273 0 Ada pter for MIC 17 MI C-17P q q q q q q q

799-601 -274 0 Ada pter for MIC 21 MI C-21P q q q q q q q
799-601 -295 0 Ada pter for MIC 9 M IC-9P q q q q
799-601 -275 0 Ada pter for ECONO 2 ECONO2P q q

799 -601 -279 0 Ada pter for ECONO 12 ECONO12 P q q
799 -601 -281 0 Ad apter for DLI 8 D LI-8P q q
799 -601 -282 0 Ada pter for DLI 12 D LI-12 P q q
799 -601 -283 0 Ada pter for DLI 16 D LI-16 P q q
799 -601 -28 40 Exten sion cab le (ECON O type) 12 ECONO12 P q q q
799 -601 -285 0 C ase q

799 -601 -42 10 Ad apter for DR C 50 DRC 50 q
799-601 -701 0 Ada pter for X (T-adap ter) 1 q q
799-601 -702 0 Ada pter for X 2 X2P q q q q
799-601 -705 0 Ada pter for SWP 6 SW 6P q q q
799-601 -706 0 Ada pter for SWP 8 SW 8P q q q
799-601 -731 0 Ada pter for SWP 12 SW1 2P q
PC20 0, 220 -8 35
T-adapte r kit
Nu mber of pins
799 -601 -250 0

799 -601 -270 0
799 -601 -280 0
799 -601 -290 0
799 -601 -300 0
799 -601 -550 0
799 -601 -600 0
799 -601 -650 0
799 -601 -700 0
799 -601 -710 0
799 -601 -740 0
799 -601 -750 0
799 -601 -800 0
799 -601 -900 0
799 -601 -910 0
799 -601 -920 0
799 -601 -930 0
Out of kit
Iden tif ica-
tion symbol
799-601 -707 0 Ada pter for SWP 14 SW1 4P q q

799-601 -732 0 Ada pter for SWP 16 SW1 6P q
799-601 -708 0 Ada pter for M (T -ada pter) 1 q q
799 -601 -709 0 Ada pter for M 2 M 2P q q q q
799-601-7110 Adap ter f or M 3 M3 P q q q q
799 -601 -734 0 Ada pter for M 8 M 8P q

799-601 -714 0 Ada pter for S 8 S8P q q q q
799-601 -715 0 Ada pter for S (Wh ite) 10 S10P q q q q
799-601 -716 0 Ada pter for S (Blue) 12 S12P q q q
799-601 -717 0 Ada pter for S (Blue) 16 S16P q q q q
799-601 -733 0 Ada pter for S (Wh ite) 16 S16 PW q
799-601 -735 0 Ada pter for S (Wh ite) 12 S12 PW q

799-601 -718 0 Ada pter for AMP040 8 A8P q
799 -601 -719 0 Ada pter for AMP040 12 A12P q q
799 -601 -721 0 Ada pter for AMP040 16 A16P q q q q
799 -601 -722 0 Ada pter for AMP040 20 A20P q q q q
799-601 -723 0 Sho rt conn ector f or X 2 q q q q
799 -601 -724 0 C ase q q

799 -601 -727 0 C ase q
799 -601 -751 0 Ada pter for 070 10 0 7-10 q
799 -601 -752 0 Ada pter for 070 12 0 7-12 q
799 -601 -753 0 Ada pter for 070 14 0 7-14 q
799 -601 -754 0 Ada pter for 070 18 0 7-18 q

799 -601 -755 0 Ada pter for 070 20 0 7-20 q
799 -601 -736 0 Ada pter for relay 5 REL -5P q
799 -601 -737 0 Ada pter for relay 6 REL -6P q
799-601 -738 0 Ada pter for JF C 2 q
799 -601 -901 0 Ada pter for DT M 2 DT M2 q q
799 -601 -902 0 Ada pter for DT 2 DT 2 q q

799-601 -906 0 Ada pter for DT (Gray) 8 D T8 GR q q
799-601 -907 0 Ada pter for DT (Black) 8 D T8B q q
799 -601 -908 0 Ada pter for DT (Green) 8 DT 8G q q

799 -601 -909 0 Ada pter for DT (Brown ) 8 DT 8BR q q
799 -601 -9110 Adap ter f or D T (Gra y) 12 DT 12GR q q
799-601 -912 0 Ada pter for DT (Black) 12 D T1 2B q q
799 -601 -913 0 Ada pter for DT (Green) 12 DT 12G q q
799 -601 -914 0 Ada pter for DT 12 DT 12BR q q
799 -601 -921 0 Ada pter for HD3 0-18 8 D18 -8 q q
799 -601 -922 0 Ada pter for HD3 0-18 14 D18-14 q q
799 -601 -923 0 Ada pter for HD3 0-18 20 D18-20 q q
36 PC200 , 220 -8
T-adapte r kit
Nu mber of pins
799 -601 -250 0

799 -601 -270 0
799 -601 -280 0
799 -601 -290 0
799 -601 -300 0
799 -601 -550 0
799 -601 -600 0
799 -601 -650 0
799 -601 -700 0
799 -601 -710 0
799 -601 -740 0
799 -601 -750 0
799 -601 -800 0
799 -601 -900 0
799 -601 -910 0
799 -601 -920 0
799 -601 -930 0
Out of kit
Iden tif ica-
tion symbol
799 -601 -931 0 Plate for H D30 (24 -pin) q q q
799 -601 -932 0 T -box (for DT /HD ) 12 q q q

799 -601 -933 0 C ase q
799 -601 -934 0 C ase q
799 -601 -935 0 Ad apter for DRC 40 D RC -40 q
799 -601 -936 0 Ad apter for DRC 24 D RC -24 q
799-601 -941 0 Ada pter for engine (CR I-T 2) 2 G q
Adapt er fo r en gin e (C RI-T2 )

799 -601 -942 0 3 A3 q
799 -601 -943 0 2 P q
799-601 -944 0 Ada pter for engine (CR I-T 2) 3 1,2,3 q
795-799 -552 0 Ada pter for engine (HPI-T2) 2 S q
Adapt er fo r en gin e (H PI-T 2)
795 -799 -553 0 2 C q
Adapt er fo r en gin e (H PI-T 2)
795 -799 -554 0 2 A q
795-799 -546 0 Ada pter for engine (HPI-T2) 3 q

799-601 -416 0 Ada pter for engine (CR I-T 3) 2 OIL q
799 -601 -413 0 Ada pter for engine (CR I-T 3) 3 F CIN q
799 -601 -414 0 Ada pter for engine (CR I-T 3) 3 F CIG q
799 -601 -415 0 Ada pter for engine (CR I-T 3) 3 F C IB q
799-601 -418 0 Ada pter for engine (CR I-T 3) 3 F CIP3 q
799-601 -423 0 Ada pter for engine (CR I-T 3) 4 1,2,3,4 q
799 -601 -426 0 Ada pter for co ntro ller (EN G) 4 D TP4 q
799 -601 -421 0 Ada pter for co ntro ller (EN G) 50 DRC 50 q
799 -601 -422 0 Ada pter for co ntro ller (EN G) 60 DRC 60 q
799-601 -428 0 Box fo r controlle r (PUMP) 1 21 q
799-601 -972 0 Ada pter for co ntro ller (HS T) 16 HST 16A q
799-601 -971 0 Ada pter for co ntro ller (HS T) 16 HST 16B q
799-601 -937 0 Ada pter for co ntro ller (HS T) 26 HST 26A q
PC20 0, 220 -8 37
SE N0 0231- 01
PC200, 220(LC)-8 Hydraulic exc av ator
Form No. SEN00231-01
© 2 006 KO MATSU
All Rights Reserved
Pri nted in Japa n 0 3-06 (01 )
38
SE N00 240- 01
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Troubleshooting by failure code
(Display of code), Part 1
Tr ouble sh ooting by failu re co de (Di spla y of cod e), P art 1 .............................................................................. 3
Failur e code s table ............................................................................................................................... 3
Be fore carryin g o ut troubl esh ooting when failure code is displayed .................................................... 8
Info rmation in tro ublesho otin g tabl e ................................................................................................... 1 2
Failur e cod e [98 9L00] Engin e Co ntr oller Lock Cau tio n 1 ................................................................... 1 4
Failur e code [989 M0 0] En gine Controll er L ock Caution 2.................................................................. 1 4
Failur e code [989 N0 0] En gine Controlle r L ock Caution 3 .................................................................. 1 5
Failur e cod e [AA 10NX] A ir Cle aner Clogg ing .................................................................................... 15
Failur e code [AB 00KE ] Charge Voltage Lo w ..................................................................................... 1 6
Failur e code [B@BAZG] Eng Oil Pr ess. L ow ..................................................................................... 1 8
Failur e code [B@BAZK] Eng Oil Le ve l Lo w ....................................................................................... 18
Failur e code [B@BCNS] En g Water Overhe at................................................................................... 1 9
Failur e code [B@BCZK] En g Water Level Low .................................................................................. 1 9
Failur e code [B@HANS] Hydr Oil Overhe at....................................................................................... 20
PC20 0, 220 -8 1
Failur e code [CA111] EMC Critica l Interna l Failu re ............................................................................ 20

Failur e cod e [CA115] E ng Ne an d Bkup Sp eed Sen s Err or ............................................................... 2 1
Failur e code [CA122 ] Chg Air Press Sensor High Erro r..................................................................... 2 2
Failur e code [CA123 ] Chg Air Press Sensor Low Erro r ..................................................................... 2 4
Failur e cod e [CA131 ] Throttl e S ensor High Error ............................................................................... 26
Failur e cod e [CA132 ] Throttl e S ensor Low Error ............................................................................... 2 8
Failur e code [CA144 ] Coolan t Temp Sens Hig h Error ........................................................................ 3 0
Failur e code [CA145 ] Coolan t Temp Sens Low Error ......................................................................... 3 2
Failur e code [CA153 ] Chg Air Temp Sensor High Erro r ..................................................................... 3 4
Failur e code [CA154 ] Chg Air Temp Sensor Low Erro r...................................................................... 3 6
Failur e code [CA155 ] Chg Air Temp Hig h Sp eed Derate ................................................................... 3 8
Failur e code [CA187 ] Se ns Su pply 2 Volt Low E rror .......................................................................... 4 0
Failur e code [CA221 ] Ambie nt Pr ess Sen s High Error ....................................................................... 4 2
Failur e code [CA222 ] Ambie nt Pr ess Sen s Low Error ....................................................................... 4 4
Failur e code [CA227 ] Se ns Su pply 2 Volt Hig h Error ......................................................................... 4 6
Failur e code [CA234 ] En g O ve rsp eed................................................................................................ 47
Failur e code [CA238 ] Ne Sp eed Sen s Sup ply Volt Error .................................................................... 4 8
Failur e code [CA271 ] IMV /P CV 1 S hort Error ..................................................................................... 49
Failur e code [CA272 ] IMV /P CV 1 O pen Err or ..................................................................................... 5 0
Failur e code [CA322 ] Inj #1 (L#1) Op en/Shor t Erro r .......................................................................... 5 2
2 PC200 , 220 -8
Troubleshooting by failure code (Display of code), Part 1 1

Failure codes table 1
a This fa ilure codes table is the same as that in Testing and adjusting, Special function s of machin e monitor.
User Alarm Device in Catego ry

Failure code Troub le (Displayed on scr een)
code buz zer charge of histor y
Electrical
989L00 Engine Controller Lock Caution 1 MON
sys tem
Electrical
989M00 Engine Controller Lock Caution 2 MON
sys tem
Electrical
989N00 Engine Controller Lock Caution 3 MON
sys tem
Mechani-
AA10NX Air Cleaner Clogging MON
cal sy stem
Mechani-
AB00KE C harge Voltage Low MON
cal sy stem
Mechani-
B@BAZG Eng Oil Press . Low e ENG
cal sy stem
Mechani-
B@BAZK Eng Oil Level Low MON
cal sy stem
Mechani-
B@BCNS Eng Water Overheat e ENG
cal sy stem
Mechani-
B@BCZK Eng Water Level Low e MON
cal sy stem
Mechani-
B@HANS Hydr Oil Overheat e PUMP
cal sy stem
Electrical
E10 CA111 EMC Critical Internal Failure q ENG
sys tem
Electrical
E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG
sys tem
Electrical
E11 CA122 Chg Air Pres s Sensor High Error q ENG
sys tem
Electrical
E11 CA123 Chg Air Press Sensor Low Error q ENG
sys tem
Electrical
E14 CA131 Throttle Sensor High Error q ENG
sys tem
Electrical
E14 CA132 Throttle Sensor Low Error q ENG
sys tem
Electrical
E15 CA144 Coolant Temp Sens High Error q ENG
sys tem
Electrical
E15 CA145 Coolant Temp Sens Low Error q ENG
sys tem
Electrical
E15 CA153 Chg Air Temp Sensor High Error q ENG
sys tem
Electrical
E15 CA154 Chg Air Temp Sensor Low Error q ENG
sys tem
Electrical
E11 CA155 Chg Air Temp High Speed Derate q ENG
sys tem
Electrical
E15 CA187 Sens Supply 2 Volt Low Error q ENG
sys tem
Electrical
E11 CA221 Ambient Press Sens High Error q ENG
sys tem
PC20 0, 220 -8 3

Electric al
E11 C A222 Ambient Press Sens Low Error q ENG
sys tem
Electric al
E15 CA227 Sens Supply 2 Volt High Error q ENG
sys tem
Mechani-
CA234 Eng Overspeed ENG
cal sy stem
Electric al
E15 CA238 Ne Speed Sens Supply Volt Error q ENG
sys tem
Electric al
E10 CA271 IMV/PCV1 Short Error q ENG
sys tem
Electric al
E10 CA272 IMV/PCV1 Open Error q ENG
sys tem
Electric al
E11 C A322 Inj #1 (L#1) Open/Short Error q ENG
sys tem
Electric al
sys tem
Electric al
sys tem
Electric al
sys tem
Electric al
sys tem
Electric al
sys tem
Electric al
E10 CA342 Calibration Code Incompatibility q ENG
sys tem
Electric al
E10 CA351 Injectors Drive Circuit Error q ENG
sys tem
Electric al
E15 CA352 Sens Supply 1 Volt Low Error q ENG
sys tem
Electric al
E15 CA386 Sens Supply 1 Volt High Error q ENG
sys tem
Electric al
E15 CA428 Water in Fuel Sens or High Error q ENG
sys tem
Electric al
E15 CA429 Water in Fuel Sens or Low Error q ENG
sys tem
Electric al
E15 CA435 Eng Oil Press Sw Error q ENG
sys tem
Electric al
E10 CA441 Battery Voltage Low Error q ENG
sys tem
Electric al
E10 CA442 Battery Voltage High Error q ENG
sys tem
Electric al
E11 C A449 Rail Press Very High Error q ENG
sys tem
Electric al
E11 C A451 Rail Press Sens or High Error q ENG
sys tem
Electric al
E11 C A452 Rail Press Sensor Low Error q ENG
sys tem
Electric al
E11 C A488 Chg Air Temp High Torque Derate q ENG
sys tem
4 PC200 , 220 -8

Electrical
E15 CA553 Rail Press High Error q ENG
sys tem
Electrical
E15 CA559 Rail Press Low Error q ENG
sys tem
Electrical
E15 CA689 Eng N e Speed Sensor Error q ENG
sys tem
Electrical
E15 CA731 Eng Bkup Speed Sens Phase Error q ENG
sys tem
Electrical
E10 CA757 All Continuous Data Lost Error q ENG
sys tem
Electrical
E15 CA778 Eng Bkup Speed Sens or Error q ENG
sys tem
Electrical
E0E CA1633 KOMNET Datalink Timeout Error q ENG
sys tem
Electrical
E14 CA2185 Throt Sens Sup Volt High Error q ENG
sys tem
Electrical
E14 CA2186 Throt Sens Sup Volt Low Error q ENG
sys tem
Electrical
E11 CA2249 Rail Press Very Low Error q ENG
sys tem
Electrical
E11 CA2311 IMV Solenoid Error q ENG
sys tem
Electrical
E15 CA2555 Grid Htr Relay Volt High Error q ENG
sys tem
Electrical
E15 CA2556 Grid Htr Relay Volt Low Error q ENG
sys tem
Electrical
E01 D 19JKZ Personal Code Relay Abnormality q MON2
sys tem
Electrical
D862KA GPS Antenna Disc on MON2
sys tem
Electrical
E0E DA22KK Pump Solenoid Power Low Error q PUMP
sys tem
Electrical
DA25KP 5V Sens or 1 Power Abnormality PU MP
sys tem
Electrical
DA29KQ Model Selec tion Abnormality PUMP
sys tem
Electrical
E0E DA2RMC C AN Discon (Pump Con Detected) q PUMP
sys tem
Electrical
DAFGMC GPS Module Error MON 2
sys tem
Electrical
E0E DAFRMC C AN Discon (Monitor Detected) q MON
sys tem
Electrical
DGH2KB Hydr Oil Sensor Short PUMP
sys tem
Electrical
DHPAMA F Pump Press Sensor Abnormality PUMP
sys tem
Electrical
DHPBMA R Pump Press Sens or Abnormality PUMP
sys tem
Electrical
DHS3MA Arm Curl PPC Press Sens or Abnormality PUMP
sys tem
PC20 0, 220 -8 5

Electric al
DHS4MA Buc ket Curl PPC Press Sensor Abnormality PUMP
sys tem
Electric al
DHS8MA Boom Raise PPC Press Sensor Abnormality PUMP
sys tem
Electric al
DHSAMA Swing RH PPC Pres s Sensor Abnormality PUMP
sys tem
Electric al
DHSBMA Swing LH PPC Press Sensor Abnormality PUMP
sys tem
Electric al
DHSDMA Bucket Dump PPC Press Sensor Abnormality PUMP
sys tem
Electric al
DHX1MA Ov erload Sensor Abnormality (Analog) PUMP
sys tem
Electrical
DW43KA Travel Speed Sol Disc on PUMP
sys tem
Electric al
DW43KB Travel Speed Sol Short PUMP
sys tem
Electric al
E03 DW45KA Swing Brak e Sol Dis con q PUMP
sys tem
Electric al
E03 DW45KB Swing Brak e Sol Short q PUMP
sys tem
Electric al
DW91KA Travel Junction Sol Discon PUMP
sys tem
Electric al
DW91KB Travel Junction Sol Short PUMP
sys tem
Electric al
DWA2KA Serv ic e Sol Disc on PUMP
sys tem
Electric al
DWA2KB Servic e Sol Short PUMP
sys tem
Electric al
DWK0KA 2-stage Relief Sol Discon PUMP
sys tem
Electric al
DWK0KB 2-stage Relief Sol Short PUMP
sys tem
Electric al
E02 DXA8KA PC-EPC (F) Sol Discon q PUMP
sys tem
Electric al
E02 DXA8KB PC-EPC (F) Sol Short q PUMP
sys tem
Electric al
E02 DXA9KA PC-EPC (R) Sol Discon q PUMP
sys tem
Electric al
E02 DXA9KB PC-EPC (R) Sol Short q PUMP
sys tem
Electric al
DXE0KA LS-EPC Sol D is con PUMP
sys tem
Electric al
DXE0KB LS-EPC Sol Short PUMP
sys tem
Electric al
DXE4KA Servic e Current EPC Discon PUMP
sys tem
Electric al
DXE4KB Servic e Current EPC Short PUMP
sys tem
Electric al
DXE5KA Merge-div ider Main Sol Disc on PUMP
sys tem
6 PC200 , 220 -8

Electrical
DXE5KB Merge-div ider Main Sol Short PUMP
sys tem
Electrical
DXE6KA Merge-div ider LS Sol Disc on PUMP
sys tem
Electrical
DXE6KB Merge-div ider LS Sol Short PUMP
sys tem
Electrical
DY20KA Wiper Work ing Abnormality PU MP
sys tem
Electrical
DY20MA Wiper Parking Abnormality PUMP
sys tem
Electrical
DY2C KA Washer Drive D is con PUMP
sys tem
Electrical
DY2C KB Washer D rive Short PUMP
sys tem
Electrical
DY2D KB Wiper Driv e (For) Short PUMP
sys tem
Electrical
DY2EKB Wiper D rive (Rev) Short PUMP
sys tem
a En try order of ite ms in tabl e

The ite ms are en tere d in the or der of their failure code s (incre men tal or der).
a Use r cod e
Atta ch ed : If th e failu re co de i s detected , th e u se r code , fai lure co de, an d telep hone No. (if regis-
tered) ar e d isp layed on th e o rdina ry scr een to n otify the ope rator of the abn ormality.
Not atta ch ed: Even if the failu re code is d ete cted, the machine mo nitor doe s n ot notify the op erator of
the abno rma lity.
a Ala rm bu zzer
q : When occur rence of an er ror is notified to th e ope rato r, th e buzzer sound s ( The opera to r ca n stop
the buzzer with th e a larm buzze r can ce l switch) .
e : Sin ce the caution monitor is also turned O N, its fun ction sound s the buzze r.
a Compon ent in charg e
MON: The machine moni tor is i n cha rge of de te ction of a bnorma lity.
MON2: The KO MTRAX section of the machine monitor is i n char ge of de tection of a bnormal ity.
ENG: Th e e ngine control ler is in charge o f detectio n o f abn ormality.
PUMP: The pu mp control ler is in charge o f detectio n of abn ormality.
a Category of re cor d
Mechanical system: Abnormality information is recorded in the mechanical system abnormality record.
Electrical system: Abnormality info rmation is recorded in the electrical system abnormality record.
PC20 0, 220 -8 7
Before carrying out troubleshooting when failure code is displayed 1

Connec tion table of fuse box
a This con nectio n tabl e sho ws th e device s to wh ich e ach p ower su pply o f the fu se bo x suppl ies po wer (A
switch power supply is a device whi ch suppl ies powe r while the starting switch is in the ON p ositio n a nd
a con stant p ower sup ply is a device which supplie s power wh ile the starting swi tch i s in the OFF and ON
positions).
a When carrying o ut troub leshooting rel ate d to the electrical syste m, yo u sho uld check the fuses an d fus-
ible lin ks to see if the power is sup plied nor mally.
Type o f
Fuse
power Fusib le link Fuse No. Destination of power
capacity
supply
Lamp relay, rear lamp relay, cab lamp relay
PC-EPC (F) solenoid valve, PC-EPC (R ) solenoid valv e
1 10 A [When pump drive switc h is operated in emergency ]
Swing holding brake s olenoid valve
[When swing holding brake release switc h is operated]
2 30 A Pump controller (Solenoid power supply )
Switch power F04
supply (60 A) PPC oil pressure loc k solenoid valve
3 10 A Starting motor cut-out relay (PPC lock)
Starting motor cut-out relay (Personal c ode)
Cigarette lighter
4 10 A
Windshield washer motor
5 10 A Horn relay, horn
6 10 A Elec trical intak e air heater relay
7 10 A Rotary lamp
Switch power F04 8 20 A Right headlamp, working lamp (boom), working lamp (rear)
supply (60 A) Radio
9 10 A
Left k nob switch (pump controller input)
10 10 A (Spare)
Air conditioner unit
11 20 A
Air conditioner c ompressor electromagnetic clutch
12 10 A (Spare)
Switch power F04
13 10 A Headlamp
supply (60 A)
14 10 A Optional power supply (1)
Trav el alarm
15 10 A
Optional power supply (2)
Radio (backup power supply )
16 10 A
Room lam p
Starting switch
Cons tant F05
17 20 A Machine monitor
power s upply (30 A)
Pump c ontroller
18 10 A (Spare)
19 30 A Engine controller
Switch power Starting switch
20 5A Engine controller (ACC s ignal)
supply ACC
8 PC200 , 220 -8
Loc ations of fus ible link s
Location of fuse box and fuse Nos .
PC20 0, 220 -8 9
Troubles that oc cur when power supply of pump c ontroller is defective

a The co ntr oller power supply (F01-17 ) of the pu mp controlle r d rives the co ntro ller system. A ccord ingly, if
it is turn ed o ff, th e contro ller cann ot co ntrol th e syste m a nd the trou bles sho wn be low occur si mu lta-
neo usly (The following is an example of the tr ouble s).
q The wo rking mode canno t be change d.
q The auto-de ce lerator doe s not wo rk or is n ot reset.
q The tra ve l spee d does not chan ge.
q The power maximizin g fun ction doe s no t work.
q The swin g h oldin g br ake can not be re se t automatically.
q The machine deviates during travel.
a If th e above pro blems occur, check the rela te d fuse (F01-1 7) and "g reen LE D" o f the pump controller to
see if the power is sup plied nor ma lly.
q Lig htin g: The controller po we r is su pplie d ( Th ere is no t an erro r an d the po we r supp ly is normal).
q Flashing: The con tro ller power is sup plied (Ther e is an error ).
q Pu t out: The controller po wer is not sup plied.
a Gre en LED of pu mp controlle r (a)
10 PC200 , 220 -8
Troubles that oc cur when power supply of pump c ontroller is defective

a The so lenoid po wer supply (F01-2) of the pump co ntr oller is used by the con tr oller to drive th e sole noids
an d r ela ys. Accor din gly, i f th e so len oi d po wer supp ly is tu rne d o ff, whe n the con tr ol ler outp uts the
power to the so lenoi ds o r r elays, th e power is not sup plied to any of the sole noids and rel ays and a ll or
some of the fo llowing failure codes are displayed simultaneo usl y.
q [DW43 KA], [DW4 3KB]: Travel spe ed so lenoid system
q [DW45 KA], [DW4 5KB]: Swing h olding b rake sole noid system
q [DW91 KA], [DW9 1KB]: Travel j unctio n sol enoid system
q [DWA2K A], [DWA2KB ]: Service sol enoid system
q [DWK0 KA], [DWK 0KB]: 2- stage rel ief solen oid syste m
q [DX A8KA ], [DXA8 KB]: PC-EP C (F) so lenoid system
q [DX A9KA ], [DXA9 KB]: PC-E PC (R) so leno id system
q [DX E0KA ], [DXE0 KB]: LS -EPC sol enoid system
q [DX E4KA ], [DXE4 KB]: Se rvice curren t EPC syste m (if a ttachment i s insta lled)
q [DX E5KA ], [DXE5 KB]: Merge -divider main soleno id syste m
q [DX E6KA ], [DXE6 KB]: Merge -divider LS solen oid syste m
a If th e a bove probl ems occur, ch eck th e r elated fu se (F01 -2) and inle t vo lta ge of the pump controller.
1) Discon nect conne ctors C0 1 a nd C02 o f th e con trol ler and connect a T-a dapter box to the wir ing
har ness side.
2) Tur n the star tin g switch ON.
3) Measure th e voltage between each o f pins C02 (11 6), (118), an d (1 21) a nd each of p ins C01 (2)
and (5 ).
a Pin s C02 (116 ), (118), an d ( 121) are the power su pply a nd pins C01 (2) an d (5 ) ar e the chassis
gro und.
a If th e vol tage is 20 30 V, it is nor ma l.
a Po wer supp ly conne ctors (C0 1, C02) of pump co ntroller
PC20 0, 220 -8 11
Information in troubleshooting table 1

a The fo llowing information is su mma rized in the trou bleshooting table an d the re lated electr ica l circuit
dia gram. Before carrying ou t tr ouble sh ooting, u nderstand that infor ma tion fully.
User code Failure c ode
Display on
Display o n machin e Trouble Trouble name displayed in abnorm ality r ecord machine monitor
machin e moni-
m onitor
tor
Contents of
Con tents of trou ble detected by m achine m onitor or co ntroller
trouble
Action of
Action taken by m achin e monitor or contro ller to pr otect system or d evices when eng ine con-
machine moni-
troller d etects trou ble
tor or controller
Problem that
Problem that appear s on m ach ine as result of action taken by m achine mo nitor or con tr oller
appears on
(shown above)
machine
Related infor-
In for mation related to detected tr ouble o r tro ubleshooting
mation
Cause Standard value in norm al state/Remarks on tr oubleshooting
<Contents of descr iptio n>

Standard value in norm al state to judge possible causes
Rem ar ks o n ju dgment
1
<Troubles in wir ing harness>
Disconn ection
Conn ector is co nnected imperfectly o r wiring harn ess is br o-
ken .
Grou nd fault
Wir ing har ness which is not con nected to chassis gro und
circuit is in contact with chassis grou nd cir cuit.
Ho t sh ort
Wir ing har ness which is not con nected to p ower so urce (24
2 V) circuit is in co ntact with po wer sour ce (24 V) circuit.
Shor t circuit
Ind epend ent wir ing h ar nesses are in contact with each o ther
Pos sible causes abnorm ally.
Pos sible c auses of trouble
and s tandard
value in normal (Given numbers are refer-
<Precaution s fo r tro ubleshooting >
state enc e numbers , which do not
(1) Method of ind icatin g connector No . and handling of T-
indicate priority)
adapter
In sert o r connect T-adapter as explained b elow for tr ouble-
shootin g, u nless other wise specified.
3 If connector No. has no marks of "m ale" and "female",
disconnect connector and insert T-adapter s in b oth m ale
side and fem ale side.
If connector No. has marks of "male" and "fem ale", dis-
connect co nnector and connect T-adapter to only male
side or female side.
(2) Entry or der of p in N os. and han dlin g of tester leads
Con nect po sitive (+) lead an d negative () lead of tester as
exp lained below fo r tro ubleshootin g, u nless o th er wise
specified .
4 Co nnect p ositive (+) lead to pin No . or wiring h ar ness
enter ed on fr ont side.
Co nnect n egative () lead to p in No . o r harn ess enter ed
on rear side.
12 PC200 , 220 -8
Related circuit diagra m
This drawing is a part of the elec tric c ircuit diagram related

to troubleshooting.
C onnec tor No.: Indicates (Model Number of pins) and
(Color).
"Connec tor No. and pin N o." from each branching/merg-
ing point: Shows the ends of branc h or sourc e of merging
within the parts of the s ame w iring harnes s.
Arrow (io): Roughly shows the location on the machine.
PC20 0, 220 -8 13
Failure code [989L00] Engine Controller Lock Caution 1 1

User code Failure c ode Engine controller loc k caution 1
Trouble
989L00 (Machine monitor system)
Contents of
Engine controller lock is detec ted (F ac tor 1).
trouble
Action of None in particular.
machine monitor If cause of failure disappears , sy stem resets itself.
Problem that
appears on Engine cannot be started.
machine
If this failure code is displayed after machine monitor is replaced, user password must be changed to
Related infor-
one before replacement.
mation
Method of reproduc ing failure code: Turn starting switch ON.
Pos sible causes Cause Standard value in normal state/Remark s on troubleshooting

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

Trouble
989M00 (Machine monitor system)
Contents of
trouble
Problem that
appears on Engine cannot be started.
machine
If this failure code is displayed after machine monitor is replaced, user password must be changed to
Related infor-
one before replacement.
mation
Cause Standard value in normal state/Remark s on troubleshooting

Pos sible causes Replacement of mac hine
1 This trouble may be caused by replacement of mac hine monitor.
and s tandard monitor
value in normal
If this failure code is displayed while machine monitor is not
state
2 Defectiv e mac hine monitor replaced, machine monitor may be defective. (Since trouble is in
sys tem, troubles hooting cannot be carried out.)
14 PC200 , 220 -8
Failure code [989N00] Engine Controller Lock Caution 3 1

Trouble
989N00 (Machine monitor system)
Contents of
trouble
Action of Tries automatic resetting.
Problem that
appears on
machine
Related infor- Method of reproduc ing failure code: Failure code is not reproduc ed s ince s ystem is res et automati-
mation cally.

and s tandard If this failure code is dis played repeatedly, engine controller may be
value in normal 1 Defectiv e engine controller defec tive. (Since trouble is in sys tem, troubleshooting c annot be
state carried out.)
Failure code [AA10NX] Air Cleaner Clogging 1

User code Failure c ode Air cleaner clogging
Trouble
AA10NX (Machine monitor system)
Contents of While engine was running, signal circuit of air cleaner clogging switch detected clogging of air
trouble cleaner (sensor contact opened).
Action of Dis plays air c leaner clogging monitor on mac hine monitor.
Problem that
appears on If machine is operated as it is, engine may be damaged.
machine
Condition of air cleaner clogging s witch s ignal can be c heck ed with monitoring function.
Related infor-
(Code: 04501 Monitor input 2)
mation
Method of reproduc ing failure code: Start engine.

Pos sible causes Clogging of air cleaner (when Air cleaner may be clogged. Check it for clogging and then clean or
1
and s tandard sys tem is normal) replace if clogged.
value in normal If cause 1 is not detected, air cleaner clogging monitor sys tem may
state Defectiv e air c leaner c log-
2 be defective. Carry out troubleshooting for "E-7 Caution item
ging monitor system
flashes while engine is running" in E-mode.
PC20 0, 220 -8 15
Failure code [AB00KE] Charge Voltage Low 1

User code Failure c ode Charge voltage low
Trouble
AB00KE (Machine monitor system)
Contents of
While engine is running, signal circuit of alternator detected low charge voltage (below 7.8 V).
trouble
Action of Dis plays charge lev el monitor on machine monitor.
machine monitor Even if cause of failure disappears , sy stem does not reset its elf until starting switc h is turned O FF.
Problem that
appears on If machine is operated as it is, battery may not be charged.
machine
Related infor- Signal voltage of alternator can be chec ked with monitoring function. (Code: 04300 Charge voltage)
mation Method of reproduc ing failure code: Start engine.

a Prepare with s tarting sw itch OFF, then start engine and c arry out
troubleshooting.
Pos sible causes Defectiv e charge of alterna-
1 E12 (male) Engine speed Voltage
and s tandard tor (when system is normal)
value in normal Between (1) chas -
Min. medium speed 27.5 29.5 V
state sis ground
If cause 1 is not detected, charge level monitor sy stem may be
Defectiv e charge lev el moni-
2 defec tive. Carry out troubleshooting for "E-7 Caution item flashes
tor
while engine is running" in E-mode.
16 PC200 , 220 -8
Circuit diagra m relate d to preheating/starting of e ngine a nd charge of ba ttery
PC20 0, 220 -8 17
Failure code [B@BAZG] Eng Oil Press. Low 1

User code Failure c ode Engine oil pressure low
Trouble
B@BA ZG (Engine c ontroller system)
Contents of While engine was running, signal circuit of engine oil pressure switc h detected low engine oil pres-
trouble sure (sens or c ontact opened).
Action of Dis plays engine oil pres sure monitor on mac hine monitor.
controller If cause of failure disappears , sy stem resets itself.
Problem that
machine
Engine oil press ure switch signal is input to engine controller and then transmitted to mac hine moni-
Related infor-
tor.
mation

Low ering of engine oil pres-
Pos sible causes Engine oil pressure may be low. Check it and remove cause if it is
1 sure (when sy stem is nor-
and s tandard low.
mal)
value in normal
state If cause 1 is not detected, engine oil pres sure m onitor sys tem may
Defectiv e engine oil pressure
2 be defective. Carry out troubleshooting for "E-8 Emergency stop
monitor system
item lights up while engine is running" in E-mode.
Failure code [B@BAZK] Eng Oil Level Low 1

User code Failure c ode Engine oil level low
Trouble
B@B AZK (Machine monitor system)
Contents of When starting switc h is turned ON (but engine is not started), signal c ircuit of engine oil level s witch
trouble detec ted low engine oil level (sensor contact opened).
Action of Dis plays engine oil level monitor on machine monitor.
machine monitor Even if cause of failure disappears , sy stem does not reset its elf until starting switc h is turned O FF.
Problem that
machine
Related infor- Engine oil level switch signal can be checked with monitoring func tion. (Code: 04501 Monitor input 2)
mation Method of reproduc ing failure code: Turn starting switch ON.

Low ering of engine oil level
Pos sible causes 1 Engine oil level may be low. Check it and add new oil if it is low.
(when s ystem is normal)
and s tandard
value in normal If cause 1 is not detected, engine oil level monitor s ystem may be
state Defectiv e engine oil level defec tive. C arry out troubleshooting for "E-2 Basic chec k item lights
2
monitor system up when s tarting sw itch is turned ON (but engine is not started)" in
E-m ode.
18 PC200 , 220 -8
Failure code [B@BCNS] Eng Water Overheat 1

User code Failure c ode Engine coolant overheat
Trouble
B@BC NS (Engine c ontroller system)
Contents of While engine was running, signal circuit of engine coolant temperature s ensor detec ted overheating
trouble of engine coolant (above about 102°C).
Action of Dis plays engine c oolant temperature monitor with red on machine m onitor.
Problem that
appears on If machine is operated as it is, engine may be s eized.
machine
Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor.
Related infor-
Engine coolant temperature can be c hecked with monitoring function
mation
(Code: 04107 Engine coolant temperature)

Overheating of engine
Pos sible causes Engine c oolant may be ov erheating. Check it and remov e c ause if it
1 coolant (when sys tem is nor-
and s tandard is overheating.
mal)
value in normal
state If cause 1 is not detected, engine c oolant temperature gauge sys -
Defectiv e engine c oolant
2 tem may be defectiv e. Carry out troubleshooting for "E-9 Engine
temperature gauge system
coolant temperature gauge does not work normally" in E-mode.
Failure code [B@BCZK] Eng Water Level Low 1

User code Failure c ode Engine coolant level low
Trouble
B@BC ZK (Machine monitor system)
Contents of When starting switch is turned ON, signal circuit of radiator coolant lev el sensor detected low rad iator
trouble coolant level (sensor contac t opened).
Action of Dis plays radiator coolant level monitor on machine m onitor.
machine monitor Even if cause of failure disappers, system does not reset itself until starting switch is turned OFF.
Problem that
appears on If machine is operated as it is, engine may ov erheats .
machine
Condition of radiator coolant level sw itch can be chec ked with monitoring function
Related infor-
mation

Low ering of radiator coolant
Radiator c oolant lev el may be low. Chec k it and add coolant if it is
Pos sible causes 1 level (when sy stem is nor-
low.
and s tandard mal)
value in normal If caus e 1 is not detec ted, radiator c oolant lev el monitor s ystem may
state
Defectiv e radiator coolant be defective. Carry out troubleshooting for "E-2 Basic chec k item
2
level monitor sy stem lights up when starting sw itch is turned ON (but engine is not
started)" in E-mode.
PC20 0, 220 -8 19
Failure code [B@HANS] Hydr Oil Overheat 1

User code Failure c ode Hydraulic oil overheat
Trouble
B@HA NS (Pump c ontroller s ystem)
Contents of While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating o f
trouble hydraulic oil (above about 102°C).
Action of Dis plays hy draulic oil temperature monitor with red on machine monitor.
Problem that
appears on If machine is operated as it is, engine may be s eized.
machine
Hy draulic oil temperature s ensor signal is input to engine c ontroller and then transmitted to machine
monitor.
Related infor-
Hy draulic oil temperature can be c hecked with monitoring function
mation
(Code: 04401 Hydraulic oil temperature)

Pos sible causes Overheating of hydraulic oil Hydraulic oil may be ov erheating. C heck it and remov e c ause if it is
1
and s tandard (when s ystem is normal) overheating.
value in normal
If cause 1 is not detected, hy draulic oil temperature gauge s ystem
state Defectiv e hy draulic oil tem-
2 may be defec tive. Carry out troubleshooting for "E-10 Hy draulic oil
perature gauge system
temperature gauge does not work normally " in E-mode.
Failure code [CA111] EMC Critical Internal Failure 1

User code Failure c ode Critical internal failure
Trouble
E10 CA111 (Engine c ontroller system)
Contents of
Memory or pow er supply c ircuit in engine c ontroller is defec tive.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine does not start.
machine
Related infor-
mation

and s tandard
value in normal Engine controller may be defec tive.
1 Defectiv e engine controller
(Since trouble is in system, troubleshooting c annot be carried out.)
state
20 PC200 , 220 -8
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 1

User code Failure c ode Engine Ne and Bkup speed sensor error
Trouble
Contents of
Both signals of engine Ne speed s ensor and engine Bkup speed sensor are abnormal.
trouble
Action of
None in particular.
controller
Problem that
Engine stops.
appears on
Engine does not start.
machine
Related infor-
mation

and s tandard Connectors of Ne speed sensor and Bk up s peed sens or may be
value in normal Defectiv e connection of sen-
1 connected defectiv ely (or c onnec ted to wrong parts). Check them
state sor connector
directly.
PC20 0, 220 -8 21
Failure code [CA122] Chg Air Press Sensor High Error 1

User code Failure c ode Charge air press ure sensor high error
Trouble
E11 CA 122 (Engine c ontroller system)
Contents of
Pressure signal circuit of boost pressure/temperature sensor detected high voltage.
trouble
Action of
F ix es charge pres sure v alue and c ontinues operation.
controller
Problem that
appears on Engine output lowers.
machine
Signal voltage on boost pressure side of boost press ure/temperature s ensor can be chec ked with
Related infor-
monitoring function. (Code: 36501 Boost pressure sensor voltage)
mation

Defectiv e sensor power sup- If failure c ode [ CA227] is also indicated, c arry out troubleshooting
1
ply 2 sy stem for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and c arry out troubleshooting.
Defectiv e boost pressure/ BOOST PRESS & IMT Voltage
2 temperature sensor [pres- Between (3) (1) Power s upply 4.75 5.25 V
sure signal s ystem]
Voltage is measured with wiring harness connected. Ac cordingly, if
voltage is abnormal, chec k wiring harnes s and controller, too, for
another cause of trouble, and then judge.
Hot short (Short circuit with 5 and c arry out troubleshooting.
3 V/24 V circuit) in wiring har-
Wiring harness between CE01 (female) (44)
nes s Voltage Max. 1 V
Pos sible causes BOOST PRESS & IMT (female) (4)
and s tandard
value in normal a Prepare w ith starting switch OFF, then carry out troubleshooting
without turning s tarting s witch ON.
state Short circuit in wiring har-
4 nes s (with another w iring Wiring harness between CE01 (female) (44)
harness) BOOST PRESS & IMT (female) (4) and Resis- Min. 100
between CE01 (female) (37) JC01 tance kz
BOOST PRESS & IMT (female) (3)
Connecting parts between boos t pressure/temperature sensor
engine wiring harness engine controller may be defective. Chec k
Defectiv e wiring harness them direc tly.
5
connector Loos eness of connector, breakage of lock, or breakage of seal
Corrosion, bend, breakage, push-in, or expans ion of pin
Moisture or dirt in connector or defective insulation
CE01 Voltage
Between (37) (47) Power supply 4.75 5.25 V
22 PC200 , 220 -8
Circuit diagra m relate d to boost pres sure/tem pe ra ture sensor ( Combination sensor)
PC20 0, 220 -8 23
Failure code [CA123] Chg Air Press Sensor Low Error 1

User code Failure c ode Charge air press ure sensor low error
Trouble
Contents of
Pressure signal circuit of boost pressure/temperature sensor detected low voltage.
trouble
Action of
F ix es charge pres sure v alue and c ontinues operation.
controller
Problem that
machine
Signal voltage on boost pressure side of boost press ure/temperature s ensor can be chec ked with
Related infor-
monitoring function. (Code: 36501 Boost pressure sensor voltage)
mation

1
Defectiv e boost pressure/ BOOST PRESS & IMT Voltage
2 temperature sensor [pres- Between (3) (1) Power s upply 4.75 5.25 V
sure signal s ystem]
a Prepare w ith starting switch OFF, then carry out troubleshooting
Ground fault in wiring har- without turning s tarting s witch ON.
3 nes s (Short circuit with GND
Wiring harness between CE01 (female) (44) Resis- Min. 100
circuit)
Pos sible causes BOOST PRESS & IMT (female) (4) tance kz
and s tandard
harness) BOOST PRESS & IMT (female) (4) and Resis- Min. 100
BOOST PRESS & IMT (female) (1)
5
CE01 Voltage
24 PC200 , 220 -8
PC20 0, 220 -8 25
Failure code [CA131] Throttle Sensor High Error 1

User code Failure c ode Throttle sensor high error
Trouble
Contents of
Signal c ircuit of fuel control dial detected high v oltage.
trouble
If trouble oc curs while starting switch is in ON position, controller fixes v oltage value to lev el just
Action of before detection of trouble and continues operation.
controller If starting s witch is turned ON while voltage is abnormally high, controller continues operation with
voltage at 100% value.
Problem that
appears on Engine speed c annot be controlled with fuel control dial.
machine
Signal voltage of fuel control dial c an be checked with monitoring function. (Code: 03000 Fuel con -
Related infor-
trol dial voltage)
mation

Defectiv e throttle sens or If failure c ode [ CA2185] is also indicated, carry out troubleshooting
1
pow er s upply sy stem for it first.
P20 Voltage
2 Defectiv e fuel control dial Between (1) (3) Power s upply 4.75 5.25 V
Hot short (Short circuit with 5 and c arry out troubleshooting.
3 V/24 V circuit) in wiring har-
Pos sible causes Wiring harness between CE02 (female) (9)
and s tandard P20 (female) (2)
value in normal
state
Short circuit in wiring har- without turning s tarting s witch ON.
harness) Resis- Min. 100
P20 (female) (2) and between CE02 (fem ale)
tance kz
(22) P20 (female) (1)
Connecting parts between fuel c ontrol dial mac hine wiring har-
nes s engine controller may be defective. Check them direc tly.
Defectiv e wiring harness
5 Loos eness of connector, breakage of lock, or breakage of seal
connector
CE02 Voltage
26 PC200 , 220 -8
Circuit diagra m relate d to f ue l control dial
PC20 0, 220 -8 27
Failure code [CA132] Throttle Sensor Low Error 1

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

Defectiv e throttle sens or If failure c ode [ CA2186] is also indicated, carry out troubleshooting
1
P20 Voltage
2 Defectiv e fuel control dial Between (1) (3) Power s upply 4.75 5.25 V
Pos sible causes Wiring harness between CE02 (female) (9) Resis- Min. 100
circuit)
and s tandard P20 (female) (2) tance kz
value in normal
state
P20 (female) (2) and between CE02 (fem ale)
tance kz
(23) P20 (female) (3)
nes s engine controller may be defective. Check them directly.
connector
CE02 Voltage
28 PC200 , 220 -8
PC20 0, 220 -8 29
Failure code [CA144] Coolant Temp Sens High Error 1

User code Failure c ode Coolant temperature s ensor high error
Trouble
Contents of
Signal circuit of coolant temperature sensor detected high v oltage.
trouble
Action of
F ix es coolant temperature value and continues operation.
controller
Problem that
Exhaus t gas becomes white.
appears on
Overheat prevention function does not work.
machine
Signal voltage of coolant temperature sensor c an be c hecked with monitoring function. (Code: 04105
Related infor-
Coolant temperature s ensor voltage)
mation

Defectiv e coolant tempera-
1
ture sensor COOLANT TEMP (male) Resistance
Between (A) (B) 0.18 160 kz
Disconnection in wiring har-
nes s (Dis connection in wiring Wiring harness between CE01 (female) (15) Resis-
2 Max. 10 z
or defec tive contact in con- COOLANT TEMP (female) (B) tance
nec tor) Wiring harness between CE01 (female) (38) Resis-
Max. 10 z
JC03 COOLANT T EMP (female) (A) tance
Pos sible causes
and s tandard without turning s tarting s witch ON.
Short circuit in wiring har-
value in normal
state Resis- Min. 100
harness) eac h of CE01 (female) pins (With all wiring
tance kz
harness c onnec tors disconnected)
Connecting parts between coolant temperature sensor engine wir-
ing harnes s engine controller may be defec tive. Check them
Defectiv e wiring harness directly.
4
CE01 (female) Resistance
Between (15) (38) 0.18 160 kz
30 PC200 , 220 -8
Circuit diagra m relate d to coolant temperature s ensor
PC20 0, 220 -8 31
Failure code [CA145] Coolant Temp Sens Low Error 1

User code Failure c ode Coolant temperature s ensor low error
Trouble
Contents of
Signal circuit of coolant temperature sensor detected low voltage.
trouble
Action of
F ix es coolant temperature value and continues operation.
controller
Problem that
appears on
Overheat prevention function does not work.
machine
Signal voltage of coolant temperature sensor c an be c hecked with monitoring function. (Code: 04105
Related infor-
Coolant temperature s ensor voltage)
mation

Defectiv e coolant tempera- COOLANT TEMP (male) Resistance
1
ture sensor
Between (A) (B) 0.18 160 kz
Between (B) chassis ground Min. 100 kz
circuit) Wiring harness between CE01 (female) (15) Resis- Min. 100
COOLANT TEMP (female) (B) tance kz
Pos sible causes without turning s tarting s witch ON.
and s tandard
value in normal Resis- Min. 100
state tance kz
Connecting parts between coolant temperature sensor engine wir-
4
5 Defectiv e engine controller CE01 (female) Resistance

Between (15) (38) 0.18 160 kz
Between (15) chas sis ground Min. 100 kz
32 PC200 , 220 -8
Circuit diagra m relate d to coolant temperature s ensor
PC20 0, 220 -8 33
Failure code [CA153] Chg Air Temp Sensor High Error 1

User code Failure c ode Charge air temperature sens or high error
Trouble
Contents of
Temperature signal circuit of boost pressure/temperature sensor detected high v oltage.
trouble
Action of
F ix es charge temperature value and continues operation.
controller
Problem that
appears on
Engine protection func tion based on boost temperature does not work
machine
Signal voltage on boost temperature side of boost pressure/temperature sensor can be chec ked with
Related infor-
monitoring function. (Code: 18501 Boost temperature sensor voltage)
mation

Defectiv e boost pressure/ without turning s tarting s witch ON.
1 temperature sensor [temper-
BOOST PRESS & IMT (male) Res is tance
ature signal sy stem]
Between (2) (1) 0.18 160 kz
nes s (Dis connection in wiring Wiring harness between CE01 (female) (23) Resis-
2 Max. 10 z
or defec tive contact in con- BOOST PRESS & IMT (female) (2) tance
Max. 10 z
JC02 BOOST PRESS & IMT (female) (1) tance
Pos sible causes
value in normal
state Resis- Min. 100
tance kz
4
Between (23) (47) 0.18 160 kz
34 PC200 , 220 -8
PC20 0, 220 -8 35
Failure code [CA154] Chg Air Temp Sensor Low Error 1

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

Defectiv e boost pressure/
1 temperature sensor [temper- BOOST PRESS & IMT (male) Res is tance
ature signal sy stem] Between (2) (1) 0.18 160 kz
Between (2) chassis ground Min. 100 kz
BOOST PRESS & IMT (female) (2) tance kz
and s tandard
state tance kz
4

Between (23) (47) 0.18 160 kz
36 PC200 , 220 -8
PC20 0, 220 -8 37
Failure code [CA155] Chg Air Temp High Speed Derate 1

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

Cooling performance of aftercooler may be low. Check following
points directly.
Low ering of cooling perfor-
Pos sible causes 1 Loos eness and breakage of fan belt.
manc e of aftercooler
and s tandard Ins ufficiency of c ooling air
value in normal Clogging of aftercooler fins
state Abnormal ris e of turbo- Outlet temperature of turbocharger m ay be abnormally high. Chec k
2
charger outlet temperature related parts directly.
If caus es 1 2 are not detected, engine controller may be defec tive.
38 PC200 , 220 -8
Failure code [CA187] Sens Supply 2 Volt Low Error 1

User code Failure c ode Sensor power supply 2 v oltage low error
Trouble
Contents of
Low voltage was detected in sens or power supply 2 circuit.
trouble
F ix es boost press ure value and continues operation.
Action of
controller
Problem that
machine
Related infor-
mation

a Disconnect connector with starting switch OFF, then turn s tarting
switch ON and c arry out troubles hooting.
Disconnect sensors Boost press ure/tem- BOOST PRESS &
and wiring harness at perature sens or IMT
right in order and
Defectiv e sensor or wiring carry out operation to Common rail pres -
1 FUEL RAIL PRESS
harness reproduce trouble. If sure sens or
"E" of failure code
Pos sible causes
goes off when a sen-
and s tandard Bkup sensor CAM SENSOR
sor or wiring harness
value in normal
is disconnected, that
state Engine wiring har-
sensor or wiring har-
CE01
nes s is defective. nes s
Connecting parts between each sensor engine wiring harnes s

engine controller may be defec tive. Chec k them direc tly.
connector
If caus es 1 2 are not detected, engine controller may be defec tive.
40 PC200 , 220 -8
Circuit diagra m relate d to sensor pow er supply 2
PC20 0, 220 -8 41
Failure code [CA221] Ambient Press Sens High Error 1

User code Failure c ode Ambient pressure sensor high error
Trouble
Contents of
High voltage was detec ted in signal circuit of ambient pressure sensor.
trouble
Action of
F ix es ambient pressure value and continues operation.
controller
Problem that
Engine does not start easily.
appears on
machine
Signal voltage of ambient pressure sens or c an be checked with monitoring function. (Code: 37401
Related infor-
Ambient pressure sensor v oltage
mation

1
AMBAIR PR ESURE Voltage
Defectiv e ambient press ure
2 Between (1) (2) Power supply 4.75 5.25V
sensor
Hot short (Short circuit w ith and c arry out troubleshooting.
3 5V/24V circuit) in wiring har-
Pos sible causes nes s Voltage Max. 1 V
and s tandard AMBAIR PR ESSURE (female) (3)
state without turning s tarting s witch ON.
harness) AMBAIR PR ESSURE (female) (3) and Resis- Min. 100
between CE01 (female) (33) AMBAIR tance kz
PRESSURE (female) (1)
Connecting parts between ambient press ure sensor engine wiring
harness engine controller may be defectiv e. Check them directly.
connector
CE01 Voltage
Between (33) (38) Voltage 4.75 5.25 V
42 PC200 , 220 -8
Circuit diagra m relate d to a mbient pressure sensor
PC20 0, 220 -8 43
Failure code [CA222] Ambient Press Sens Low Error 1

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

1
AMBAIR PR ESURE Voltage
Defectiv e ambient press ure
2 Between (1) (2) Power supply 4.75 5.25V
sensor
Pos sible causes circuit)
and s tandard AMBAIR PR ESSURE (female) (3) tance kz
harness) AMBAIR PR ESSURE (female) (3) and Resis- Min. 100
AMBAIR PR ESSURE (female) (2)
harness engine controller may be defectiv e. Check them directly.
connector
CE01 Voltage
Between (33) (38) Voltage 4.75 5.25 V
44 PC200 , 220 -8
Circuit diagra m relate d to a mbient pressure sensor
PC20 0, 220 -8 45
Failure code [CA227] Sens Supply 2 Volt High Error 1

User code Failure c ode Sensor power supply 2 v oltage high error
Trouble
Contents of
High voltage was detec ted in sens or power supply 2 circuit.
trouble
F ix es boost press ure value and continues operation.
Action of
controller
Problem that
machine
Related infor-
mation

Pos sible causes engine controller may be defec tive. Chec k them direc tly.
and s tandard 1 Loos eness of connector, breakage of lock, or breakage of seal
connector
value in normal Corrosion, bend, breakage, push-in, or expans ion of pin
state Moisture or dirt in connector or defective insulation
If cause 1 is not detected, engine c ontroller may be defectiv e.
46 PC200 , 220 -8
Failure code [CA234] Eng Overspeed 1

User code Failure c ode Engine ov erspeed
Trouble
CA234 (Engine c ontroller system)
Contents of
Engine speed exc eeded c ontrol upper speed limit.
trouble
Action of
Stops injection until engine speed lowers to normal level.
controller
Problem that
appears on Engine speed fluc tuates .
machine
Related infor- Engine speed c an be checked with monitoring function. (Code: 01002 Engine speed)
mation Method of reproduc ing failure code: Run engine at high idle.
Pos sible causes 1 Use of improper fuel Fuel us ed may be improper. Check it directly.
and s tandard Machine may be used improperly. Teach operator proper using
value in normal 2 Improper use
method.
state
If causes 1 2 are detec ted, engine controller may be defec tive.
PC20 0, 220 -8 47
Failure code [CA238] Ne Speed Sens Supply Volt Error 1

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

Disconnect sensor
and wiring harness at
right in order and Ne speed s ensor CRAN K SENSOR
Defectiv e sensor or wiring carry out operation to
1 reproduce trouble. If
Pos sible causes harness
and s tandard "E" of failure code
value in normal goes off when s ensor
state or wiring harness is Engine wiring har-
disconnected, that CE01
nes s
nes s is defective.
connector
Circuit diagra m relate d to e ngine Ne spee d sensor
48 PC200 , 220 -8
Failure code [CA271] IMV/PCV1 Short Error 1

User code Failure c ode IMV/PCV1 short circuit error
Trouble
Contents of
Short circuit w as detected in drive circuit of supply pump actuator.
trouble
Action of
None in particular.
controller
Problem that Engine speed does not rise from low idle.
machine Common rail fuel pressure rises abov e c ommand value.
Related infor-
mation

Defectiv e supply pump actu- without turning s tarting s witch ON.
1
ator CP3 PU MP REGULATOR (male) Resis tance
Between (1) chassis ground Min. 100 k z
Ground fault in wiring har-
CP3 PU MP REGULATOR (female) (1) tance kz
Pos sible causes a Prepare w ith starting switch OFF, then carry out troubleshooting
and s tandard
value in normal 3 nes s (with another w iring Wiring harness between CE01 (female) (2)
state eac h of CE01 (fem ale) pins (With all wiring
tance kz
Connecting parts between s upply pump actuator engine wiring
harness engine controller may be defectiv e. Chec k them direc tly.
connector
Between (2) chassis ground Min. 100 k z
Circuit diagra m relate d to supply pump actuator (m etering unit)
PC20 0, 220 -8 49
Failure code [CA272] IMV/PCV1 Open Error 1

User code Failure c ode IMV/PCV1 open error
Trouble
E10 CA272 (Engine controller system)
Contents of
Opening was detected in drive c irc uit of s upply pump ac tuator.
trouble
Action of
None in particular.
controller
Problem that
Engine runs but its operation is unstable.
appears on
Common rail fuel pressure rises above c ommand value.
machine
Related infor-
mation

a Prepare with starting s witch OFF, then c arry out troubleshooting
Defectiv e supply pump actu- without turning s tarting s witch ON.
1
ator CP3 PUMP REGULATOR (male) R esis tance
Between (1) (2) Max. 5 z
Disconnection in wiring har- without turning s tarting s witch ON.
nes s (Disconnection in wiring Wiring harness between CE01 (female) (2) Resis-
2 Max. 10 z
or defec tive contact in c on- CP3 PU MP REGULATOR (female) (1) tance
nec tor) Wiring harness betw een CE01 (female) (32) Resis-
Max. 10 z
CP3 PUMP REGULATOR (female) (2) tance
a Prepare w ith starting switc h OFF, then turn starting s witch ON
Hot s hort (Short circuit w ith and c arry out troubleshooting.
Pos sible c auses 3
24V c irc uit) in wiring harness Wiring harness between CE01 (female) (2)
and s tandard Voltage Max. 3 V
CP3 PU MP REGULATOR (female) (1)
value in normal
state
Short circuit in wiring harness
4 Wiring harness between CE01 (female) (2)
(with another wiring harness ) Resis- Min. 100
eac h of CE01 (fem ale) pins (With all wiring
tance kz
Connecting parts between supply pump actuator engine wiring
connector
Moisture or dirt in connector or defectiv e insulation
6 Defec tive engine controller
50 PC200 , 220 -8
Failure code [CA322] Inj #1 (L#1) Open/Short Error 1

User code Failure c ode Injector #1 (L#1) open/short circuit error
Trouble
E11 CA 322 (Engine controller system)
Contents of
Opening or short circuit was detected in drive circuit of No. 1 injec tor.
trouble
Action of
None in particular.
controller
Problem that
Combustion becomes irregular or engine hunts.
appears on
Engine output low ers.
machine
Related infor-
mation

If follow ing failure c odes are also display ed, trouble is in engine con-
troller. [CA322], [CA324], [CA331]
2 Defec tive No. 1 injector INJ CYL 1 (male) Resistance
nes s (Disconnection in wiring Wiring harness betw een CE01 (female) (45) Resis-
3 Max. 2 z
or defec tive contact in c on- INJ CYL 1 (female) (1) tance
nec tor)
Wiring harness betw een CE01 (female) (53) Resis-
Max. 2 z
INJ CYL 1 (female) (2) tance
Pos sible c auses 4 nes s (Short circ uit with GND
circuit) Wiring harness betw een CE01 (female) (45) Resis-
and s tandard Max. 2 z
value in normal
state a Prepare with starting s witch OFF, then c arry out troubleshooting
Wiring harness betw een CE01 (female) (45)
Resis- Min. 100
Short circuit in wiring harness eac h of CE01 (female) pins (With all wiring
5 tance kz
(with another wiring harness ) harness c onnec tors disconnected)
Resis- Min. 100
eac h of CE01 (female) pins (With all wiring
tance kz
Connecting parts between No. 1 injector engine wiring harness
connector
7 Defec tive engine controller CE01 (female) Resistance

Between (45) (53) Max . 2 z
52 PC200 , 220 -8
Circuit diagra m relate d to No. 1 injec tor
PC20 0, 220 -8 53

Trouble
Contents of
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related infor-
mation

troller. [CA323], [CA325], [CA332]
3 Max. 2 z
nec tor)
Max. 2 z
value in normal
Resis- Min. 100
5 tance kz
Resis- Min. 100
tance kz
connector

54 PC200 , 220 -8
PC20 0, 220 -8 55

Trouble
Contents of
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related infor-
mation

troller. [CA322], [CA324], [CA331]
3 Max. 2 z
nec tor)
Max. 2 z
value in normal
Resis- Min. 100
5 tance kz
Resis- Min. 100
tance kz
connector

56 PC200 , 220 -8
PC20 0, 220 -8 57

Trouble
Contents of
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related infor-
mation

troller. [CA323], [CA325], [CA332]
3 Max. 2 z
nec tor)
Max. 2 z
value in normal
Resis- Min. 100
5 tance kz
Resis- Min. 100
tance kz
connector

58 PC200 , 220 -8
PC20 0, 220 -8 59

Trouble
Contents of
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related infor-
mation

troller. [CA322], [CA324], [CA331]
3 Max. 2 z
nec tor)
Max. 2 z
value in normal
Resis- Min. 100
5 tance kz
Resis- Min. 100
tance kz
connector

60 PC200 , 220 -8
PC20 0, 220 -8 61

Trouble
Contents of
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related infor-
mation

troller. [CA323], [CA325], [CA332]
3 Max. 2 z
nec tor)
Max. 2 z
value in normal
Resis- Min. 100
5 tance kz
Resis- Min. 100
tance kz
connector

62 PC200 , 220 -8
PC20 0, 220 -8 63
SE N0 0240- 01
© 2 006 KO MATSU
All Rights Reserved
64
SE N00 241- 01
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Tr ouble sh ooting by failu re cod e ( Di spla y of cod e), P art 2 .............................................................................. 3
Failur e code [CA342 ] Calibra tio n Cod e Incompa tibi lity ........................................................................ 3
Failur e code [CA351 ] Injecto rs Drive Cir cu it Erro r ............................................................................... 4
Failur e code [CA352 ] Se ns Su pply 1 Volt Low E rror ............................................................................ 6
Failur e code [CA386 ] Se ns Su pply 1 Volt Hig h Error ........................................................................... 8
Failur e cod e [CA428 ] Wa te r in Fuel Se nsor Hig h E rror ..................................................................... 1 0
Failur e cod e [CA429 ] Wa te r in Fuel Se nsor L ow E rror ...................................................................... 1 2
Failur e code [CA435 ] En g O il P ress Sw Error ................................................................................... 14
Failur e code [CA441 ] Ba ttery Voltage Lo w Err or ............................................................................... 1 5
Failur e code [CA442 ] Ba ttery Voltage High Er ror............................................................................... 18
Failur e code [CA449 ] Rail Press Very High Error .............................................................................. 2 0
Failur e code [CA451 ] Rail Press S ensor High Error .......................................................................... 2 2
Failur e code [CA452 ] Rail Press S ensor Low Error ........................................................................... 2 4
Failur e code [CA488 ] Chg Air Temp Hig h Tor que Derate .................................................................. 2 6
PC20 0, 220 -8 1
Failur e code [CA553 ] Rail Press High E rror ....................................................................................... 26

Failur e code [CA559 ] Rail Press L ow E rror........................................................................................ 2 7
Failur e code [CA689 ] En g Ne Speed S ensor Error ............................................................................ 2 8
Failur e code [CA731 ] Eng B ku p Spe ed Sens Phase Err or ................................................................ 3 0
Failur e code [CA757 ] All Continuo us Data Lost Erro r ........................................................................ 3 2
Failur e code [CA778 ] En g B ku p Spe ed Sensor Err or ........................................................................ 3 4
Failur e code [CA163 3] KO MNE T Datalink Timeout Error .................................................................. 3 6
Failur e code [CA218 5] Throt Sens Sup Volt Hig h E rror ..................................................................... 3 8
Failur e code [CA218 6] Throt Sens Sup Volt L ow E rror ...................................................................... 3 9
Failur e code [CA224 9] Rail Pre ss Ve ry Low Erro r ............................................................................. 4 0
Failur e code [CA2311] IMV Sole noid Err or ........................................................................................ 42
Failur e code [CA255 5] G rid Htr Re lay Volt Hi gh Error ....................................................................... 4 4
Failur e code [CA255 6] G rid Htr Re lay Volt Low Error ........................................................................ 4 6
Failur e code [D19JKZ] Pe rso nal Code Relay Abno rmality................................................................. 4 8
Failur e code [D862K A] G PS Antenn a Discon .................................................................................... 5 0
Failur e code [DA22K K] P ump S olen oid Power Low Erro r.................................................................. 5 1
Failur e code [DA25K P] 5 V S ensor 1 Power Abn ormality................................................................... 5 3
Failur e code [DA29K Q] Mod el Selection Abn ormality........................................................................ 6 0
2 PC200 , 220 -8

Failure code [CA342] Calibration Code Incompatibility 1
User code Failure c ode Calibration code incompatibility
Trouble
Contents of
Inc ompatibility of data occurred in engine controller.
trouble
Action of
None in particular.
controller
Problem that
Continues normal operation.
appears on
Engine stops or does not start.
machine
Related infor-
mation

Pos sible causes
and s tandard 1 Defect in related sys tem If another failure c ode is displayed, carry out troubleshooting for it.
value in normal
Engine controller may be defectiv e. (Troubleshooting cannot be c ar-
state 2 Defectiv e engine controller
ried out.)
PC20 0, 220 -8 3
Failure code [CA351] Injectors Drive Circuit Error 1

User code Failure c ode Injectors Drive C ircuit Error
Trouble
Contents of
T here is error in drive pow er circ uit of injec tor.
trouble
Action of
controller
Exhaus t gas becomes black .
Problem that
Combustion bec omes irregular.
appears on
machine
Engine cannot be started.
Related infor-
mation

1 Defect in related sys tem If another failure c ode is displayed, carry out troubleshooting for it.
2 Defectiv e fuse No. 19 If fuse is broken, c ircuit probably has ground fault.
Defectiv e relay for engine
3 Replace relay (R23, R24) for engine controller with another relay
controller pow er supply
and perform reproducing operation. If "E" of failure code goes off at
Pos sible causes this time, replaced relay is defective.
and s tandard a Prepare w ith starting switch OFF, then carry out troubleshooting
value in normal without turning s tarting s witch ON.
state
Disconnection in wiring har- Wiring harness between F01-19 R23, R 24 Resis- Max. 0.5
nes s (Dis connection in w iring (female) (3) tance z
4
or defec tive contact in con- Wiring harness between R23, R24 (female) Resis- Max. 0.5
nec tor) (5) CE03 (female) (3) tance z
Wiring harness between CE03 (female) (1) Resis-
Max. 10 z
chassis ground (T12) tance
If caus es 1 4 are not detected, engine c ontroller may be defective.
(Since trouble is in sys tem, troubleshooting cannot be carried out.)
4 PC200 , 220 -8
Circuit diagra m relate d to e ngine c ontroller
PC20 0, 220 -8 5
Failure code [CA352] Sens Supply 1 Volt Low Error 1

User code Failure c ode Sensor power supply 1 v oltage low error
Trouble
Contents of
Low voltage was detected in sens or power supply 1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related infor-
mation

Disconnect sensor
and wiring harness at
Ambient pres sure
right in order and AMBAIR PRESURE
sensor
Defectiv e sensor or wiring carry out operation to
1 reproduce trouble. If
harness
Pos sible causes "E" of failure code
goes off when s ensor
and s tandard
or wiring harness is Engine wiring har-
value in normal CE01
disconnected, that nes s
state
nes s is defective.
connector
6 PC200 , 220 -8
PC20 0, 220 -8 7
Failure code [CA386] Sens Supply 1 Volt High Error 1

User code Failure c ode Sensor power supply 1 v oltage high error
Trouble
Contents of
High voltage was detec ted in sens or power supply 1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related infor-
mation

Pos sible causes harness engine controller may be defectiv e. Chec k them direc tly.
and s tandard 1 Loos eness of connector, breakage of lock, or breakage of seal
connector
value in normal Corrosion, bend, breakage, push-in, or expans ion of pin
state Moisture or dirt in connector or defective insulation
If cause 1 is not detected, engine c ontroller may be defective.
Circuit diagra m relate d to sensor pow er s upply 1
8 PC200 , 220 -8
Failure code [CA428] Water in Fuel Sensor High Error 1

User code Failure c ode Water-in-fuel s ensor high error
Trouble
Contents of
High voltage was detec ted in signal circuit of water-in-fuel sens or.
trouble
Action of
None in particular.
controller
Problem that
appears on Water separator monitor does not display normally.
machine
Condition w ater-in-fuel s ensor signal c an be checked with monitoring function. (Code: 18800 Condi-
Related infor-
tion of WIF s ensor)
mation

Defectiv e water-in-fuel s en-
1
sor P47 (female) Resistance
nes s (Dis connection in w iring Wiring harness between CE01 (female) (14) Resis-
2 Max. 10 z
or defec tive contact in con- P47 (male) (1) tance
Max. 10 z
JC02 P47 (male) (2) tance
Pos sible causes
value in normal Short circuit in wiring har- without turning s tarting s witch ON.
state 3 nes s (with another w iring Wiring harness between CE01 (female) (14)
tance kz
Connecting parts between water-in-fuel sensor engine wiring har-
connector
10 PC200 , 220 -8
Circuit diagra m relate d to wate r-in-fuel sens or
PC20 0, 220 -8 11
Failure code [CA429] Water in Fuel Sensor Low Error 1

User code Failure c ode Water-in-fuel s ensor low error
Trouble
Contents of
Low voltage was detected in signal circuit of water-in-fuel sensor.
trouble
Action of
None in particular.
controller
Problem that
appears on Water separator monitor does not display normally.
machine
Condition w ater-in-fuel s ensor signal c an be checked with monitoring function. (Code: 18800 Condi-
Related infor-
tion of WIF s ensor)
mation

Defectiv e water-in-fuel s en- P47 (female) Resistance
1
sor
P47 (male) (1) tance kz
and s tandard Short circuit in wiring har- without turning s tarting s witch ON.
value in normal 3 nes s (with another w iring Wiring harness between CE01 (female) (14)
Resis- Min. 100
state harness) eac h of CE01 (female) pins (With all wiring
tance kz
Connecting parts between water-in-fuel sensor engine wiring har-
connector

12 PC200 , 220 -8
Circuit diagra m relate d to wate r-in-fuel sens or
PC20 0, 220 -8 13
Failure code [CA435] Eng Oil Press Sw Error 1

User code Failure c ode Engine oil pressure switc h error
Trouble
Contents of
T here is error in signal circuit of engine oil pres sure s witch.
trouble
Action of
None in particular.
controller
Problem that
Engine protec tion func tion based on engine oil pres sure does not work.
appears on
Engine oil press ure monitor does not display normally
machine
Related infor-
Method of reproduc ing failure code: Turn starting switch ON or start engine.
mation

Defectiv e engine oil pressure without turning s tarting s witch ON.
1
switch OIL PRESSURE SWITCH (male) Resistance
Between (1) chassis ground Max. 10 z
Disconnection in wiring har- a Prepare w ith starting switch OFF, then carry out troubleshooting
nes s (Dis connection in w iring without turning s tarting s witch ON.
2
or defec tive contact in con- Wiring harness between CE01 (female) (17) Resis-
nec tor) Max. 10 z
OIL PRESSURE SWITCH (m ale) (1) tance
Pos sible causes Short circuit in wiring har- without turning s tarting s witch ON.
and s tandard
state tance kz
Connecting parts between engine oil press ure switch engine wir-
4
Between (17) chas sis ground Max. 10 z
Circuit diagra m relate d to e ngine oil pre ssure s witch
14 PC200 , 220 -8
Failure code [CA441] Battery Voltage Low Error 1

User code Failure c ode Battery voltage low error
Trouble
Contents of
T here is low v oltage in controller power supply circuit.
trouble
Action of
None in particular.
controller
Problem that
Engine stops.
appears on
machine
Related infor-
mation

Loosenes s or corros ion of
1 Battery terminal may be loosened or corroded. Check it directly.
battery terminal
a Prepare w ith starting switch OF F, then k eep starting switch OFF
and s tart engine and c arry out troubles hooting in each c ase.
2 Low battery voltage Battery (1 piec e) Starting s witch Voltage
Between (+) () OFF Min. 12 V
terminals START Min. 6.2 V
3 Defectiv e fuse No. 19 If fuse is broken, circuit probably has ground fault. (See Caus e 6)
this time, replaced relay is defective.
Disconnection in wiring har- Wiring harness between F01-19 R23, R 24 Resis-

Max. 10 z
Pos sible causes nes s (Dis connection in w iring (female) (3) tance
5
and s tandard or defec tive contact in c on- Wiring harness between R23, R24 (female) Resis-
Max. 10 z
value in normal nec tor) (5) CE03 (female) (3) tance
state
Max. 10 z
Wiring harness between F01-19 R23, R 24 Resis- Min. 100
(female) (3) tance kz
circuit)
Wiring harness between R23, R24 (female) Resis-
Max. 10 z
(5) CE03 (female) (3) tance
Resis- Min. 100
CE03 (female) (1) pin (with battery terminal
tance kz
Short circuit in wiring har- disconnected)
eac h of CE02 (female) pins (With battery ter-
tance kz
minal disc onnec ted)
Resis- Min. 100
eac h of CE02 (female) pins (With battery ter-
tance kz
minal disc onnec ted)
PC20 0, 220 -8 15

Connecting parts between fus e No. 19 machine wiring harnes s
engine controller may be defec tive. Check them directly.
connector
Pos sible causes Corrosion, bend, breakage, push-in, or expans ion of pin
and s tandard Moisture or dirt in connector or defective insulation
value in normal
state and s tart engine and c arry out troubleshooting in each c ase.
9 Defectiv e engine controller CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) (1)
START Min. 12 V
16 PC200 , 220 -8
Circuit diagra m relate d to e ngine c ontroller power supply
PC20 0, 220 -8 17
Failure code [CA442] Battery Voltage High Error 1

User code Failure c ode Battery voltage high error
Trouble
Contents of
T here is high voltage (36 V or higher) in controller power supply c ircuit.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine may s top.
machine
Related infor-
mation

1 Defectiv e battery voltage
Battery Voltage
Between (+) () terminals Max. 32 V
Pos sible causes a Prepare with s tarting sw itch OFF, then start engine and c arry out
and s tandard troubleshooting.
value in normal 2 Defectiv e alternator E12 (male) Engine speed Voltage
state
Between (1) chas-
Medium or higher 27.5 29.5 V
sis ground
CE03 (female) Voltage
Between (3) (1) Max. 32 V
18 PC200 , 220 -8
PC20 0, 220 -8 19
Failure code [CA449] Rail Press Very High Error 1

User code Failure c ode Common rail pressure very high error
Trouble
Contents of
T here is high pressure error in common rail c ircuit.
trouble
Action of
controller
Problem that
Engine sound becomes large when no or light load is applied.
appears on
machine
Common rail pressure can be check ed with monitoring func tion.
Related infor-
(Code: 36400 Comm on rail pressure)
mation

There may be air in low pres sure c ircuit. Check it directly according
to the following procedure.
2 Air in low pressure circuit 1) Remov e pressure pickup plug (outlet side) of fuel main filter.
2) Operate feed pump of fuel pre-filter.
3) Chec k pres sure pickup plug for leakage of fuel and air.
a For check of fuel return circuit pres sure, see Testing and adjust-
Defect in fuel return circuit ing, Checking fuel pressure.
3
parts Fuel return circuit Low idle running or Max. 0.02 MPa
Pos sible causes press ure crank ing {Max. 0.19 kg/cm 2}
and s tandard
a Prepare with starting s witch ON, then keep starting switch ON
value in normal
and c arry out troubleshooting in each c as e.
state
Monitoring code
Defectiv e common rail pres- Monitoring information
4 (Machine monitor)
sure sens or
36400
While engine is 0 ± 0.39 MPa
Common rail
stopped {0 ± 4 kg/cm 2}
press ure
a For chec k of leakage through pres sure limiter, s ee Testing and
adjusting, Checking fuel return rate and leakage.
5 Defectiv e pressure limiter
Leakage through
During low idle 0 c c (No leak age)
press ure limiter
6 Defectiv e supply pump If causes 1 5 are not detected, supply pump may be defective.
20 PC200 , 220 -8
Failure code [CA451] Rail Press Sensor High Error 1

User code Failure c ode Common rail pressure sensor high error
Trouble
Contents of
T here is high voltage in signal c irc uit of common rail pressure sens or.
trouble
Action of
controller
Problem that
appears on
Engine speed or output lowers .
machine
Signal v oltage of common rail pressure sens or c an be checked with monitoring function.
Related infor-
(Code: 36401 Comm on rail pressure sensor voltage)
mation

Defectiv e sensor power sup- If failure c ode [ CA227] is also displayed, c arry out troubles hooting
1
FUEL RAIL PRESS Voltage
Defectiv e common rail pres-
2 Between (3) (1) Power supply 4.75 5.25 V
sure sens or
Voltage is meas ured with wiring harness connected. Ac cordingly, if
Pos sible causes FUEL RAIL PRESS (female) (2)
and s tandard
harness) FUEL RAIL PRESS (female) (2) and Resis- Min. 100
between CE01 (female) (37) JC01 FUEL tance kz
RAIL PRESS (female) (3)
Connecting parts between c ommon rail pressure sensor engine
wiring harness engine controller may be defective. C heck them
5
CE01 Voltage
22 PC200 , 220 -8
Circuit diagra m relate d to c ommon rail pre ssure s ensor
PC20 0, 220 -8 23
Failure code [CA452] Rail Press Sensor Low Error 1

User code Failure c ode Common rail pressure sensor low error
Trouble
Contents of
T here is low v oltage in signal circuit of common rail pressure sensor.
trouble
Action of
controller
Problem that
appears on
Engine speed or output lowers .
machine
Signal v oltage of common rail pressure sens or c an be checked with monitoring function.
Related infor-
(Code: 36401 Comm on rail pressure sensor voltage)
mation

Defectiv e sensor power sup- If failure c ode [ CA187] is also displayed, c arry out troubles hooting
1
FUEL RAIL PRESS Voltage
Defectiv e common rail pres-
sure sens or
Ground fault in wiring har- and c arry out troubleshooting.
circuit)
Pos sible causes FUEL RAIL PRESS (female) (2) tance kz
and s tandard
harness) FUEL RAIL PRESS (female) (2) and Resis- Min. 100
between CE01 (female) (47) JC02 FUEL tance kz
RAIL PRESS (female) (1)
Connecting parts between c ommon rail pressure sensor engine
wiring harness engine controller may be defective. C heck them
5
CE01 Voltage
24 PC200 , 220 -8
Circuit diagra m relate d to c ommon rail pre ssure s ensor
PC20 0, 220 -8 25
Failure code [CA488] Chg Air Temp High Torque Derate 1

User code Failure c ode Charge air temperature high torque derate
Trouble
Contents of
Temperature signal of boost pres sure/temperature s ensor exceeded control upper temperature limit.
trouble
Action of
controller
Problem that
machine
Related infor- Boos t temperature c an be checked with monitoring function. (Code: 18500 Boost temperature)
mation Method of reproduc ing failure code: Start engine.

Cooling performance of aftercooler may be low. C heck following
points directly.
Low ering of cooling perfor-
Pos sible causes 1 Loos eness and breakage of fan belt.
manc e of aftercooler
and s tandard Ins ufficiency of c ooling air
value in normal Clogging of aftercooler fins
state Abnormal ris e of turbo- Outlet temperature of turbocharger m ay be abnormally high. Chec k
2
charger outlet temperature related parts directly.
Failure code [CA553] Rail Press High Error 1

User code Failure c ode Common rail pressure high error
Trouble
Contents of
T here is high pressure error in common rail c ircuit.
trouble
Action of
None in particular.
machine monitor
Problem that
Engine sound becomes large when no or light load is applied.
appears on
machine
Related infor-
mation

Ground terminal may be connected defectively. Check following ter-
Pos sible causes minals directly.
and s tandard Defectiv e connection of Ground terminal of mac hine (() terminal of battery)
value in normal 2
ground terminal Ground terminal of engine
state Ground terminal of engine c ontroller
Ground terminal of starting motor
Breakage of O-ring of supply
3 O-ring of supply pump actuator may be broken. Check it directly.
pump actuator
26 PC200 , 220 -8
Failure code [CA559] Rail Press Low Error 1

User code Failure c ode Common rail pres sure low error
Trouble
Contents of
T here is low pressure error in common rail circuit.
trouble
Action of
None in particular.
controller
Problem that Engine does not start at all or does not s tart eas ily.
appears on Exhaus t gas becomes black .
machine Engine output lowers.
Common rail pressure can be check ed with monitoring func tion. (Code: 36400 C ommon rail pres-
Related infor-
sure)
mation

Fuel may be leaking to outside. Check it directly (Check v is ually
1 Fuel leakage to outside
while running engine at low idle).
a For check of press ure in fuel low pres sure c ircuit, see Testing
and adjus ting, Checking fuel pressure.
During c ranking (if
0.3 1.1 MPa
Defect in low pressure cir- engine cannot be
2 {3.1 11.3 kg/c m2}
cuit parts Press ure in fuel low- started)
press ure circuit During low idle (if
0.5 1.3 MPa
engine can be
{5.1 13.3 kg/cm 2}
started)
a For chec k of leakage through pres sure limiter, s ee Testing and
3 Defectiv e pressure limiter
Leakage through
Pos sible causes During low idle 0 cc (No leak age)
press ure limiter
and s tandard
value in normal a For check of return rate from injector, see Testing and adjusting,
state Checking fuel return rate and leakage.
Defectiv e injector (including engine cannot be Max. 90 c c/min.
4
high pressure piping in head) Return rate from started)
injector During low idle (if
engine can be Max. 180 cc /min.
started)
a For check of return rate from supply pump, s ee Testing and
engine cannot be Max. 140 cc /min.
5 Defectiv e supply pump
Return rate from sup- started)
ply pump During low idle (if
engine can be Max. 1,000 cc /min.
started)
PC20 0, 220 -8 27
Failure code [CA689] Eng Ne Speed Sensor Error 1

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

Defectiv e Ne speed sensor If failure c ode [ CA238] is also displayed, c arry out troubles hooting
1
CRANK SENSOR Voltage
Defectiv e engine Ne s peed
sensor
Breakage or improper clear-
Engine Ne speed sensor may be broken or may have improper
3 anc e of engine Ne speed
clearance. C heck it direc tly.
sensor
Breakage of rotation s ensor
4 Rotation sens or wheel may be broken. Check it direc tly.
wheel
Pos sible causes 5
value in normal nec tor) CRANK SENSOR (female) (3) tance
state a Prepare w ith starting switch OFF, then carry out troubleshooting
CRANK SENSOR (female) (3) tance kz
nes s Wiring harness between CE01 (female) (27)
Voltage Max. 1 V
CRANK SENSOR (female) (3)
CRANK SENSOR (female) (3) or between Resis- Min. 100
CE01 (female) (16) CRANK SENSOR tance kz
8 nes s (with another w iring
(female) (1)
harness)
CRANK SENSOR (female) (3) or between Resis- Min. 100
CE01 (female) (48) CRANK SENSOR tance kz
(female) (2)
28 PC200 , 220 -8

Connecting parts between engine Ne speed sensor engine wiring
Pos sible causes 9 Loos eness of connector, breakage of lock, or breakage of seal
connector
and s tandard Corrosion, bend, breakage, push-in, or expans ion of pin
value in normal Moisture or dirt in connector or defective insulation
state a Prepare with starting switch OFF, then turn starting switch ON
10 Defective engine controller
CE01 Voltage
Circuit diagra m relate d to e ngine Ne speed sensor
PC20 0, 220 -8 29
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1

User code Failure c ode Engine Bk up s peed sens or phas e error
Trouble
Contents of
Phas e error was detected in signals from engine Ne speed sensor and engine Bkup speed sensor
trouble
Action of
Continues control with signal from engine Ne s peed sens or.
controller
Problem that Engine does not start at all or does not s tart eas ily.
appears on Idle s peed is unstable.
machine Exhaus t gas becomes black .
Related infor-
mation

Breakage of engine Ne
1 Engine Ne speed sensor may be broken. C heck it direc tly.
speed s ensor
Breakage of engine Bk up
2 Engine Bk up s peed sens or may be broken. Check it directly.
speed s ensor
Rotation sens or wheel on cranks haft side may be ins talled defec -
tively or broken. Check it according to the following procedure.
Defectiv e installation or
1) Set N o. 1 cylinder at compression top dead c enter (Match
3 breakage of rotation s ensor
stamped mark).
wheel on crankshaft s ide
2) If c enter of oblong hole of rotation s ensor wheel is at tip of Ne
speed s ensor, rotation s ensor wheel is ins talled normally.
Pos sible causes Rotation sens or ring on camshaft side may be installed defectively
and s tandard
or broken. C heck it according to the following procedure.
value in normal
Defectiv e installation or 1) Set N o. 1 cylinder at compression top dead c enter (Match
state 4 breakage of rotation s ensor stamped mark).
ring on camshaft side 2) Remove Bkup speed sensor.
3) If 2 groov es (1 cres t) of rotation sensor ring are seen through
sensor mounting hole, rotation sensor ring is installed normally.
Defectiv e timing of crank - Timing of cranks haft and c ams haft may be defective. Check it
5
shaft and camshaft directly.
Ground terminal may be connected defectively. Check following ter-
minals directly.
Defectiv e connection of Ground terminal of mac hine (() terminal of battery)
6
ground terminal Ground terminal of engine
Ground terminal of engine c ontroller
Ground terminal of starting motor
30 PC200 , 220 -8
Failure code [CA757] All Continuous Data Lost Error 1

User code Failure c ode All continuous data lost error
Trouble
Contents of
All data in engine c ontroller are lost.
trouble
Action of
None in particular.
controller
Problem that
Engine may s top and may not be s tarted again.
appears on
Monitoring function of mac hine monitor (engine controller sys tem) may not work normally.
machine
Related infor-
mation

Loosenes s or corros ion of
2 Battery terminal may be loosened or corroded. Check it directly.
battery terminal
a Prepare w ith starting switch OF F, then k eep starting switch OFF
and s tart engine and c arry out troubles hooting in each c ase.
3 Low battery voltage Battery (1 piec e) Starting switch Voltage
Between (+) () OFF Min. 12 V
terminals START Min. 6.2 V
4 Defectiv e fuse No. 19 If fuse is broken, c ircuit probably has ground fault.
this time, replaced relay is defective.
Pos sible causes
state Wiring harness between F01-19 R23, R 24 Resis-
Disconnection in wiring har- Max. 10 z
nes s (Dis connection in w iring (female) (3) tance
6
or defec tive contact in con- Wiring harness between R23, R24 (female) Resis-
Max. 10 z
nec tor) (5) CE03 (female) (3) tance
Max. 10 z
Connecting parts between fus e No. 19 machine wiring harnes s
engine controller may be defec tive. Check them directly.
connector
and s tart engine and c arry out troubleshooting in each c ase.
8 Defectiv e engine controller CE03 (female) Starting switc h Voltage
ON Min. 24 V
Between (3) (1)
START Min. 12 V
32 PC200 , 220 -8
PC20 0, 220 -8 33
Failure code [CA778] Eng Bkup Speed Sensor Error 1

User code Failure c ode Engine Bk up s peed sens or error
Trouble
Contents of
T here is error in signal from engine Bk up s peed sens or.
trouble
Action of
Continues control with signal from engine Ne s peed sens or.
controller
Problem that
appears on
machine
Related infor-
mation

Defectiv e sensor power sup- If failure c ode [CA187] is also display ed, carry out troubleshooting
1
CAM SEN SOR Voltage
Defectiv e engine Bkup
speed s ensor
Breakage or improper clear-
Engine Bk up s peed sens or m ay be broken or may have improper
3 anc e of engine Bk up s peed
clearance. C heck it direc tly.
sensor
Breakage of rotation s ensor
4 Rotation sens or ring may be broken. C heck it direc tly.
ring
Pos sible causes 5
value in normal nec tor) JC03 CAM SENSOR (female) (3) tance
JC03 CAM SENSOR (female) (3) tance kz
nes s Wiring harness between CE01 (female) (26)
Voltage Max. 1 V
JC03 CAM SENSOR (female) (3)
JC03 CAM SENSOR (female) (3) or Resis- Min. 100
between CE01 (female) (37) JC01 CAM tance kz
8 nes s (with another w iring
SENSOR (female) (1)
harness)
JC03 CAM SENSOR (female) (3) or Resis- Min. 100
between CE01 (female) (47) JC02 CAM tance kz
SENSOR (female) (2)
34 PC200 , 220 -8

Connecting parts between engine Bkup speed sensor engine w ir-
Pos sible causes 9
and s tandard Corrosion, bend, breakage, push-in, or expans ion of pin
value in normal Moisture or dirt in connector or defective insulation
state
10 Defective engine controller
CE01 Voltage
Circuit diagra m relate d to e ngine Bk up speed s ensor
PC20 0, 220 -8 35
Failure code [CA1633] KOMNET Datalink Timeout Error 1

User code Failure c ode KOMNET Datalink timeout error
Trouble
E0E CA1633 (Engine c ontroller system)
Contents of Engine controller detected communication error in KOMN ET communication circuit between pump
trouble controller and mac hine monitor.
Action of Continues operation in default mode.
Problem that
Information may not transmitted normally by KOMNET communic ation and machine may not operate
appears on
normally. (Trouble phenomenon depends on failed s ection.)
machine
Related infor-
mation

Disconnection in wiring har- Wiring harness betw een CM02 (female) (8),
Resis-
nes s (Dis connection in w iring (9) C01 (female) (45), CE02 (female) Max. 1 z
1 tance
or defec tive contact in con- (46), K02 (female) (A)
nec tor)
Wiring harness between C M02 (female) (10)
Resis-
C01 (female) (64), C E02 (female) (47), Max. 1 z
tance
K02 (female) (B)
Wiring harness betw een CM02 (female) (8),
Ground fault in wiring har- Resis-
(9) C01 (female) (45), CE02 (female) Min. 1 M z
2 nes s (Short circuit with GND tance
(46), K02 (female) (A), N08 (male) (3)
circuit)
Pos sible causes Wiring harness between C M02 (female) (10)
and s tandard Resis-
C01 (female) (64), C E02 (female) (47), Min. 1 M z
value in normal tance
K02 (female) (B), N08 (male) (10)
state
Max.
Hot short (Short circuit w ith (9) C01 (female) (45), CE02 (female) Voltage
3 5.5 V
24V c irc uit) in wiring harness (46), K02 (female) (A), N08 (male) (3)
Max.
C01 (female) (64), C E02 (female) (47), Voltage
5.5 V
K02 (female) (B), N08 (male) (10)
Defectiv e CAN terminal without turning s tarting s witch ON.
4 resistanc e (Internal short c ir-
K02 (male) R esis tance
cuit or disconnection)
Between (A) (B) 120 ± 12 z
If caus es 1 4 are not detected, engine c ontroller may be defec tive.
5 Defectiv e pump controller
36 PC200 , 220 -8
Circuit diagra m relate d to CAN com munic ation
PC20 0, 220 -8 37
Failure code [CA2185] Throt Sens Sup Volt High Error 1

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

Short circuit in wiring har- Wiring harness between CE02 (female) (22)
Resis- Min. 100
1 nes s (with another w iring eac h of CE02 (female) pins (With P20 dis-
tance kz
harness) connected)
Pos sible causes
and s tandard Wiring harness between CE02 (female) (22) Resis- Min. 100
value in normal CE03 (female) (3) (With P20 disconnected) tance kz
state Connecting parts between fuel c ontrol dial mac hine wiring har-
connector
38 PC200 , 220 -8
Failure code [CA2186] Throt Sens Sup Volt Low Error 1

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

P20 (female) (1) tance kz
Pos sible causes
and s tandard 2 nes s (with another w iring Wiring harness between CE02 (female) (9)
value in normal eac h of CE02 (fem ale) pins (With P20 dis-
tance kz
state connected)
nes s engine controller may be defective. Check them direc tly.
connector
PC20 0, 220 -8 39
Failure code [CA2249] Rail Press Very Low Error 1

User code Failure c ode Common rail pres sure very low error
Trouble
Contents of
T here is low pressure error in common rail circuit.
trouble
Action of
controller
Problem that Engine does not start easily.
appears on Exhaus t gas becomes black .
Related infor-
mation

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

User code Failure c ode IMV s olenoid error
Trouble
Contents of
Resis tance of supply pump actuator circuit is abnormally high or low.
trouble
Action of
None in particular.
controller
Problem that
machine
Related infor-
mation

Defectiv e supply pump actu- CP3 PUMP REGULATOR (male) R esis tance
2
ator
3 Max. 5 z
or defec tive contact in con- CP3 PU MP REGULATOR (female) (1) tance
Pos sible causes Max. 5 z
and s tandard CP3 PUMP REGULATOR (female) (2) tance
state Ground fault in wiring har- without turning s tarting s witch ON.
circuit)
CP3 PU MP REGULATOR (female) (1) tance kz
Connecting parts between s upply pump ac tuator engine wiring
connector

42 PC200 , 220 -8
PC20 0, 220 -8 43
Failure code [CA2555] Grid Htr Relay Volt High Error 1

User code Failure c ode Grid heater relay v olt high error
Trouble
Contents of
Dis connection was detected in drive circ uit of intake air heater relay.
trouble
Action of
None in particular.
controller
Problem that
Intak e air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related infor- Method of reproduc ing failure code: Turn starting switch ON when engine coolant temperature is
mation below 4°C.

without turning starting switch ON. (Troubleshooting for relay
unit)
R18 (male) R esis tance
Defectiv e automatic pre-
Between (1) (2) 300 600 z
1 heater relay (Internal discon-
nec tion) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Troubleshooting by replac ement)
Replace automatic preheater relay (R18)) with another relay and
perform reproducing operation. If "E" of failure code goes off at this
time, replaced relay is defective.
2 Max. 10 z
Pos sible causes or defec tive contact in con- R18 (female) (1) tance
and s tandard nec tor)
value in normal Max. 10 z
R18 (female) (2) tance
state
eac h of CE02 (female) pins (With R18 dis -
tance kz
connected)
Connecting parts between automatic preheater relay machine wir-
4
Between (40) (42) 300 600 z
44 PC200 , 220 -8
Circuit diagra m relate d to e ngine preheate r/starting motor/charging sy stem
PC20 0, 220 -8 45
Failure code [CA2556] Grid Htr Relay Volt Low Error 1

User code Failure c ode Grid heater relay v olt low error
Trouble
Contents of
Short circuit w as detected in drive circuit of intak e air heater relay.
trouble
Action of
None in particular.
controller
Problem that
Intak e air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related infor- Method of reproduc ing failure code: Turn starting switch ON when engine coolant temperature is
mation below 4°C.

unit)
Defectiv e automatic pre-
Between (1) (2) 300 600 z
1 heater relay (Internal discon-
nec tion) a Prepare with starting switch OFF, then turn starting switch ON
Replace automatic preheater relay (R18)) with another relay and
perform reproducing operation. If "E" of failure code goes off at this
time, replaced relay is defective.
Pos sible causes Wiring harness between CE02 (female) (40) Resis- Min. 100
circuit)
and s tandard R18 (female) (1) tance kz
value in normal
eac h of CE02 (female) pins (With R18 dis -
tance kz
connected)
Connecting parts between automatic preheater relay machine wir-
4
Between (40) (42) 300 600 z
46 PC200 , 220 -8
PC20 0, 220 -8 47
Failure code [D19JKZ] Personal Code Relay Abnormality 1

User code Failure c ode Personal code relay abnormality
Trouble
E01 D19JKZ (KOMTRAX sy stem in machine monitor)
Contents of
Dis connection or short circuit was detected in personal code relay c irc uit.
trouble
None in particular (when disconnection is detected).
Turns output to personal code relay OFF (w hen short circuit is detec ted).
Action of
If cause of failure disappears , sy stem resets itself (when disc onnec tion is detec ted).
controller
Even if cause of failure disappears , sy stem does not reset its elf until starting switc h is turned OFF
(when disconnection is detec ted).
Problem that
appears on
machine
T his failure code is display ed only when engine lock function is effective.
Related infor-
Method of reproduc ing failure code: Turn starting switch ON (Disconnection). Trouble cannot be
mation
reproduced on machine (Short circuit).

1 Defectiv e fuse No. 3 If fuse is broken, c ircuit probably has ground fault (See cause 4).
unit)
Defectiv e personal c ode
Between (1) (2) (300 600 z)
2 relay (Internal disconnection
or short circuit) a Prepare with starting switch OFF, then turn starting switch ON
Replace personal code relay (R07)) with another relay and perform
reproducing operation. If "E" of failure code goes off at this time,
replaced relay is defec tive.
Pos sible causes
and s tandard
value in normal Disconnection in wiring har- without turning s tarting s witch ON.
state nes s (Dis connection in w iring Wiring harness betw een F01 (3) R07 Resis-
3 Max. 1 z
or defec tive contact in con- (female) (1) tance
nec tor)
Wiring harness betw een R07 (female) (2) Resis-
Max. 1 z
CM01 (female) (6) tance
Wiring harness betw een F01 (3) R07 Resis-
4 nes s (Short circuit with GND Min. 1 Mz
(female) (1) tance
circuit)
Min. 1 Mz
If caus es 1 4 are not detected, machine monitor (KOM TRAX) may
Defectiv e mac hine monitor
5 be defective. (Sinc e trouble is in sy stem, troubles hooting cannot be
(KOMTRAX section)
carried out.)
48 PC200 , 220 -8
PC20 0, 220 -8 49
Failure code [D862KA] GPS Antenna Discon 1

User code Failure c ode GPS antenna disconnection
Trouble
D862KA (KOMTRAX sy stem in machine monitor)
Contents of
Dis connection was detected in GPS antenna circuit.
trouble
Problem that
appears on GPS cannot measure position.
machine
Related infor-
mation

and s tandard Pos sible causes are defectiv e GPS antenna, disc onnec tion or short
value in normal Defectiv e GPS antenna or
1 circuit in antenna c able, and defectiv e connection of antenna cable
state antenna cable
connector (GPS).
Configura tion drawing
50 PC200 , 220 -8
Failure code [DA22KK] Pump Solenoid Power Low Error 1

User code Failure c ode Low ering of solenoid power supply voltage
Trouble
E0E DA22KK (Pump c ontroller s ystem)
Contents of
Solenoid power supply voltage of controller is below 20 V.
trouble
While this failure code is displayed, detection of failure codes (disconnec tion/short circuit) of all the
Action of
solenoid systems is stopped.
controller
Even if cause of failure disappears , sy stem does not reset its elf until starting switc h is turned OFF.
Problem that
appears on Since no solenoid v alve is driv en normally, machine does not operate normally.
machine
Related infor-
mation

Defectiv e fusible link F 04 or If fusible link or fuse is broken, circuit probably has ground fault.
1
fuse No. 2 (See Cause 3.)
Disconnection in wiring har- Wiring harness between C02 (female) (116), Resis-
Max. 1 z
nes s (Dis connection in w iring (118), (121) F01-2 tance
2
or defec tive contact in c on- Wiring harness between F01-1A F04 Resis-
Max. 1 z
nec tor) (male) (2) tance
Wiring harness betw een F04 (male) (1) Resis-
Max. 1 z
R03 tance
Pos sible causes
state
Wiring harness between C02 (female) (116), Resis-
Ground fault in wiring har- Min. 1 Mz
(118), (121) F01-2 tance
circuit) Wiring harness between F01-1A F04 Resis-
Min. 1 Mz
(male) (2), c irc uit branch end tance
Min. 1 Mz
R03 tance
4 Defectiv e pump controller C01 (female), C02 (female) Voltage
Between C02 (116), (118),
20 30 V
(121) C 01 (2), (5)
PC20 0, 220 -8 51
Circuit diagram re lat ed to pump cont roller pow er supply
52 PC200 , 220 -8
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 1

Ov erload a larm monitor non-dis play specification
User code Failure c ode 5V sens or power supply output 1 abnormality
Trouble
DA25KP (Pump c ontroller s ystem)
Contents of
Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
trouble
Action of Turns output of 5V sensor power supply output 1 OF F.
controller Even if cause of failure disappears , sy stem does not reset its elf until starting switc h is turned OFF.
Problem that Automatic gear shifting func tion does not work (pump pressure sensor system).
appears on Auto-decelerator keeps working and is not reset or fine c ontrol performance of work equipment is
machine lowered (PPC pressure sens or s ystem).
Related infor-
mation

switch ON and carry out troubles hooting.
Buc ket CUR L PPC
P01
press ure sensor
Swing LEFT PPC
P03
press ure sensor
Arm IN PPC press ure
P04
sensor
Disconnect sensors at right in
Defectiv e pressure sens or order and carry out operation to Buc ket DUMP PPC
1 P05
(Internal s hort circ uit) reproduce trouble. If "E" of failure press ure sensor
code goes off when a sensor is Boom R AISE PPC
disconnected, that sensor is P06
press ure sensor
defec tive.
Swing RIGH T PPC
P07
press ure sensor
F pump pres sure
P25
sensor
Pos sible causes
and s tandard R pump press ure
value in normal P26
sensor
state
Wiring harness betw een C01 (female) (9)
Resis-
J06 P01 (female) (3) Min. 1 Mz
tance
[Bucket C URL PPC pressure sens or s ystem]
Resis-
tance
[Swing LEFT PPC pressure sens or s ystem]
2 nes s (Short circuit with GND Wiring harness betw een C01 (female) (9) Resis-
circuit) tance
[Arm IN PPC press ure sensor system ]
J06 P05 (female) (3) Resis-
Min. 1 Mz
[Bucket DUMP PPC pressure sens or sys- tance
tem]
Resis-
tance
[Boom RAISE PPC pressure sensor sy stem]
PC20 0, 220 -8 53

Resis-
tance
[Swing RIGHT PPC pressure sens or s ystem]
Ground fault in wiring har- Wiring harness betw een C01 (female) (9)
Resis-
2 nes s (Short circuit with GND J06 P25 (female) (3) Min. 1 Mz
tance
circuit) [F pump pressure sensor s ystem]
Resis-
tance
[R pump pres sure sensor sy stem]
J06 P01 (female) (3) Voltage Max. 1 V
Pos sible causes [Swing LEFT PPC pressure sens or s ystem]
and s tandard Wiring harness betw een C01 (female) (9)
value in normal J06 P04 (female) (3) Voltage Max. 1 V
state [Arm IN PPC press ure sensor system ]
P05 (female) (3)
Hot short (Short circuit w ith Voltage Max. 1 V
3 [Bucket DUMP PPC pressure sens or sys-
24V c irc uit) in wiring harness
tem]
[F pump pressure sensor s ystem]
If causes 1 3 are not detected, pump controller may be defec tive.
54 PC200 , 220 -8
Circuit dia gram related to pump controller 5V sensor powe r supply output 1 (O verload a larm monitor
non-display s pe cif ica tion)
PC20 0, 220 -8 55
Ov erload a larm monitor display specification

User code Failure c ode 5V sens or power supply output 1 abnormality
Trouble
DA25KP (Pump c ontroller s ystem)
Contents of
Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
trouble
Action of Turns output of 5V sensor power supply output 1 OF F.
Problem that Automatic gear shifting func tion does not work (pump pressure sensor system).
appears on Since no solenoid v alve is driv en normally, machine does not operate normally.
machine Overload alarm monitor does not dis play normally (Overload alarm pressure sensor system)
Related infor-
mation

Buc ket CUR L PPC
P01
press ure sensor
Swing LEFT PPC
P03
press ure sensor
Arm IN PPC press ure
P04
sensor
Disconnect sensors at right in Buc ket DUMP PPC

P05
Defectiv e pressure sens or press ure sensor
1 order and carry out operation to
(Internal s hort circ uit) reproduce trouble. If "E" of failure Boom R AISE PPC
P06
code goes off when a sensor is press ure sensor
disconnected, that sensor is
Swing RIGH T PPC
defec tive. P07
press ure sensor
F pump pres sure
P25
sensor
Pos sible causes R pump press ure

P26
and s tandard sensor
value in normal Overload alarm pres -
state P46
sure sens or
Resis-
tance
Resis-
tance
2 nes s (Short circuit with GND Wiring harness betw een C01 (female) (9) Resis-
circuit) J06 P04 (female) (3) Min. 1 Mz
tance
J06 P05 (female) (3) Resis-
Min. 1 Mz
[Bucket DUMP PPC pressure sens or sys- tance
tem]
Resis-
tance
56 PC200 , 220 -8

Resis-
tance
Resis-
Ground fault in wiring har- tance
circuit) Wiring harness betw een C01 (female) (9)
Resis-
tance
Resis-
tance
[Overload alarm pressure sens or system]
Pos sible causes
and s tandard Wiring harness betw een C01 (female) (9)
value in normal J06 P04 (female) (3) Voltage Max. 1 V
state
P05 (female) (3)
Voltage Max. 1 V
[Bucket DUMP PPC pressure sens or sys-
Hot short (Short circuit w ithtem]
3
24V c irc uit) in wiring harness Wiring harness betw een C01 (female) (9)
[Overload alarm pressure sens or system]
PC20 0, 220 -8 57
Circuit dia gram related to pump controller 5V sensor powe r supply output 1 (O verload a larm monitor
dis play specification)
58 PC200 , 220 -8
Failure code [DA29KQ] Model Selection Abnormality 1

PC20 0, 200 LC-8
User code Failure c ode Model s election abnormality
Trouble
DA29KQ (Pump c ontroller s ystem)
Contents of
Model code s ignal for model w hich is not registered in controller is input.
trouble
Action of Changes input model code to code of default model (PC200) and continues control.
Problem that
appears on Since control is carried out on assumption that model is PC200, no particular problem occur.
machine
Model code of pump c ontroller c an be checked with monitoring function.
(Code: 00200 Controller model code)
Related infor-
Condition of model selection signal c an be checked with monitoring function.
mation
(Code: 02201 Switch input 2)

Defectiv e model selec tion
1 connector (Internal dis con- S30 (female) Resistance
nec tion or short circuit) Between (1), (2), (4), (7) (8) Min. 1 Mz
nes s (Dis connection in w iring Wiring harness between C01 (female) (77) Resis-
2 Max. 1 z
or defec tive contact in con- S30 (male) (3) tance
nec tor) Wiring harness betw een S30 (male) (8) Resis-
Max. 1 z
J05 chassis ground (T07) tance
value in normal iring harness betw een C01 (female) (40) Resis-
state Min. 1 Mz
S30 (male) (1) tance
Wiring harness between C01 (female) (21) Resis-
circuit)
Min. 1 Mz
Min. 1 Mz
C01 (female) Resistance
Between (21), (39), (40), (58)
Min. 1 Mz
chassis ground
Between (77) chas sis ground Max . 1 z
60 PC200 , 220 -8
Circuit diagra m relate d to m ode l select ion connector (P C2 00, 2 00LC-8)
PC20 0, 220 -8 61
PC22 0, 220 LC-8

User code Failure c ode Model s election abnormality
Trouble
DA29KQ (Pump c ontroller s ystem)
Contents of
Model code s ignal for model w hich is not registered in controller is input.
trouble
Action of Changes input model code to code of default model (PC200) and continues control.
Problem that
appears on Since control is carried out on assumption that model is PC200, power or speed is low.
machine
Model code of pump c ontroller c an be checked with monitoring function.
(Code: 00200 Controller model code)
Related infor-
Condition of model selection signal c an be checked with monitoring function.
mation

Defectiv e model selec tion
1 connector (Internal dis con- S30 (female) Resistance
nec tion or short circuit) Between (2), (4), (7) (8) Min. 1 Mz
Between (1), (3) (8) Max . 1 z
Disconnection in wiring har- Wiring harness between C01 (female) (40) Resis-
Max. 1 z
nes s (Dis connection in w iring S30 (male) (1) tance
2
or defec tive contact in con- Wiring harness between C01 (female) (77) Resis-
nec tor) Max. 1 z
Wiring harness betw een S30 (male) (8) Resis-
and s tandard
circuit) Min. 1 Mz
Min. 1 Mz
4 Defectiv e pump controller Between (21), (39), (58) chas-
Min. 1 Mz
sis ground
Between (40), (77) c hassis
Max. 1 z
ground
62 PC200 , 220 -8
Circuit diagra m relate d to m ode l select ion connector (P C2 20, 2 20LC-8)
PC20 0, 220 -8 63
SE N0 0241- 01
© 2 006 KO MATSU
All Rights Reserved
64
SE N00 242- 01
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Tr ouble sh ooting by failu re cod e ( Di spla y of cod e), P art 3 .............................................................................. 4
Failur e code [DA2RMC] CAN Discon (Pump Con Detected) ............................................................... 4
Failur e cod e [DAFGMC] GPS Mo dule Erro r ........................................................................................ 6
Failur e code [DAFRMC] CAN Discon (Mon ito r Detecte d).................................................................... 8
Failur e code [DGH2KB ] Hyd r O il Sensor Sho rt.................................................................................. 1 0
Failur e code [DHPAMA ] F Pu mp P ress Sen so r A bnormal ity ............................................................. 1 2
Failur e code [DHP BMA] R Pump Pre ss Sensor Ab normality ............................................................ 1 4
Failur e code [DHS3MA] A rm Curl PP C Pre ss Sensor Ab normality ................................................... 1 6
Failur e code [DHS4MA] B ucke t Cu rl PPC P ress Se nsor Abno rma lity ............................................... 1 8
Failur e code [DHS 8MA] B oom Ra ise P PC Pr ess Sen sor Ab normality .............................................. 2 0
Failur e code [DHS AMA] Swi ng RH PPC Press S ensor Abn ormality ................................................. 2 2
Failur e code [DHS BMA] S wi ng LH P PC Pr ess Sen so r A bnormal ity.................................................. 2 4
Failur e code [DHS DMA ] Bucket Dump PPC Press Sensor Ab normality ........................................... 2 6
Failur e code [DHX1MA] O ve rload Se nsor A bnor ma lity (Ana log) ....................................................... 2 9
PC20 0, 220 -8 1
Failur e code [DW43KA ] Tra ve l Spe ed Sol Discon ............................................................................. 3 2

Failur e code [DW43KB ] Tra ve l Spe ed Sol Sho rt................................................................................ 3 4
Failur e code [DW45KA ] Swing Br ake S ol Discon .............................................................................. 3 6
Failur e code [DW45KB ] Swing Br ake S ol Short ................................................................................. 3 8
Failur e code [DW91KA ] Tra ve l Junction Sol Disco n .......................................................................... 4 0
Failur e code [DW91KB ] Tra ve l Junction Sol Sh ort............................................................................. 4 2
Failur e code [DWA 2KA] Service Sol Discon ...................................................................................... 44
Failur e code [DWA 2KB] Service Sol Sho rt......................................................................................... 45
Failur e code [DWK0KA ] 2-sta ge Re lief S ol Discon ............................................................................ 4 6
Failur e code [DWK0KB ] 2-sta ge Re lief S ol Short .............................................................................. 4 8
2 PC200 , 220 -8

Failure code [DA2RMC] CAN Discon (Pump Con Detected) 1
User code Failure c ode CAN disconnection (Pump c ontroller detected)
Trouble
E0E DA2RMC (Pump c ontroller s ystem)
Contents of Pump controller detected communic ation error in CAN communication circuit between machine mon-
trouble itor and engine controller.
Action of Continues operation w ith information of CAN comm unication just before detection of error.
Problem that
Information may not transmitted normally by C AN comm unication and machine may not operate nor-
appears on
mally. (Trouble phenomenon depends on failed section.)
machine
Related infor-
mation

Resis-
1 tance
nec tor) Wiring harness between C M02 (female) (10)
Resis-
tance
K02 (female) (B)
(46), K02 (female) (A), N08 (male) (3)
circuit)
K02 (female) (B), N08 (male) (10)
state
Max.
3 5.5 V
Max.
5.5 V
K02 (female) (B), N08 (male) (10)
K02 (male) Resistance
Between (A) (B) 120 ± 12 z
4 PC200 , 220 -8
PC20 0, 220 -8 5
Failure code [DAFGMC] GPS Module Error 1

User code Failure c ode GPS module operation error
Trouble
DAFGMC (KOMTRAX sy stem in machine monitor)
Contents of Position data is not sent from GPS module (in mac hine monitor) to KOMTRAX communication
trouble MODEM in 50 s ec onds after KOMTRAX is started.
Problem that
appears on
machine
Related infor- Method of reproducing failure code: Turn starting switc h ON (At least 50 seconds after starting switc h
mation is turned ON).

and s tandard
value in normal GPS module of machine monitor may be defectiv e. (Since trouble is
1 Defectiv e mac hine monitor
state in sys tem, troubles hooting cannot be carried out.)
6 PC200 , 220 -8
Failure code [DAFRMC] CAN Discon (Monitor Detected) 1

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

Resis-
1 tance
nec tor)
Resis-
tance
K02 (female) (B)
(46), K02 (female) (A), N08 (male) (3)
circuit)
K02 (female) (B), N08 (male) (10)
state
Max.
3 5.5 V
Max.
5.5 V
K02 (female) (B), N08 (male) (10)
Between (A) (B) 120 ± 12 z
If caus es 1 4 are not detected, machine monitor may be defective.
8 PC200 , 220 -8
PC20 0, 220 -8 9
Failure code [DGH2KB] Hydr Oil Sensor Short 1

User code Failure c ode Hydraulic oil temperature s ensor short
Trouble
DGH2K B (Pump c ontroller s ystem)
Contents of
Ground fault was detected in hydraulic oil temperature sensor circuit.
trouble
Action of F ix es hydraulic oil temperature value at 40° C and continues operation.
Problem that
While hydraulic oil temperature rises normally, hydraulic oil temperature gauge does not mov e from
appears on
top of white range (bottom of green range).
machine
Signal voltage of hydraulic oil temperature sensor can be c heck ed with monitoring function.
Related infor-
(Code: 04402 Hydraulic oil temperature sensor voltage)
mation

Defectiv e hy draulic oil tem-
1 perature sensor (Internal dis - P22 (male) Resistance
connection or short circuit) Between (1) (2) 3.5 90 kz
Between (2) chassis ground Min. 1 Mz
Pos sible causes
and s tandard Ground fault in wiring har- without turning s tarting s witch ON.
value in normal 2 nes s (Short circuit with GND
state circuit) Wiring harness between C01 (female) (29) Resis-
Min. 1 Mz
P22 (female) (2) tance
3 Defectiv e pump controller C01 (female) Resistance

Between (29) (46) 3.5 90 kz
Between (29) chas sis ground Min. 1 M z
Circuit diagra m relate d to hy draulic oil temperature sensor
10 PC200 , 220 -8
Failure code [DHPAMA] F Pump Press Sensor Abnormality 1

User code Failure c ode F pump pres sure s ensor abnormality
Trouble
DHPAMA (Pump c ontroller s ystem)
Contents of
Signal voltage of F pump pres sure s ensor circuit is below 0.3 V or abov e 4.5 V.
trouble
Action of F ix es F pump press ure at 0 MPa {0 kg/cm 2} and continues control.
Problem that
Automatic gear shifting func tion does not work.
appears on
Straight trav el performance or steering performance lowers.
machine
a If 5V circuit (3) and ground circ uit (1) of press ure s ensor are connected inv ersely, pressure sens or
Related infor- will be broken. Accordingly, take extreme care when check ing.
mation F pump pressure can be c hecked with monitoring function. (C ode: 01100 F pump pressure)

Defectiv e 5V s ensor pow er a If failure code [DA25KP] is also dis played, carry out trouble-
1
supply 1 system shooting for it first.
a Prepare with starting s witch OFF, then turn starting switch ON or
start engine and carry out troubleshooting in each case.
P25 Voltage
Defectiv e F pump pressure Between (3) (1) Power supply 4.5 5.5 V
2
sensor (Internal defect) Between (2) (1) Signal 0.3 4.5 V
If voltage is abnormal, replace F pump press ure sensor with R
pump pressure s ensor and check failure code. (If "E" of failure code
goes off at this time, F pump press ure sensor is defective.)
Pos sible causes
and s tandard Disconnection in wiring har- Wiring harness between C01 (female) (18) Resis-
Max. 1 z
nes s (Dis connection in w iring P25 (female) (1) tance
value in normal 3
state or defec tive contact in con- Wiring harness between C01 (female) (49) Resis-
nec tor) Max. 1 z
Wiring harness betw een C01 (female) (9) Resis-
Max. 1 z
J06 P25 (female) (3) tance
circuit) Wiring harness between C01 (female) (49) Resis-
Min. 1 Mz
5
24V c irc uit) in wiring harness Wiring harness between C01 (female) (49)
Voltage Max. 1 V
P25 (female) (2)
12 PC200 , 220 -8
Circuit diagra m relate d to F pum p pressure s ensor
PC20 0, 220 -8 13
Failure code [DHPBMA] R Pump Press Sensor Abnormality 1

User code Failure c ode R pump press ure sensor abnormality
Trouble
DHPBMA (Pump c ontroller s ystem)
Contents of
Signal voltage of R pump press ure sensor circuit is below 0.3 V or abov e 4.5 V.
trouble
Action of F ix es R pump press ure at 0 MPa {0 kg/c m 2} and continues control.
Problem that
Automatic gear shifting func tion does not work.
appears on
Straight trav el performance or steering performance lowers.
machine
Related infor- will be broken. Accordingly, take extreme care when check ing.
mation R pump pressure can be c hecked with monitoring function. (C ode: 01101 R pump pressure)

Defectiv e 5V s ensor pow er If failure code [ DA25KP] is also displayed, c arry out troubleshooting
1
supply 1 system for it first.
P26 Voltage
Defectiv e R pum p pressure Between (3) (1) Power supply 4.5 5.5 V
2
sensor (Internal defect) Between (2) (1) Signal 0.3 4.5 V
If voltage is abnormal, replace R pump press ure sensor with F
pump pressure s ensor and check failure code. (If "E" of failure code
goes off at this time, R pump pressure sensor is defective.)
Pos sible causes
Max. 1 z
value in normal 3
state or defec tive contact in con- Wiring harness between C01 (female) (68) Resis-
nec tor) Max. 1 z
Max. 1 z
Min. 1 Mz
5
Voltage Max. 1 V
P26 (female) (2)
14 PC200 , 220 -8
Circuit diagra m relate d to R pum p pressure sensor
PC20 0, 220 -8 15
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 1

User code Failure c ode Arm curl PPC pressure sensor abnormality
Trouble
DHS3MA (Pump c ontroller s ystem)
Contents of
Signal voltage of arm curl PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of F ix es arm curl PPC pressure at 0 MPa {0 kg/cm 2} and continues control.
Problem that
Automatic decelerator cannot be reset.
appears on
Arm c url performance lowers.
machine
will be broken. Accordingly, take extreme care when check ing.
Related infor-
Arm curl PPC press ure can be checked with monitoring function.
mation
(Code: 07200 Arm c url PPC pres sure)

1
P04 Voltage
Defectiv e arm c url PPC pres-
2 Between (2) (1) Signal 0.3 4.5 V
sure sens or (Internal defec t)
If voltage is abnormal, replace arm curl PPC pressure sens or with
another PPC pressure sensor and check failure code. (If "E" of fail-
ure code goes off at this time, arm curl PPC pressure sensor is
defec tive.)
state 3
nec tor) Max. 1 z
Max. 1 z
circuit) Min. 1 Mz
5
Voltage Max. 1 V
P04 (female) (2)
16 PC200 , 220 -8
Circuit diagra m relate d to a rm c url P PC pressure sensor
PC20 0, 220 -8 17
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 1

User code Failure c ode Buc ket curl PPC press ure sensor abnormality
Trouble
Contents of
Signal voltage of buc ket c url PPC press ure s ensor circuit is below 0.3 V or abov e 4.5 V.
trouble
Action of F ix es buc ket curl PPC press ure at 0 MPa {0 kg/c m 2} and continues control.
Problem that
appears on
Bucket curl performance lowers.
machine
Related infor-
Bucket curl PPC pressure can be c hecked with monitoring function.
mation
(Code: 07300 Bucket curl PPC pressure)

1
P01 Voltage
Defectiv e bucket curl PPC Between (3) (1) Power supply 4.5 5.5 V
2 press ure sensor (Internal Between (2) (1) Signal 0.3 4.5 V
defec t)
If voltage is abnormal, replace buc ket curl PPC press ure sensor
with another PPC press ure sensor and check failure code. (If "E" of
failure c ode goes off at this tim e, buc ket curl PPC press ure sensor
is defectiv e.)
state 3
nec tor) Max. 1 z
Max. 1 z
circuit) Min. 1 Mz
5
Voltage Max. 1 V
P01 (female) (2)
18 PC200 , 220 -8
Circuit diagra m re late d to buck et c url P PC pressure s ensor
PC20 0, 220 -8 19
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality 1

User code Failure c ode Boom raise PPC press ure sensor abnormality
Trouble
Contents of
Signal voltage of boom raise PPC press ure s ensor circuit is below 0.3 V or abov e 4.5 V.
trouble
Action of F ix es boom raise PPC press ure at 0 MPa {0 kg/c m 2} and continues control.
Problem that
appears on
Boom raise performance lowers.
machine
Related infor-
Boom raise PPC pressure c an be checked with monitoring function.
mation
(Code: 07400 Boom rais e PPC pressure)

1
P06 Voltage
Defectiv e boom rais e PPC Between (3) (1) Power supply 4.5 5.5 V
defec t)
If voltage is abnormal, replace boom raise PPC press ure sensor
failure c ode goes off at this time, boom raise PPC pressure sensor
is defectiv e.)
state 3
nec tor) Max. 1 z
Max. 1 z
circuit) Min. 1 Mz
5
Voltage Max. 1 V
P06 (female) (2)
20 PC200 , 220 -8
Circuit diagram re lat ed to boom ra is e P PC pressure sensor
PC20 0, 220 -8 21
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality 1

User code Failure c ode Swing right PPC press ure sensor abnormality
Trouble
DHSAMA (Pump c ontroller s ystem)
Contents of
Signal voltage of swing right PPC pressure sens or circ uit is below 0.3 V or above 4.5 V.
trouble
Action of F ix es swing right PPC pressure at 0 MPa {0 kg/cm 2} and continues control.
Problem that
Automatic decelerator and s wing holding brake c annot be res et.
appears on
Swing right performance lowers.
machine
Related infor-
Swing right PPC pressure can be c hecked with monitoring function.
mation
(Code: 09002 Swing right PPC pressure)

1
P07 Voltage
Defectiv e swing right PPC Between (3) (1) Power supply 4.5 5.5 V
defec t)
If voltage is abnormal, replace swing right PPC pressure sens or
failure code goes off at this time, s wing right PPC pressure sensor is
defec tive.)
state 3
nec tor) Max. 1 z
Max. 1 z
circuit) Min. 1 Mz
5
Voltage Max. 1 V
P07 (female) (2)
22 PC200 , 220 -8
Circuit diagra m relate d to swing right P PC pressure sensor
PC20 0, 220 -8 23
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality 1

User code Failure c ode Swing left PPC pressure sens or abnormality
Trouble
DHSBMA (Pump c ontroller s ystem)
Contents of
Signal voltage of swing left PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of F ix es swing left PPC pres sure at 0 MPa {0 k g/cm 2} and continues control.
Problem that
Automatic decelerator and s wing holding brake c annot be res et.
appears on
Swing left performance lowers.
machine
Related infor-
Swing left PPC press ure can be checked with monitoring function.
mation
(Code: 09002 Swing left PPC pres sure)

1
P03 Voltage
Defectiv e swing left PPC Between (3) (1) Power supply 4.5 5.5 V
defec t)
If voltage is abnormal, replace swing left PPC pres sure s ensor with
another PPC pressure sensor and check failure code. (If "E" of fail-
ure code goes off at this time, swing left PPC pres sure sensor is
defec tive.)
state 3
nec tor) Max. 1 z
Max. 1 z
circuit) Min. 1 Mz
5
Voltage Max. 1 V
P03 (female) (2)
24 PC200 , 220 -8
Circuit diagra m relate d to s wing le ft P PC pressure s ensor
PC20 0, 220 -8 25
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 1

User code Failure c ode Buc ket dump PPC pressure sens or abnormality
Trouble
DHSDMA (Pump c ontroller s ystem)
Contents of
Signal voltage of buc ket dump PPC pressure sens or circ uit is below 0.3 V or above 4.5 V.
trouble
Action of F ix es buc ket dump PPC pressure at 0 MPa {0 kg/cm 2} and continues control.
Problem that
appears on
Bucket dump performance low ers.
machine
Related infor-
Bucket dump PPC pressure can be chec ked with monitoring func tion.
mation
(Code: 07301 Bucket dump PPC press ure)

1
P05 Voltage
Defectiv e bucket dump PPC Between (3) (1) Power supply 4.5 5.5 V
defec t)
If voltage is abnormal, replace buc ket dump PPC pressure sens or
with another PPC pres sure s ensor and c heck failure code. (If "E" of
failure code goes off at this time, bucket dump PPC press ure sens or
is defectiv e.)
state 3
nec tor) Max. 1 z
Max. 1 z
circuit) Min. 1 Mz
5
Voltage Max. 1 V
P05 (female) (2)
26 PC200 , 220 -8
Circuit diagra m relate d to buck et dump PPC press ure sensor
PC20 0, 220 -8 27
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) 1

Ov erload a larm monitor non-dis play specification
User code Failure c ode Overload sens or (analog)
Trouble
DHX1MA (Pump c ontroller s ystem)
Contents of
Monitor which is not s et to be displayed (Overload alarm monitor) is displayed.
trouble
Problem that
appears on
machine
Related infor-
Method of reproducing failure c ode: Turn starting switc h ON.
mation

and s tandard
Pump controller may be defective. (Since trouble is in sys tem, trou-
value in normal 1 Defectiv e pump controller
state bles hooting cannot be carried out.)
PC20 0, 220 -8 29
Ov erload a larm monitor display specification

User code Failure c ode Overload sensor (analog)
Trouble
DHX1MA (Pump c ontroller s ystem)
Contents of
Signal voltage of overload alarm pressure sensor circuit is below 0.3 V or above 4.4 V.
trouble
Action of Outputs overload alarm constantly.
Problem that
appears on If display of overload alarm monitor is set, ov erload alarm monitor is displayed constantly.
machine
Overload alarm pressure sens or is installed to only machine on which display of overload alarm
monitor is set.
Related infor-
mation
Overload alarm pressure (Boom cylinder bottom pres sure) can be check ed with monitoring function.
(Code: 15900 Boom bottom pres sure)

1
P46 Voltage
Defectiv e ov erload alarm Between (3) (1) Power supply 4.5 5.5 V
2 press ure sensor (Internal
Between (2) (1) Signal 0.3 4.4 V
defec t)
If voltage is abnormal, replac e ov erload alarm pressure sensor with
F pump press ure sensor or R pump pressure sensor and check fail-
ure code. (If "E" of failure code goes off at this time, ov erload alarm
press ure sensor is defectiv e.)
and s tandard Wiring harness between C01 (female) (18) Resis-
Disconnection in wiring har- Max. 1 z
value in normal P46 (female) (1) tance
nes s (Dis connection in w iring
state 3
Max. 1 z
nec tor) P46 (female) (2) tance
Max. 1 z
circuit) Wiring harness betw een C01 (female) (9) Resis-
Min. 1 Mz
5
Voltage Max. 1 V
P46 (female) (2)
30 PC200 , 220 -8
Circuit diagra m re late d to ov erload a la rm pre ssure s ensor
PC20 0, 220 -8 31
Failure code [DW43KA] Travel Speed Sol Discon 1

User code Failure c ode Trav el speed solenoid system dis connection
Trouble
DW43K A (Pump c ontroller s ystem)
Contents of
When output to travel speed shifting solenoid was turned ON, disconnection w as detected in circ uit.
trouble
Action of None in particular. (Since no current flow s, s olenoid does not operate.)
PC200: Speed is low at High travel speed position (Mac hine monitor is set to High but ac tual speed
Problem that
is about Middle).
appears on
PC220: Speed is low at High and Middle trav el speed pos ition (Machine monitor is set to High or
machine
Middle but actual s peed is about Low).
Operating condition of trav el speed shifting solenoid can be c hecked with monitoring function.
Related infor-
(Code: 02300: Solenoid 1)
mation
Method of reproduc ing failure code: Start engine + Set trav el speed to High + Operate travel lever.

Defectiv e travel speed shift- without turning s tarting s witch ON.
1 ing solenoid (Internal dis con-
V04 (male) Resistance
nec tion)
Between (1) (2) 20 60 z
and s tandard nes s (Dis connection in w iring Wiring harness between C02 (female) (87) Resis-
value in normal 2 Max. 1 z
or defec tive contact in con- V04 (female) (1) tance
state nec tor)
Max. 1 z
(117), (120) V04 (female) (2) tance
Between (87) (115), (117),
20 60 z
(120)
32 PC200 , 220 -8
Circuit diagra m relate d to t rav el spee d shift ing s olenoid
PC20 0, 220 -8 33
Failure code [DW43KB] Travel Speed Sol Short 1

User code Failure c ode Trav el speed solenoid system short
Trouble
DW43K B (Pump c ontroller s ystem)
Contents of
When output to travel speed shifting solenoid was turned ON, s hort circ uit was detected in circuit.
trouble
Action of Turns output to travel s peed shifting solenoid OFF.
PC200: Speed is low at High travel speed position (Mac hine monitor is set to High but ac tual speed
Problem that
is about Middle).
appears on
PC220: Speed is low at High and Middle trav el speed pos ition (Machine monitor is set to High or
machine
Middle but actual s peed is about Low).
Operating condition of trav el speed shifting solenoid can be c hecked with monitoring function.
Related infor-
mation
Method of reproduc ing failure code: Start engine + Set trav el speed to High + Operate travel lever.

Defectiv e travel speed shift-
1 ing solenoid (Internal dis con- V04 (male) Resistance
nec tion) Between (1) (2) 20 60 z
value in normal Wiring harness between C02 (female) (87) Resis-
state circuit) Min. 1 Mz
V04 (female) (1) tance
Between (87) (115), (117),
20 60 z
(120)
34 PC200 , 220 -8
PC20 0, 220 -8 35
Failure code [DW45KA] Swing Brake Sol Discon 1

User code Failure c ode Swing holding brak e solenoid s ystem disconnection
Trouble
E03 DW45KA (Pump c ontroller s ystem)
Contents of
When output to swing holding brake solenoid was turned OFF, dis connection was detected in circuit.
trouble
Problem that
appears on Machine cannot s wing (Swing holding brak e is not reset).
machine
If solenoid and wiring harness are norm al, operator can swing machine by setting s wing holding
brake release switch in release position (Swing holding brake does not work, however, when
machine s tops).
Related infor- Keep s wing lock switc h in OFF position and swing holding brak e release switc h in releas e position
mation during troubleshooting.
Operating condition of s wing holding brake solenoid c an be checked with monitoring function.

Defectiv e swing holding without turning s tarting s witch ON.
1 brak e s olenoid (Internal dis-
connection)
Between (1) (2) 20 60 z
Defectiv e ass em bled-type without turning s tarting s witch ON.
2 diode D01 (Internal discon-
D01 (male) Digital circuit tester Continuity
nec tion)
Between (7) (3) Diode mode There is c ontinuity
Defectiv e swing lock switc h S04 (male) Swing lock switch Resistance
3
(Internal disconnection)
OFF Max. 1 z
Pos sible causes Between (3) (4)
ON M in. 1 Mz
and s tandard
Max. 1 z
Disconnection in wiring har- D01 (female) (7) tance
nes s (Dis connection in w iring Wiring harness betw een D01 (female) (3) Resis-
4 Max. 1 z
or defec tive contact in con- J02 S04 (female) (3) tance
nec tor) Wiring harness between S04 (female) (4) Resis-
Max. 1 z
Max. 1 z
(117), (120) V03 (female) (2) tance
5 Defectiv e pump controller C02 (female) Disconnect D01 and Resistance

connect pins (3) and
Between (101) (7) on female side 20 60 z
(115), (117), (120) directly.
36 PC200 , 220 -8
Circuit diagra m relate d to s wing holding brake solenoid
PC20 0, 220 -8 37
Failure code [DW45KB] Swing Brake Sol Short 1

User code Failure c ode Swing holding brak e solenoid s ystem s hort
Trouble
E03 DW45KB (Pump c ontroller s ystem)
Contents of
When output to swing holding brake solenoid was turned ON, short circuit was detec ted in circuit.
trouble
Action of Turns output to s wing holding brake s olenoid OFF.
Problem that
appears on Machine cannot s wing (Swing holding brak e is not reset).
machine
If solenoid and wiring harness are norm al, operator can swing machine by setting s wing holding
brake release switch in release position (Swing holding brake does not work, however, when
machine s tops).
Related infor- Keep s wing lock switc h in OFF position and swing holding brak e release switc h in releas e position
mation during troubleshooting.
Operating condition of s wing holding brake solenoid c an be checked with monitoring function.
Method of reproduc ing failure code: Start engine + Swing with left work equipment control lever.

Defectiv e swing holding
1 brak e solenoid (Internal short V03 (male) Resistance
circuit or ground fault) Between (1) (2) 20 60 z
Pos sible causes Ground fault in wiring har- without turning s tarting s witch ON.
and s tandard nes s (Dis connection in w iring
2
value in normal or defec tive contact in con- Wiring harness betw een C02 (female) (101) Resis-
D01 J 02 S04 V03 (female) (1), S25 Min. 1 Mz
state nec tor) tance
(female) (14)
3 Defectiv e pump controller Disconnect D01 and
Between (101)
connect pins (3) and 20 60 z
(115), (117), (120)
(7) on female side
Between (101) directly. Min. 1 Mz
chassis ground
38 PC200 , 220 -8
PC20 0, 220 -8 39
Failure code [DW91KA] Travel Junction Sol Discon 1

User code Failure c ode Trav el junction solenoid system disconnection
Trouble
DW91K A (Pump c ontroller s ystem)
Contents of
When output to travel junc tion solenoid w as turned ON, disc onnec tion was detec ted in circuit.
trouble
Problem that
appears on Machine is not s teered easily during trav el.
machine
Operating condition of trav el junction solenoid can be c heck ed with monitoring function.
Related infor-
(Code: 02300 Solenoid 1)
mation
Method of reproduc ing failure code: Start engine + Steer mac hine with right and left travel levers .

Defectiv e travel junction without turning s tarting s witch ON.
1 solenoid (Internal disconnec-
tion)
Between (1) (2) 20 60 z
and s tandard nes s (Dis connection in w iring Wiring harness betw een C02 (female) (110) Resis-
state nec tor) Wiring harness between C02 (female) (115), Resis-
Max. 1 z
(117), (120) V05 (female) (2) tance
Between (110) (115), (117),
20 60 z
(120)
40 PC200 , 220 -8
Circuit diagra m relate d to t rav el junc tion s olenoid
PC20 0, 220 -8 41
Failure code [DW91KB] Travel Junction Sol Short 1

User code Failure c ode Trav el junction solenoid system short
Trouble
DW91K B (Pump c ontroller s ystem)
Contents of
When output to travel junc tion solenoid w as turned ON, s hort circuit was detected in circuit.
trouble
Action of Turns output to travel junction solenoid OFF.
Problem that
appears on Machine is not s teered easily during trav el.
machine
Operating condition of trav el junction solenoid can be c heck ed with monitoring function.
Related infor-
mation
Method of reproduc ing failure code: Start engine + Steer mac hine with right and left travel levers .

Defectiv e travel junction
1 solenoid (Internal short c ir- V05 (male) Resistance
cuit or ground fault) Between (1) (2) 20 60 z
state Min. 1 Mz
Between (110) (115), (117),
20 60 z
(120)
42 PC200 , 220 -8
Circuit diagra m relate d to t rav el junc tion s olenoid
PC20 0, 220 -8 43
Failure code [DWA2KA] Service Sol Discon 1

User code Failure c ode Servic e solenoid disconnection
Trouble
DWA2KA (Pump c ontroller s ystem)
Contents of
When output to service solenoid is turned OF F, disconnection w as detec ted in circuit.
trouble
Problem that
appears on Hy draulic circuit for attachment does not c hange to single operation circuit.
machine
Operating condition of s ervice solenoid c an be checked with monitoring function.
Related infor- (Code: 02301 Solenoid 2)
mation Method of reproduc ing failure code: Turn starting switch ON + Set machine in mode other than
breaker mode (B).

Defectiv e serv ic e solenoid without turning s tarting s witch ON.
1
(Internal disconnection) V06 (male) Resistance
Between (1) (2) 20 60 z
and s tandard Disconnection in wiring har-
nes s (Dis connection in w iring Wiring harness between C02 (female) (86) Resis-
state or defec tive contact in con- V06 (female) (1) tance
nec tor)
Wiring harness between V06 (female) (2) Resis-
Max. 1 z
Between (86) chas sis ground 20 60 z
Circuit diagra m relate d to s ervic e solenoid
44 PC200 , 220 -8
Failure code [DWA2KB] Service Sol Short 1

User code Failure c ode Servic e solenoid s hort
Trouble
DWA2KB (Pump c ontroller s ystem)
Contents of
When output to service solenoid is turned ON, short circuit was detec ted in circuit.
trouble
Action of Turns output to s ervice s olenoid OFF
Problem that
appears on Hy draulic circuit for attachment is not does not change to s ingle operation c irc uit.
machine
Operating condition of s ervice solenoid c an be checked with monitoring function.
Related infor-
mation
Method of reproduc ing failure code: Turn starting switch ON + Set machine in break er m ode (B).

Defectiv e serv ic e solenoid
1 (Internal s hort circ uit or V06 (male) Resistance
ground fault) Between (1) (2) 20 60 z
Pos sible causes Between (1) chassis ground Min. 1 Mz
value in normal Ground fault in wiring har- without turning s tarting s witch ON.
state 2 nes s (Short circuit with GND
Min. 1 Mz
Between (86) chas sis ground 20 60 z
Circuit diagra m relate d to s ervic e solenoid
PC20 0, 220 -8 45
Failure code [DWK0KA] 2-stage Relief Sol Discon 1

User code Failure c ode 2-stage relief solenoid disconnection
Trouble
DWK0KA (Pump c ontroller s ystem)
Contents of
When output to 2-stage relief solenoid is turned OF F, disconnection was detected in circ uit.
trouble
Problem that
Power max imiz ing function does not work.
appears on
Travel power is low.
machine
Operating condition of 2-stage relief solenoid c an be checked with monitoring function.
Related infor-
mation
Method of reproduc ing failure code: Turn starting switch ON + Set machine in mode other than (L).

Defectiv e 2-stage relief sole-
1
noid (Internal dis connection) V02 (male) Resistance
Between (1) (2) 20 60 z
and s tandard nes s (Dis connection in w iring Wiring harness betw een C02 (female) (109) Resis-
Max. 1 z
(117), (120) V02 (female) (2) tance
Between (109) (115), (117),
20 60 z
(120)
46 PC200 , 220 -8
Circuit diagra m relate d to 2 -stage re lief sole noid
PC20 0, 220 -8 47
Failure code [DWK0KB] 2-stage Relief Sol Short 1

User code Failure c ode 2-stage relief solenoid short
Trouble
DWK0KB (Pump c ontroller s ystem)
Contents of
When output to 2-stage relief solenoid is turned ON, short circuit was detected in circuit.
trouble
Action of Turns output to 2-stage relief s olenoid OFF.
Problem that
Power max imiz ing function does not work.
appears on
Travel power is low.
machine
Operating condition of 2-stage relief solenoid c an be checked with monitoring function.
Related infor-
mation
Method of reproduc ing failure code: Turn starting switch ON + Set machine in working mode (L).

Defectiv e 2-stage relief sole-
1 noid (Internal short circuit or V02 (male) Resistance
state Min. 1 Mz
Between (109) (115), (117),
20 60 z
(120)
Between (109) c hassis ground Min. 1 Mz
48 PC200 , 220 -8
PC20 0, 220 -8 49
SE N0 0242- 01
© 2 006 KO MATSU
All Rights Reserved
50
SE N00 243- 01
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Tr ouble sh ooting by failu re co de (Di spla y of cod e), P art 4 .............................................................................. 4
Failur e code [DXA8K A] P C-E PC (F) So l Discon .................................................................................. 4
Failur e code [DXA8K B] P C-E PC (F) So l S hort .................................................................................... 6
Failur e code [DXA9K A] P C-E PC (R) So l Discon ................................................................................. 8
Failur e code [DXA9K B] P C-E PC (R) So l S hort .................................................................................. 1 0
Failur e code [DXE0K A] L S-EP C Sol Disco n ...................................................................................... 1 2
Failur e code [DXE0K B] L S-EP C Sol Sh ort ........................................................................................ 14
Failur e code [DXE4K A] S ervice Curre nt EP C Disco n ........................................................................ 1 6
Failur e code [DXE4K B] S ervice Curr ent EP C Sh ort .......................................................................... 1 8
Failur e code [DXE5K A] Merg e-divide r Main S ol Di scon .................................................................... 2 0
Failur e code [DXE5K B] Merg e-divide r Main So l S hort....................................................................... 22
Failur e code [DXE6K A] Merg e-divide r L S S ol Discon ........................................................................ 2 4
Failur e code [DXE6K B] Merg e-divide r L S Sol Sho rt .......................................................................... 2 6
Failur e code [DY20K A] Wip er Workin g A bnormal ity .......................................................................... 2 8
PC20 0, 220 -8 1
Failur e code [DY20MA ] Wiper Pa rkin g Abnor ma lity........................................................................... 3 0

Failur e code [DY2CKA ] Wa she r Dri ve Disco n.................................................................................... 3 2
Failur e code [DY2CKB ] Wa she r Dri ve Sh ort ...................................................................................... 34
Failur e code [DY2DKB ] Wiper Drive (For) Sh ort ................................................................................ 36
Failur e cod e [DY2E KB] Wip er Dri ve (Rev) Short ............................................................................... 3 8
2 PC200 , 220 -8

Failure code [DXA8KA] PC-EPC (F) Sol Discon 1
User code Failure c ode PC-EPC (F) solenoid s ystem disconnection
Trouble
E02 DXA8KA (Pump c ontroller s ystem)
Contents of
When PC-EPC (F) s olenoid was driven, disconnection was detected in circuit.
trouble
Action of None in particular (Since no current flows, solenoid does not operate).
Problem that
appears on If pump load increas es, engine speed lowers largely and engine may stall.
machine
Drive c urrent of PC-EPC (F) solenoid can be check ed w ith monitoring func tion.
Related infor-
(Code: 01300 PC-EPC solenoid current (F))
mation

Defectiv e PC-EPC (F) sole- without turning s tarting s witch ON.
1
Between (1) (2) 7 14 z
Emergenc y pump
S25 (male) Resistance
Defectiv e emergency pump driv e switch
2 driv e switch (Internal discon- Normal Max. 1 z
nec tion) Between (3) (2)
Emergency M in. 1 Mz
Normal Max. 1 z
Between (6) (5)
Pos sible causes Emergency M in. 1 Mz
and s tandard
value in normal
state
Max. 1 z
S25 (female) (3) tance
nes s (Dis connection in wiring Wiring harness between S25 (female) (2) Resis-
3 Max. 1 z
nec tor) Wiring harness between C02 (female) (115), Resis-
Max. 1 z
(117), (120) S25 (female) (6) tance
Wiring harness between S25 (female) (5) Resis-
Max. 1 z
Between (96) (115), (117),
7 14 z
(120)
4 PC200 , 220 -8
Circuit diagra m relate d to PC-EPC (F) solenoid and PC-EP C (R) solenoid
PC20 0, 220 -8 5
Failure code [DXA8KB] PC-EPC (F) Sol Short 1

User code Failure c ode PC-EPC (F) s olenoid s ystem s hort
Trouble
E02 DXA8KB (Pump c ontroller s ystem)
Contents of
When PC-EPC (F) s olenoid was driven, short c irc uit was detected in circuit.
trouble
Action of Turns output to PC-EPC (F) solenoid OFF.
Problem that
machine
Drive c urrent of PC-EPC (F) solenoid can be check ed w ith monitoring func tion.
Related infor-
(Code: 01300 PC-EPC solenoid current (F))
mation

Defectiv e PC-EPC (F) sole-
Defectiv e emergency pump Emergenc y pump
2 driv e switch (Internal short driv e switch
circuit or ground fault) Between (2), (3) (4) Min. 1 Mz
Pos sible causes
Between (2), (3) Normal
and s tandard Min. 1 Mz
value in normal chassis ground
3 nes s (Contac t with GND cir- Min. 1 Mz
cuit)
Min. 1 Mz
Between (96) (115), (117),
7 14 z
(120)
6 PC200 , 220 -8
PC20 0, 220 -8 7
Failure code [DXA9KA] PC-EPC (R) Sol Discon 1

User code Failure c ode PC-EPC (R) s olenoid sy stem disconnection
Trouble
E02 DXA9KA (Pump c ontroller s ystem)
Contents of
When PC-EPC (R) s olenoid was driven, disconnection was detected in circuit.
trouble
Problem that
machine
Drive c urrent of PC-EPC (R) solenoid can be check ed with monitoring function.
Related infor-
(Code: 01302 PC-EPC solenoid current (R))
mation

Defectiv e PC-EPC (R) sole-
1
Between (1) (2) 7 14 z
Emergenc y pump
Defectiv e emergency pump driv e switch
2 driv e switch (Internal discon- Normal Max. 1 z
nec tion) Between (9) (8)
Emergency M in. 1 Mz
Normal Max. 1 z
Between (12) (11)
Pos sible causes Emergency M in. 1 Mz
and s tandard
value in normal
state
Min. 1 Mz
Disconnection in wiring har- S25 (female) (9) tance
nes s (Dis connection in wiring Wiring harness between S25 (female) (8) Resis-
3 Min. 1 Mz
nec tor)
Min. 1 Mz
(117), (120) S25 (female) (12) tance
Min. 1 Mz
Between (104) (115), (117),
7 14 z
(120)
8 PC200 , 220 -8
PC20 0, 220 -8 9
Failure code [DXA9KB] PC-EPC (R) Sol Short 1

User code Failure c ode PC-EPC (R) s olenoid sy stem s hort
Trouble
E02 DXA9KB (Pump c ontroller s ystem)
Contents of
When PC-EPC (R) s olenoid was driven, short c irc uit was detected in circuit.
trouble
Action of Turns output to PC-EPC (R ) solenoid OFF.
Problem that
machine
Drive c urrent of PC-EPC (R) solenoid can be check ed with monitoring function.
Related infor-
(Code: 01302 PC-EPC solenoid current (R))
mation

Defectiv e PC-EPC (R) sole-
Emergenc y pump
Defectiv e emergency pump S25 (male) Resistance
driv e switch
2 driv e switch (Internal short
Between (8), (9)
circuit or ground fault) Min. 1 Mz
Pos sible causes (10)
Normal
and s tandard Between (8), (9)
value in normal Min. 1 Mz
chassis ground
state
3 nes s (Contac t with GND cir- Min. 1 Mz
cuit)
Min. 1 Mz
Between (104) (115), (117),
7 14 z
(120)
Between (104) c hassis ground Min. 1 Mz
10 PC200 , 220 -8
PC20 0, 220 -8 11
Failure code [DXE0KA] LS-EPC Sol Discon 1

User code Failure c ode LS-EPC solenoid sys tem disconnection
Trouble
DXE0KA (Pump c ontroller s ystem)
Contents of
When LS-EPC solenoid was driv en, disc onnec tion was detec ted in circuit.
trouble
Problem that
Travel speed is high at Lo and Mi.
appears on
Work equipment speed and swing speed are high in lifting mode (L).
machine
Drive c urrent of LS-EPC solenoid c an be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid current)
mation

Defectiv e LS-EPC solenoid
1
(Internal disconnection) V19 (male) Resistance
Between (1) (2) 7 14 z
and s tandard nes s (Dis connection in wiring Wiring harness between C02 (female) (88) Resis-
Max. 1 z
(117), (120) V19 (female) (2) tance
Between (88) (115), (117),
7 14 z
(120)
12 PC200 , 220 -8
Circuit diagra m relate d to LS -EPC solenoid
PC20 0, 220 -8 13
Failure code [DXE0KB] LS-EPC Sol Short 1

User code Failure c ode LS-EPC solenoid system short
Trouble
DXE0KB (Pump c ontroller s ystem)
Contents of
When LS-EPC solenoid was driv en, short circuit was detected in circuit.
trouble
Action of Turns output to LS-EPC s olenoid OFF.
Problem that
Travel speed is high at Lo and Mi.
appears on
Work equipment speed and swing speed are high in lifting mode (L).
machine
Drive c urrent of LS-EPC solenoid c an be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid c urrent)
mation

Defectiv e LS-EPC solenoid
1 (Internal s hort circ uit or V19 (male) Resistance
state Min. 1 Mz
Between (88) (115), (117),
7 14 z
(120)
14 PC200 , 220 -8
Circuit diagra m relate d to LS -EPC solenoid
PC20 0, 220 -8 15
Failure code [DXE4KA] Service Current EPC Discon 1

User code Failure c ode Service current EPC solenoid dis connection
Trouble
Contents of
When service EPC solenoid was driv en, disc onnec tion was detec ted in circuit.
trouble
Problem that
appears on Attac hment does not operate.
machine
Drive current of serv ic e EPC s olenoid can be checked with monitoring function.
Related infor-
(Code: 01700 serv ic e solenoid current)
mation
Method of reproduc ing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Defectiv e serv ic e EPC s ole-
1
Between (1) (2) 7 14 z
Max. 1 z
(117), (120) V30 (female) (2) tance
Between (97) (115), (117),
7 14 z
(120)
16 PC200 , 220 -8
Circuit diagra m relate d to s ervic e EPC s olenoid
PC20 0, 220 -8 17
Failure code [DXE4KB] Service Current EPC Short 1

User code Failure c ode Servic e current EPC solenoid short
Trouble
Contents of
When service EPC solenoid w as driv en, short circuit was detected in circuit.
trouble
Action of Turns output to s ervice EPC solenoid OFF.
Problem that
appears on Attac hment does not operate.
machine
Drive current of serv ic e EPC s olenoid can be checked with monitoring function.
Related infor-
(Code: 01700 service EPC solenoid current)
mation
Method of reproduc ing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Defectiv e serv ic e EPC s ole-
state Min. 1 Mz
Between (97) (115), (117),
7 14 z
(120)
18 PC200 , 220 -8
Circuit diagra m relate d to s ervic e EPC s olenoid
PC20 0, 220 -8 19
Failure code [DXE5KA] Merge-divider Main Sol Discon 1

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

Defectiv e merge-divider without turning s tarting s witch ON.
1 main EPC s olenoid (Internal
disconnection)
Between (1) (2) 7 14 z
and s tandard nes s (Dis connection in wiring Wiring harness betw een C02 (female) (112) Resis-
Max. 1 z
(117), (120) V23 (female) (2) tance
Between (112) (115), (117),
7 14 z
(120)
20 PC200 , 220 -8
Circuit diagra m relate d to m erge-div ider m ain EPC sole noid
PC20 0, 220 -8 21
Failure code [DXE5KB] Merge-divider Main Sol Short 1

User code Failure c ode Merge-div ider main solenoid short
Trouble
DXE5K B (Pump c ontroller s ystem)
Contents of
When merge-divider main EPC solenoid was driven, short circuit was detec ted in circuit.
trouble
Action of Turns output to merge-divider main EPC solenoid OFF.
Problem that
machine
Drive current of merge-divider main EPC solenoid can be check ed with monitoring function.
Related infor-
(Code: 08000 merge-divider main EPC solenoid current)
mation

Defectiv e merge-divider
1 main EPC s olenoid (Internal V23 (male) Resistance
short circuit or ground fault) Between (1) (2) 7 14 z
state Min. 1 Mz
Between (112) (115), (117),
7 14 z
(120)
22 PC200 , 220 -8
Circuit diagra m relate d to m erge-div ider m ain EPC sole noid
PC20 0, 220 -8 23
Failure code [DXE6KA] Merge-divider LS Sol Discon 1

User code Failure c ode Merge-div ider LS solenoid disc onnec tion
Trouble
Contents of
When merge-divider LS EPC s olenoid was driven, disconnection was detected in circuit.
trouble
Problem that
machine
Drive c urrent of merge-divider LS EPC solenoid can be check ed with monitoring function.
Related infor-
(Code: 08001 merge-divider LS solenoid current)
mation

Defectiv e merge-divider LS without turning s tarting s witch ON.
1 EPC solenoid (Internal dis-
connection)
Between (1) (2) 7 14 z
Max. 1 z
(117), (120) V24 (female) (2) tance
Between (89) (115), (117),
7 14 z
(120)
24 PC200 , 220 -8
Circuit diagra m relate d to m erge-div ider LS EPC sole noid
PC20 0, 220 -8 25
Failure code [DXE6KB] Merge-divider LS Sol Short 1

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

Defectiv e merge-divider LS
1 EPC solenoid (Internal short V24 (male) Resistance
circuit or ground fault) Between (1) (2) 7 14 z
state Min. 1 Mz
Between (89) (115), (117),
7 14 z
(120)
26 PC200 , 220 -8
Circuit diagra m relate d to m erge-div ider LS EPC sole noid
PC20 0, 220 -8 27
Failure code [DY20KA] Wiper Working Abnormality 1

User code Failure c ode Wiper working abnormality
Trouble
DY20KA (Pump c ontroller s ystem)
Contents of
When windshield wiper works, W signal of working ends is not input.
trouble
Action of Turns working output to wiper motor OFF.
Problem that
appears on Wiper motor does not work.
machine
Condition of W contact signal of w iper working area can be c hecked with monitoring function.
Related infor-
(Code: 02204 switch 5)
mation
Method of reproduc ing failure code: Turn starting switch ON + Set w iper switc h to IN T or ON.

M05 (female) Wiper blade Resistance
Defectiv e wiper motor (Inter-
1 Operating range top Max. 1 z
nal disc onnec tion)
Between (6) (5) Other than operating
Min. 1 Mz
range top
Between (1) (3) All range Max. 20 z
M05 (male) (6) tance
and s tandard Disconnection in wiring har-
value in normal nes s (Dis connection in wiring Wiring harness between M05 (female) (5) Resis-
2 Max. 1 z
or defec tive contact in con- J04 chassis ground (T05, T06) tance
state
nec tor) Wiring harness between C02 (female) (114) Resis-
Max. 1 z
Max. 1 z
C01 (female) Wiper blade Resistance
3 Defectiv e pump controller Operating range top Max. 1 z
Between (56) chas -
sis ground Other than operating
Min. 1 Mz
range top
28 PC200 , 220 -8
Circuit diagra m re late d to windshield wiper and w indow w asher
PC20 0, 220 -8 29
Failure code [DY20MA] Wiper Parking Abnormality 1

User code Failure c ode Wiper parking abnormality
Trouble
DY20M A (Pump c ontroller s ystem)
Contents of
When windshield wiper parks , P s ignal of storage area is not input.
trouble
Action of Turns parking output to wiper motor OF F.
Problem that
appears on Wiper motor does not park.
machine
Condition of P contac t s ignal of wiper parking area can be check ed with monitoring func tion.
Related infor-
(Code: 02204 switch 5)
mation
Method of reproduc ing failure code: Turn starting switch ON + Set wiper switc h to IN T/ON to OFF.

M05 (female) Wiper blade Resistance
Storage area Max. 1 z
Between (4) (5)
Defectiv e wiper motor (Inter- Work ing area Min. 1 Mz
1
Max. 1 z
Max. 1 z
and s tandard
value in normal Wiring harness between C01 (female) (75) Resis-
Max. 1 z
state Disconnection in wiring har-
nes s (Dis connection in wiring Wiring harness between M05 (female) (5) Resis-
3 Max. 1 z
or defec tive contact in con- J04 chassis ground (T05, T06) tance
nec tor)
Max. 1 z
Max. 1 z
C01 (female) Wiper blade Resistance
Between (75) chas - Storage area Max. 1 z
sis ground Work ing area Min. 1 Mz
30 PC200 , 220 -8
PC20 0, 220 -8 31
Failure code [DY2CKA] Washer Drive Discon 1

User code Failure c ode Window washer driv e system dis connection
Trouble
DY2C KA (Pump c ontroller s ystem)
Contents of When output to window washer drive s ystem w as turned OFF (when ground circuit w as connected),
trouble disconnection was detected in circuit.
Action of None in particular (Since no current flow s, w as her motor does not operate).
Problem that
appears on Window washer does not operate.
machine
Related infor-
mation

1 Defectiv e fuse No. 4 If fuse is broken, c ircuit probably has ground fault. (See c ause 5.)
Defectiv e was her motor M06 (male) Resistance
2 (Internal s hort circ uit or
Between (1), (2) chassis
Min. 1 Mz
ground
3 diode D02 (Internal short c ir-
D02 (female) Continuity (Resistance)
cuit)
Between (3) (7) No c ontinuity (Min. 1 Mz)
value in normal
nes s (Dis connection in wiring Wiring harness between F01 (4) J03 M06 Resis-
state 4 Max. 1 z
nec tor) Wiring harness betw een C01 (female) (3) Resis-
Max. 1 z
J04 M06 (female) (2) tance
Wiring harness between F01 (4) J03 M06 Resis-
(female) (1), D 02 (female) (3) tance
circuit)
Min. 1 Mz
J04 M06 (female) (2), D02 (female) (7) tance
C01 (female) Voltage
Between (3) chassis ground 20 30 V
32 PC200 , 220 -8
PC20 0, 220 -8 33
Failure code [DY2CKB] Washer Drive Short 1

User code Failure c ode Window washer driv e system short
Trouble
DY2C KB (Pump c ontroller s ystem)
Contents of When output to window was her drive system was turned ON (ground circuit was disconnected),
trouble short circuit was detected in circuit.
Action of Turns output to washer motor OF F.
Problem that
appears on Window washer does not operate.
machine
Related infor-
Method of reproduc ing failure code: Turn starting switch ON + Turn washer s witch ON.
mation

Defectiv e was her motor
1
(Internal s hort circ uit) M06 (male) Resistance
Pos sible causes Between (1) (2) 5 20 z
and s tandard
value in normal
state 2
Voltage Max. 1 V
J04 M6 (female) (2), D02 (female) (7)
If causes 1 and 2 are not detected, pump controller may be defec-
3 Defectiv e pump controller tive. (Sinc e trouble is in sy stem, troubles hooting cannot be carried
out.)
34 PC200 , 220 -8
PC20 0, 220 -8 35
Failure code [DY2DKB] Wiper Drive (For) Short 1

User code Failure c ode Wiper motor drive forward system short
Trouble
DY2D KB (Pump c ontroller s ystem)
Contents of
When output to wiper motor drive forward side was turned ON, short circuit w as detected in c irc uit.
trouble
Action of Turns output to wiper motor drive forward side OF F.
Problem that
appears on Windshield wiper does not operate.
machine
Related infor-
mation

1 nal short circuit or ground M05 (female) Resistance
fault) Between (3) (1) There is continuity
Pos sible causes
and s tandard Between (3) chassis ground Min. 1 Mz
state Ground fault in wiring har-
Min. 1 Mz
out.)
36 PC200 , 220 -8
PC20 0, 220 -8 37
Failure code [DY2EKB] Wiper Drive (Rev) Short 1

User code Failure c ode Wiper motor drive revers e system short
Trouble
DY2EKB (Pump c ontroller s ystem)
Contents of
When output to wiper motor drive reverse side was turned ON, short circuit w as detected in c irc uit.
trouble
Action of Turns output to wiper motor drive reverse side OF F.
Problem that
appears on Windshield wiper does not operate.
machine
Related infor-
mation

1 nal short circuit or ground M05 (female) C ontinuity/Resistance
fault) Between (1) (3) There is continuity
Pos sible causes
and s tandard Between (1) chassis ground Min. 1 Mz
Min. 1 Mz
out.)
38 PC200 , 220 -8
PC20 0, 220 -8 39
SE N0 0243- 01
© 2 006 KO MATSU
All Rights Reserved
40
SE N00 244- 01
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Troubleshooting of electrical system
(E-mode)
Tr ouble sh ooting of e lectrical system (E -mode) ............................................................................................... 3
Be fore carryin g o ut troubl esh ooting of e lectri cal system...................................................................... 3
Info rmation in tro ublesho otin g tabl e ..................................................................................................... 5
E-1 Whe n starting switch turn ed ON, machine mon ito r di spl ays nothing ............................................ 6
E-2 Whe n starting switch turn ed ON ( before starting en gine) , basic check i tem lights up ................... 8
E-3 E ngine do es no t start (Eng ine does not turn ) ...............................................................................11
E-4 P rehea ter do es no t ope rate ......................................................................................................... 1 4
E-5 A uto ma tic warm-up system d oes n ot ope rate (in col d sea so n) ................................................... 1 6
E-6 A ll work equi pment, swi ng, an d travel mechan ism do not mo ve or canno t be locked ................. 1 8
E-7 P recaution lights up whil e e ngine is runn ing ............................................................................... 20
E-8 E me rgency stop item lig hts up while engi ne is run ning ............................................................... 2 5
E-9 E ngine coola nt tempera ture g auge do es no t indicate norma lly................................................... 2 6
E-1 0 Hydra ulic o il tempe rature gaug e d oes not ind icate no rmally ..................................................... 2 7
E-11 Fuel level gaug e d oes n ot ind ica te no rmally.............................................................................. 29
PC20 0, 220 -8 1
E-1 2 Co nte nts of displa y by ma chi ne mo nitor are differe nt from a pplicab le ma chi ne ........................ 31
E-1 3 Ma chi ne monitor does not d isp lay some items.......................................................................... 3 1
E-1 4 Fun ction switch doe s not wo rk................................................................................................... 31
E-1 5 A uto-decel erator does not op erate norma lly.............................................................................. 3 2
E-1 6 Wo rkin g mod e does not chan ge ................................................................................................ 33
E-1 7 Travel speed do es no t chang e................................................................................................... 34
E-1 8 A larm buzzer can not b e stoppe d ............................................................................................... 35
E-1 9 Wi ndshield wipe r an d win dow washe r d o n ot op erate ............................................................... 3 6
E-2 0 P ower maximi zin g function doe s not opera te no rmally ............................................................. 3 8
E-2 1 S wing hold ing brake doe s not opera te nor mally........................................................................ 4 0
E-2 2 Travel alar m do es no t so und or doe s not stop sound ing ........................................................... 4 2
E-2 3 A ir con ditioner do es no t ope rate n ormally (includin g a ir con diti oner abn ormality re cor d) ......... 44
E-2 4 Wh ile starting swi tch is in OFF p ositio n, service meter is n ot displa ye d.................................... 5 6
E-2 5 Ma ch ine monitor ca nnot b e set in se rvice mode ....................................................................... 5 6
E-2 6 Mo nitoring functio n does not d isp lay le ver control signal no rma lly............................................ 5 7
E-2 7 K OMTRA X syste m doe s no t oper ate no rmally .......................................................................... 6 5
2 PC200 , 220 -8
Troubleshooting of electrical system (E-mode) 1

Before carrying out troubleshooting of electrical system 1
1
Connec tion table of fuse box
a This con nectio n tabl e sho ws th e device s to wh ich ea ch p ower su pply o f the fu se bo x suppl ies po we r (A
switch power supply is a device whi ch suppl ies powe r while the starting switch is in the ON p ositio n a nd
a con stant p ower sup ply is a device which su pplie s power wh ile the starting swi tch is in the OFF and ON
positions).
a When carrying o ut troub leshooting rel ate d to the electrical syste m, yo u sho uld check the fuse s and fus-
ible li nks to see if the power is sup plied no rmally.
Type of Fuse
Fusible link Fuse No. Destination of pow er
pow er s upply capacity
Lamp relay, rear lamp relay, c ab lamp relay
PC-EPC (F) solenoid v alve, PC-EPC (R) s olenoid v alve
1 10 A [When pump drive switch is operated in emergency ]
Swing holding brake solenoid v alve
[When swing holding brake release switch is operated]
2 30 A Pump controller (Solenoid power supply)
Switch power F04
supply (60 A) PPC oil pressure loc k solenoid valve
3 10 A Starting motor cut-out relay (PPC lock)
Starting motor cut-out relay (Personal c ode)
Cigarette lighter
4 10 A
Windshield was her motor
5 10 A Horn relay, horn
6 10 A Electrical intake air heater relay
7 10 A Rotary lamp
Switch power F04 8 20 A Right headlamp, working lamp (boom), working lamp (rear)
supply (60 A) Radio
9 10 A
Left k nob switch (pump controller input)
10 10 A (Spare)
Air conditioner unit
11 20 A
Air conditioner c ompressor electromagnetic clutch
12 10 A (Spare)
Switch power F04
13 10 A Headlamp
supply (60 A)
14 10 A Optional power supply (1)
Trav el alarm
15 10 A
Optional power supply (2)
Radio (backup power supply )
16 10 A
Room lam p
Starting switch
Cons tant F05
17 20 A Machine monitor
pow er s upply (30 A)
Pump controller
18 10 A (Spare)
19 30 A Engine controller
Switch power Starting sw itch
20 5A Engine controller (ACC signal)
supply ACC
PC20 0, 220 -8 3
Loc ations of fus ible link s
Location of fuse box and fuse Nos .
4 PC200 , 220 -8

a The fo llowing information is su mma rized in the trou bleshooting table an d the re lated electr ica l circuit
dia gram. Before carrying ou t tr ouble sh ooti ng, u ndersta nd th at information fully.
Trouble Trouble which occurr ed in th e machine

Related infor-
In for mation related to detected tr ouble o r tro ubleshooting
mation

<Co ntents of d escription>
Stan dar d value in nor mal state to jud ge possible causes
Rem arks on judgm en t
1
<Trou bles in wirin g harness>
Disco nnectio n
Con nector is connected imp er fectly or wiring har ness is b ro-
ken .
Gr ound fault
Wir ing h ar ness wh ich is not conn ected to chassis gr ound cir -
cuit is in con tact with chassis g round circuit.
Hot short
Wir ing har ness which is not con nected to power source (24
2 V) circuit is in contact with po wer sou rce (24 V) circuit.
Sho rt circuit
Ind ep end ent wiring harnesses are in contact with each other
Pos sible causes
Possible cau ses of tro uble abnor mally.
and s tandard
value in normal (Given num ber s ar e refer - <Precau tions for troubleshoo ting>
state ence num ber s, which do 1) Method of ind icating connector N o. and handling o f T-
not indicate priority) adapter
In sert o r connect T-adapter as explained b elow for tr ouble-
shootin g, u nless other wise specified.
3 If connecto r No. has no m ar ks of male and female, dis-
connect conn ector and inser t T-adap ters in both m ale side
and female sid e.
If connector N o. h as m arks of m ale and fem ale , d is-
connect co nnector and conn ect T-ad apter to only male
side or female side.
2) Entry or der of pin Nos. and han dlin g of tester leads
Con nect po sitive (+) lead an d negative () lead of tester as
exp lained below fo r tro ubleshootin g, u nless o th er wise
specified .
4
Connect positive (+) lead to pin No. or wir ing harness
enter ed on fr ont side.
Connect neg ative () lead to p in No. or har ness enter ed on
rear sid e.
Related circuit diagra m
This draw ing is a part of the circuit diagram related to troubleshooting.

Connector No.: Indicates (Model Number of pins) and (Color).
Connector No. and pin No. from each branc hing/merging point:
Shows the ends of branc h or source of merging within the parts of the
same wiring harness .
Arrow ( ): Roughly shows the loc ation on the machine.
PC20 0, 220 -8 5
E-1 When starting switch turned ON, machine monitor displays nothing1
Trouble When s tarting s witch turned ON, machine monitor displays nothing.
When starting switc h is turned ON, mac hine monitor displays KOMATSU logo, screen to input pass-
word (if set), screen to check breaker mode (if set), screen of chec k before s tarting, screen to che ck
Related infor-
working m ode and trav el s peed, and ordinary screen in order.
mation
When the engine is started, the battery voltage may lower suddenly, depending on the ambient tem-
perature and the c ondition of the battery.

1 Low charge level of battery Electrolyte spec ific gravity
Battery voltage (2 pieces)
(1 piece)
Min. 24 V Min. 1.26
Defectiv e fusible link F 05 or If fusible link or fuse is broken, circuit probably has ground fault.
2
fuse N o. 17 (See Cause 5.)
Wrong connection of connec- Machine monitor connector may be c onnec ted wrongly. Check it
3
tor directly. (Check mounting bracket plate with connector.)
Wiring harness betw een battery () chas- Resis-
Max. 1 z
sis ground tance
Wiring harness betw een battery (+) R04 Resis-
Max. 1 z
F05 (male) (1) tance
Disconnection in wiring har- Wiring harness betw een F05 (male) (2) Resis-
Max. 1 z
nes s (Dis connection in wiring F01-16D tance
4
or defec tive contact in con- Wiring harness between F01-17 J06 Resis-
nec tor) Max. 1 z
CM01 (female) (1), (2) tance
Wiring harness betw een CM01 (female) (3), Resis-
(4) chas sis ground (T05) tance
and s tandard
Wiring harness between F01-17 H15 Resis-
(female) (1) tance
state
Wiring harness betw een H15 (female) (5) Resis-
Max. 1 z
J03 CM01 (female) (14) tance
Wiring harness betw een battery (+) R04 Resis-
Min. 1 Mz
F05 (male) (1) tance
F01-16D tance
Wiring harness between F01-17 J06 Resis-
circuit) Min. 1 Mz
CM01 (female) (1), (2) tance
Wiring harness between F01-17 H15 Resis-
Min. 1 Mz
(female) (1) tance
Min. 1 Mz
J03 CM01 (female) (14) tance
a Prepare with s tarting switc h OFF, then hold starting switch OFF
and ON and carry out troubleshooting in each case.
CM01 Starting switch Voltage
6 Defectiv e mac hine monitor Between
OFF 20 30 V
(1), (2) (3), (4)
Between
ON 20 30 V
(14) (3), (4)
6 PC200 , 220 -8
Circuit diagra m relate d to machine m onitor pow er supply
PC20 0, 220 -8 7
E-2 When starting switch turned ON (before starting engine),

basic check item lights up 1
Trouble (1) Radiator coolant level monitor lights up red.
Although radiator c oolant level monitor is basic c heck item, it is als o checked while engine is runn ing.
Related infor- (If monitor lights up red while engine is running, c arry out this troubleshooting, too.)
mation Condition of radiator coolant level switch signal c an be checked with monitoring function.

Low ering of radiator coolant
Coolant level in radiator sub tank may be low. Check it and add
1 level (When sys tem is nor-
coolant if necessary.
mal)
Defectiv e radiator coolant Sub tank coolant

P24 (male) Resistance
2 level switch (Internal discon- level
nec tion) Between
Max. 1 z
Between (1) (2) FULL LOW
Below LOW M in. 1 Mz
Pos sible causes
value in normal Disconnection in wiring har- without turning s tarting s witch ON.
state
nes s (Dis connection in wiring Wiring harnes s betw een C M02 (female) (3) Resis-
3 Max. 1 z
or defec tive contact in con- P24 (female) (1) tance
nec tor)
Wiring harness between P24 (female) (2) Resis-
Max. 1 z
Sub tank coolant
CM02 Voltage
4 Defectiv e mac hine monitor level
Between
Between (3) Max. 1 V
FULL LOW
chassis ground
Below LOW 20 30 V
8 PC200 , 220 -8
Circuit diagra m relate d to radiator coola nt level switch
PC20 0, 220 -8 9
Trouble (2) Engine oil lev el monitor lights up red.

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

Low ering of engine oil level
1 Engine oil level may be low. Check it and add oil if necessary.
(When sy stem is normal)
Defectiv e engine oil level
2 switch (Internal disconnec- P44 (male) Engine oil level Resistance
tion) Between H L Max. 1 z
Between (1)
Possible chassis ground Below L Min. 1 Mz
causes and
standard value Disconnection in wiring har- a Prepare w ith starting switch OFF, then carry out troubleshooting
in normal state nes s (Dis connection in wiring without turning s tarting s witch ON.
3
or defec tive contact in con- Wiring harnes s betw een C M02 (female) (2) Resis-
Max. 1 z
nec tor) P44 (female) (1) tance
4 Defectiv e mac hine monitor CM02 Engine oil lev el Voltage
Between (2) Between H L Max . 1 V

chassis ground Below L 20 30 V
Circuit diagra m relate d to e ngine oil level switch
10 PC200 , 220 -8
E-3 Engine does not start (Engine does not turn) 1
Trouble Engine does not s tart (Engine does not turn).

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

1 Low charge level of battery Electrolyte spec ific gravity
Battery voltage (2 pieces)
(1 piece)
Min. 24 V Min. 1.26
2 Defectiv e fuse No. 3 If fuse is broken, circuit probably has ground fault. (See cause 10.)
a Prepare w ith starting switc h OF F, then k eep starting switch OFF
and turn it to START and c arry out troubleshooting in each case.
Defectiv e starting switch H15 (male) Starting s witch Resistance
3
OFF Min. 1 Mz
Between (1) (4)
START Max. 1 z
Defectiv e lock lever switch S14 (female) Lock lev er Res istanc e
4
Free Min. 1 Mz
Pos sible causes Between (1) (3)
Loc k Max. 1 z
and s tandard
Defectiv e starting motor cut-
out relay R06 or R07 (Inter- R06 (male), R07 (male) Resistanc e
5
nal disc onnec tion or short Between (1) (2) 300 600 z
circuit) Between (3) (4) Max. 1 z
Between (3) (5) Min. 1 Mz
a Prepare with starting s witch OFF (with only terminal C dis con-
nected), then turn starting switc h to START and carry out trou-
bles hooting.
Safety relay terminal Voltage
Between B E Power supply 20 30 V
Defectiv e starting motor Between R
6 Generation input Max. 1 V
safety relay (Internal defec t) (R17-2) E
Between S
Starting input 20 30 V
(R17-1) E
Between C (R18) E Starting output 20 30 V
If pow er s upply, generation input, and starting input are normal but
starting output is not normal, starting motor safety relay is defective.
PC20 0, 220 -8 11

a Prepare with starting s witch OF F, then turn starting switch to
START and carry out troubleshooting.
Starting motor terminals Voltage
Between B (SB)
Defectiv e starting motor Power s upply 20 30 V
7 chassis ground
(Internal defect)
Between C (SC)
Starting input 20 30 V
chassis ground
If power supply and starting input are normal but starting motor does
not turn, s tarting motor is defective.
Defectiv e alternator (Internal
8 Alternator Voltage
short circuit)
Between L
Generation output Max. 1 V
chassis ground
Max. 1 z
J01 R06 (female) (5) tance
Max. 1 z
Max. 1 z
Disconnection in wiring har- Wiring harness between starting motor Resis-
Max. 1 z
nes s (Dis connection in wiring safety relay B heater relay battery relay B tance
9
or defec tive contact in con- Wiring harness between starting motor Resis-
Pos sible causes nec tor) Max. 1 z
safety relay E chass is ground tance
and s tandard
value in normal Wiring harness between starting motor Resis-
Max. 1 z
state safety relay C starting motor C (SC) tance
Wiring harness between F01-3 S14 (male) Resis-
Max. 1 z
(1) tance
Max. 1 z
Max. 1 z
Min. 1 M z
J01 R06 (female) (5), c ircuit branch end tance
Min. 1 M z
Ground fault in wiring har- Min. 1 M z
circuit) Wiring harness between starting motor Resis-
Min. 1 M z
safety relay B heater relay battery relay B tance
Wiring harness between starting motor Resis-
Min. 1 M z
safety relay C starting motor C (SC) tance
Min. 1 M z
(1) tance
Min. 1 M z
11
24V c irc uit) in wiring harness Wiring harness betw een R17 (female) (2)
Voltage Max. 1 V
alternator L, circ uit branch end
12 PC200 , 220 -8
PC20 0, 220 -8 13
E-4 Preheater does not operate 1
Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up or flash.
Preheater monitor lights up when starting switch is turned to HEAT and starts flashing about 30 seconds
after to notify completion of preheating (It stops flashing about 10 seconds after).
Related informa- If engine coolant temperature is below 20°C, automatic warm-up system operates and preheating monitor
tion lights up for up to 30 seconds.
Condition of starting switch (preheating) signal can be checked with the monitoring function.
Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switc h OFF, then keep starting switch OFF and
turn it to HEAT and carry out troubleshooting in each case.
Defective starting switch (Inter-
1 H15 (male) Starting switch Res istance
nal disconnection)
OFF Min. 1 Mz
Between (1) (3)
HEAT Max. 1 z
Possible causes
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
and s tandard
ness (Disconnection in wiring without turning starting s witch ON.
value in normal 2
or defective contact in connec- Wiring harness between CM01 (female) Resis-
state Max. 1 z
tor) (16) J02 H15 (female) (3) tance
a Prepare with starting switc h OFF, then keep starting switch OFF and
turn it to HEAT and carry out troubleshooting in each case.
3 Defective machine monitor CM01 Starting switch Voltage
Between (16) OFF Max. 1 V
chassis ground HEAT 20 30 V
Trouble (2) When starting switch is turned to HEAT position, intake air heater mounting part does not become warm.
Related informa- Check that engine can be turned with starting motor (If engine cannot be turned, carry out troubleshooting
tion for E-1 Engine does not start (Engine does not turn)).

a Prepare with starting switch OFF (with wiring harness connected),
then keep starting switc h OFF and turn it to HEAT and carry out
troubleshooting in each case.
Defective heater relay (Internal Heater relay Starting switch Continuity/Resistance
1
disconnection) Between R15
OFF There is continuity
chassis ground
Between power
HEAT Max. 1 z
supply terminal R16
a Prepare with starting switch OFF (with wiring harness connected),
then turn starting switch to HEAT and carry out troubleshooting in
Pos sible causes each case.
and s tandard
Defective intake air heater E01 Starting switch Voltage
value in normal 2
(Internal disconnection) Between terminal
state HEAT 20 30 V
chassis ground
If voltage is normal but heater mounting part does not become warm,
intake air heater is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting s witch ON.
Disconnection in wiring har- Wiring harness between H15 (female) (3) Resis-
Max. 1 z
ness (Disconnection in wiring J02 heater relay R15 tance
3
or defective contact in connec- Wiring harness between battery relay R03 Resis-
Max. 1 z
tor) heater relay contact terminal tance
Wiring harness between heater relay R16 Resis-
Max. 1 z
intake air heater E01 tance
14 PC200 , 220 -8
PC20 0, 220 -8 15
E-5 Automatic warm-up system does not operate (in cold season) 1
Trouble Automatic warm-up sy stem does not operate (in cold s eason).
When engine c oolant temperature is below 30°C automatic warm-up sys tem rais es engine speed to
1,200 rpm.
If fuel c ontrol dial is opened more than 70% for 3 seconds when starting switch is turned ON or after
Related infor-
engine is started, autom atic warm-up sys tem is turned OFF. (Automatic w arm-up system s tops auto-
mation
matically after operating for 10 minutes .)
If engine coolant temperature is below 10°C turbocharger protec tion func tion operates to keep the
engine speed at low idle.

a Turn starting switc h ON or start engine and carry out trouble-
shooting.
Engine coolant Coolant temperature
Monitoring code
temperature level
105°C 6 (a: Red)
102°C 5 (a: Red)
Pos sible causes
Defectiv e engine c oolant 04107
and s tandard 1 100°C 4 (a: Blue)
temperature signal s ystem Engine coolant
value in normal 85°C 3 (a: Blue)
state temperature
60°C 2 (a: Blue)
30°C 1 (a: White)
If level of coolant temperature gauge is different from actual coolant
temperature, carry out troubles hooting for E-9 Engine coolant tem-
perature gauge does not indicate normally.
Engine coolant t em pe rature gauge a nd e ngine

coola nt tem pera ture monit or
16 PC200 , 220 -8
E-6 All work equipment, swing, and travel mechanism do not move or
cannot be locked 1
Trouble (1) All work equipment, s wing, and travel mechanism do not mov e.
Related infor-
mation

2
Loc k Min. 1 Mz
Between (1) (2)
Free Max. 1 z
Defectiv e PPC lock solenoid
3 (Internal disconnection or V01 (male) Resistance
short circuit) Between (1) (2) 20 60 z
Pos sible causes Defectiv e ass em bled-type without turning s tarting s witch ON.
and s tandard 4 diode D01 (Internal short c ir-
D01 (male) Res istanc e (Continuity)
value in normal cuit)
state Between (4) (8) Min. 1 Mz (No c ontinuity)
Disconnection in wiring har- Wiring harness between F01-3 S14 (male) Resis-
Max. 1 z
nes s (Dis connection in wiring (1) tance
5
or defec tive contact in con- Wiring harness betw een S14 (male) (2) Resis-
nec tor) Max. 1 z
Wiring harness between V01 (female) (2) Resis-
Max. 1 z
(1), circuit branc h end tance
circuit)
Min. 1 Mz
V01 (female) (1), D01 (female) (4) tance
18 PC200 , 220 -8
Trouble (2) All work equipment, s wing, and travel mechanism cannot be locked.
Related infor-
mation

Pos sible causes 1
(Internal s hort circ uit)
and s tandard Loc k Min. 1 M z
value in normal Between (1) (2)
Free Max. 1 z
state
2
24V c irc uit) in wiring harness Wiring harness betw een S14 (male) (2)
Voltage Max. 1 V
V01 (female) (1), D01 (female) (4)
Circuit diagra m re late d to PPC lock solenoid
PC20 0, 220 -8 19
E-7 Precaution lights up while engine is running 1
Trouble (1) Charge level monitor lights up red.

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

troubleshooting.
Defectiv e generation by
1 alternator (when system is E12 (male) Engine speed Voltage
normal) Between (1) chas-
Middle or higher 27.5 29.5 V
sis ground
nes s (Dis connection in wiring without turning s tarting s witch ON.
2
Pos sible causes or defec tive contact in con- Wiring harness between CM01 (female) Resis-
nec tor) Max. 1 z
and s tandard (11) J02 E12 (female) (1) tance
state
3 nes s (Short circuit with GND Wiring harness between CM01 (female)
circuit) Resis-
(11) J02 E12 (female) (1), circuit Min. 1 Mz
tance
branch end
troubleshooting.
4 Defectiv e mac hine monitor CM02 Engine Voltage
Between (11)
Running Min. 7.8 V
chassis ground
20 PC200 , 220 -8
PC20 0, 220 -8 21
Trouble (2) Fuel level monitor lights up red.

Related infor- Signal voltage of fuel sensor can be check ed with monitoring function.
mation (Code: 04200 Fuel s ensor voltage)

Pos sible causes Low fuel lev el (w hen sys tem Fuel lev el may be low (below about 41 l). Chec k it and add fuel if
1
and s tandard is normal) nec es sary.
value in normal If cause 1 is not detec ted, fuel level gauge system may be defective.
state Defectiv e fuel level gauge
2 Carry out troubleshooting for E-11 Fuel lev el gauge does not indi-
sys tem
cate normally.
Trouble (3) Air cleaner clogging monitor lights up red.

Related infor- Condition of signal of air c leaner c logging sw itch can be chec ked with monitoring function.
mation (Code: 04501 Monitor input 2)

Clogging of air cleaner (when Air cleaner may be clogged. C heck it, then clean or replace if nec-
1
sys tem is normal) essary.
troubleshooting.
P23 (male) Air cleaner Resistance
Defectiv e air c leaner c log- When normal
2 ging s witch (Internal disc on- (Air intake Max. 1 z
nec tion) resistanc e: *1)
Between (1) (2)
When c logged
(Air intake Min. 1 Mz
resistanc e: *2)
Pos sible causes
and s tandard
value in normal
state nes s (Dis connection in wiring Wiring harnes s betw een C M02 (female) (4) Resis-
3 Max. 1 z
nec tor)
Max. 1 z
troubleshooting.
CM02 Air c leaner Voltage
When normal
4 Defectiv e mac hine monitor (Air intake Max. 1 V
Between (4) resistanc e: *1)
chassis ground When c logged
(Air intake 20 30 V
resistanc e: *2)
*1: M ax. 3,43 0 Pa {Max. 35 0 mmH 2O}

*2: 7 ,470 ± 490 Pa {76 2 ± 50 mmH 2O}
22 PC200 , 220 -8
Circuit diagra m relate d to a ir cle aner clogging sw itch
PC20 0, 220 -8 23
Trouble (4) Engine coolant temperature monitor lights up white.

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

If monitor lights up white, engine c oolant temperature may be low
Insuffic ient warm-up of
Pos sible causes (below about 30°C). Warm up engine.
1 machine (when system is
and s tandard Lighting up white: Engine c oolant temperature is low.
normal)
value in normal Lighting up blue: Engine c oolant temperature is proper.
state If cause 1 is not detected, engine c oolant temperature gauge sys -
2 tem may be defectiv e. Carry out troubles hooting for E-9 Engine
coolant temperature gauge does not indic ate normally.
Trouble (5) Water separator monitor lights up red.

Related infor- Condition of signal of water-in-fuel sensor sw itch can be chec ked with monitoring function.
mation (Code: 18800 WIF s ensor condition)

Pos sible causes Water separator is full (when
1 Water separator may be full of water. C heck it, then drain if full.
and s tandard sys tem is normal)
value in normal
If cause 1 is not detected, water-in-fuel sensor sy stem may be
state Defectiv e water-in-fuel s en-
2 defec tive. Carry out troubleshooting for failure codes [CA428] and
sor sy stem
[CA429].
Trouble (6) Hy draulic oil temperature monitor lights up white.

Signals of hydraulic oil temperature sens or are input to pump controller and then transmitted to
mation Hy draulic oil temperature can be c hecked with monitoring function.

If monitor lights up white, hy draulic oil temperature may be low
Insuffic ient warm-up of
Pos sible causes (below about 20°C). Warm up engine.
1 machine (when system is
and s tandard Lighting up white: H ydraulic oil temperature is low.
normal)
value in normal Lighting up blue: Hydraulic oil temperature is proper.
state If cause 1 is not detected, hy draulic oil temperature gauge s ystem
2 may be defec tive. Carry out troubleshooting for E-10 Hydraulic oil
temperature gauge does not indicate normally.
24 PC200 , 220 -8
E-8 Emergency stop item lights up while engine is running 1
Trouble (1) Engine coolant temperature monitor lights up red.


If monitor lights up red, engine coolant temperature m ay be high
(above about 102°C). Cool dow n engine c oolant (Run engine at low
Pos sible causes Overheating of engine cool- idle).
1
and s tandard ant (when system is normal) Lighting up red: Engine coolant temperature is high
value in normal (ov erheating).
state Lighting up blue: Engine coolant temperature is proper.
If cause 1 is not detected, engine c oolant temperature gauge sys -
2 tem may be defectiv e. C arry out troubles hooting for E-9 Engine
coolant temperature gauge does not indic ate normally.
Trouble (2) Hy draulic oil temperature monitor lights up red.


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

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

Pos sible causes Low ering of engine oil pres-
Engine oil pressure may be low. If it is low, carry out troubleshooting
and s tandard 1 sure (when sy stem is nor-
for S-12 Oil press ure lowers.
value in normal mal)
state Defectiv e engine oil pressure If caus e 1 is not detec ted, engine oil pressure gauge sys tem may be
2
switch system defec tive. Carry out troubleshooting for failure code [CA435].
PC20 0, 220 -8 25
E-9 Engine coolant temperature gauge does not indicate normally 1
(1) While engine c oolant temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While engine c oolant temperature is s tabilized normally, temperature gauge ris es to red range (H).

Pos sible causes If cause 1 is not detected, engine c oolant temperature sensor sys-
and s tandard 1 tem may be defectiv e. C arry out troubles hooting for failure c odes
temperature sensor system
value in normal [CA144] and [ CA145].
state If cause 1 is not detected, machine monitor may be defectiv e.
(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 c oolant temperatu re
monitor.

shooting.
Engine coolant Coolant tem perature Color of monitor light
Pos sible causes temperature level (a)
and s tandard 105°C 6
value in normal 1 Defectiv e mac hine monitor Red
102°C 5
state
100°C 4
85°C 3 Blue
60°C 2
30°C 1 White
Engine coolant t em pe rature gauge a nd e ngine

coola nt tem pera ture monit or
26 PC200 , 220 -8
E-10 Hydraulic oil temperature gauge does not indicate normally 1
(1) While hydraulic oil temperature is ris ing normally, temperature gauge does not rise from white ra nge
Trouble (C).
(2) While hy draulic oil temperature is stabilized normally, temperature gauge rises to red range (H).

Defectiv e hy draulic oil tem- without turning s tarting s witch ON.
1 perature sensor (Internal dis- P22 (male) Resistance
connection or short circuit) Between (1) (2) 3.5 90 k z
nes s (Dis connection in wiring Wiring harness between C01 (female) (29) Resis-
2 Max. 1 z
or defec tive contact in c on- P22 (female) (2) tance
nec tor) Wiring harness between C01 (female) (46) Resis-
Max. 1 z
Pos sible causes
state circuit) Wiring harness between C01 (female) (29) Resis-
Min. 1 Mz
4
Voltage Max. 1 V
P22 (female) (2)
Between (29) (46) 3.5 90 kz
Between (29) chas sis ground Min. 1 Mz
If caus es 1 5 are not detected, machine monitor may be defec tive.
Circuit diagra m relate d to hy draulic oil temperature s ensor
PC20 0, 220 -8 27
(3) Display of hy draulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature mon-
itor.

shooting.
Hydraulic oil Hydraulic oil tempera- Color of monitor light
Pos sible causes temperature ture level (a)
and s tandard 105°C 6
value in normal Red
1 Defectiv e mac hine monitor 102°C 5
state
100°C 4
85°C 3 Blue
40°C 2
20°C 1 White
Hydraulic oil te mperat ure ga uge and hydra ulic

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

Defectiv e fuel level s ensor
1 (Internal disconnection or P21 (male) Fuel level Resistance
short circuit) Between (1) FULL 7 11 z
chassis ground EMPTY 85 95 z
nes s (Dis connection in wiring without turning s tarting s witch ON.
2
or defec tive contact in c on- Wiring harnes s betw een C M01 (female) (9) Resis-
nec tor) Max. 1 z
Pos sible causes
and s tandard Ground fault in wiring har-
state circuit) Wiring harnes s betw een C M01 (female) (9) Resis-
Min. 1 Mz
4
24V c irc uit) in wiring harness Wiring harnes s betw een C M01 (female) (9)
Voltage Max. 1 V
P21 (female) (1)
5 Defectiv e mac hine monitor CM01 (female) F uel level Resistance
Between (9) FULL 7 11 z

chassis ground EMPTY 85 95 z
Circuit diagra m relate d to f ue l le vel s ensor
PC20 0, 220 -8 29
(3) Display of fuel level gauge is different from actual fuel level.
Trouble
(4) Display of fuel level gauge is different from display of fuel level monitor.
Related infor- Signal voltage of fuel level sens or can be checked with m onitoring function.
mation (Code: 04200 Fuel level sensor voltage)

shooting.
Reading of fuel level Color of monitor light
Quantity of fuel
Pos sible causes gauge (a)
and s tandard 289 l 6
value in normal 1 Defectiv e mac hine monitor 244.5 l 5
state
200 l 4 Blue
100 l 3
60 l 2
41 l 1 Red
Fue l level gauge and fuel lev el monit or
30 PC200 , 220 -8
E-12 Contents of display by machine monitor are different from

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

a Turn starting switch ON and carry out troubles hooting (with
monitoring function).
Pos sible causes Monitoring code N ormal display

and s tandard 1 Defectiv e model code signal PC200-8: PC200-8
value in normal 00200 Controller model code
PC220-8: PC220-8
state
If display of monitoring is abnormal, carry out troubles hooting for
failure c ode [DA29KQ].
If cause 1 is not detected, machine monitor may be defectiv e.
E-13 Machine monitor does not display some items 1
Trouble Machine monitor does not display some items.

T he LCD panel s ometimes has black points (points which are not lighted) and bright points (points
Related infor-
which do not go off) for the reas on of its c haracteristics. If the number of the bright points and black
mation
points does not exc eed 10, those points are not a failure or a defect.

a Turn s tarting s witch ON and carry out troubleshooting.
Pos sible causes
Defectiv e mac hine monitor When following switches are operated, if all LCD panel is lighted up
and s tandard 1
(LCD panel) (all surfac e becomes white), LCD panel is normal.
value in normal
state Operation of sw itches : [ 4] + [F2] (Pres s simultaneously)
Defectiv e mac hine monitor If cause 1 is not detected, machine monitor may be defectiv e.
2
(body) (Since trouble is in system, troubleshooting c annot be carried out.)
E-14 Function switch does not work 1
Trouble Func tion switch does not work.

Related infor- Condition of signal of func tion switch c an be checked with monitoring function.
mation (Code: 04503 Monitor function switch)

and s tandard
Machine monitor may be defec tive.
value in normal 1 Defectiv e mac hine monitor
state (Since trouble is in system, troubleshooting c annot be carried out.)
PC20 0, 220 -8 31
E-15 Auto-decelerator does not operate normally 1
(1) When auto-decelerator switc h is operated, auto-decelerator monitor does not light up or does not go
Trouble
off.
Related infor- Condition of signal of auto-dec elerator switch c an be checked with monitoring function.
mation (Code: 04504 Monitor 1st, 2nd line switches)

and s tandard
value in normal Machine monitor may be defec tive. (Since trouble is in system,
troubleshooting cannot be carried out.)
state
Trouble (2) Auto-decelerator is not operated or reset with lev er.

Related infor- Set s peed of auto-decelerator is 1,400 rpm. If fuel control dial is not s et above this speed, auto-
mation dec elerator is not operated or res et.

a Start engine and c arry out troubleshooting (with m onitoring func-
tion).
Monitoring code Item Normal display
Swing
Trav el
When lev er is
01900 Boom lower operated: ON
Press ure switch 1 Boom raise When lever is in
Defectiv e PPC pressure sig- neutral: OFF
1 Arm curl
nal
Pos sible causes Arm dump
and s tandard
Buc ket curl When lever is
value in normal
01901 operated: ON
state Buc ket dump
Press ure switch 2 When lever is in
Service neutral: OFF
If display of monitoring is abnormal, c arry out troubles hooting for
E-26 Monitoring function does not dis play lever control signal nor-
mally.
If caus e 1 is not detected, pump c ontroller may be defective. (Since
trouble is in system, troubleshooting cannot be carried out.)
32 PC200 , 220 -8
E-16 Working mode does not change 1
Trouble (1) When work ing mode switch is operated, working mode selec tion screen is not displayed.
Related infor- Condition of signal of work ing mode switch c an be checked with monitoring function. (Code: 04504
mation Monitor 1st, 2nd line switches)

and s tandard
state troubleshooting cannot be carried out.)
Trouble (2) When work ing mode is changed, setting of engine and hydraulic pump is not changed.
Related infor-
mation

Pos sible causes
Machine monitor may be defec tive. (Since trouble is in system,
and s tandard 1 Defectiv e mac hine monitor
value in normal
state Pump controller may be defective. (Since trouble is in s ystem, trou-
bles hooting cannot be carried out.)
PC20 0, 220 -8 33
E-17 Travel speed does not change 1

Trouble (1) When travel speed switch is operated, trav el s peed monitor does not change.
Related infor- Condition of signal of travel speed switch can be check ed w ith monitoring func tion.

and s tandard
state
Trouble (2) When travel speed is shifted, actual travel speed does not change.
Related infor-
If cause 1 occ urs, actual travel speed does not lower when travel speed is shifted to Lo.
mation

Pos sible causes 1
and s tandard Voltage Max. 1 V
V04 (female) (1)
value in normal
state If cause 1 is not detected, machine monitor may be defectiv e.
34 PC200 , 220 -8
E-18 Alarm buzzer cannot be stopped 1
Trouble Alarm buzzer cannot be stopped.

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

and s tandard
PC20 0, 220 -8 35
E-19 Windshield wiper and window washer do not operate 1
Trouble (1) When wiper sw itch is operated, wiper monitor does not light up or go off.
Related infor- Condition of wiper s witch signal can be c hecked with monitoring function.

and s tandard
Trouble (2) When wiper sw itch is operated, wiper does not operate.
Related infor- Condition of window rear limit sw itch signal c an be checked with monitoring function.
mation (Code: 02204 Switch 5)

W03 (male) Front w indow Resistance
Defectiv e window rear limit
1 When installed to
switch (Internal short c ircuit) Min. 1 Mz
front
Between (1) (2)
When retracted to
Max. 1 z
rear
2
nal disc onnec tion) M05 (female) C ontinuity
Between (1) (3) There is continuity
nes s (Dis connection in wiring Wiring harness betw een C02 (female) (119) Resis-
Pos sible causes 3 Max. 1 z
or defec tive contact in con- M05 (male) (3) tance
and s tandard nec tor)
value in normal Wiring harness betw een C02 (female) (114) Resis-
Max. 1 z
state M05 (male) (1) tance
circuit) Resis-
C01 (female) (57) W03 (female) (1) Min. 1 Mz
tance
C01 (female) Front window Resistance
Defectiv e pump controller
(Rear limit switc h system) When installed to
Min. 1 Mz
Between (57) front
5 chassis ground When retracted to
Max. 1 z
rear
Defectiv e pump controller
(Wiper motor sy stem) C02 (female) Continuity
Between (119) (114) There is c ontinuity
36 PC200 , 220 -8
Trouble (3) When window washer switc h is operated, window was her does not operate.
Related infor- Condition of window washer switch signal can be checked with monitoring function.

and s tandard
PC20 0, 220 -8 37
E-20 Power maximizing function does not operate normally 1
(1) When left knob s witch is pressed, one-touch power max im iz ing monitor is not display ed.
Trouble
(2) When left knob s witch is pressed, work equipment power is not increased.
One-touch power max imiz ing function does not work when work ing mode is not power mode (P) or
Related infor- economy mode (E).
mation Condition of left k nob switch signal c an be checked with monitoring function.

Defectiv e left knob switc h S11 (male) Left knob switch Resistance
2
Released Min. 1 Mz
Between (1) (2)
Press ed Max. 1 z
nes s (Dis connection in wiring Wiring harness between F01-9 S11 Resis-
3 Max. 1 z
Pos sible causes nec tor) Wiring harness betw een S11 (female) (2) Resis-
Max. 1 z
and s tandard C01 (female) (41) tance
Wiring harness between F01-9 S11 Resis-
(female) (1) tance
circuit)
Wiring harness betw een S11 (female) (2) Resis-
Min. 1 Mz
C01 (female) (41) tance
5 Defectiv e pump controller C01 (female) Left knob switc h Resistance
Between (41) Released Min. 1 Mz
chassis ground Press ed Max. 1 z
Machine monitor may be defec tive. (Since trouble is in system,
Circuit diagra m relate d to left knob sw itc h
38 PC200 , 220 -8
Trouble (3) When left knob switc h is released, work equipment power does not return to normal lev el.
Related infor- Condition of left k nob switch signal c an be checked with monitoring function.
mation (Code: 02200 Switch input 1)

Pos sible causes and c arry out troubleshooting.
Hot short (Short circuit w ith
and s tandard 1
value in normal Voltage Max. 1 V
state V02 (female) (1)
PC20 0, 220 -8 39
E-21 Swing holding brake does not operate normally 1
Trouble (1) When swing lock switch is operated, s wing lock monitor does not light up or go off.
Condition of swing loc k sw itch signal c an be checked with monitoring function.
Related infor-
(Machine monitor system code: 04502 Monitor input 3)
mation
(Pump c ontroller system code: 02200 Switc h input 1)

Defectiv e swing lock switc h without turning s tarting s witch ON.
1 (Internal disconnection or S04 (male) Swing lock switch Resistance
short circuit) OFF Min. 1 Mz
Between (5) (6)
ON Max. 1 z
nes s (Dis connection in wiring Wiring harnes s betw een C M02 (female) (5) Resis-
Pos sible causes 2 Max. 1 z
or defec tive contact in con- J02 S04 (female) (5) tance
and s tandard
nec tor) Wiring harness between S04 (female) (6) Resis-
state J05 chassis ground (T07) tance
Wiring harnes s betw een C M02 (female) (5) Resis-
circuit) Min. 1 Mz
J02 S04 (female) (5), C01 (female) (19) tance
4 Defectiv e mac hine monitor CM02 Sw ing lock s witch Voltage
Between (5) OFF 20 30 V
chassis ground ON Max. 1 V
(2) When swing lock switch is turned ON, sw ing lock does not operate. (Hy draulic drift of s wing occu rs
Trouble
on slope.)
Related infor-
mation

Defectiv e swing lock switc h S04 (male) Swing lock switch Resistance
1
(Internal s hort circ uit)
OFF Min. 1 Mz
Between (3) (4)
ON Max. 1 z
and s tandard Defectiv e swing holding Swing holding brake
2 brake release switch (Inter- S25 (male) Resistance
value in normal release switch
state nal short circuit)
Loc k Min. 1 Mz
Between (13) (14)
Release Max. 1 z
Hot short (Short circuit w ith Wiring harness betw een D01 (female) (3)
3 Voltage Max. 1 V
24V c irc uit) in wiring harness J02 S04 (female) (3), S25 (female) (14)
Wiring harness between S04 (female) (4)
Voltage Max. 1 V
V03 (female) (1), D03 (female) (3)
40 PC200 , 220 -8
PC20 0, 220 -8 41
E-22 Travel alarm does not sound or does not stop sounding 1
Trouble (1) Alarm does not s ound during trav el.

Related infor-
mation

1 Defectiv e fuse No. 15 If fuse is broken, circuit probably has ground fault. (See cause 4.)
a Start engine and carry out troubleshooting.
When lever is
01900 operated: ON
Defectiv e travel signal sy s- Trav el
2 Press ure switch 1 When lever is in
tem
neutral: OFF
If display of monitoring is abnormal, c arry out troubles hooting for
E-26 Monitoring function does not dis play lever control signal nor-
Pos sible causes
mally.
and s tandard
value in normal
state
nes s (Dis connection in wiring Wiring harness between F01-15 J03 M14 Resis-
3 Max. 1 z
nec tor) Wiring harness between M14 (female) (2) Resis-
Max. 1 z
J01 (19) P09 (female) (2) tance
Wiring harness between F01-15 J03 M14 Resis-
circuit) Min. 1 Mz
(female) (1), c irc uit branch end tance
Defectiv e travel alarm (Inter-
5 If causes 1 4 are not detec ted, travel alarm is defective.
nal defect)
Trouble (2) Alarm does not stop sounding w hile machine is stopped.
Related infor-
mation

a Start engine and carry out troubleshooting.
When lever is oper-
ated: ON
Defectiv e travel signal sy s- Press ure switch 1 Travel
1 When lever is in neu-
tem
tral: OFF
Pos sible causes If display of monitoring is abnormal, c arry out troubles hooting for E-
and s tandard 26 Monitoring func tion does not display lev er control s ignal nor-
value in normal mally.
2 diode D02 (Short c ircuit with
D02 (male) C ontinuity
GND circuit)
Between (4) (8) No continuity
Wiring harness between M14 (female) (2) Resis-
circuit) Min. 1 Mz
J01 P09 (female) (2), D02 (female) (4) tance
42 PC200 , 220 -8
Circuit diagra m relate d to t ra vel alarm and trave l PPC oil press ure switch
PC20 0, 220 -8 43
E-23 Air conditioner does not operate normally

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

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

If fuse in unit is broken, c ircuit in unit probably has ground fault.
2 Defectiv e fuse in unit
(See c ause 4.)
nes s (Dis connection in wiring Wiring harness between F01-11 fuse in Resis-
3 Max. 1 z
or defec tive contact in con- unit AC W (wiring side) (6) tance
nec tor)
Wiring harness betw een AC W (wiring side) Resis-
Max. 1 z
(16) c hassis ground (T 07) tance
Pos sible causes
and s tandard
value in normal
state 4 nes s (Short circuit with GND Wiring harness between F01-11 fuse in
circuit) Resis-
unit AC W (wiring side) (6), c irc uit branch Min. 1 Mz
tance
end
Defectiv e air conditioner con- ACW (wiring side) Voltage
5
troller Between (6) (16) 20 30 V
If above voltage is normal, air conditioner c ontroller m ay be defec-
tive.
44 PC200 , 220 -8
Trouble (3) Air does not come out (Air flow is insufficient).
Related infor-
mation

without turning s tarting s witch ON (coil side).
Between (1) (3) 140 340 z
Defectiv e blower relay (Inter-
1 a Prepare with starting switch OFF, then turn starting switch ON
and c arry out troubleshooting (contact side).
R20 Air conditioner switc h Voltage
Between (4)
Air blow position 20 30 V
chassis ground
Defectiv e power transistor
2 Fan switch If air flow changes acc ording to
(Internal defect)
Operate between Low and operation of fan switch, power
Medium and High. transistor is normal.
Defectiv e blower motor M B (wiring side) Air conditioner sw itch Voltage
Pos sible causes 3
and s tandard (Internal defect) Between (1) (2) Air blow pos ition 20 30 V
value in normal If above v oltage is normal and blower motor does not revolv e,
state blower motor is defective.
Wiring harness between F01-11 fuse in Resis-
Max. 1 z
unit R20 (female) (1) tance
Max. 1 z
ACW (wiring side) (36) tance
Wiring harness between F01-11 R20 Resis-
Max. 1 z
(female) (5) tance
nes s (Dis connection in wiring Wiring harness betw een R20 (female) (4) Resis-
4 Max. 1 z
or defec tive contact in c on- M B (wiring side) (1) tance
nec tor)
Wiring harness between M B (wiring side) (2) Resis-
Max. 1 z
PTR (wiring side) (3) tance
Wiring harness between PTR (wiring side) (1) Resis-
Max. 1 z
Max. 1 z
AC W (wiring side) (8) tance
Max. 1 z
AC W (wiring side) (7) tance
PC20 0, 220 -8 45

Min. 1 Mz
M B (wiring side) (1) tance
Pos sible causes circuit)
and s tandard Wiring harness between M B (wiring side) (2) Resis-
Min. 1 Mz
value in normal P TR (wiring side) (3) tance
state Wiring harness between P TR (wiring side) Resis-
Min. 1 Mz
(2) AC W (wiring side) (8) tance
If causes 1 5 are not detected, air conditioner controller may be
Defectiv e air conditioner con-
6 defec tive. (Since trouble is in sys tem, troubleshooting c annot be
troller
carried out.)
If causes 1 5 are not detected, air conditioner system may be
Defectiv e air c onditioner sys -
7 defec tive. See Machine Component Volume of Shop Manual, Air
tem
conditioner, Troubleshooting.
46 PC200 , 220 -8
Trouble (4) Air is not cooled (Cooling performance is ins ufficient).

Related infor-
mation

without turning s tarting s witch ON (coil side).
Between (1) (3) 140 340 z
Defectiv e compressor relay
1 a Prepare with starting switch OFF, then turn starting switch ON
and c arry out troubleshooting (contact side).
R21 Air conditioner switc h Voltage
Between (2)
Cooling pos ition 20 30 V
chassis ground
Internal air s ensor may be defective. Carry out troubleshooting for
2 Defectiv e internal air s ensor
Abnormality in internal air sens or.
Defectiv e high and low pres- High and low pres sure switches may be defective. Carry out trou-
3
sure switc hes bles hooting for Abnormality in refrigerant.
Defectiv e compressor clutch
4 Compressor c lutc h may be defec tive. Chec k it directly.
(Internal defect)
Defectiv e com pressor (Inter-
5 Compress or may be defectiv e. C heck it direc tly.
nal defect)
Pos sible causes
value in normal
state Wiring harness between F01-11 fuse in Resis-
Max. 1 z
unit R21 (female) (1) tance
nes s (Dis connection in wiring Wiring harness betw een R21 (female) (3) Resis-
6 Max. 1 z
or defec tive contact in c on- ACW (wiring side) (35) tance
nec tor) Wiring harness between F01-11 R21 Resis-
Max. 1 z
(female) (4) tance
Max. 1 z
AC02 (female) (1) tance
circuit)
Min. 1 Mz
AC02 (female) (1) tance
troller
carried out.)
If causes 1 7 are not detected, air conditioner system may be
Defectiv e air c onditioner sys -
9 defec tive. See Machine Component Volume of Shop Manual, Air
tem
conditioner, Troubleshooting.
PC20 0, 220 -8 47
(5) Air conditioner abnormality record: Communication c ondition CAN dis connection, Communication
Trouble
condition Abnormal
While abnormality in communication is being detected, CAN disconnection is dis played.
If abnormality in c ommunication has been detected and res et, Abnormality is dis played.
Related infor-
If CAN disconnection is dis played as communic ation condition, communication cannot be c arried
mation
out normally. Acc ordingly, c ondition of other items is not displayed.
Method of reproduc ing abnormality record: Turn s tarting s witch ON.

nes s (Dis connection in wiring Wiring harness betw een N10 (female) (2) Resis-
1 Max. 1 z
or defec tive contact in con- CM02 (female) (8), (9) tance
nec tor) Wiring harness betw een N10 (female) (1) Resis-
Max. 1 z
Wiring harness betw een N10 (male) (2)
CM02 (female) (8), (9), C 01 (female) (45), Resis-
CE02 (fem ale) (46), K02 (female) (A), tance
N08 (male) (3)
circuit)
Wiring harness betw een N10 (female) (1)
CM02 (female) (10), C01 (female) (64), Resis-
Min. 1 Mz
CE02 (female) (47), K02 (female) (B), tance
Pos sible causes N08 (male) (10)
and s tandard
value in normal
state
N10 (male) (2) CM02 (female) (8), (9),
C01 (female) (45), CE02 (female) (46), Voltage Max. 5.5 V
Hot short (Short circuit w ith
3 K02 (female) (A), N08 (male) (3)
24V c irc uit) in wiring harness
Wiring harness betw een N10 (female) (1)
CM02 (female) (10), C01 (female) (64),
Voltage Max. 5.5 V
CE02 (female) (47), K02 (female) (B),
N08 (male) (10)
Between (A) (B) 47 67 z
troller
carried out.)
48 PC200 , 220 -8
Trouble (6) Air conditioner abnormality record: Setting condition Abnorm ality
If s etting of air conditioner controller model is different from setting of machine monitor model,
Abnormality is dis played.
Related infor-
mation
out normally. Acc ordingly, this condition is not displayed.
Method of reproduc ing abnormality record: Turn s tarting s witch ON.

Pos sible causes
Defectiv e air conditioner con- Air conditioner c ontroller may be defective. (Sinc e trouble is in sy s-
and s tandard 1
troller tem, troubleshooting cannot be c arried out.)
value in normal
state Machine monitor may be defec tive. (Since trouble is in system,
Trouble (7) Air conditioner abnormality record: Internal air sensor Abnormality
Related infor- out normally. Acc ordingly, this condition is not displayed.
mation Method of reproduc ing abnormality record: Turn s tarting sw itch ON + Turn air conditioner (A/C)
switch ON .

Defectiv e internal air s ensor without turning s tarting s witch ON.
1 (Internal disconnection or
TH I (device side) Resistance
short circuit)
Between (1) (2) 300 z 430 kz
nes s (Dis connection in wiring Wiring harness betw een ACW (wiring side) Resis-
2 Max. 1 z
or defec tive contact in c on- (11) TH I (wiring side) (2) tance
Pos sible causes nec tor) Wiring harness betw een ACW (wiring side) Resis-
(27) T HI (wiring side) (1) tance
value in normal
state Ground fault in wiring har- without turning s tarting s witch ON.
Wiring harness betw een ACW (wiring side) Resis-
circuit) Min. 1 Mz
(11) TH I (wiring side) (2) tance
4
24V c irc uit) in wiring harness Wiring harness betw een ACW (wiring side)
Voltage Max. 1 V
(11) TH I (wiring side) (2)
troller
carried out.)
PC20 0, 220 -8 49
Trouble (8) Air conditioner abnormality record: External air s ensor Unused
External air s ensor is not us ed in air conditioner system of this machine.
Related infor-
mation
out normally. Acc ordingly, this condition is not displayed.

and s tandard
Since external air sens or is not used in air conditioner sys tem of this
value in normal 1 Normal display
state machine, above display is normal.
Trouble (9) Air conditioner abnormality record: Air flow s ensor Abnormality
switch ON .

Defectiv e air flow sensor without turning s tarting s witch ON.
1 (Internal disconnection or
THF (device side) Resistance
short circuit)
Between (1) (2) 100 z 115 kz
nes s (Dis connection in wiring Wiring harness betw een AC W (wiring side) Resis-
2 Max. 1 z
or defec tive contact in con- (12) T H F (wiring side) (2) tance
Pos sible causes nec tor) Wiring harness betw een AC W (wiring side) Resis-
(27) T H F (wiring side) (1) tance
value in normal
circuit) Wiring harness betw een AC W (wiring side) Resis-
Min. 1 Mz
(12) T H F (wiring side) (2) tance
4
24V c irc uit) in wiring harness Wiring harness betw een AC W (wiring side)
Voltage Max. 1 V
(12) T H F (wiring side) (2)
troller
carried out.)
50 PC200 , 220 -8
Trouble (10) Air conditioner abnormality record: Daylight sens or Abnormality

switch ON .

Defectiv e daylight sensor
1 Daylight sens or may be defective.
(Internal defect)
nes s (Dis connection in wiring Wiring harness betw een ACW (wiring side) Resis-
2 Max. 1 z
or defec tive contact in c on- (3) P31 (female) (1) tance
nec tor)
Max. 1 z
(15) P31 (female) (2) tance
and s tandard Wiring harness betw een ACW (wiring side) Resis-
value in normal 3 nes s (Short circuit with GND Min. 1 Mz
(3) P31 (female) (1), circuit branch end tance
state circuit)
Min. 1 Mz
(15) P31 (female) (2) tance
Hot short (Short circuit w ith Wiring harness betw een ACW (wiring side)
4 Voltage Max. 1 V
24V c irc uit) in wiring harness (3) P31 (female) (1), circuit branch end
Wiring harness betw een ACW (wiring side)
Voltage Max. 1 V
(15) P31 (female) (2)
troller
carried out.)
PC20 0, 220 -8 51
Trouble (11) Air conditioner abnormality record: Air outlet damper Abnormality
switch ON .

Defectiv e air outlet s ervo-
1 Air outlet servomotor may be defectiv e.
motor (Internal defect)
Wiring harness between M V1 (wiring side) Resis-
Max. 1 z
Disconnection in wiring har- Wiring harness between M V1 (wiring side) Resis-

Max. 1 z
nes s (Dis connection in wiring (3) AC W (wiring side) (27) tance
2
or defec tive contact in con- Wiring harness between M V1 (wiring side) Resis-
Max. 1 z
nec tor) (5) AC W (wiring side) (9) tance
Max. 1 z
Max. 1 z
Wiring harness between M V1 (wiring side)
Resis-
(1) AC W (wiring side) (3), c ircuit branch Min. 1 Mz
tance
end
Pos sible causes Ground fault in wiring har- Resis-
and s tandard 3 nes s (Short circuit with GND tance
end
value in normal circuit)
state Wiring harness between M V1 (wiring side)
Resis-
(6) AC W (wiring side) (24), circuit branc h Min. 1 Mz
tance
end
Resis-
tance
end
(1) AC W (wiring side) (3), c ircuit branch Voltage Max. 1 V
end
Hot short (Short circuit w ith (5) AC W (wiring side) (9), c ircuit branch Voltage Max. 1 V
4
24V c irc uit) in wiring harness end
(6) AC W (wiring side) (24), circuit branc h Voltage Max. 1 V
end
end
troller
carried out.)
52 PC200 , 220 -8
Trouble (12) Air conditioner abnormality record: A/M damper Abnormality

switch ON .

Defectiv e air mix serv omotor
1 Air mix servomotor may be defec tive.
(Internal defect)
Wiring harness between M AM (wiring side) Resis-
Max. 1 z
Disconnection in wiring har- Wiring harness between M AM (wiring side) Resis-

Max. 1 z
nes s (Dis connection in wiring (3) AC W (wiring side) (3) tance
2
or defec tive contact in c on- Wiring harness between M AM (wiring side) Resis-
Max. 1 z
nec tor) (5) AC W (wiring side) (2) tance
Max. 1 z
Max. 1 z
Wiring harness between M AM (wiring side)
Resis-
tance
end
Pos sible causes Ground fault in wiring har- Resis-
and s tandard 3 nes s (Short circuit with GND tance
end
value in normal circuit)
state Wiring harness between M AM (wiring side)
Resis-
tance
end
Resis-
tance
end
(3) AC W (wiring side) (3), c ircuit branch Voltage Max. 1 V
end
Hot short (Short circuit w ith (5) AC W (wiring side) (2), c ircuit branch Voltage Max. 1 V
4
24V c irc uit) in wiring harness end
end
end
troller
carried out.)
PC20 0, 220 -8 53
Trouble (13) Air conditioner abnormality record: Refrigerant Abnormality

switch ON .

Insuffic ient refrigerant (gas)
1 Refrigerant (gas ) may be insufficient. Check it directly.
(when s ystem is normal)
Defectiv e high and low pres- without turning s tarting s witch ON.
2 sure switc hes (Internal dis-
P17 (male) Resistance
connection)
Pos sible causes Between (1) (2) Max. 1 z
value in normal
state Disconnection in wiring har-
nes s (Dis connection in wiring Wiring harness betw een AC W (wiring side) Resis-
3 Max. 1 z
or defec tive contact in con- (4) P17 (female) (1) tance
nec tor)
Max. 1 z
troller
carried out.)
54 PC200 , 220 -8
Circuit diagra m relate d to air conditioner
PC20 0, 220 -8 55
E-24 While starting switch is in OFF position, service meter is not displayed1
Trouble When s tarting s witch is turned OF F, serv ic e meter is not display ed.
While starting sw itch is at OF F position, if following switches are operated, service meter is displayed
Related infor-
at top center of screen.
mation
Operation of switc hes: [4] + [1] (Press simultaneously)

When s tarting s witch is turned ON, if machine monitor dis plays
Pos sible causes
Defectiv e backup power sup- nothing, backup power s upply sy stem may be defective. In this
and s tandard 1
ply sy stem case, carry out troubleshooting for E-1 When starting switc h turned
value in normal
ON, machine monitor display s nothing.
state
E-25 Machine monitor cannot be set in service mode 1

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

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

and s tandard
value in normal Defectiv e boom rais e PPC
1 Carry out troubleshooting for failure code [DHS8MA].
state press ure sensor sys tem
Trouble (2) Arm curl operation is not displayed norm ally by monitoring func tion.
Related infor-
mation

and s tandard
Defectiv e arm curl PPC pres-
value in normal 1 Carry out troubleshooting for failure code [DHS3MA].
state sure sens or s ystem
Trouble (3) Bucket c url operation is not displayed normally by monitoring function.
Related infor-
mation

and s tandard
value in normal Defectiv e bucket curl PPC
1 Carry out troubleshooting for failure code [DHS4MA].
Trouble (4) Bucket dump operation is not displayed normally by monitoring function.
Related infor-
mation

and s tandard
value in normal Defectiv e bucket dump PPC
1 Carry out troubleshooting for failure code [DHSDMA].
PC20 0, 220 -8 57
Trouble (5) Boom lower operation is not display ed normally by monitoring func tion.
Related infor-
mation

troubleshooting.
Defectiv e boom lower PPC Right work equipment
1 pres sure s witch (Internal dis- P02 (male) Resistance
control lev er
connection or short circuit)
Neutral Min. 1 Mz
Between (1) (2)
Boom raise Max. 1 z
2 Max. 1 z
nec tor) Wiring harness between P02 (female) (2) Resis-
and s tandard
Min. 1 Mz
4
Voltage Max. 1 V
P02 (female) (1)
troubleshooting.
Right work equipment
control lev er
Between (14) chas - Neutral Min. 1 Mz
sis ground Boom raise Max. 1 z
Circuit diagra m relate d to boom lowe r PPC pres sure sw itc h
58 PC200 , 220 -8
Trouble (6) Arm dump operation is not dis played normally by monitoring function.
Related infor-
mation

troubleshooting.
Defectiv e arm dump PPC Left work equipment
1 pres sure s witch (Internal dis- P08 (male) Resistance
control lev er
connection or short circuit)
Neutral Min. 1 Mz
Between (1) (2)
Arm dump Max. 1 z
2 Max. 1 z
or defec tive contact in c on- P08 (female) (1) tance
nec tor) Wiring harness between P08 (female) (2) Resis-
and s tandard
Min. 1 Mz
4
Voltage Max. 1 V
P08 (female) (1)
troubleshooting.
Left work equipment
control lev er
Between (15) Neutral Min. 1 Mz
chassis ground Arm dump Max. 1 z
Circuit diagra m relate d to arm dump PPC press ure switch
PC20 0, 220 -8 59
Trouble (7) Swing operation is not dis played normally by monitoring function.
Related infor-
mation

Pos sible causes
Defectiv e swing right PPC
and s tandard 1 Carry out troubleshooting for failure code [DHSAMA].
press ure sensor sys tem
value in normal
state Defectiv e swing left PPC
2 Carry out troubleshooting for failure code [DHSBMA].
press ure sensor sys tem
Trouble (8) Travel operation is not displayed normally by m onitoring function.

Related infor-
mation

Prepare w ith starting switch OFF, then start engine and carry out
troubleshooting.
Defectiv e trav el PPC pres- P09 (male) Travel lever Resistance
1 sure switc h (Internal discon-
nec tion or short circuit) Neutral Min. 1 Mz
Between (1) (2) Trav el forward or
Max. 1 z
reverse
2 diode D02 (Internal discon-
D02 (male) C ontinuity
nec tion)
Between (8) (4) There is continuity
Max. 1 z
nes s (Dis connection in wiring D02 (female) (8) tance
3
or defec tive contact in con- Wiring harness betw een D02 (female) (4) Resis-
Pos sible causes nec tor) Max. 1 z
and s tandard
value in normal Wiring harness between P09 (female) (1) Resis-
Max. 1 z
state J05 chassis ground (T07) tance
D02 (female) (8) tance
circuit)
Wiring harness betw een D02 (female) (4) Resis-
Min. 1 Mz
J01 P09 (female) (2), circuit branch end tance
5
Voltage Max. 1 V
D02 (female) (8)
troubleshooting.
C01 (female) Trav el lever Continuity
Neutral No continuity
Between (55)
chassis ground Trav el forward or
There is continuity
reverse
60 PC200 , 220 -8
Circuit diagra m relate d to tra vel P PC pressure switch a nd travel a la rm
PC20 0, 220 -8 61
Trouble (9) Travel differential pressure is not displayed normally by monitoring function.
Related informa-
Monitoring code: 01901 Pressure switch 2
tion

a Prepare with starting switch OFF, then start engine and carry out
Defective travel steering PPC troubleshooting.
1 pressure switch (Internal dis - P10 (male) Travel lever Resistance
connection or short circuit) Neutral Min. 1 Mz
Between (1) (2)
Only 1 side operated Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting s witch ON.
ness (Disconnection in wiring Wiring harness between C01 (female) (36) Resis-
2 Max. 1 z
or defective contact in connec- P10 (female) (2) tance
tor) Wiring harness between P10 (female) (1) J05 Resis-
Max. 1 z
Possible causes chassis ground (T07) tance
and s tandard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Ground fault in wiring harness without turning starting s witch ON.
state 3
(Short circuit with GND circuit) Wiring harness between C01 (female) (36) Resis-
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between C01 (female) (36)
Voltage Max. 1 V
P10 (female) (2)
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
C01 (female) Travel lever Resis tance
5 Defective pump controller
Neutral Min. 1 Mz
Between (36)
Only one side oper-
chassis ground Max. 1 z
ated
Circuit diagra m relate d to tra vel st eering P PC pressure s witch
62 PC200 , 220 -8
Trouble (10) Service operation is not displayed normally by monitoring function.

Related infor-
mation

troubleshooting.
Defectiv e serv ic e front PPC
1 pres sure s witch (Internal dis- S10 (male) Service pedal Resistance
Between (1) (2)
Forward Max. 1 z
troubleshooting.
Defectiv e serv ic e rear PPC
2 pres sure s witch (Internal dis- S11 (male) Service pedal Resistanc e
Between (1) (2)
Revers e Max. 1 z
Max. 1 z
Pos sible causes nes s (Dis connection in wiring S10 (female) (1), S11 (fem ale) (1) tance
and s tandard 3
or defec tive contact in c on- Wiring harness between S10 (female) (2) Resis-
value in normal nec tor) Max. 1 z
state
Wiring harness betw een S11 (female) (2) Resis-
Max. 1 z
Min. 1 Mz
S10 (female) (1), S11 (fem ale) (1) tance
5
Voltage Max. 1 V
S10 (female) (1), S11 (fem ale) (1)
troubleshooting.
6 Defectiv e pump controller C01 (female) Service pedal Resistance
Between (52) Neutral Min. 1 Mz
chassis ground Forward or revers e Max. 1 z
PC20 0, 220 -8 63
Circuit diagra m relate d to servic e PPC press ure switch
64 PC200 , 220 -8
E-27 KOMTRAX system does not operate normally 1

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

a Turn starting switch ON and chec k Setting c ondition or termi-
nal s creen.
1 Defectiv e com munication 1
Chec k item Normal display
Communication start chec k Completion
a Turn s tarting s witch ON and check Condition of positioning and
communication s creen.
N ###,##,## (Latitude)
2 Defectiv e GPS
Pos itioning E ###,##,## (Longitude)
Pos sible causes
In positioning
and s tandard
value in normal If latitude and longitude are not displayed in 5 minutes on open
state ground, notify KOMTRAX service hot line.
Defectiv e com munication Chec k item Normal display
3
env ironment Communication Zone level 1 Zone level 3
If zone lev el 1 3 is not displayed within communic ation z one of
ORBC OMM, notify KOMTRAX serv ic e hot line.
4 Defectiv e com munication 2
Number of items not transmitted 0 9 (Normally 0)
a Se lect Termina l Status fro m 12 Disp lay of a Se lect G PS & Communication Statu s fro m
KO MTRA X settin g in the se rvice menu o f the 1 2 Disp la y of KO MTRAX settin g i n the ser -
machine monitor. vice men u of th e ma ch ine monitor.
PC20 0, 220 -8 65
SE N0 0244- 01
© 2 006 KO MATSU
All Rights Reserved
66
SE N00 245- 00
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
Tr ouble sh ooting of h ydra ulic and mechanical system (H-mod e) .................................................................... 4
Syste m dia gram of hydra ulic a nd me ch anical system ......................................................................... 4
Info rmation in tro ublesho otin g tabl e ..................................................................................................... 6
H-1 Speed or po we r o f whole work e quipme nt, swing , and travel is low ............................................. 7
H-2 Eng ine sp eed lowers extre me ly or eng ine stalls ........................................................................... 9
H-3 Wo rk eq uipment, swing, and tr avel systems do not work............................................................ 1 0
H-4 Abno rmal sou nd comes ou t fr om aro und hydraulic pump ........................................................... 10
H-5 Auto-d ece lerator doe s not oper ate ...............................................................................................11
H-6 Fi ne co ntro l p erformance or response is low ...............................................................................11
H-7 Speed or po we r o f boom is l ow ................................................................................................... 1 2
H-8 Speed or po we r o f arm is low ...................................................................................................... 13
H-9 Speed or po we r o f bucket is low.................................................................................................. 14
H-10 Work eq uipmen t doe s not mo ve singl y ..................................................................................... 1 4
H-11 Hydraul ic dri ft of wo rk eq uipment is larg e .................................................................................. 15
PC20 0, 220 -8 1
H-12 Time lag o f work eq uipmen t is lar ge .......................................................................................... 17

H-13 When par t of work equip ment is relieved sing ly, other parts of wo rk equ ipment mo ve ............. 1 7
H-14 Power maximizing fu nctio n d oes n ot work ................................................................................ 1 8
H-15 In compo und ope ration of work equip ment, speed of part lo aded more is l ow ......................... 1 8
H-16 When machine swings and raises boom simu ltan eously, b oom r isin g spe ed is lo w ................. 19
H-17 When machine swings and travels simultaneo usly, trave l spe ed lowers l argely ....................... 1 9
H-18 Machine de via tes durin g travel .................................................................................................. 20
H-19 Tr ave l spe ed is low .................................................................................................................... 21
H-20 Machine is not steered well or ste ering po we r is low ................................................................ 2 2
H-21 Tr ave l spe ed does not chan ge or tra ve l spe ed is low/high ........................................................ 2 3
H-22 Tr ave l system does not mo ve (on ly one side ) ........................................................................... 2 4
H-23 Upper str ucture do es n ot swing ................................................................................................. 25
H-24 Swing acceler atio n or swing spee d i s low ................................................................................. 27
H-25 Upper str ucture over runs r emarkably wh en it stop s swi nging ................................................... 2 8
H-26 La rge sh ock is mad e whe n upper structur e stops swingi ng ...................................................... 2 9
H-27 Lar ge so und is mad e whe n u pper str ucture stops swingin g...................................................... 2 9
H-28 Hyd raulic drift of swing is l arge .................................................................................................. 3 0
H-29 Atta chme nt circuit is not chan ged .............................................................................................. 31
H-30 Oil flow i n a ttachment circuit can not b e con tro lled .................................................................... 3 1
2 PC200 , 220 -8
Troubleshooting of hydraulic and mechanical system (H-mode) 1

System diagram of hydraulic and mechanical system 1
4 PC200 , 220 -8
a This system diag ram is a ro ugh g ener al hydrau lic ci rcu it d iagram ma de as re fer ence material for tr ou-
ble sho oting of the hydraul ic and mecha nical systems.
PC20 0, 220 -8 5

a The following information is summarized in th e tro ublesho otin g tab le. Before carr yin g o ut troub leshoot-
ing , unde rstand that info rmation fu lly.
Trouble Trouble which occurr ed in machine

Related
Infor mation related to detected tro uble o r tro ubleshooting
information
Caus e Standard value in normal state/Remarks on troubleshooting
Pos sible 2 Possible cau ses of tr ou-

causes and <Contents of descr iption )
standard value ble (Given nu mbers are
Stand ar d value in nor mal state to judge p ossible cau ses
in normal state refer ence n umbers, wh ich
Rem ar ks o n judgment
do not in dicate p rior ity)
3
6 PC200 , 220 -8
H-1 Speed or power of whole work equipment, swing, and travel is low1
Trouble Speed or power of w hole work equipment, sw ing, and travel is low.
Related
Carry out all troubleshooting in power mode (P) of working mode.
information

a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
1 Malfunction of unload v alv e Control levers Unload pressure
3.5 ± 1.0 MPa
All levers in neutral
{36 ± 10 kg/cm 2}
Left work equipment control lever Main relief pres sure
Defective adjus tment or mal- 33.3 36.8 MPa
2 Arm curl relief
function of main relief valv e {340 375 kg/cm 2}
If oil pres sure does not bec ome normal after adjus tment, main relief
valve may have malfunc tion or internal defect. Check main relief
valve directly.
Malfunc tion of self-reducing
3 Control levers Control c irc uit basic press ure
press ure valve
2.84 3.43 MPa
{29 35 k g/cm 2}
low idle and carry out troubleshooting at each s peed.
Pos sible
PC-EPC v alve
causes and Engine Control lever
standard value Malfunc tion of PC-EPC output pressure
4
in normal state valve 2.9 MPa
Low idle
{30 kg/cm 2}
All lev ers in neutral
0.52 0.91 MPa
High idle
{5.3 9.3 kg/cm 2}
Meas ured oil Meas urement
Oil pressure ratio
press ure condition
Defective adjus tment or Pump disc harge
5 Swing lock switc h: 1
malfunc tion of PC valve press ure
ON
PC valve output Approx . 0.6
Arm curl relief
press ure (Approx . 3/5)
If oil pressure does not become normal after adjustment, PC valve
may have malfunc tion or internal defect. Check PC valv e directly.
LS-EPC valv e output
Trav el speed Travel lever
press ure
6 Malfunction of LS-EPC valve
Approx. 2.9 MPa
Lo Neutral 2
{30 kg/cm }
0 MPa
Hi Operated
{0 kg/cm 2}
PC20 0, 220 -8 7

Operation of lev ers and oil press ure ratio
Meas ured oil Trav el w ith no load
press ure All lev ers in neutral (Lever operated half-
Pos sible Defective adjus tment or mal- way)
7
causes and function of LS valve Pump disc harge
1
standard value press ure Almost same
in normal state PC valve output press ure Approx. 0.6
If oil press ure does not become normal after adjustment, LS v alve
may have malfunc tion or internal defect. Check LS valv e directly.
8 Malfunction of servo pis ton Servo piston may have malfunc tion. Chec k it directly.
Caus e may be lowering of performance, malfunc tion, or internal
9 Defective piston pump
defec t of pis ton pump.
8 PC200 , 220 -8
H-2 Engine speed lowers extremely or engine stalls 1
Trouble Engine speed lowers extremely or engine stalls.

Related
information

Left work equipment control lever Main relief pres sure
Defective adjus tment or
1 malfunc tion of main relief 33.3 36.8 MPa
Arm curl relief
valve {340 375 kg/cm 2}
If oil pres sure does not bec ome normal after adjus tment, main relief
valve may have malfunc tion or internal defect. Check main relief
valve directly.
low idle and carry out troubleshooting at each s peed.
PC-EPC v alve
Engine Control lever
Malfunc tion of PC-EPC output pressure
2
valve 2.9 MPa
Low idle
{30 kg/cm 2}
All lev ers in neutral
0.52 0.91 MPa
High idle
{5.3 9.3 kg/cm 2}
Pos sible Meas ured oil Meas urement
Oil pressure ratio
causes and press ure condition
standard value Defective adjus tment or Pump disc harge
in normal state 3 Swing lock switc h: 1
malfunc tion of PC valve press ure
ON
PC valve output Arm curl relief Approx . 0.6
If oil pressure does not become normal after adjus tment, PC valv e
may have malfunc tion or internal defect. Check PC valv e directly.
Defective adjus tment or way)
4
malfunc tion of LS valv e Pump disc harge
1
press ure Almost same
PC valve output press ure Approx . 0.6
may have malfunc tion or internal defect. Check LS valve direc tly.
Clogging of orifice or filter in Orific es or filters in pump servo dev ic es may be clogged. Check
5
serve dev ic es them directly.
6 Malfunction of servo pis ton Servo piston may have malfunc tion. Check it direc tly.
PC20 0, 220 -8 9
H-3 Work equipment, swing, and travel systems do not work 1
Trouble Whole work equipment, swing, and travel system s do not work.
Related
information

PPC loc k solenoid valve output
Loc k lever
Malfunc tion of PPC lock press ure
1
solenoid valve 0 MPa
Loc k
{0 kg/cm 2}
2.9 MPa
Free
{30 kg/cm 2}
Pos sible
causes and a Prepare with engine stopped, then run engine at high idle and
standard value carry out troubleshooting.
in normal state Malfunc tion of self pressure
2 Control lever Control c irc uit bas ic press ure
reducing valv e
2.84 3.43 MPa
{29 35 k g/cm 2}
Pis ton pump may have malfunction or internal defect. Check it by
follow ing method.
3 Defective piston pump 1) Remov e pump discharge press ure pickup plugs (F and R).
2) Crank engine at flywheel (m anually).
3) If oil flows out of pic kup plugs, piston pump is norm al.
Pump s haft may not revolve bec ause of defect in damper. Chec k
4 Defective damper
damper directly.
H-4 Abnormal sound comes out from around hydraulic pump 1
Trouble Abnormal sound c omes out from around hydraulic pump

Related
information

Lowering of hydraulic oil
1 Hydraulic oil level may be low. Check it directly.
level
Pos sible 2 Defective hydraulic oil Air may be in hydraulic oil. Check oil directly.
causes and
standard value Clogging of hydraulic tank Negativ e pressure may be generated in hydraulic tank because of
3
in normal state cap clogged hydraulic tank c ap. Check cap directly.
Clogging of hydraulic tank Negativ e pressure may be generated in s uc tion c irc uit bec ause of
4
strainer clogged hydraulic tank strainer. Check strainer directly.
5 Defective piston pump Piston pump may have internal defect. Chec k it directly.
10 PC200 , 220 -8
H-5 Auto-decelerator does not operate 1
Trouble Auto-decelerator does not operate.

Carry out this troubleshooting if auto-dec elerator does not operate w hen travel lever is operated.
Related Shuttle valv e (in PPC valve) is installed between PPC valve and oil press ure switch of only in trav el
information circuit.

Pos sible
causes and Trav el lever PPC valv e output pressure
standard value Malfunc tion of travel PPC
1 0 MPa
in normal state valve (shuttle valve) Neutral
{0 kg/cm 2}
Forward 2.84 3.43 MPa
Reverse {29 35 k g/cm 2}
H-6 Fine control performance or response is low 1
Trouble F ine control performanc e or respons e is low.

Related
information

LS-EPC valve output
press ure
Approx. 2.9 MPa
Lo Neutral
{Approx . 30 kg/c m 2}
0 MPa
Hi Operated
{0 kg/cm 2}
Orific e of LS circuit (between pump piping control valve) may be
2 Clogging of LS circuit orifice
Pos sible clogged. Check it directly.
causes and a Prepare with engine stopped, then run engine at high idle and
standard value carry out troubleshooting.
in normal state
3
1
press ure Almost same
PC valve output press ure Approx . 0.6
4 Malfunction of servo pis ton Servo piston may have malfunc tion. Chec k it directly.
PC20 0, 220 -8 11
H-7 Speed or power of boom is low 1
Trouble Speed or power of boom is low

Related
information

Right work equipment control
PPC valve output pressure
Malfunc tion of right PPC lever
1
valve (boom c ircuit) 0 MPa
Neutral
{0 kg/cm 2}
Boom raise 2.84 3.43 MPa
Boom lower {29 35 k g/cm 2}
Malfunc tion of merge-divider Merge-div ider main EPC v alve may have malfunction. Check it
2
main EPC v alve directly.
Malfunc tion of merge-divider Merge-div ider LS-EPC valve may have malfunc tion. Chec k it
3
LS-EPC valve directly.
Malfunc tion of merge-divider
4 Merge-div ider main valv e may hav e malfunction. Check it directly.
main valv e
5 Merge-div ider LS valve may have malfunction. Check it directly.
LS valv e
Malfunc tion of boom c ontrol Spool of boom c ontrol valve may have malfunction. Check it
6
valve (spool) directly.
Pos sible
causes and Malfunc tion of boom c ontrol
Press ure compensation valve of boom control v alv e m ay have mal-
standard value 7 valve (pressure compensa-
function. Check it directly.
in normal state tion valve)
Malfunc tion of boom c ontrol Regeneration valve of boom control valve may have malfunction.
8
valve (regeneration valv e) Chec k it directly.
Malfunc tion of boom c ontrol Loc k valve of boom control valve may have malfunc tion. Chec k it
9
valve (loc k valve) directly.
Malfunc tion or defective seal Safety valve for lock valve may have malfunction or defective seal.
10
of s afety valve for lock valve Chec k it directly.
Malfunc tion or defective seal
Suc tion valv e of boom control valve may have malfunction or
11 of boom control valv e (s uc -
defec tive seal. Check it direc tly.
tion valve)
Safety-suction valve of boom control v alv e may hav e malfunction or
12 of boom control valv e
(safety-suction valve)
Malfunc tion of eac h control LS shuttle valve of left travel control valve, bucket c ontrol valve, or
13
valve (LS shuttle valve) service control valve may have malfunction. Check it directly.
14 Defective boom cy linder Right work equipment control
Leakage from boom cylinder
lever
Boom raise relief 20 cc/min
12 PC200 , 220 -8
H-8 Speed or power of arm is low 1
Trouble Speed or power of arm is low

Related
information

Left work equipment control lever PPC v alve output pressure
Malfunc tion of left PPC v alve
1 0 MPa
(arm circuit) Neutral
{0 kg/cm 2}
Arm curl 2.84 3.43 MPa
Arm dump {29 35 k g/cm 2}
2
3
LS-EPC valve directly.
4 Merge-div ider main valv e may hav e malfunction. Check it directly.
main valv e
LS valv e
Malfunc tion of arm control
6 Spool of arm control valv e may hav e malfunction. Check it direc tly.
valve (spool)
Pos sible Malfunc tion of arm control
causes and Press ure compensation valve of arm control v alve may have mal-
7 valve (pressure compensa-
standard value function. Check it directly.
tion valve)
in normal state
Malfunc tion of arm control Regeneration valve of arm control valve may have malfunction.
8
valve (regeneration valv e) Chec k it directly.
Malfunc tion of arm control Quick return v alve of arm control valv e may hav e malfunction.
9
valve (quick return v alve) Chec k it directly.
Malfunc tion or defective seal Safety valve for lock valve may have malfunction or defective seal.
10
of s afety valve for lock valve Chec k it directly.
Suc tion v alv e of arm control valv e may hav e malfunction or defec-
11 of arm c ontrol valve (suction
tive s eal. Check it directly.
valve)
Safety-suction valve of arm c ontrol valve may have malfunc tion or
12 of arm c ontrol valve (safety-
suction valve)
LS s huttle v alve of right travel c ontrol valve, boom control v alve, left
Malfunc tion of each control
13 travel control valve, bucket c ontrol valve, or s ervic e control v alve
valve (LS shuttle valve)
may have malfunc tion. Chec k it directly.
14 Defective arm cylinder
Left work equipment control lever Leakage from arm cylinder
Arm curl relief 20 cc/min
PC20 0, 220 -8 13
H-9 Speed or power of bucket is low 1
Trouble Speed or power of bucket is low.

Related
information

Right work equipment control
Malfunc tion of right PPC lever
1
valve (buck et circuit) 0 MPa
Neutral
{0 kg/cm 2}
Buc ket curl 2.84 3.43MPa
Buc ket dump {29 35 k g/cm 2}
Malfunc tion of buc ket control Spool of buc ket control valve may have malfunc tion. Chec k it
2
Pos sible valve (spool) directly.
causes and Malfunc tion of buc ket control
standard value Press ure compensation valve of bucket control valv e may hav e
in normal state malfunc tion. Chec k it directly.
tion valve)
Safety-suction valve of bucket control v alve may have m alfunction
4 of bucket control v alve
or defective seal. Check it directly.
(safety-suction valve)
Malfunc tion of service con- LS shuttle valve of s ervic e control v alve may have malfunction.
5
trol valve (LS shuttle valve) Chec k it directly.
6 Defective bucket cylinder Right work equipment control
Leakage from buc ket c ylinder
lever
Buc ket curl relief 20 cc /min
H-10 Work equipment does not move singly 1
(1) Boom does not move singly.

Trouble (2) Arm does not move s ingly.
(3) Bucket does not mov e singly.
Related
information

Pos sible Work equipment control lever PPC valv e output pressure
causes and 1 Malfunction of PPC valv e 0 MPa
standard value Neutral
{0 kg/cm 2}
in normal state
2.84 3.43 MPa
Operated 2
{29 35 k g/cm }
Malfunc tion of control valv e
2 Spool of control valv e may hav e malfunction. Check it directly.
(spool)
14 PC200 , 220 -8
H-11 Hydraulic drift of work equipment is large 1
Trouble (1) Hydraulic drift of boom is large.

Related
information

a Prepare with engine stopped, then run engine at high idling
Pos sible 1 Defective boom cylinder Right work equipment control

Leakage from boom cylinder
causes and lever
standard value Boom raise relief 20 cc/min
in normal state
Defective seal of boom Seal of lock valv e of boom control valve may be defective. Check it
2
control valve (lock valve) directly.
Defectiv e seal of safety Seal of safety valv e for loc k valve may be defective. Chec k it
3
valve for lock valv e directly.
Trouble (2) Hydraulic drift of arm is large.

Related
information

1 Defective arm c ylinder
Left work equipment control lever Leakage from arm cylinder
Arm curl relief 20 cc/min
Defective seal of arm
2 Seal of arm control v alve s pool may be defec tive. C heck it directly.
Pos sible control valv e (spool)
causes and
standard value Defective seal of arm con-
Seal of pressure compensation valve of arm control valve may be
3 trol valve (press ure compen-
in normal state defec tive. Check it direc tly.
sation valve)
Seal of suction valve of arm control valve may be defec tive. C heck
Defective seal of arm it directly.
4
control valv e (suction valve) a This suction valve may be check ed by replacing it with another
suction valve and seeing change of c ondition.
Defectiv e seal of safety Seal of safety valv e for loc k valve may be defective. Chec k it
5
valve for lock valv e directly.
PC20 0, 220 -8 15
Trouble (3) Hydraulic drift of bucket is large.

Related
information

1 Defective bucket cylinder
Left work equipment control lever Leakage from buc ket cy linder
Buc ket curl relief 20 cc /min
Pos sible Defective seal of buck et Seal of buck et control valv e spool may be defective. Chec k it
2
causes and control valv e (spool) directly.
standard value Defective s eal of bucket con-
in normal state Seal of pressure compensation valve of bucket c ontrol valve may
be defective. Check it directly.
sation valve)
Seal of safety-suction valve of bucket control valv e may defec tive.
Defective seal of buck et Chec k it directly.
4 control valv e (safety-suction a Safety-suction valves on bottom side and head side may be
valve) checked by replacing them with eac h other and s eeing change
of c ondition.
16 PC200 , 220 -8
H-12 Time lag of work equipment is large 1
Trouble Time lag of w ork equipment is large.

Related
information

LS-EPC valve output
press ure
Approx. 2.9 MPa
Lo Neutral
0 MPa
Hi Operated
Pos sible {0 kg/cm 2}
causes and Malfunc tion of control valv e
standard value Regeneration valve of control valve may have malfunc tion. Check it
2 (regeneration valv e) [Boom
directly.
in normal state and arm only]
Safety-suction valve of control v alve may have malfunction. Check
it directly.
Malfunc tion of control valv e a This s afety-suction valve may be checked by replacing it with
3
(safety-suction v alve) safety -s uc tion valv e of normal control valve and s eeing
change of c ondition. (Set pres sure of safety-suction v alve for
boom head circuit is different, however.)
Press ure compensation valve of control v alve may have malfunc-
4 (press ure compensation
tion. Check it directly.
valve)
H-13 When part of work equipment is relieved singly, other parts of work
equipment move 1
Trouble When part of work equipment is relieved singly, other parts of work equipment move
Related
information
Pos sible Caus e Standard value in normal state/Remarks on troubleshooting

causes and Defective seal of control
standard value Seal of pressure compensation valve of c ontrol valve on moving
in normal state side may be defec tive. C heck it direc tly.
tion valve) on mov ing side
PC20 0, 220 -8 17
H-14 Power maximizing function does not work 1
Trouble Power max im iz ing function does not work.

Related
information

2-s tage relief solenoid valve
Pos sible Swing lock switc h
Malfunc tion of 2-s tage relief output pressure
causes and 1
solenoid valve 0 MPa
standard value OFF
in normal state {0 kg/cm 2}
2.9 MPa
ON
{30 kg/cm 2}
Malfunc tion of main relief
2 Main relief v alve may have malfunction. Check it directly.
valve
H-15 In compound operation of work equipment, speed of part loaded

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

Press ure compensation valve of control v alve on less load side
may have malfunc tion. Chec k it directly.
Compound operation Larger load side Less load side
Boom raise
+ Boom raise Arm c url
Arm curl
Pos sible Boom raise

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

rising speed is low 1
Trouble When machine s wings and rais es boom s imultaneously, boom ris ing speed is low.
Related If speed of single boom raise operation is als o low, carry out troubleshooting for "H-7 Speed or
information pow er of boom is low" first.

causes and Malfunction or defectiv e seal
standard value LS selector valv e of control valve may have malfunction or defec-
1 of s wing c ontrol valve (LS
in normal state tive s eal. Chec k it directly.
selec tor valve)
H-17 When machine swings and travels simultaneously, travel speed

lowers largely 1
Trouble When machine s wings and travels simultaneously, travel speed lowers largely.
Related If speed of single travel operation is als o low, c arry out troubleshooting for "H-19 Travel s peed is
information low" first.

causes and
standard value Malfunc tion of each control LS shuttle valve of left travel control valve or swing control v alve
1
in normal state valve (LS shuttle valve) may have malfunc tion. Chec k it directly.
PC20 0, 220 -8 19
H-18 Machine deviates during travel 1
Trouble Mac hine dev iates during trav el.

Related
information

Trav el lever PPC valv e output pressure
Malfunc tion of travel PPC
1 0 MPa
valve Neutral
{0 kg/cm 2}
Malfunc tion of self pressure
reducing valv e
2.84 3.43 MPa
{29 35 k g/cm 2}
3
1
Pos sible press ure Almost same
causes and PC valve output press ure Approx. 0.6
standard value press ure (Approx . 3/5)
in normal state
Trav el junction solenoid valve
Trav el lever
Malfunc tion of travel output pressure
4
junction solenoid v alve 0 MPa
Both sides in neutral
{0 kg/cm 2}
2.9 MPa
Either s ide operated
{30 kg/cm 2}
Malfunc tion of travel
5 Trav el junction valve may have malfunc tion. Chec k it directly.
junction v alve
Malfunc tion of travel control Spool of travel control valve may have malfunction. Check it
6
7 Defective trav el motor
Trav el lever Leakage from travel motor
Trav el relief 27.2 l/min
Final drive may have internal defect. Check it directly.
8 Defective final drive a It may be checked by abnormal sound, abnormal heating,
metal chips in drain oil, etc.
20 PC200 , 220 -8
H-19 Travel speed is low 1
Trouble Travel speed is low.

Related
information

Trav el lever PPC valv e output pressure
Malfunc tion of travel PPC
1 0 MPa
valve Neutral
{0 kg/cm 2}
Malfunc tion of self pressure
reducing valv e
2.84 3.43 MPa
{29 35 k g/cm 2}
Meas ured oil LS-EPC valve output
Trav el lever
press ure press ure
Pos sible 3 Malfunction of LS-EPC valve
causes and Approx. 2.9 MPa
Lo Neutral
standard value {Approx . 30 kg/c m 2}
in normal state 0 MPa
Hi Operated
{0 kg/cm 2}
Malfunc tion of travel control Spool of travel control valv e may have malfunction. Check it
4
Malfunc tion of travel control
Press ure compensation valve of control v alve may have malfunc-
tion. Check it directly.
tion valve)
Malfunc tion of travel control Suc tion v alv e of control valve may have malfunction. Check it
6
valve (suction valve) directly.
Malfunction of buck et control LS shuttle valve of bucket control v alve m ay have malfunction.
7
valve (LS shuttle valve) Chec k it directly.
Trav el relief 27.2 l/min
PC20 0, 220 -8 21
H-20 Machine is not steered well or steering power is low 1
Trouble Mac hine is not s teered well or steering power is low

Related
information

Trav el lever
Malfunc tion of travel PPC (Steering)
1
valve (steering s pool) 0 MPa
{0 kg/cm 2}
2.84 3.43 MPa
{29 35 k g/cm 2}
Trav el junction solenoid valve
Trav el lever
Malfunc tion of travel output pressure
2
junction solenoid v alve 0 MPa
{0 kg/cm 2}
2.9 MPa
{30 kg/cm 2}
Malfunc tion of travel
3 Trav el junction valve may have malfunc tion. Chec k it directly.
junction v alve
4
5
Pos sible LS-EPC valve directly.
causes and
standard value 6 Merge-div ider main valv e may hav e malfunction. Check it directly.
main valv e
in normal state
LS valv e
Malfunc tion of travel control Spool of travel control valve may have malfunction. Check it
8
Malfunc tion of travel control
Press ure compensation valve of trav el control valve may have mal-
tion valve)
Malfunc tion of travel control Suction valve of travel control valve may have malfunction. Check it
10
valve (suction valve) directly.
Malfunction of buck et control LS shuttle valve of bucket control v alve m ay have malfunction.
11
valve (LS shuttle valve) Chec k it directly.
Defective seal of check valve
Seal of check valve of LS pressure sensing part (control valve s ide)
12 of LS pres sure s ensing part
may be defec tive. Check it directly.
(control valv e side)
Seal of safety valv e of travel motor may be defective. Check it
directly.
Defective seal of travel
13 a Motors of same type on forw ard and reverse sides or on right
motor (safety valv e)
and left sides may be checked by replacing them with each
other and seeing c hange of condition.
Seal of chec k valve of trav el motor may be defectiv e. C heck it
directly.
motor (chec k valve)
22 PC200 , 220 -8
H-21 Travel speed does not change or travel speed is low/high 1
Trouble Travel speed does not change or travel speed is low/high

Related
information

a Run engine at high idle and c arry out troubles hooting
(with monitoring function).
Monitoring
code: 01500
663 mA (PC200-8)
Lo 578 mA (PC220-8)
(* Referenc e)
Operated
424 mA (PC200-8)
Mi
641 mA (PC220-8)
Hi 0 mA
Pos sible LS-EPC valve
causes and output pressure
standard value Approx. 2.9 MPa
in normal state Lo Neutral
0 MPa
Hi Operated
{0 kg/cm 2}
Trav el speed s hifting
Trav el speed Travel lever solenoid valve output
Malfunc tion of travel speed press ure
2
shifting solenoid valve
0 MPa
Lo Neutral
{0 kg/cm 2}
Approx. 2.9 MPa
Hi Operated
Malfunc tion of travel motor Speed s hifting s ection of travel motor may have malfunction.
3
(speed shifting section) Chec k it directly.
*: Tra ve l sp eed Lo ca n be ad juste d with the adjusting functi on of th e machine mon ito r. Acco rding ly, if th e
initial value ha s bee n cha nged, the mea su red va lue varies mor e or less.
PC20 0, 220 -8 23
H-22 Travel system does not move (only one side) 1
Trouble Travel sys tem does not move (only one side).
Related
information

Defective seal of travel con- Seal of suction valv e of travel control valv e may hav e malfunction.
1
trol valve (suction valve) Chec k it directly.
Seal of safety valv e of travel control valve may have malfunction.
Chec k it directly.
motor (safety valv e)
Seal of chec k valve of travel control v alve may have malfunction.
Chec k it directly.
Pos sible Defective seal of travel
causes and motor (chec k valve)
standard value and left sides may be checked by replacing them with each
in normal state other and seeing c hange of condition.
Malfunc tion of travel motor Parking brake of travel motor may have malfunction. Chec k it
4
(parking brake) directly.
Trav el system relief 27.2 l/min
24 PC200 , 220 -8
H-23 Upper structure does not swing 1
Trouble (1) Upper struc ture does not sw ing in either direction.
Related
information

Swing holding brake
Left work equipment control lever
Malfunc tion of swing holding solenoid valve output pressure
1
brake s olenoid valve 0 MPa
Neutral
{0 kg/cm 2}
Left s wing 2.9 MPa
Right swing {30 kg/cm 2}
Malfunc tion of swing control Spool of swing control valv e may hav e malfunction. Check it
2
Malfunc tion of swing motor Parking brake of swing motor may have malfunction. Check it
3
Pos sible a Prepare with engine stopped, then run engine at high idle and
causes and carry out troubleshooting.
standard value Left work equipment
in normal state Swing lock switc h Swing relief press ure
Defective adjus tment or control lever
4 malfunc tion of swing motor 28.9 32.9 MPa
(safety valv e) ON Swing relief
{295 335 kg/cm 2}
If oil pressure does not become normal after adjus tment, swing
motor safety valve may have malfunction or internal defect. Check
safety valve directly.
5 Defective s wing motor Left work equipment Leakage from swing
Swing lock switc h
control lever motor
ON Swing relief Max. 10 l/min
Swing machinery may hav e internal defect. C heck it direc tly.
6 Defective s wing machinery a It may be checked by abnormal sound, abnormal heating,
PC20 0, 220 -8 25
Trouble (2) Upper s truc ture swings only in one direction.

Related
information

Malfunc tion of swing PPC
1 0 MPa
valve Neutral
{0 kg/cm 2}
Left s wing 2.84 3.43 MPa
Pos sible Right sw ing {29 35 k g/cm 2}
causes and
standard value Malfunc tion of swing control Spool of swing control valv e may hav e malfunction. Check it
2
in normal state valve (spool) directly.
Suc tion valv e of swing motor may have malfunc tion. Chec k it
Malfunc tion of swing motor directly.
3
(suction valve) a Suction valves on right s ide and left side may be checked by
replacing them w ith each other and seeing change of condition.
Chec k valve of swing motor may hav e malfunction. Check it
4
(chec k valve) a Check valves on right side and left side may be checked by
26 PC200 , 220 -8
H-24 Swing acceleration or swing speed is low 1
Trouble (1) Swing acceleration or swing speed is low in both directions .

Related
information

1
Malfunc tion of all control LS shuttle valves of all c ontrol valves may have malfunction.
2
valves (LS shuttle valves) Chec k them directly.
3
Left work equipment
Swing lock switc h Swing relief press ure
Pos sible Defective adjus tment or control lever
causes and 4 malfunc tion of swing motor 28.9 32.9 MPa
ON Swing relief
standard value (safety valv e) {295 335 kg/cm 2}
in normal state
If oil pressure does not become normal after adjus tment, swing
motor safety valve may have malfunction or internal defect. Check
Swing lock switc h
control lever motor
Swing machinery may hav e internal defect. Chec k it directly.
6 Defective s wing machinery a It may be check by abnorm al s ound, abnormal heating, metal
chips in drain oil, etc .
Trouble (2) Swing acceleration or swing speed is low in only one direction.
Related
information

1 0 MPa
valve Neutral
{0 kg/cm 2}
Right swing {29 35 k g/cm 2}
Pos sible Malfunc tion of swing control Spool of swing control valv e may hav e malfunction. Check it
2
causes and valve (spool) directly.
standard value Malfunc tion of swing control
Press ure compensation valve of sw ing control valv e may have mal-
in normal state 3 valve (pressure compensa-
tion valve)
Suc tion v alv e of swing motor may have malfunc tion. Chec k it
4
(suction valve) a Suction valves on right s ide and left side may be check ed by
replac ing them with each other and seeing change of condition.
Chec k valve of swing motor may hav e malfunction. Chec k it
5
PC20 0, 220 -8 27
H-25 Upper structure overruns remarkably when it stops swinging 1
Trouble (1) Upper s truc ture overruns remarkably when it stops s winging in both direc tions .
Related
information

Prepare with engine stopped, then run engine at high idle and
Left work equipment
Swing lock switc h Swing relief press ure
Defective adjus tment or control lever
1 malfunc tion of swing motor 28.9 32.9 MPa
Pos sible (safety valv e) ON Swing relief
{295 335 kg/cm 2}
causes and
standard value If oil pressure does not become normal after adjus tment, swing
in normal state motor safety valve may have malfunction or internal defect. Check
Swing lock switc h
control lever motor
Trouble (2) Upper struc ture overruns remarkably when it stops s winging in only one direction.
Related
information

1 0 MPa
valve Neutral
{0 kg/cm 2}
Right sw ing {29 35 k g/cm 2}
Swing PPC slow return valve may have malfunction. Check it
Pos sible directly.
Clogging of swing PPC slow
causes and 2 a Slow return valves on right side and left side may be chec ked
return v alve
standard value by replac ing them with each other and seeing change of condi-
in normal state tion.
3
Suc tion valv e of swing motor may have malfunc tion. Chec k it
4
(suction valve) a Suction valves on right s ide and left side may be checked by
Chec k valve of swing motor may hav e malfunction. Check it
5
28 PC200 , 220 -8
H-26 Large shock is made when upper structure stops swinging 1
Trouble Large shock is made when upper s tructure stops swinging.

Related
information

1 0 MPa
valve Neutral
{0 kg/cm 2}
Pos sible
causes and Left s wing 2.84 3.43 MPa
standard value Right swing {29 35 k g/cm 2}
in normal state Swing PPC slow return valve may have malfunction. Check it
directly.
Clogging of swing PPC slow
2 a Slow return valves on right side and left side may be chec ked
return v alve
by replacing them with each other and seeing c hange of con-
dition.
Malfunc tion of swing motor Shockless valve of s wing motor may have malfunction. Check it
3
(shoc kles s valve) directly.
H-27 Large sound is made when upper structure stops swinging 1
Trouble Large sound is made when upper s truc ture stops swinging.
Related
information

Malfunction of back pressure
1 Bac k pres sure v alve may have malfunction. Check it direc tly.
valve
Malfunc tion of swing motor Safety v alve of swing motor may hav e malfunction. Check it
2
Pos sible (safety valv e) directly.
causes and
Suc tion v alv e of swing motor may have malfunc tion. Chec k it
standard value
in normal state 3
(suction valve) a Suction valves on right s ide and left side may be check ed by
Swing machinery may hav e internal defect. C heck it direc tly.
4 Defective s wing machinery a It may be checked by abnormal sound, abnormal heating,
PC20 0, 220 -8 29
H-28 Hydraulic drift of swing is large 1
Trouble (1) Hydraulic drift of swing is large (when swing holding brake is applied).
When swing lock switch is turned ON or when swing holding brake release switch is in normal posi-
Related
tion, s wing holding brake operates and upper structure is fixed with disc brake.
information

Swing holding brake
Pos sible Left work equipment control lever
Malfunc tion of swing holding solenoid valve output pressure
causes and 1
brake s olenoid v alve 0 MPa
standard value Neutral
in normal state {0 kg/cm 2}
Left s wing 2.9 MPa
Right sw ing {30 kg/cm 2}
2
Trouble (2) Hydraulic drift of swing is large (when swing holding brake is releas ed).
When swing holding brake releas e s witch is in releas e position, swing holding brake is released and
Related
upper structure is secured by only hydraulic pressure.
information

Malfunction or defectiv e seal Swing c ontrol valve spool may hav e malfunction or defec tive seal.
1
of sw ing control v alve (spool) Chec k it directly.
Defective seal of swing con-
Seal of press ure compensation v alve of s wing control v alve may be
defec tive. Check it direc tly.
sation valve)
Pos sible
causes and Defective seal of swing Seal of safety valv e of swing motor may be defec tive. Check it
3
standard value motor (safety valv e) directly.
in normal state
Defective seal of swing Seal of suction valve of sw ing motor may be defective. Check it
4
motor (suction valve) directly.
Defective seal of swing Seal of chec k valve of swing m otor may be defectiv e. Check it
5
motor (chec k valve) directly.
Defective seal of swing Seal of shoc kles s valve of swing motor may be defectiv e. Check it
6
motor (shoc kles s valve) directly.
30 PC200 , 220 -8
H-29 Attachment circuit is not changed 1

Attachme nt ins tallation spec ification
Trouble Attac hment circuit is not changed.
When attachment ins tallation specification is employ ed, serv ice circuit is changed as follows
according to s elected working mode.
Related
1) ATT mode: Service circuit is changed to double acting circuit and safety valve is set to low pressure.
information
2) B mode: Service circuit is changed to single acting circuit and safety valve is set to high pressure.
Safety valv e set pressure on only B port side is c hanged; that on A port side is kept low.

ATT return selector solenoid
Work ing mode
Malfunc tion of ATT return valve output press ure
Pos sible 1
selec tor solenoid valve 0 MPa
causes and ATT mode
{0 kg/cm 2}
standard value
in normal state 2.9 MPa
B mode
{30 kg/cm 2}
Malfunc tion of ATT return
2 ATT return selector valve may have malfunc tion. Check it directly.
selec tor valve
Malfunc tion of service Safety v alve (B port side) of service c ontrol valve may have
3
control valv e (safety valv e) malfunc tion. Chec k it directly.
H-30 Oil flow in attachment circuit cannot be controlled 1

Attachme nt ins tallation spec ification
Trouble Oil flow in attachment circuit cannot be c ontrolled.
When attachment installation s pecific ation is employed, oil flow in service circuit changes accordin g
Related to s elected user mode.
information Procedure for adjusting oil flow in ATT mode of work ing mode is different from that in B mode.
For details, see Operation and Maintenanc e Manual.

Pos sible
Malfunc tion of ATT flow ATT flow adjustment EPC valv e may hav e malfunction. C heck it
causes and 1
adjustment EPC v alve directly.
standard value
in normal state Malfunc tion of service PPC
2 Servic e PPC v alve may have malfunction. Check it directly.
valve
PC20 0, 220 -8 31
SE N0 0245- 00
© 2 005 KO MATSU
All Rights Reserved
32
SE N00 246- 01
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Troubleshooting of engine (S-mode)
Tr ouble sh ooting of e ngine (S -mo de)............................................................................................................... 4
Method of u sin g tro ublesho otin g cha rt ................................................................................................. 4
S-1 Starting performan ce is poor ......................................................................................................... 8
S-2 E ngine do es n ot start ..................................................................................................................... 9
S-3 E ngine do es no t pick up smoothly ............................................................................................... 12
S-4 E ngine sto ps du ring ope rati ons ................................................................................................... 13
S-5 E ngine do es no t rotate smoothly ................................................................................................. 1 4
S-6 E ngine la ck output (o r l acks p ower) ............................................................................................ 15
S-7 E xh aust smo ke is black (in co mp lete combu stion )....................................................................... 1 6
S-8 O il con sump tio n is exce ssive (or exhaust smoke is blu e) ........................................................... 1 7
S-9 O il b ecomes contaminated qu ickly .............................................................................................. 18
S-1 0 Fue l con su mp tio n is excessive .................................................................................................. 1 9
S-11 Oil is in cool ant (o r cool ant spurts ba ck or co olant level goes down) ........................................ 2 0
S-1 2 O il pressure drop s ..................................................................................................................... 2 1
S-1 3 O il level rises (En try of coola nt/fuel) .......................................................................................... 22
S-1 4 Co olant temp erature becomes too h igh (overhe atin g) .............................................................. 2 3
PC20 0, 220 -8 1

Hydraulic Excavator PC200-8 PC200LC-8 PC220-8 PC220LC-8: 40 Troubleshooting

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Hydraulic Excavator PC200-8 PC200LC-8 PC220-8 PC220LC-8: 40 Troubleshooting

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SE N00 231- 01

HYDRAULIC EXCAVATOR 1SH OP MA NU AL

Machine model Serial number

General information on troubleshooting 1

Sequence of events in troubleshooting 1

Check before troubleshooting 1

Item Criterion Remedy

Classification and procedures for troubleshooting 1

Procedure for troubleshooting

Phenomena looking like troubles and troubleshooting Nos.

How to read electric wire code 1

Indicates color of wire by c olor code.

Indicates size of wire by nominal No.

Indicates ty pe of wire by symbol.

1. Type, s ymbol, a nd mat erial

Annealed copper for

AVS, AV, A EX, AVSS

Nominal No. 8 15 20 30 40 50 60 85 100

"f" of n ominal No. de notes "fle xibl e".

3. Color codes table

4. Types of c ircuits and color codes

Connection table for connector pin numbers 1

Part No.: 08055-00282 Part No.: 08055-00292

Part No.: 08055-00381 Part No.: 08055-00391

Part No.: 08055-00481 Part No.: 08055-00491

SWP type connector

Part No.: 08055-10681 Part No.: 08055-10691

Part No.: 08055-10881 Part No.: 08055-10891

Part No.: 08055-11281 Part No.: 08055-11291

Part No.: 08055-11481 Part No.: 08055-11491

SWP type connector

Part No.: 08055-11681 Part No.: 08055-11691

Part No.: 08056-00271 Part No.: 08056-00281

Part No.: 08056-00371 Part No.: 08056-00381

Part No.: 08056-00471 Part No.: 08056-00481

Part No.: 08056-00671 Part No.: 08056-00681

Part No.: 08056-00871 Part No.: 08056-00881

Part No.: 08056-10871 Part No.: 08056-10881

Part No.: 08056-11071 Part No.: 08056-11081

Part No.: 08056-11271 Part No.: 08056-11281

Part No.: 08056-11671 Part No.: 08056-11681

Part No.: 08056-11272 Part No.: 08056-11282

Part No.: 08056-11672 Part No.: 08056-11682

MIC type connector

MIC type connector

AMP040 type connector

 Housing part No.: 79A-222-3430 (Qty: 5)

 Housing part No.: 79A-222-3440 (Qty: 5)

 Housing part No.: 79A-222-3450 (Qty: 5)

 Housing part No.: 79A-222-3460 (Qty: 5)

AMP070 type connector

 Part No.: 7821-92-7330

 Part No.: 7821-92-7340

 Part No.: 7821-92-7350

 Part No.: 7821-92-7360

 Part No.: 7821-92-7310

KES 1 (Automobile) connector

Part No.:08027-10310 Part No.:08027-10360

KES 1 (Automobile) connector

Connector for relay (Soc ket type)

[Th e p in No . is also marked on the co nnector (electric wire insertion en d)]

Pin (male terminal) Pin (female termial)

Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

Housing part No.: 79A-222-3430 (Qty: 5)

Housing part No.: 79A-222-3440 (Qty: 5)

Housing part No.: 79A-222-3450 (Qty: 5)

Housing part No.: 79A-222-3460 (Qty: 5)

Part No.: 7821-92-7330

Part No.: 7821-92-7340

Part No.: 7821-92-7350

Part No.: 7821-92-7360

Part No.: 7821-92-7310