PC200 (LC) - 8E0 SEN05245-02 Hybrid Troubleshooting

SEN05245-02
PC200, 200LC-8E0 (Hybrid)

SEN05245-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)
PC200LC-8E0 (Hybrid)
Machine model Serial number

PC200-8E0 (Hybrid) 1001 and up
PC200LC-8E0 (Hybrid) 1001 and up
40 Troubleshooting
100 Failure code table and fuse locations
Failure code table ....................................................................................................................................... 2

Fuse locations............................................................................................................................................. 8
PC200, 200LC-8E0 (Hybrid) 40-100 1

SEN05245-02 Failure code table
Failure code table

a This failure code table is the same as that in Testing and adjusting, “Special functions of machine
monitor”.
User Device to Document No.
Failure code Failure (Displayed on screen) Category of system
code work to refer
- 989L00 Engine Controller Lock Caution 1 MON Electrical system
- 989M00 Engine Controller Lock Caution 2 MON Electrical system
- 989N00 Engine Controller Lock Caution 3 MON Electrical system
- AA10NX Air Cleaner Clogging MON Mechanical system
- AB00KE Charge Voltage Low MON Mechanical system
- B@BAZG Eng Oil Press. Low ENG Mechanical system
- B@BAZK Eng Oil Level Low MON Mechanical system
- B@BCNS Eng Water Overheat ENG Mechanical system
- B@BCZK Eng Water Level Low MON Mechanical system
- B@HANS Hydr Oil Overheat PUMP Mechanical system
E10 CA111 EMC Critical Internal Failure ENG Electrical system
E10 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical system
E11 CA122 Chg Air Press Sensor High Error ENG Electrical system
E10 CA123 Chg Air Press Sensor Low Error ENG Electrical system
E14 CA131 Throttle Sensor High Error ENG Electrical system
E14 CA132 Throttle Sensor Low Error ENG Electrical system Troubleshooting
by failure code
E15 CA144 Coolant Temp Sens High Error ENG Electrical system
(Part 1),
E15 CA145 Coolant Temp Sens Low Error ENG Electrical system SEN05247-00
E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system
E15 CA154 Chg Air Temp Sensor Low Error ENG Electrical system
E11 CA155 Chg Air Temp High Speed Derate ENG Electrical system
E15 CA187 Sens Supply 2 Volt Low Error ENG Electrical system
E11 CA221 Ambient Press Sens High Error ENG Electrical system
E11 CA222 Ambient Press Sens Low Error ENG Electrical system
E15 CA227 Sens Supply 2 Volt High Error ENG Electrical system
- CA234 Eng Overspeed ENG Mechanical system
E15 CA238 Ne Speed Sens Supply Volt Error ENG Electrical system
E10 CA271 IMV/PCV1 Short Error ENG Electrical system
E10 CA272 IMV/PCV1 Open Error ENG Electrical system
E11 CA322 Inj #1 Open/Short Error ENG Electrical system
E10 CA342 Calibration Code Incompatibility ENG Electrical system
E10 CA351 Injectors Drive Circuit Error ENG Electrical system
E15 CA352 Sens Supply 1 Volt Low Error ENG Electrical system
E15 CA386 Sens Supply 1 Volt High Error ENG Electrical system
E15 CA428 Water in Fuel Sensor High Error ENG Electrical system
E15 CA429 Water in Fuel Sensor Low Error ENG Electrical system
E15 CA435 Eng Oil Press Sw Error ENG Electrical system Troubleshooting
E10 CA441 Battery Voltage Low Error ENG Electrical system by failure code
E10 CA442 Battery Voltage High Error ENG Electrical system (Part 2),
E11 CA449 Rail Press Very High Error ENG Electrical system SEN05248-00
E11 CA451 Rail Press Sensor High Error ENG Electrical system
E11 CA452 Rail Press Sensor Low Error ENG Electrical system
E11 CA488 Chg Air Temp High Torque Derate ENG Electrical system
E15 CA553 Rail Press High Error ENG Electrical system
E15 CA559 Rail Press Low Error ENG Electrical system
E15 CA689 Eng Ne Speed Sensor Error ENG Electrical system
40-100 2 PC200, 200LC-8E0 (Hybrid)

Failure code table SEN05245-02

code work to refer
E15 CA731 Eng Bkup Speed Sens Phase Error ENG Electrical system
E10 CA757 All Continuous Data Lost Error ENG Electrical system
E15 CA778 Eng Bkup Speed Sensor Error ENG Electrical system
E0E CA1633 KOMNET Datalink Timeout Error ENG Electrical system
E14 CA2185 Throt Sens Sup Volt High Error ENG Electrical system
E14 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system
E11 CA2249 Rail Press Very Low Error ENG Electrical system Troubleshooting
E11 CA2311 IMV Solenoid Error ENG Electrical system by failure code
E15 CA2555 Grid Htr Relay Volt High Error ENG Electrical system (Part 2),
E15 CA2556 Grid Htr Relay Volt Low Error ENG Electrical system SEN05248-00
E01 D19JKZ Personal Code Relay Abnormality MON2 Electrical system
- D862KA GPS Antenna Discon MON2 Electrical system
E0E DA22KK Pump Solenoid Power Low Error PUMP Electrical system
- DA25KP 5 V Sensor 1 Power Abnormality PUMP Electrical system
- DA26KP 5 V sensor 2 power Abnormality PUMP Electrical system
- DA29KQ Model Selection Abnormality PUMP Electrical system
E0E DA2RMC CAN Discon (Pump Con Detected) PUMP Electrical system
- DAF8KB Short circuit in camera power supply MON Electrical system
- DAFGMC GPS Module Error MON2 Electrical system
E0E DAFRMC CAN Discon (Monitor Detected) MON Electrical system
- DGH2KB Hydr Oil Sensor Short PUMP Electrical system
- DHPAMA F Pump Press Sensor Abnormality PUMP Electrical system
- DHPBMA R Pump Press Sensor Abnormality PUMP Electrical system
Arm Curl PPC Press Sensor
- DHS3MA PUMP Electrical system Troubleshooting
Abnormality
Bucket Curl PPC Press Sensor by failure code
- DHS4MA PUMP Electrical system (Part 3),
Abnormality
E20 DHS5KK Travel PPC pressure sensor Abnormality PUMP Electrical system SEN05249-00
Boom Raise PPC Press Sensor
- DHS8MA PUMP Electrical system
Abnormality
Swing RH PPC Press Sensor
- DHSAMA PUMP Electrical system
Abnormality
Swing LH PPC Press Sensor
- DHSBMA PUMP Electrical system
Abnormality
Bucket Dump PPC Press Sensor
- DHSDMA PUMP Electrical system
Abnormality
HYB Arm Dig PPC Pr. Sen.
E09 DHV3KZ HYB Electrical system
Opn/Short Cir.
HYB Boom Lower PPC Pr. Sen.
E09 DHV9KZ HYB Electrical system
Opn/Short Cir. Troubleshooting
HYB Swing-R PPC Pr. Sen. by failure code
E09 DHVAKZ HYB Electrical system
Opn/Short Cir. (Part 5),
HYB Swing-L PPC Pr. Sen. SEN05251-03
E09 DHVBKZ HYB Electrical system
Opn/Short Cir.
HYB Arm Dump PPC Pr. Sen.
E09 DHVCKZ HYB Electrical system
Opn/Short Cir.
Troubleshooting
- DW43KA Travel Speed Sol Discon PUMP Electrical system
by failure code
(Part 3),
- DW43KB Travel Speed Sol Short PUMP Electrical system SEN05249-00
E09 DW45KA Swing Brake Sol. Valve Open Cir. HYB Electrical system Troubleshooting
E09 DW45KB Swing Brake Sol. Valve Short Cir. HYB Electrical system by failure code
Swing Brake Sol. Valve Pow. Short (Part 5),
E09 DW45KY HYB Electrical system
Cir. SEN05251-03
- DW91KA Travel Junction Sol Discon PUMP Electrical system Troubleshooting
- DW91KB Travel Junction Sol Short PUMP Electrical system by failure code
- DWK0KA 2-stage Relief Sol Discon PUMP Electrical system (Part 3),
- DWK0KB 2-stage Relief Sol Short PUMP Electrical system SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-100 3


code work to refer
E02 DXA8KA PC-EPC (F) Sol Discon PUMP Electrical system
E02 DXA8KB PC-EPC (F) Sol Short PUMP Electrical system
E02 DXA9KA PC-EPC (R) Sol Discon PUMP Electrical system
E02 DXA9KB PC-EPC (R) Sol Short PUMP Electrical system
- DXE0KA LS-EPC Sol Discon PUMP Electrical system
- DXE0KB LS-EPC Sol Short PUMP Electrical system
- DXE5KA Merge-divider Main Sol Discon PUMP Electrical system
Troubleshooting
- DXE5KB Merge-divider Main Sol Short PUMP Electrical system by failure code
- DXE6KA Merge-divider LS Sol Discon PUMP Electrical system (Part 4),
SEN05250-01
- DXE6KB Merge-divider LS Sol Short PUMP Electrical system
- DY20KA Wiper Working Abnormality PUMP Electrical system
- DY20MA Wiper Parking Abnormality PUMP Electrical system
- DY2CKA Washer Drive Discon PUMP Electrical system
- DY2CKB Washer Drive Short PUMP Electrical system
- DY2DKB Wiper Drive (For) Short PUMP Electrical system
- DY2EKB Wiper Drive (Rev) Short PUMP Electrical system
E09 GA01KA Power Cable Interlock Open Circuit HYB Electrical system
E09 GA02KZ DC Line Open & Short Circuit HYB Electrical system
Abnormal DC HW Volt. Before
E09 GA04KG HYB Electrical system
Booster
Abnormal DC SW Volt. Before
E09 GA05KG HYB Electrical system
Booster
Low DC SW Output Volt. Bef.
E09 GA05KP HYB Electrical system
Booster
DC Vlt. Sen. Opn./Shrt.Cir. Bef.
E09 GA06KZ HYB Electrical system
Booster
E09 GA08KG Abnorm. DC HW Volt. After Booster HYB Electrical system
E09 GA09KG Abnorm. DC SW Volt. After Booster HYB Electrical system
Low DC SW Output Volt. After
E09 GA09KP HYB Electrical system
Booster
DC Vlt. Sen. Op./Shrt cir. Aft.
E09 GA0AKZ HYB Electrical system
booster
E09 GA0BKZ AC line Open & Short Circuit HYB Electrical system
HYB Controller In General And Troubleshooting
E09 GA10Z9 HYB Electrical system by failure code
Others
(Part 5),
E09 GA11KK HYB Cont. Low Supply Voltage HYB Electrical system
SEN05251-03
E09 GA12MC HYB Cont. Pow. Suppl. Failure HYB Electrical system
HYB Cont. Pow. Suppl. Not Turn.
E09 GA12NK HYB Electrical system
ON
HYB Cont. Pow. Suppl. Not Turn.
E09 GA12NL HYB Electrical system
OFF
HYB Control. Sen. Power Sup.
E09 GA13MC HYB Electrical system
Failure
HYB Control. KOMNET Comm.
E09 GA14KR HYB Electrical system
Failure
HYB Cont. Bad Insul. Sen.
Open/Short Cir.
E09 GA16KK Low HYB Cont. VDD Suppl. Volt. HYB Electrical system
Gen. Mot. Drv. Communication
Failure
Gen. Mot Dr. Power Line Short
E09 GA17KY HYB Electrical system
Circuit
Gen. Motor Driver Open/Short
Circuit
40-100 4 PC200, 200LC-8E0 (Hybrid)


code work to refer
E09 GA17MB Gen. Mot. Drv. Function Degraded HYB Electrical system
Gen. Mo.Dr. Excite. Pow. Sup.
Failure
Gen. Mot. Drv. Sub-CPU Low Sup.
E09 GA19KK HYB Electrical system
Volt.
Gen. Motor Driver Sub-CPU Comm.
Failure
Int. Abnorm. Gen. Mot. Drv. Sub-
E09 GA19KT HYB Electrical system
CPU Con.
Gen. Mot. Drv. Sub-CPU
E09 GA19MA HYB Electrical system
Malfunction
Gen. Mot. Drv. Sub-CPU Defect.
Operation
Gen. Mot. Drv. Sub-CPU Start
E09 GA19NA HYB Electrical system
Disabled
Gen. Mot. Dr. Temp. Sens.
E09 GA1AKZ HYB Electrical system
Opn/Short Cir.
Gen. Mot. Dr. DC Vlt. Sens.
E09 GA1BMA HYB Electrical system
Malfunction
Gen. Motor Driver IPM1
E09 GA1DMA HYB Electrical system
Abnormality
Gen. Motor Driver IPM2
E09 GA1EMA HYB Electrical system
Abnormality
Swing Mot. Drv. Communication
E09 GA1FKR HYB Electrical system
Failure
E09 GA1FMA Abnormal Swing Motor Driver HYB Electrical system
Low Sup. Volt. Swing Motor Drv.
E09 GA1GKK HYB Electrical system
Sub-CPU
Swing Mot. Driver Sub-CPU Comm.
E09 GA1GKR HYB Electrical system Troubleshooting
Faliure
Swing Mot. Drv. Sub-CPU Cont. by failure code
E09 GA1GKT HYB Electrical system (Part 5),
Abnormal
Swing Motor Drv. Sub-CPU SEN05251-03
E09 GA1GMA HYB Electrical system
Malfunction
Swing Mot. Drv. Sub-CPU Funct.
E09 GA1GMB HYB Electrical system
Degraded
Swing Mot. Drv. Sub-CPU Defect
E09 GA1GMC HYB Electrical system
Op.
Swing Mot. Drv. Sub-CPU Start
E09 GA1GNA HYB Electrical system
Disabled
Swg Mot. Dr. Ph-U Tem. Sens
E09 GA1HKZ HYB Electrical system
Opn/Shrt Cir.
Swg Mot. Dr. Ph-V Tem. Sens
E09 GA1JKZ HYB Electrical system
Opn/Shrt Cir.
Swg Mot. Dr. Ph-W Tem. Sens
E09 GA1KKZ HYB Electrical system
Opn/Shrt Cir.
Swg Mot. Dr. Current. Sens
E09 GA1LKZ HYB Electrical system
Opn/Shrt Cir.
Swg Mot. Dr. DC Vlt. Sens
E09 GA1MKZ HYB Electrical system
Opn/Shrt Cir.
E09 GA1NNS Swing Motor Driver IGBT Overheat HYB Electrical system
Swg Mot. Driver IPM Ph-U Not
E09 GA1PNV HYB Electrical system
Warm Up
Swg Mot. Driver IPM Ph-V Not
E09 GA1QNV HYB Electrical system
Warm Up
Swg Mot. Driver IPM Ph-W Not
E09 GA1RNV HYB Electrical system
Warm Up
E09 GA1SFS Contactor Locked HYB Electrical system
E09 GA1SMC Contactor Failure HYB Electrical system
E09 GA1TKG Capacitor HVPS Abnormal Voltage HYB Electrical system
E09 GA1TKP Capacitor Low Output Voltage HYB Electrical system
PC200, 200LC-8E0 (Hybrid) 40-100 5


code work to refer
E09 GA1TNS Capacitor Overheat HYB Electrical system
Capacitor Temp. Sensor Opn/Short
E09 GA1UKZ HYB Electrical system
Cir.
E09 GA1VFS Capacitor Contactor Locked HYB Electrical system
E09 GA1VMC Capacitor Contactor Failure HYB Electrical system
Boost. Ind. Temp. Sens. Open/Shrt.
E09 GA1XKZ HYB Electrical system
Circ.
E09 GA1YNS Booster Inductor Overheat HYB Electrical system
E09 GA1YNV Booster Inductor Not Warming Up. HYB Electrical system
Booster IGBT Temp. Sens.
E09 GA1ZKZ HYB Electrical system
Opn/Shrt. Circ.
Booster IGBT Temp. Sens.
E09 GA1ZNS HYB Electrical system
Overheat
Booster IGBT Temp. Sens. Not
E09 GA1ZNV HYB Electrical system
Warm Up
E09 GA21KB Booster IGBT Open Circuit HYB Electrical system
E09 GA22NS Booster IGBT Junction Overheat HYB Electrical system
E09 GA60MC Generator Motor Failure HYB Electrical system
E09 GA60MD Gen. Mot. Defective Movement HYB Electrical system
E09 GA60N1 Generator Motor Overrun HYB Electrical system
Gen. Motor Temp. Sens.
Opn/Short Cir.
Generator Motor Temp. Sensor
E09 GA61NS HYB Electrical system
Overheat
Gen. Mot. Ph-A Cur. Sen. Power
E09 GA62KY HYB Electrical system Troubleshooting
Short Cir
Gen. Mot. Ph-A Cur. Sen. by failure code
E09 GA62KZ HYB Electrical system (Part 5),
Open/Short Cir
Gen. Mot. Ph-A Current Sen. SEN05251-03
Malfunction
Gen. Mot. Ph-B Cur. Sen. Power
Short Cir.
Gen. Mot. Ph-B Cur. Sen.
Open/Short Cir.
Gen. Mot. Ph-B Current Sen.
Malfunction
Gen. Mot. Ph-C Cur. Sen. Power
Short Cir.
Gen. Mot. Ph-C Cur. Sen.
Open/Short Cir.
Gen. Mot. Ph-C Current Sen.
Malfunction
E09 GA70KB HYB Swing Motor Short Circuit HYB Electrical system
HYB Swing Motor Defective Stirr.
E09 GA70MD HYB Electrical system
Motion
E09 GA70NS HYB Swing Motor Overheat HYB Electrical system
HYB Swing Mot. Temp. Sens.
Opn/Shrt Cir.
HYB Swing Motor Resolver
Malfunction
HYB Swing Motor Resolver Defect
Op.
Swing Motor Power Cable
Opn/Shrt Circ.
40-100 6 PC200, 200LC-8E0 (Hybrid)

User code E09 is an exclusive code for hybrid models, which is described in "Troubleshooting by failure code
(Part 5)".
Precautions related to hybrid machines

k When testing or adjusting a hybrid machine, ensure that you fully understand the following mat-
ters.
1. Never disassemble the hybrid devices.
2. The hybrid devices and high-voltage wiring (covered by orange conduits) must be replaced by the unit.
3. When handling hybrid devices, be sure to discharge the capacitor completely first.
(For details, see 00-200 Introduction, safety and basic information, Handling of hybrid devices and
high-voltage wiring, "Discharge procedure for capacitor", or 30 -102 Testing and adjusting (Part 2), Special
functions of machine monitor, "Discharge of capacitor".)
k Since the items with the above mark are related to handling of the hybrid devices, ensure that you
understand the descriptions of 00-200 Introduction, safety, and basic information, "Handling of hy-
brid devices and high-voltage wiring", before beginning the work on them.
a Order of items described in table

The items are listed in the order of failure codes (incremental order).
a User code
Attached: If the failure code is detected, the user code, failure code, and telephone No. (if registered) are
displayed on the ordinary screen to notify the operator of the failure.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the
failure.
a Device to work
MON: The machine monitor works for detection of failure.
MON2: The KOMTRAX section of the machine monitor works for detection of failure.
ENG: The engine controller works for detection of failure.
PUMP: The pump controller works for detection of failure.
HYB: The hybrid controller works for detection of failure.
a Category of system
Mechanical system: Failure information is recorded in the mechanical system failure history.
Electrical system: Failure information is recorded in the electrical system failure history.
The capacitor cannot be discharged with the machine monitor, depending on the error that occurred.
PC200, 200LC-8E0 (Hybrid) 40-100 7

SEN05245-02 Fuse locations
Fuse locations
Table of fuse box connection
a This connection table shows the devices to which each power supply through the fuse box supplies power
(A switch power supply is a power supplied while the starting switch is turned to the ON position and an
unswitched power supply is a power while the starting switch is turned to the OFF or ON positions).
a When carrying out the troubleshooting related to the electrical system, you should check the fuses and
fusible links to see if the power is supplied normally.
Type of power Fuse
Fusible link Fuse No. Destination of power
supply capacity
Lamp relay, rear lamp relay, cab lamp relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve
1 10A [When emergency pump drive switch is operated]
Swing holding brake solenoid valve
[When swing holding brake release switch is operated]
Pump controller (Solenoid power supply)
2 30A
Switch power F04 Capacitor (M terminal), Inverter (M terminal)
supply (60A) PPC oil pressure lock solenoid valve
3 10A Starting motor cut-out relay (PPC lock)
Starting motor cut-out relay (Personal code)
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Electrical intake air heater relay
7 10A Revolving warning lamp
Switch power F04 8 20A Right headlamp, working lamp (boom), working lamp (rear)
supply (60A) Radio
9 10A
Left knob switch (pump controller input)
10 10A (Spare)
Air conditioner unit
11 20A
Air conditioner compressor electromagnetic clutch
12 10A (Spare)
Switch power F04
13 10A Headlamp
supply (60A)
14 10A Optional power supply (1)
Travel alarm
15 10A
Optional power supply (2)
Radio (backup power supply)
16 10A
Room lamp
Starting switch
Unswitched F05 Machine monitor
17 20A
power supply (30A) Pump controller
Hybrid controller
18 10A (Spare)
19 30A Engine controller
Switch power Starting switch
20 5A Engine controller (ACC signal), Inverter (ACC signal)
supply ACC
40-100 8 PC200, 200LC-8E0 (Hybrid)

Fuse locations SEN05245-02
Locations of fusible links
Location of fuse box and fuse Nos.
PC200, 200LC-8E0 (Hybrid) 40-100 9

Problems that occur when power supply of pump controller is defective

a The controller power supply (F01-17) of the pump controller drives the controller system. Accordingly, if it
is turned off, the controller cannot control the system and the troubles shown below occur simultaneously
(The following is an example of the troubles).
q The working mode cannot be changed.
q The auto-decelerator does not work or is not canceled.
q The travel speed does not change.
q The one-touch power maximizing function does not work.
q The swing holding brake cannot be canceled automatically.
q The machine deviates during travel.
a If the above problems occur, check the related fuse (F01-17) and "green LED" of the pump controller to
see if the power is supplied normally.
q Lighting: The controller power is supplied (There is not an error and the power supply is normal).
q Flashing: The controller power is supplied (There is an error).
q Not lighting: The controller power is not supplied.
a Green LED of pump controller (a)
40-100 10 PC200, 200LC-8E0 (Hybrid)

Problems that occur when power supply for pump controller is defective
a The solenoid power supply (F01-2) for the pump controller is used by the controller to drive the solenoids
and relays. Accordingly, if the solenoid power supply is cut off, when the controller works to output the
power to the solenoids or relays, the power is not supplied to any of the solenoids and relays and all or
some of the following failure codes are displayed simultaneously.
q [DW43KA], [DW43KB]: Travel speed solenoid system
q [DW45KA], [DW45KB]: Swing holding brake solenoid system
q [DW91KA], [DW91KB]: Travel junction solenoid system
q [DWA2KA], [DWA2KB]: Service solenoid system
q [DWK0KA], [DWK0KB]: 2-stage relief solenoid system
q [DXA8KA], [DXA8KB]: PC-EPC (F) solenoid system
q [DXA9KA], [DXA9KB]: PC-EPC (R) solenoid system
q [DXE0KA], [DXE0KB]: LS-EPC solenoid system
q [DXE4KA], [DXE4KB]: Attachment oil flow throttle EPC system (if attachment is installed)
q [DXE5KA], [DXE5KB]: Merge-divide main solenoid system
q [DXE6KA], [DXE6KB]: Merge-divide LS solenoid system
a If the above problems occur, check the related fuse (F01-2) and input voltage of the pump controller.
1) Disconnect connectors C01 and C02 of the controller and connect a T-adapter box to the connectors
on the wiring harness side.
2) Turn the starting switch ON position.
3) Measure the voltage between each of pins C02(116)(118)(121) and each of pins C01(2)(5).
a Pins C02(116)(118)(121) are the power supply and pins C01(2)(5)are the chassis ground.
a If the voltage is 20 to30V, the solenoid power supply is normal.
a Power supply connectors (C01, C02) of pump controller
PC200, 200LC-8E0 (Hybrid) 40-100 11

Problems when controller power supply of hybrid controller (inverter) is defective

a Controller power supply (F01-17) of the hybrid controller is a power supply that works the controller sys-
tem. Accordingly, if the controller power supply is cut off, the controller cannot control the system, thus the
following problems may occur simultaneously. (The following is only an example of the problems)
q Machine cannot swing the upper structure
q Since the low-speed matching function does not work, the engine speed is maintained at the throttle
indication value.
a If the above problems occur simultaneously, check corresponding fuse (F01-17).
Problems when solenoid power supply of hybrid controller (inverter) is defective

a Solenoid power supply (F01-2) of the hybrid controller is a power supply with which the controller works
the solenoids and relays. Accordingly, if the solenoid power supply is cut off, when the controller works to
output a signal to a solenoid or a relay, power is not supplied to any solenoid or relay circuit, thus all or
some of the following failure codes are displayed simultaneously.
q [GA18MC]: Defective operation of generator motor driver excitation power supply
q [DW45KA], [DW45KB], [DW45KY]: Swing holding brake solenoid system
q [GA1VMC]: Contactor opening failure, contactor output ground fault or disconnection on capacitor side
a If the above problems occur simultaneously, check corresponding fuse (F01-2) and hybrid controller inlet
power supply.
1) Disconnect HC01 of the controller and connect a T-adapter box to the connector on the wiring harness
side.
2) Turn the starting switch to ON position.
3) Measure the voltage between pins HC01 (1), (7) and HC01 (13), (19).
* Pins HC01 (1) and (7) are the power supply and pins HC01 (13) and (19) are the ground.
* If the voltage is in the range of 20 to 30 V, the solenoid power supply is normal.
40-100 12 PC200, 200LC-8E0 (Hybrid)

a Power supply connector (HC01) of hybrid controller (inverter)
PC200, 200LC-8E0 (Hybrid) 40-100 13

SEN05245-02
PC200, 200LC-8E0 (Hybrid) Hydraulic excavator
Form No. SEN05245-02
©2011 KOMATSU
All Rights Reserved
Printed in Japan 08-11
40-100 14
SEN05246-01
SEN05246-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
200 General Information on troubleshooting
Points to remember when troubleshooting ................................................................................................. 2

Sequence of events in troubleshooting....................................................................................................... 3
Check before troubleshooting ..................................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................................... 5
Probable problems and troubleshooting No................................................................................................ 7
Information in troubleshooting table ............................................................................................................ 9
Connection table for connector pin numbers .............................................................................................. 11
T-adapter and box table .............................................................................................................................. 47
PC200, 200LC-8E0 (Hybrid) 40-200 1

SEN05246-01 Points to remember when troubleshooting
Points to remember when troubleshooting

k Stop the machine on a level ground, and check that the lock pin, blocks, and parking brake are se-
curely installed or applied.
k When carrying out the operation with two or more service technitians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, the hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the cable prom the negative (–) terminal of the bat-
tery first.
k When removing the plug or cap from a component which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of probable causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry 3) Make checks of other items.
to disassemble the components. 4) Check other maintenance matters which can
If components are disassembled immediately be checked externally and are considered to
after any failure occurs: be necessary.
q Parts that have no connection with the failure
or other unnecessary parts may be disas- 4. Checking failure
sembled. See the extent of the failure by yourself, and
q It may become impossible to find the cause judge whether it is a real failure or a problem
of the failure. caused by handling or operating the machine.
It may also cause a waste of manhours, parts, or a When operating the machine to re-occur the
oil or grease, and at the same time, may also problem, do not carry out any investigation or
lose the confidence of the user or operator. measurement that may make the problem
For this reason, when carrying out trouble- worse.
shooting, it is necessary to carry out prior inves-
tigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. Use the results of the investigation and inspec-
tion in Items 2 to 4 to narrow down the causes of
2. Points to ask the user or operator failure, then use the troubleshooting flowchart to
1) Have any other problems occurred apart locate the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is as
2) Was there anything strange about the follows.
machine before the failure occurred? 1] Start from the easy work.
3) Did the failure occur suddenly, or were there 2] Start from the components most likely to
problems with the machine condition before be in failure.
the failure? 3] Investigate other related parts or informa-
4) Under what conditions did the failure occur? tion.
5) Had any repairs been carried out before the
failure? When were those repairs carried 6. Measures to remove root cause of failure
out? Even if the failure is removed, if the root cause of
6) Has the same kind of failure occurred the failure is not repaired, the same failure will
before? occur again.To prevent this, always investigate
why the problem occurred. Then, remove the
3. Check before troubleshooting root cause.
1) Is there any sign of the problem on the
machine?
2) Make checks before starting day's work.
40-200 2 PC200, 200LC-8E0 (Hybrid)

Sequence of events in troubleshooting SEN05246-01
Sequence of events in troubleshooting
PC200, 200LC-8E0 (Hybrid) 40-200 3

SEN05246-01 Check before troubleshooting
Check before troubleshooting

Item Criterion Remedy
1. Check for level and type of fuel - Add oil
2. Check for fuel for foreign matter - Clean and drain
Between H
3. Check for hydraulic oil level Add oil
and L
4. Check of hydraulic oil strainer - Clean and drain
Lubricating Between H
5. Check for swing machinery oil level Add oil
oil/Coolant and L
Between H
6. Check for level and type of engine oil (in oil pan) Add oil
and L
Between H
7. Check for coolant level (in sub tank) Add coolant
and L
8. Check of dust indicator for clogging No red part Clean or replace
9. Check of hydraulic oil filter - Replace
1. Check for abnormal noise/smell - Repair
Hydrau-
lic/Mechanical 2. Check for oil leakage - Repair
equipment
3. Bleeding air - Bleed air
1. Check of battery terminals and wiring for looseness and cor-
- Retighten or replace
rosion
2. Check of alternator terminals and wiring for looseness and
corrosion
3. Check of starting motor terminals and wiring for looseness
and corrosion
4. Check of battery voltage (with engine stopped) 20 to 30 V Charge or replace
Between H
5. Check of battery for electrolyte level Add or replace
and L
6. Check of wires for discoloration, burn, and removal of cover - Repair or replace
Electric, electri-
cal equipment 7. Check for released wire clamp and drooping wire - Repair
8. Check of wiring for wetness (Check connectors and terminals
- Dry
in particular)
9. Check of fuse for disconnection and corrosion - Replace
After operat-
ing for sev-
10. Check of alternator for voltage (while engine speed is at
eral minutes: Replace
middle or higher)
27.5 to 129.5
V
11. Check of battery relay for operating sound (when starting
- Replace
switch is turned ON or OFF)
40-200 4 PC200, 200LC-8E0 (Hybrid)

Classification and procedures for troubleshooting SEN05246-01
Classification and procedures for troubleshooting

Classification of troubleshooting
Mode Description
Display of code Troubleshooting by failure code
E-mode Troubleshooting electrical system
H-mode Troubleshooting hydraulic and mechanical system
Y-mode* Troubleshooting hybrid system
S-mode Troubleshooting engine
*: Exclusive mode for hybrid model
Procedure for troubleshooting

If a problem may indicate a failure occurs in the machine, select a proper troubleshooting No. according to
the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when user code and failure code are displayed on machine
monitor:
If a user code and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding "Display of code" according to the displayed failure code.
2. When electrical system error code or mechanical system error code is recorded in failure history:
If a user code and a failure code are not displayed on the machine monitor, check a mechanical system
failure code and an electrical system failure code with the failure history function of the machine monitor.
If a code is recorded, carry out troubleshooting for the corresponding "Display of code" according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes once and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner failure history or heater failure history by the failure history
function, carry out the corresponding troubleshooting in E-mode.
3. When user code and failure code is not displayed and no failure code is recorded in failure code:
If a user code and a failure code are not displayed on the machine monitor and no failure code is recorded
in the failure history, a failure that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the problem which seems to be a failure again and select the same problem from the
table of "Problem which seems to be failures and troubleshooting Nos.", and then carry out troubleshooting
corresponding to that problem in the "E-mode", "H-mode", "Y-mode", or "S-mode".
PC200, 200LC-8E0 (Hybrid) 40-200 5

SEN05246-01 Classification and procedures for troubleshooting

ters.
high-voltage wiring, "Discharge procedure for capacitor", or 30-102 Testing and adjusting (Part 2), Special
40-200 6 PC200, 200LC-8E0 (Hybrid)

Probable problems and troubleshooting No. SEN05246-01
Probable problems and troubleshooting No.

Troubleshooting
No. Problem seemed to be failure Display of
E-mode H-mode Y-mode S-mode
code
Problem related to user code/failure code
User code and failure code are displayed on ordinary screen
1
of machine monitor
According to
When failure history is checked, failure code is displayed in
2 displayed
mechanical system failure history
code
When failure history is checked, failure code is displayed in
3
electrical system failure history
When failure history is checked, failure code is displayed in air
4 E-23
conditioner or heater failure history
Problem related to engine
5 Starting performance is poor S-1
6 Engine does not start E-3 S-2
7 Engine does not pick up smoothly S-3
8 Engine stops during operations S-4
9 Engine does not run smoothly S-5
10 Engine lacks output (or lacks power) S-6
11 Exhaust smoke is black (incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Oil becomes contaminated quickly S-9
14 Fuel consumption is excessive S-10
Oil is in coolant (or coolant spurts back or coolant level goes
15 S-11
down)
16 Oil pressure drops S-12
17 Oil level rises (Entry of coolant/fuel) S-13
18 Coolant temperature becomes too high (overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
21 Preheater does not operate E-4
22 Automatic warm-up system does not operate (in cold season). E-5
23 Auto-decelerator does not operate normally E-15 H-5
24 Generator motor temperature increases abnormally Y-9
Problem related to work equipment/swing/travel
Work equipment, swing, and travel mechanism do not move
25 E-6 H-3
or cannot be locked
Speed or power of whole work equipment, swing, and travel is
26 H-1
low
27 Engine speed lowers significantly or engine stalls. H-2 S-6
28 Working mode does not change E-16
29 Abnormal sound comes out from around hydraulic pump H-4
30 Fine control performance or response is low. H-6
Problem related to work equipment
31 Speed or power of boom is low H-7
32 Speed or power of arm is low H-8
33 Speed or power of bucket is low. H-9
34 Work equipment does not move singly H-10
35 Hydraulic drift of work equipment is large H-11
36 Time lag of work equipment is large H-12
When work equipment is relieved singly, other work equip-
37 H-13
ment moves
38 Power maximizing function does not operate normally E-20 H-14
Problem related to combined operation
In combined operation of work equipment, speed of equip-
39 H-15
ment loaded more is low.
When machine swings and travels simultaneously, travel
40 H-16
speed lowers largely
Problem related to travel
41 Machine deviates during travel. H-17
42 Travel speed is low. H-18
43 Machine is not steered well or steering power is low H-19
44 Travel speed does not change or travel speed is low/high E-17 H-20
PC200, 200LC-8E0 (Hybrid) 40-200 7

SEN05246-01 Probable problems and troubleshooting No.
Troubleshooting
No. Problem seemed to be failure Display of
E-mode H-mode Y-mode S-mode
code
45 Travel system does not move (only one side). H-21
46 Travel alarm does not sound or does not stop sounding E-22
Problem related to swing
47 Upper structure does not swing H-22 Y-2
48 Swing acceleration or swing speed is low H-23 Y-3
49 Upper structure overruns remarkably when it stops swinging H-24 Y-4
50 Large shock is made when upper structure stops swinging H-25 Y-5
51 Large sound is made when upper structure stops swinging H-26 Y-6
Swing holding brake does not operate normally
52 E-21 H-27 Y-7
Hydraulic drift of swing is large
53 Swing motor temperature increases abnormally Y-8
Problem is related to machine monitor
When starting switch is turned ON, machine monitor displays
54 E-1
nothing.
When starting switch is turned ON (before starting engine),
55 E-2
lamps for basic check items light up
56 Precaution lights up while engine is running E-7
57 Emergency stop item lights up while engine is running E-8
58 Engine coolant temperature gauge does not indicate normally E-9
59 Hydraulic oil temperature gauge does not indicate normally E-10
60 Fuel gauge does not operate normally E-11
Displays by machine monitor are different from ones for appli-
61 E-12
cable machine
62 Machine monitor does not display some items E-13
63 Function switch does not work E-14
64 Alarm buzzer cannot be stopped. E-18
65 Windshield wiper and window washer do not operate E-19
66 Air conditioner does not operate normally E-23
When starting switch is turned OFF, service meter is not dis-
67 E-24
played
68 Machine monitor does not change to service mode. E-25
Monitoring function does not display lever control signal nor-
69 E-26
mally
70 Hybrid monitor does not go off Y-1
Others
71 KOMTRAX system does not operate normally. E-27
40-200 8 PC200, 200LC-8E0 (Hybrid)

Information in troubleshooting table SEN05246-01
Information in troubleshooting table

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand the information fully.
User code Failure code
Description of problem that appears on machine monitor as failure
Display on Display on Trouble
history
machine monitor machine monitor
Failure descrip-
Description of the failure detected by the machine monitor or controller
tion
Action of
Action taken by machine monitor or controller to protect system or devices when machine monitor or
machine moni-
controller detects failure
tor or controller
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller (shown
appears on
above)
machine
Related informa-
Information related to detected failure or troubleshooting
tion
Cause Procedure, measuring location, standard (value) and remarks
<Details of description>
q Procedure
q Measuring location
Probable causes a "Between A - B" means "Measure voltage or resistance and so on between
A and B".
q Standard value in normal condition to evaluate assumed cause if it is good con-
dition or not.
q Remarks required to evaluate the cause is correct
<How to use the troubleshooting sheet>
1 - defective q Perform troubleshoot in the following procedure in numerical order.
q If the testing result shows failure, the cause described on the left column con-
forms.
q If it shows normal, and unless otherwise specified particularly, proceed to the
next step (cause).
Disconnection in wiring har-
q Check that the failure is fixed after a failure was found and repaired.
ness
2 <Failures in wiring harness>
(Disconnection in wiring or
q Disconnection in wiring
defective contact in connector)
The connector connection is defective or the wiring harness is disconnected.
q Ground fault
A harness not connected to ground (earth) circuit contacts the ground (earth) or
machine.
Ground fault of wiring harness q Hot short circuit
3
(Contact with GND circuit) A harness not connected to the power (24 V) circuit contacts the power (24 V)
circuit.
q Short circuit
An independent wire in the harness abnormally contacts another wire.
(Poor insulation at connector and others)
Hot short <Precautions for troubleshooting>
4
(Contact with 24 V circuit) (1) How to indicate connector number and handle T-adapter
For troubleshooting, insert or connect T-adapter as follows unless especially
specified.
q When "male" or "female" is not indicated with a connector number, discon-
nect the connector, and insert T-adapter in both male and female.
q When "male" or "female" is indicated with a connector number, disconnect
5 Short circuit in wiring harness
the connector, and connect T-adapter only to either male or female end.
(2) Description sequence of pin number and handling of tester lead
Connect positive (+) lead and negative (-) lead of tester as explained below for
troubleshooting, unless otherwise specified.
q Connect positive (+) lead to pin No. or wiring harness entered on front side.
q Connect the negative (-) lead to a pin or harness indicated in the rear side.
6 Defective controller
PC200, 200LC-8E0 (Hybrid) 40-200 9

SEN05246-01 Information in troubleshooting table
Related circuit diagram
This drawing is a part of the electric circuit diagram related

to troubleshooting.
q Connector No.: Indicates (Model – Number of pins) and
(Color).
q "Connector No. and pin No." from each branching/ merg-
ing point: Shows the ends of branch or source of merging
within the parts of the same wiring harness.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed
40-200 10 PC200, 200LC-8E0 (Hybrid)

Connection table for connector pin numbers SEN05246-01
Connection table for connector pin numbers

(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
PC200, 200LC-8E0 (Hybrid) 40-200 11

SEN05246-01 Connection table for connector pin numbers
40-200 12 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 13

40-200 14 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 15

40-200 16 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 17

40-200 18 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 19

40-200 20 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 21

40-200 22 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 23

40-200 24 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 25

40-200 26 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 27

40-200 28 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 29

40-200 30 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 31

40-200 32 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 33

40-200 34 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 35

40-200 36 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 37

40-200 38 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 39

40-200 40 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 41

40-200 42 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 43

40-200 44 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 45

40-200 46 PC200, 200LC-8E0 (Hybrid)

T-adapter and box table SEN05246-01
T-adapter and box table

(Rev. 2009. 08)
a Indicated in the vertical column are the part numbers of T-adapters and boxes while indicated on the hor-
izontal line are the part numbers of harness checker assemblies.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 - q q
799-601-7090 Adapter for M 2 M2P q q q q
PC200, 200LC-8E0 (Hybrid) 40-200 47

SEN05246-01 T-adapter and box table
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 - q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 - q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
40-200 48 PC200, 200LC-8E0 (Hybrid)

T-adapter and box table SEN05246-01
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430*
Socket for engine(CRI-T3) PCV
2 p q q
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine (CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 - q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140
Ambient pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190*
Commonrail fuel pressure
3 1, 2, 3L q q
799-601-4230*
Air intake pressure/temperature
4 1, 2, 3, 4C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1, 2, 3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1, 2, 3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1, 2, 3, G q q
799-601-4340*
Pump actuator
2 2, PA q q
Socket for engine (CRI-T3) (95)
799-601-4380*
Air intake pressure/temperature
4 1, 2, 3, 4T q
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 - q
799-601-4280* Box for controller (PUMP) 121 - q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2 – 4 and DTM2 3, - q
4
“*” Shows not T-adapter but socket.
PC200, 200LC-8E0 (Hybrid) 40-200 49

SEN05246-01
©2010 KOMATSU
All Rights Reserved
40-200 50
SEN05247-00
PC200, 200LC -8E0 (Hybrid)
SEN05247-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
301 Troubleshooting by failure code, Part 1
Failure code [989L00] Engine Controller Lock Caution 1 ........................................................................... 3

Failure code [989M00] Engine Controller Lock Caution 2 .......................................................................... 3
Failure code [989N00] Engine Controller Lock Caution 3........................................................................... 4
Failure code [AA10NX] Air Cleaner Clogging ............................................................................................. 5
Failure code [AB00KE] Charge Voltage Low .............................................................................................. 6
Failure code [B@BAZG] Eng Oil Press Low............................................................................................... 8
Failure code [B@BAZK] Eng oil level low ................................................................................................... 8
Failure code [B@BCNS] Eng Water Overheat ........................................................................................... 9
Failure code [B@BCZK] Eng Water Level Low .......................................................................................... 9
Failure code [B@HANS] Hydr oil overheat ................................................................................................. 10
Failure code [CA111] EMC Critical Internal Failure .................................................................................... 11
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ....................................................................... 11
Failure code [CA122] Chg Air Press Sensor High Error ............................................................................. 12
Failure code [CA123] Chg Air Press Sensor Low Error .............................................................................. 14
Failure code [CA131] Throttle Sensor High Error ....................................................................................... 16
Failure code [CA132] Throttle Sensor Low Error ........................................................................................ 18
Failure code [CA144] Coolant temp. sensor high error............................................................................... 20
Failure code [CA145] Coolant temp. sensor low error ................................................................................ 22
Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................. 24
Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................................. 26
PC200, 200LC-8E0 (Hybrid) 40-301 1

SEN05247-00 Shop Manual
Failure code [CA155] Chg Air Temp High Speed Derate............................................................................ 28

Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................................. 30
Failure code [CA221] Ambient Press Sens High Error ............................................................................... 32
Failure code [CA222] Ambient Press Sens Low Error ................................................................................ 34
Failure code [CA227] Sens Supply 2 Volt High Error.................................................................................. 36
Failure code [CA234] Eng Overspeed ........................................................................................................ 37
Failure code [CA238] Ne Speed Sens Supply Volt Error ............................................................................ 38
Failure code [CA271] IMV/PCV1 Short Error .............................................................................................. 39
Failure code [CA272] IMV/PCV1 Open Error.............................................................................................. 40
Failure code [CA322] Inj #1 (L#1) Open/Short Error................................................................................... 42
Failure code [CA331] Inj #2(L#2) Open/Short Error.................................................................................... 46
40-301 2 PC200, 200LC-8E0 (Hybrid)

Failure code [989L00] Engine Controller Lock Caution 1 SEN05247-00
Failure code [989L00] Engine Controller Lock Caution 1

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

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

Trouble
— 989M00 (Machine monitor system)
Failure descrip-
tion
Action of
machine moni-
tor
Problem that
appears on q Engine cannot be started.
machine
q If this failure code is displayed after machine monitor is replaced, user password must be changed
Related infor-
to one before replacement.
mation
Cause Standard value in normal condition/Remarks on troubleshooting

Probable
Replacement of machine
causes and 1 This trouble may be caused by replacement of machine monitor.
monitor
standard value
If this failure code is displayed while machine monitor is not
in normal condi-
2 Defective machine monitor replaced, machine monitor may be defective. (Since trouble is in
tion
system, troubleshooting cannot be performed.)
PC200, 200LC-8E0 (Hybrid) 40-301 3

SEN05247-00 Failure code [989N00] Engine Controller Lock Caution 3
Failure code [989N00] Engine Controller Lock Caution 3

Trouble
— 989N00 (Machine monitor system)
Failure descrip-
tion
Action of
q Tries automatic resetting.
machine moni-
tor
Problem that
appears on
machine
Related infor- q Method of reproducing failure code: Failure code is not reproduced since system is reset automat-
mation ically.

causes and
If this failure code is displayed repeatedly, engine controller may be
standard value
1 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot be
in normal condi-
performed.)
tion
40-301 4 PC200, 200LC-8E0 (Hybrid)

Failure code [AA10NX] Air Cleaner Clogging SEN05247-00
Failure code [AA10NX] Air Cleaner Clogging

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

Probable
Clogging of air cleaner Air cleaner may be clogged. Check it for clogging and then clean or
causes and 1
(when system is normal) replace if clogged.
standard value
If cause 1 is not detected, air cleaner clogging monitor system may
in normal con- Defective air cleaner clog-
2 be defective. Perform troubleshooting for "E-7 Caution item flashes
dition ging monitor system
while engine is running" in E-mode.
PC200, 200LC-8E0 (Hybrid) 40-301 5

SEN05247-00 Failure code [AB00KE] Charge Voltage Low
Failure code [AB00KE] Charge Voltage Low

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

a Prepare with starting switch OFF, then start engine and perform
Probable troubleshooting.
Defective alternator
causes and 1 E12 (male) Engine speed Voltage
(when system is normal)
standard value Between (1) and
Min. medium speed 27.5 to 29.5 V
in normal condi- chassis ground
tion If cause 1 is not detected, charge level monitor system may be
Defective charge level moni-
2 defective. Perform troubleshooting for "E-7 Caution item flashes
tor
while engine is running" in E-mode.
40-301 6 PC200, 200LC-8E0 (Hybrid)

Failure code [AB00KE] Charge Voltage Low SEN05247-00
Circuit diagram related to preheating/starting of engine and charge of battery
PC200, 200LC-8E0 (Hybrid) 40-301 7

SEN05247-00 Failure code [B@BAZG] Eng Oil Press Low
Failure code [B@BAZG] Eng Oil Press Low

User code Failure code Engine oil pressure low
Trouble
— B@BAZG (Engine controller system)
Failure q While engine was running, signal circuit of engine oil pressure switch detected low engine oil pres-
description sure (sensor contact opened).
Action of
q Displays engine oil pressure monitor on machine monitor.
machine moni-
tor
Problem that
machine
q Engine oil pressure switch signal is input to engine controller and then transmitted to machine mon-
Related infor-
itor.
mation

Probable Lowering of engine oil pres-
Engine oil pressure may be low. Check it and remove cause if it is
causes and 1 sure
low.
standard value (when system is normal)
in normal con- If cause 1 is not detected, engine oil pressure monitor system may
Defective engine oil pressure
dition 2 be defective. Perform troubleshooting for "E-8 Emergency stop item
monitor system
lights up while engine is running" in E-mode.
Failure code [B@BAZK] Eng oil level low

User code Failure code Engine Oil Level Low
Trouble
— B@BAZK (Machine monitor system)
Failure q When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch
description detected low engine oil level (sensor contact opened).
Action of
q Displays engine oil level monitor on machine monitor.
machine moni-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
tor
Problem that
machine
q Engine oil level switch signal can be checked with monitoring function.
Related infor-
mation

Probable Lowering of engine oil level
1 Engine oil level may be low. Check it and add new oil if it is low.
causes and (when system is normal)
standard value If cause 1 is not detected, engine oil level monitor system may be
in normal con- Defective engine oil level defective. Perform troubleshooting for "E-2 Basic check item lights
2
dition monitor system up when starting switch is turned to ON position (but engine is not
started)" in E-mode.
40-301 8 PC200, 200LC-8E0 (Hybrid)

Failure code [B@BCNS] Eng Water Overheat SEN05247-00
Failure code [B@BCNS] Eng Water Overheat

User code Failure code Engine coolant overheat
Trouble
— B@BCNS (Engine controller system)
Failure descrip- q While engine was running, signal circuit of engine coolant temperature sensor detected overheating
tion of engine coolant (above approximately 102 °C)
Action of con- q Displays engine coolant temperature monitor with red on machine monitor.
troller q If cause of failure disappears, system resets itself.
Problem that
appears on q If machine is operated as it is, engine may seize up.
machine
q Engine coolant temperature sensor signal is input to engine controller and then transmitted to ma-
chine monitor through communication system.
Related infor-
q Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant
mation
temperature)

Probable
Overheating of engine coolant Engine coolant may be overheating. Check it and remove cause if it
causes and 1
(when system is normal) is overheating.
standard value
If cause 1 is not detected, engine coolant temperature gauge sys-
in normal con- Defective engine coolant tem-
2 tem may be defective. Perform troubleshooting for "E-9 Engine
dition perature gauge system
coolant temperature gauge does not work normally" in E-mode.
Failure code [B@BCZK] Eng Water Level Low

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

Lowering of engine coolant
Probable Engine coolant level may be low. Check it and add coolant if it is
1 level
causes and low.
standard value
If cause 1 is not detected, engine coolant level monitor system may
in normal con-
Defective engine coolant be defective. Perform troubleshooting for "E-2 Basic check item
dition 2
level monitor system lights up when starting switch is turned to ON position (but engine is
not started)" in E-mode.
PC200, 200LC-8E0 (Hybrid) 40-301 9

SEN05247-00 Failure code [B@HANS] Hydr oil overheat
Failure code [B@HANS] Hydr oil overheat

User code Failure code Hydraulic oil overheat
Trouble
— B@HANS (Pump controller system)
Failure descrip- q While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating
tion of hydraulic oil (above approximately 102 °C).
Action of con- q Displays hydraulic oil temperature monitor with red on machine monitor.
Problem that
appears on q If machine is operated as it is, hydraulic components may be damaged.
machine
q Signal from hydraulic oil temperature sensor is input to engine controller and then transmitted to ma-
chine monitor through communication system.
Related infor-
q Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil tem-
mation
perature

Probable
Overheating of hydraulic oil Hydraulic oil may be overheating. Check it and remove cause if it is
causes and 1
(when system is normal) overheating.
standard value
If cause 1 is not detected, hydraulic oil temperature gauge system
in normal con- Defective hydraulic oil tem-
2 may be defective. Perform troubleshooting for "E-10 Hydraulic oil
dition perature gauge system
temperature gauge does not work normally" in E-mode.
40-301 10 PC200, 200LC-8E0 (Hybrid)

Failure code [CA111] EMC Critical Internal Failure SEN05247-00
Failure code [CA111] EMC Critical Internal Failure

User code Failure code Engine controller internal failure
Trouble
E10 CA111 (Engine controller system)
Failure descrip-
q Memory or power supply circuit in engine controller is defective.
tion
Action of con-
troller
Problem that
appears on q Engine does not start
machine
Related infor-
mation

causes and
standard value
Perform troubleshooting for failure codes[CA757]
in normal con-
dition
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

User code Failure code Engine Ne and Bkup speed sensor error
Trouble
Failure descrip-
q Signals from both engine Ne speed sensor and engine Bkup speed sensor are abnormal.
tion
Action of con-
troller
Problem that
q Engine stops.
appears on
q Engine does not start
machine
Related infor-
mation

Defective Ne speed sensor
1 Perform troubleshooting for Failure code [CA689].
system
Defective Bkup speed sen-
2 Perform troubleshooting for Failure code [CA778].
sor system
Probable
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
causes and 3
sensor installation of sensor, internal of flywheel, etc.)
standard value
Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
in normal con- 4
speed sensor installation of sensor, internal of supply pump, etc.)
dition
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defec-
5
connection) tive connection (wrong connection).
If causes 1 to 5 are not detected, engine controller may be defec-
6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be per-
formed.)
PC200, 200LC-8E0 (Hybrid) 40-301 11

SEN05247-00 Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA122] Chg Air Press Sensor High Error

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

Defective sensor power If failure code [CA227] is also indicated, perform troubleshooting for it
1
supply 2 system first.
a Prepare with starting switch OFF, then turn starting switch to ON
position and perform troubleshooting.
Defective boost pressure BOOST PRESS& IMT Voltage
2 and temperature sensor Between (2) and (4) Power supply 4.75 to 5.25 V
[pressure signal circuit] Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for
another cause of trouble, and then judge.
Hot short position and carry out troubleshooting.
3 (Short circuit with 5 V/24 V Wiring harness between CE01 (female) (44)
Probable circuit) in wiring harness and BOOST PRESS & IMT (female) (1), and Voltage Max. 1 V
causes and chassis ground.
standard value a Prepare with starting switch OFF, then perform troubleshooting
in normal con- Short circuit in wiring har- without turning starting switch to ON position.
dition ness Wiring harness between CE01 (female) (44)
4
(with another wiring har- and BOOST PRESS & IMT (female) (1), and Resis-
Min.100 kΩ
ness) harnessesCE01 (female) (37) to JC01 to tance
BOOST PRESS & IMT (female)(2)
Connections between boost pressure/temperature sensor and engine
wiring harness and engine controller may be defective. Check them
Defective wiring harness directly.
5
connector q Looseness of connector, breakage of lock, or breakage of seal
q Corrosion, bend, breakage, push-in, or expansion of pin
q Moisture or dirt in connector or defective insulation
6 Defective engine controller
CE01 Voltage
Between (37) and (47) 4.75 to 5.25 V
40-301 12 PC200, 200LC-8E0 (Hybrid)

Failure code [CA122] Chg Air Press Sensor High Error SEN05247-00
Circuit diagram related to boost pressure/temperature sensor (Combination sensor)
PC200, 200LC-8E0 (Hybrid) 40-301 13

SEN05247-00 Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA123] Chg Air Press Sensor Low Error

User code Failure code Charge air pressure sensor low error
Trouble
Failure descrip-
q Low voltage was detected in pressure signal circuit of boost pressure/temperature sensor.
tion
Action of con-
q Fixes charge pressure value and continues operation.
troller
Problem that
machine
q Signal voltage on boost pressure side of boost pressure/temperature sensor can be checked with
Related infor- monitoring function.
mation (Code: 36501 Boost pressure sensor voltage)

Defective sensor power sup- If failure code [CA187] is also displayed, perform troubleshooting for
1
ply 2 system it first.
Defective boost pressure BOOST PRESS & IMT Voltage
2 and temperature sensor Between (2) and (4) Power supply 4.75 to 5.25 V
[pressure signal circuit] Voltage is measured with wiring harness connected. Accordingly, if
a Prepare with starting switch OFF, position then perform trouble-
Ground fault in wiring har-
shooting without turning starting switch to ON position.
ness
3 Between wiring harness between CE01
(Short circuit with GND cir- Resis-
(female) (44) and BOOST PRESS & IMT Min.100 kΩ
Probable cuit) tance
(female) (1), and chassis ground
causes and
a Prepare with starting switch OFF, then perform troubleshooting
standard value
without turning starting switch to ON position.
in normal con- Short circuit in wiring har-
Between wiring harness between CE01
dition ness
4 (female) (44) and BOOST PRESS & IMT
(with another wiring har- Resis-
(female) (1) and harnesses CE01 ((female) Min.100 kΩ
ness) tance
(47) to JC02 to BOOST PRESS & IMT
(female) (4)
Connections between boost pressure/temperature sensor and engine
harness and engine controller are suspected to be defective. Visually
Defective wiring harness check it.
5
CE01 Voltage
Between (37) and (47) Power supply 4.75 to 5.25 V
40-301 14 PC200, 200LC-8E0 (Hybrid)

Failure code [CA123] Chg Air Press Sensor Low Error SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 15

SEN05247-00 Failure code [CA131] Throttle Sensor High Error
Failure code [CA131] Throttle Sensor High Error

User code Failure code Throttle Sensor High Error
Trouble
Failure descrip-
q High voltage was detected in signal circuit of fuel control dial.
tion
q If trouble occurs while starting switch is in ON position, controller fixes voltage value to value just
Action of con- before detection of trouble and continues operation.
troller q If starting switch is turned to ON position while voltage is abnormally high, controller continues op-
eration with voltage at 100 % value.
Problem that
appears on q Engine speed cannot be controlled with fuel control dial.
machine
q Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control
Related infor-
dial voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON operation.

Connections between fuel control dial and machine wiring harness
and engine controller may be defective. Check them directly.
Defective wiring harness
1 q Looseness of connector, breakage of lock, or breakage of seal
connector
Defective throttle sensor If failure code [CA2185] is also indicated, perform troubleshooting
2
power supply system for it first.
1) Turn starting switch to OFF position.
2) Disconnect P20 and connect T-adapter to male side.
Resis-
Between P20 (male) (1) and (3) 4 to 6 kΩ
tance
3 Defective fuel control dial
Resis-
Between P20 (male) (2) and (1) 0.25 to 5 kΩ
tance
Resis-
tance
Probable 1) Turn starting switch to OFF position.
causes and 2) Disconnect CE02 and connect T-adapter to female side.
standard value Disconnection or short circuit Resis-
4 Between CE02 (female) (22) and (23) 4 to 6 kΩ
in normal con- in wiring harness tance
dition Resis-
Between CE02 (female) (9) and (23) 0.25 to 5 kΩ
tance
a Prepare by setting starting switch to OFF position, then turn start-
Hot short ing switch to ON position and troubleshoot.
5 (Short circuit with 5 V/24 V Between wiring harness between CE02
circuit) in wiring harness (female) (9) and P20 (female) (2), and Voltage Max. 1 V
chassis ground
a Prepare by setting starting switch to OFF position, and trouble-
Short circuit in wiring har- shoot without turning starting switch to ON position.
6 ness Between wiring harnesses between CE02
Resis-
(with another wiring harness) (female) (9) and P20 (female) (2) and Min.100 kΩ
tance
CE02 (female) (22) and P20 (female) (1)
ing switch to ON position and troubleshoot.
7 Defective engine controller CE02 Voltage
Between (9) and
Signal 0.5 to 4.5 V
(23)
40-301 16 PC200, 200LC-8E0 (Hybrid)

Failure code [CA131] Throttle Sensor High Error SEN05247-00
Circuit diagram related to fuel control dial
PC200, 200LC-8E0 (Hybrid) 40-301 17

SEN05247-00 Failure code [CA132] Throttle Sensor Low Error
Failure code [CA132] Throttle Sensor Low Error

User code Failure code Throttle Sensor Low Error
Trouble
Failure
q Low voltage was detected in signal circuit of fuel control dial.
description
q If trouble occurs while starting switch is in ON position, controller fixes voltage value to value just be-
Action of con- fore detection of trouble and continues operation.
troller q If starting switch is turned to ON position while voltage is abnormally high, controller continues oper-
ation with voltage at 100 % value.
Problem that
machine
q Signal voltage of fuel control dial can be checked with monitoring function.
Related infor-
(Code: 03000 Fuel control dial voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON operation.

Connections in fuel control dial to machine wiring harness to engine
controller may be defective. Check them directly.
connector
Defective throttle sensor If failure code [CA2186] is also indicated, perform troubleshooting for
2
power supply system it first.
1) Turn starting switch to OFF position.
2) Disconnect P20 and connect T-adapter to male side.
Resis-
Between P20 (male) (1) and (3) 4 to 6 kΩ
tance
3 Defective fuel control dial
Resis-
tance
Resis-
tance
Probable 1) Turn starting switch to OFF position.
causes and 2) Disconnect CE02 and connect T-adapter to female side.
standard value Disconnection or short circuit Resis-
4 Between CE02 (female) (22) and (23) 4 to 6 kΩ
in normal con- in wiring harness tance
dition Resis-
Between CE02 (female) (9) and (23) 0.25 to 5 kΩ
tance
shoot without turning starting switch to ON position.
ness
(female) (9) and P20 (female) (2), and Min.100 kΩ
cuit) tance
chassis ground
Short circuit in wiring har-
Between wiring harnesses, between
6 ness
CE02 (female) (9) and P20 (female) (2), Resis-
(with another wiring harness) Min.100 kΩ
and CE02 (female) (23) and P20 (female) tance
(3)
CE02 Voltage
Between (9) and (23) Signal 0.5 to 4.5 V
40-301 18 PC200, 200LC-8E0 (Hybrid)

Failure code [CA132] Throttle Sensor Low Error SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 19

SEN05247-00 Failure code [CA144] Coolant temp. sensor high error
Failure code [CA144] Coolant temp. sensor high error

User code Failure code Coolant temperature sensor high error
Trouble
Failure descrip-
q High voltage was detected in signal circuit of coolant temperature sensor.
tion
Action of con-
q Fixes coolant temperature value and continues operation.
troller
Problem that q Engine does not start easily at low temperature.
appears on q Exhaust gas becomes white.
machine q Overheat prevention function does not work.
q Signal voltage of coolant temperature sensor can be checked with monitoring function.
Related infor-
(Code: 04105 Coolant temperature sensor voltage)
mation

Coolant tempera- Resistance
COOLANT TEMP (male)
ture
Defective coolant tempera-
1 0 °C 30 to 37 kΩ
ture sensor
25 °C 9.3 to 10.7 kΩ
Between (A) and (B) 50 °C 3.2 to 3.8 kΩ
80 °C 1.0 to 1.3 kΩ
95 °C 700 to 800 kΩ
Disconnection in wiring har- shoot without turning starting switch to ON position.
ness Wiring harness between CE01 (female) Resis-
Max. 10 Ω
2 (Disconnection in wiring or (15) and COOLANT TEMP (female) (B) tance
defective contact in connec- Between wiring harnesses between CE01
Resis-
tor) (female) (38) and JC03, and JC03 and Max. 10 Ω
Probable tance
COOLANT TEMP (female) (A)
causes and
standard value
in normal con-
3 ness Between CE01 (female) (15) and CE01
dition Resis-
(with another wiring harness) (female) all pins (With all connectors of wir- Min.100 kΩ
tance
ing harness disconnected)
Connections in coolant temperature sensor to engine wiring harness
to engine controller may be defective. Check them directly.
connector
Coolant tempera-
CE01 (female) Resistance
ture
5 Defective engine controller 0 °C 30 to 37 kΩ
25 °C 9.3 to 10.7 kΩ
80 °C 1.0 to 1.3 kΩ
95 °C 700 to 800 kΩ
40-301 20 PC200, 200LC-8E0 (Hybrid)

Failure code [CA144] Coolant temp. sensor high error SEN05247-00
Circuit diagram related to coolant temperature sensor
PC200, 200LC-8E0 (Hybrid) 40-301 21

SEN05247-00 Failure code [CA145] Coolant temp. sensor low error
Failure code [CA145] Coolant temp. sensor low error

User code Failure code Coolant temperature sensor low error
Trouble
Failure
q Low voltage was detected in signal circuit of coolant temperature sensor.
description
Action of con-
q Fixes coolant temperature value and continues operation.
troller
Problem that
q Exhaust gas becomes white.
appears on
q Overheat prevention function does not work.
machine
q Signal voltage of coolant temperature sensor can be checked with monitoring function.
Related infor-
(Code: 04105 Coolant temperature sensor voltage)
mation

Coolant tempera- Resistance
COOLANT TEMP
ture
Defective coolant tempera- 0 °C 30 to 37 kΩ
1
ture sensor 25 °C 9.3 to 10.7 kΩ
80 °C 1.0 to 1.3 kΩ
95 °C 700 to 800 kΩ
Between (B) and chassis ground All range Min.100 kΩ
ness
(female) (15) and COOLANT TEMP Max. 10 Ω
cuit) tance
(female) (B), and chassis ground
Probable
causes and
standard value
in normal con- Resis-
dition tance
Connections coolant temperature sensor to engine wiring harness to
engine controller may be defective. Check them directly.
connector
Coolant tempera-
ture
0 °C 30 to 37 kΩ
25 °C 9.3 to 10.7 kΩ
80 °C 1.0 to 1.3 kΩ
95 °C 700 to 800 kΩ
Between (B) and chassis ground All range Min.100 kΩ
40-301 22 PC200, 200LC-8E0 (Hybrid)

Failure code [CA145] Coolant temp. sensor low error SEN05247-00
Circuit diagram related to coolant temperature sensor
PC200, 200LC-8E0 (Hybrid) 40-301 23

SEN05247-00 Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA153] Chg Air Temp Sensor High Error

User code Failure code Change air temperature sensor high error
Trouble
Failure
q High voltage was detected in temperature signal circuit of boost pressure/temperature sensor.
description
Action of con-
q Fixes charge temperature value and continues operation.
troller
Problem that
appears on
q Engine protection function based on boost temperature does not work.
machine
q Signal voltage on boost temperature side of boost pressure/temperature sensor can be checked with
Related infor-
monitoring function. (Code: 18501 Boost temperature sensor voltage)
mation

Intake air tempera- Resistance
Defective boost pressure/ BOOST PRESS & IMT (male)
ture
1 temperature sensor [temper-
0 °C 5.5 to 6.1 kΩ
ature signal circuit]
25 °C 1.9 to 2.1 kΩ
Between (3) and (4)
40 °C 1.1 to 1.2 kΩ
100 °C 180 to185 Ω
Disconnection in wiring har- shoot without turning starting switch to ON position.
ness Wiring harness between CE01 (female)(23) Resis-
Max.10Ω
2 (Disconnection in wiring or and BOOST PRESS & IMT (female)(2) tance
defective contact in connec- Wiring harness between CE01 (female)(47)
Resis-
tor) andJC02, and JC02 and BOOST PRESS & Min.10Ω
Probable tance
IMT (female)(1)
causes and
standard value
in normal con- Between CE01 (female) (23) and CE01
3 ness
dition Resis-
tance
Connections in boost pressure/temperature sensor to engine wiring
harness to engine controller may be defective. Check them directly.
connector
Intake air tempera-
ture
0 °C 5.5 to 6.1 kΩ
25 °C 1.9 to 2.1 kΩ
Between (23) and (47)
40 °C 1.1 to 1.2 kΩ
100 °C 180 to185 Ω
40-301 24 PC200, 200LC-8E0 (Hybrid)

Failure code [CA153] Chg Air Temp Sensor High Error SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 25

SEN05247-00 Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA154] Chg Air Temp Sensor Low Error

User code Failure code Charge air temperature sensor low error
Trouble
Failure descrip-
q Low voltage was detected in temperature signal circuit of boost pressure/temperature sensor.
tion
Action of con-
troller
Problem that
appears on
q Engine protection function based on boost temperature does not work.
machine
q Signal voltage on boost temperature side of boost pressure/temperature sensor can be checked with
Related infor-
monitoring function. (Code: 18501 Boost temperature sensor voltage)
mation

Intake air temper- Resistance
Defective boost pressure/ BOOST PRESS & IMT (male)
ature
1 temperature sensor [temper- 0 °C 5.5 to 6.1 kΩ
ature signal circuit] 25 °C 1.9 to 2.1 kΩ
Between (3) and (4)
40 °C 1.1 to 1.2 kΩ
100 °C 180 to 185 Ω
Between (3) – chassis ground All range Min.100 kΩ
ness
2 Wiring harness between CE01 (female)
(23) and BOOST PRESS & IMT (female) Min.100 kΩ
cuit) tance
(2) and chassis ground
Probable
causes and
standard value Resis-
(with another wiring harness) (female) all pins (With all connectors of Min.100 kΩ
in normal con- tance
wiring harness disconnected)
dition Connections in between boost pressure/temperature sensor to
engine wiring harness to engine controller may be defective. Check
Defective wiring harness them directly.
4
Intake air temper-
ature
0 °C 5.5 to 6.1 kΩ
25 °C 1.9 to 2.1 kΩ
40 °C 1.1 to 1.2 kΩ
100 °C 180 to185 Ω
Between (23) and chassis
All range Min.100 Ω
ground
40-301 26 PC200, 200LC-8E0 (Hybrid)

Failure code [CA154] Chg Air Temp Sensor Low Error SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 27

SEN05247-00 Failure code [CA155] Chg Air Temp High Speed Derate
Failure code [CA155] Chg Air Temp High Speed Derate

User code Failure code Charge air temperature high speed derate
Trouble
Failure descrip- q Temperature signal of boost pressure/temperature sensor exceeded upper limit of control tempera-
tion ture.
Action of con-
q Limits output and continues operation.
troller
Problem that
q Engine output lowers.
appears on
q Engine stops.
machine
Related infor- q Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature)

The degradation of aftercooler cooling performance is suspected.
Directly check the following points:
Lowering of cooling perfor-
Probable 1 q Looseness and damage of fan belt
mance of aftercooler
causes and q Insufficient cooling air
standard value q Clogging of aftercooler fins
in normal state Abnormal rise of turbo- Outlet temperature of turbocharger may be abnormally high. Check
2
charger outlet temperature related parts directly.
Charge temperature sensor system may be defective. Perform trou-
bleshooting for failure codes [CA153] and [CA154].
40-301 28 PC200, 200LC-8E0 (Hybrid)

Failure code [CA155] Chg Air Temp High Speed Derate SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 29

SEN05247-00 Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error

User code Failure code Sensor power Supply 2 voltage low error
Trouble
Failure descrip-
q Low voltage was detected in sensor power supply 2 circuit.
tion
q Fixes boost pressure value and continues operation.
Action of con-
troller
Problem that
machine
Related infor-
mation
Cause Standard value in normal state/Remarks on troubleshooting

a Disconnect connector with starting switch OFF, then turn start-
ing switch to ON position and perform troubleshooting.
Disconnect sensors Boost pressure/tem- BOOST PRESS &

and wiring harness at perature sensor IMT
right in order and per-
form operation to Common rail pres-
Defective sensor or wiring FUEL RAIL PRESS
1 reproduce trouble. If sure sensor
harness
"E" of failure code
Probable
goes off when a sen-
causes and Bkup sensor CAM SENSOR
sor or wiring harness
standard value
is disconnected, that
in normal con-
sensor or wiring har- Engine wiring har-
dition CE01
ness is defective. ness
Connections in each sensor to engine wiring harness to engine
connector
If causes 1 and 2 are not detected, engine controller may be defec-
formed.)
40-301 30 PC200, 200LC-8E0 (Hybrid)

Failure code [CA187] Sens Supply 2 Volt Low Error SEN05247-00
Circuit diagram related to sensor power supply 2
PC200, 200LC-8E0 (Hybrid) 40-301 31

SEN05247-00 Failure code [CA221] Ambient Press Sens High Error
Failure code [CA221] Ambient Press Sens High Error

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

1
AMBAIR PRESSURE Voltage
Defective ambient pressure Between (1) and (2) Power supply 4.75 to 5.25 V
2
sensor Between (3) and (2) Signal 0.6 to 4.3 V
Voltage is measured with wiring harness connected. Accordingly, if
Hot short (Short circuit with
3 5 V/24 V circuit) in wiring
Probable Wiring harness between CE01 (female) (3)
harness Voltage Max. 1 V
causes and and AMBAIR PRESURE (female) (3)
in normal con- Short circuit in wiring har- without turning starting switch ON.
dition ness Between wiring harnesses between CE01
4
(with another wiring har- (female) (3) and AMBAIR PRESURE Resis-
Min. 100 kΩ
ness) (female) (3) and between CE01 (female) (33) tance
and AMBAIR PRESURE (female) (1)
Connections in ambient pressure sensor to engine wiring harness to
connector
40-301 32 PC200, 200LC-8E0 (Hybrid)

Failure code [CA221] Ambient Press Sens High Error SEN05247-00
Circuit diagram related to ambient pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-301 33

SEN05247-00 Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA222] Ambient Press Sens Low Error

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

1
position and carry out troubleshooting.
AMBAIR PRESSURE Voltage
Defective ambient pres- Between (1) and (2) Power supply 4.75 to 5.25 V
2
sure sensor Between (3) and (2) Signal 0.6 to 4.3 V
ness
3 Between wiring harnesses between CE01
Probable (female) (3) and AMBAIR PRESURE Min.100 kΩ
cuit) tance
causes and (female) (3) and chassis ground
in normal con- without turning starting switch ON.
dition Between wiring harnesses between CE01
ness
4 (female) (3) and AMBAIR PRESURE
(with another wiring har- Resis-
(female) (3), and between CE01 (female) Min.100 kΩ
ness) tance
(38) and JC03, and JC03 and AMBAIR
PRESURE (female) (2)
Connection in ambient pressure sensor to engine wiring harness to
connector
40-301 34 PC200, 200LC-8E0 (Hybrid)

Failure code [CA222] Ambient Press Sens Low Error SEN05247-00
Circuit diagram related to ambient pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-301 35

SEN05247-00 Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA227] Sens Supply 2 Volt High Error

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

causes and
standard value
Perform troubleshooting for failure code [CA187].
in normal con-
dition
40-301 36 PC200, 200LC-8E0 (Hybrid)

Failure code [CA234] Eng Overspeed SEN05247-00
Failure code [CA234] Eng Overspeed

User code Failure code Eng overspeed
Trouble
— CA234 (Engine controller system)
Failure descrip-
q Engine speed exceeded upper limit of control speed.
tion
Action of con-
q Stops injection until engine speed lowers to normal level.
troller
Problem that
appears on q Engine speed fluctuates.
machine
Related infor- q Engine speed can be checked with monitoring function. (Code: 01002 Engine speed)
mation q Method of reproducing failure code: Run engine at high idle.
Cause Standard value in normal condition /Remarks on troubleshooting

Probable 1 Use of improper fuel Fuel used may be improper. Check it directly
causes and Machine may be used improperly. Teach operator proper using
2 Improper use
standard value method.
in normal con- If causes 1 and 2 are not cause of failure, engine controller may be
dition 3 Defective engine controller defective. (Since failure is in it, troubleshooting cannot be per-
formed.)
PC200, 200LC-8E0 (Hybrid) 40-301 37

SEN05247-00 Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA238] Ne Speed Sens Supply Volt Error

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

a Disconnect connector with starting switch OFF, then turn start-
ing switch to ON position and perform troubleshooting.
Disconnect sensor Ne speed sensor CRANK SENSOR
and wiring harness at
right in order and per-
form operation to
Defective sensor or wiring
Probable 1 reproduce trouble. If
harness
causes and "E" of failure code Engine wiring har-
CE01
standard value goes off when sensor ness
in normal con- or wiring harness is
dition disconnected, that
sensor or wiring har-
ness is defective.
Connection in each sensor to engine wiring harness to engine con-
troller may be defective. Check them directly.
connector
Circuit diagrams related to engine Ne speed sensor
40-301 38 PC200, 200LC-8E0 (Hybrid)

Failure code [CA271] IMV/PCV1 Short Error SEN05247-00
Failure code [CA271] IMV/PCV1 Short Error

User code Failure code IMV/PCV1 short circuit error
Trouble
Failure
q Short circuit was detected in drive circuit of supply pump actuator.
description
Action of con-
troller
Problem that q Engine speed does not increase from low idle.
machine q Fuel pressure of common rail increases above command value.
Related infor-
q Method of reproducing failure code: Turn starting switch ON.
mation

Defective supply pump actu- CP3 PUMP REGULATOR
1 Resistance
ator (male)
Min. 100 kΩ
ground
ness
(female) (2) and CP3 PUMP REGULA- Min. 100 kΩ
cuit) tance
Probable TOR (female) (1), and chassis ground
causes and a Prepare with starting switch OFF, then perform troubleshooting
standard value Short circuit in wiring har- without turning starting switch to ON position.
in normal con- 3 ness Between CE01 (female) (2) and CE01
Resis-
dition (with another wiring harness) (female) all pins (With all wiring harness Min. 100 kΩ
tance
connectors disconnected)
Connections in supply pump actuator to engine wiring harness to
connector
5 Defective engine controller CE01 (female) Resistance
Min. 100 kΩ
ground
Circuit diagram related to supply pump actuator (metering unit)
PC200, 200LC-8E0 (Hybrid) 40-301 39

SEN05247-00 Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA272] IMV/PCV1 Open Error

User code Failure code IMV/PCV1 open error
Trouble
Failure descrip-
q Open was detected in drive circuit of supply pump actuator.
tion
Action of con-
troller
Problem that
q Engine runs but it does not stabilize.
appears on
q Common rail fuel pressure rises above command value.
machine
Related infor-
mation

Defective supply pump actu- without turning starting switch to ON position.
1
ator CP3 PUMP REGULATOR (male) Resistance
Between (1) and (2) Max. 5 Ω
ness
Wiring harness between CE01 (female) (2) Resis-
2 (Disconnection in wiring or Max. 10 Ω
and CP3 PUMP REGULATOR (female) (1) tance
defective contact in connec-
tor) Max. 10 Ω
and CP3 PUMP REGULATOR (female) (2) tance
Probable position and perform troubleshooting.
3 (24V circuit) in wiring har-
causes and Between CE01 (female) (2) and CP3 PUMP
ness Voltage Max.3 V
standard value REGULATOR (female) (1)
in normal con- a Prepare with starting switch OFF, then perform troubleshooting
dition Short circuit in wiring har- without turning starting switch to ON position.
4 ness Wiring harness between CE01 (female) (2)
Resis-
(with another wiring harness) and CE01 (female) all pins (With all wiring Max. 100 kΩ
tance
harness connectors disconnected)
Connections in supply pump actuator to engine wiring harness to
engine controller may be defective . Inspect them directly.
connector
Circuit diagram related to supply pump actuator (metering unit)
40-301 40 PC200, 200LC-8E0 (Hybrid)

Failure code [CA272] IMV/PCV1 Open Error SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 41

SEN05247-00 Failure code [CA322] Inj #1 (L#1) Open/Short Error
Failure code [CA322] Inj #1 (L#1) Open/Short Error

User code Failure code Injector #1 (L#1) open/short circuit error
Trouble
Failure descrip-
q Open or short circuit was detected in drive circuit of No. 1 injector.
tion
Action of con-
troller
Problem that
q Combustion becomes irregular or engine hunts.
appears on
machine
Related infor-
mation

1 Defective No. 1 injector INJ CYL1 (male) Resistance
Between (1) and chassis ground Min. 100 kW
ness
Wiring harness between CE01 (female) Resis-
(45) and INJ CYL 1 (female) (1) tance
tor) Max. 2 Ω
(53) and INJ CYL 1 (female) (2) tance
ness
3 Between ground and wiring harness
between CE01 (female) (45) and INJ CYL 1 Min. 100 kW
cuit) tance
(female) (1)
Probable a Prepare with starting switch OFF, then perform troubleshooting
causes and without turning starting switch to ON position.
standard value Wiring harness between CE01 (female)
Short circuit in wiring har- Resis-
in normal con- (45) - each of CE01 (female) pins (With all Min. 100 kW
4 ness tance
dition wiring harness connectors disconnected)
(with another wiring harness)
Wiring harness between CE01 (female)
Resis-
(53) - each of CE01 (female) pins (With all Min. 100 kW
tance
wiring harness connectors disconnected)
Since problem may exist in the connections between No. 1 injector
to engine harness to engine controller, check for a defective con-
Defective wiring harness nection.
5
Defective other cylinder If failure codes of other injectors are displayed, perform trouble-
6
injectors or wiring harness shooting of them, too.
a Prepare with starting switch OFF, then carry out troubleshooting
Min. 100 kW
ground
40-301 42 PC200, 200LC-8E0 (Hybrid)

Failure code [CA322] Inj #1 (L#1) Open/Short Error SEN05247-00
Circuit diagram related to No. 1 injector
PC200, 200LC-8E0 (Hybrid) 40-301 43


Trouble
Failure
q Open or short circuit was detected in drive circuit of No. 3 injector.
description
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

1 Defective No. 3 injector INJ CYL 3 (male) Resistance
Between (1) and(2) Max. 2 Ω
Between (1) and chassis ground Min. 100 kΩ
ness
and INJ CYL 3 (female) (1) tance
tor) Max. 2 Ω
ness
Probable (female) (55) and INJ CYL 3 (female) (1), and Min. 100 Ω
cuit) tance
causes and chassis ground
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normal con- without turning starting switch to ON position.
dition Wiring harness between CE01 (female) (55)
and each of CE01 (female) pins (With all wir- Min. 100 kΩ
4 ness tance
ing harness connectors disconnected)
Wiring harness between CE01 (female) (52)
Resis-
tance
q Looseness of connector, breakage of lock, or breakage of seal
5 q Corrosion, bend, breakage, push-in, or expansion of pin
connector
Defective other cylinder If the failure codes of other injectors are displayed, perform trouble-
6
40-301 44 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-301 45

SEN05247-00 Failure code [CA331] Inj #2(L#2) Open/Short Error
Failure code [CA331] Inj #2(L#2) Open/Short Error

Trouble
Failure
q A disconnection or short circuit was detected in No. 2 injector drive circuit
description
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

ness
tor) Max. 2 Ω
ness
(female) (54) and INJ CYL 2 (female) (1), Min. 100 kΩ
cuit) tance
and chassis ground
Probable
causes and
standard value Wiring harness between CE01 (female) (54)
in normal con- Short circuit in wiring har- Resis-
and each of CE01 (female) pins (With all Min. 100 kΩ
dition 4 ness tance
Resis-
and each of CE01 (female) pins (With all Min. 100 kΩ
tance
Since problem is probably at connections in No. 2 injector to engine
harness to engine controller, check for a defective connection.
connector
Defective other cylinder If the failure codes of other injectors are displayed, perform trouble-
6
Min. 100 kΩ
ground
40-301 46 PC200, 200LC-8E0 (Hybrid)

Failure code [CA331] Inj #2(L#2) Open/Short Error SEN05247-00
PC200, 200LC-8E0 (Hybrid) 40-301 47


Trouble
Failure
q Disconnection or short circuit was detected in No. 4 injector drive circuit
description
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

When following failure codes are displayed simultaneously engine
controller has its internal failure ([CA323] [CA325] [CA332])
ness
tor) Max. 2 Ω
ness
Probable 4 Between Wiring harness between CE01
causes and (female) (56) and INJ CYL 4 (female) (1), and Max. 2 Ω
cuit) tance
standard value chassis ground
in normal con- a Prepare with starting switch OFF, then perform out troubleshoot-
dition ing without turning starting switch to ON position.
Short circuit in wiring har- Wiring harness between CE01 (female) (56)
Resis-
ness and each of CE01 (female) pins (With all wir- Min. 100 kΩ
5 tance
(with another wiring har- ing harness connectors disconnected)
ness) Wiring harness between CE01 (female) (58)
Resis-
tance
Since problem is probably at connections in No. 4 injector to engine
harness to engine controller, check for a defective connection.
connector
without turning starting switch ON.
40-301 48 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-301 49

SEN05247-00
© KOMATSU
All Rights Reserved
40-301 50
SEN05248-00
SEN05248-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
Failure code [CA342] Calibration Code Incompatibility............................................................................... 3

Failure code [CA351] Injectors Drive Circuit Error ...................................................................................... 3
Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................................. 4
Failure code [CA386] Sens Supply 1 Volt High Error ................................................................................. 6
Failure code [CA428] Water in Fuel Sensor High Error .............................................................................. 8
Failure code [CA429] Water in Fuel Sensor Low Error............................................................................... 10
Failure code [CA435] Eng Oil Press Sw Error ............................................................................................ 12
Failure code [CA441] Battery Voltage Low Error ........................................................................................ 14
Failure code [CA442] Battery Voltage High Error ....................................................................................... 16
Failure code [CA449] Rail Press Very High Error ....................................................................................... 18
Failure code [CA451] Rail Press Sensor High Error ................................................................................... 20
Failure code [CA452] Rail Press Sensor Low Error.................................................................................... 22
Failure code [CA488] Chg Air Temp High Torque Derate .......................................................................... 24
Failure code [CA553] Rail Press High Error ............................................................................................... 24
Failure code [CA559] Rail Press Low Error ................................................................................................ 25
Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................... 26
Failure code [CA731] Eng Bkup Speed Sens Phase Error......................................................................... 28
Failure code [CA757] All Continuous Data Lost Error................................................................................. 30
Failure code [CA778] Eng Bkup Speed Sensor Error................................................................................. 32
Failure code [CA1633] KOMNET Datalink Timeout Error........................................................................... 34
PC200, 200LC-8E0 (Hybrid) 40-302 1

Failure code [CA2185] Throt Sens Sup Volt High Error.............................................................................. 35

Failure code [CA2186] Throt Sens Sup Volt Low Error............................................................................... 36
Failure code [CA2249] Rail Press Very Low Error ...................................................................................... 37
Failure code [CA2311] IMV Solenoid Error ................................................................................................. 37
Failure code [CA2555] Grid Htr Relay Volt High Error ................................................................................ 38
Failure code [CA2556] Grid Htr Relay Volt Low Error................................................................................. 40
Failure code [D19JKZ] Personal Code Relay Abnormality ......................................................................... 42
Failure code [D862KA] GPS Antenna Discon ............................................................................................. 44
Failure code [DA22KK] Pump Solenoid Power Low Error .......................................................................... 46
Failure code [DA25KP] 5V Sensor 1 Power Abnormality............................................................................ 48
Failure code [DA26KP] 5V Sensor 2 Power Abnormality............................................................................ 52
Failure code [DA29KQ] Model Selection Abnormality................................................................................. 54
40-302 2 PC200, 200LC-8E0 (Hybrid)

Failure code [CA342] Calibration Code Incompatibility SEN05248-00
Failure code [CA342] Calibration Code Incompatibility

User code Failure code Calibration code incompatibility
Trouble
Failure descrip-
q Incompatibility of data occurred in engine controller.
tion
Action of con-
troller
Problem that
q Continues normal operation.
appears on
q Engine stops or does not start.
machine
Related infor-
mation

causes and
standard value
Perform troubleshooting for failure code [CA757]
in normal con-
dition
Failure code [CA351] Injectors Drive Circuit Error

User code Failure code Injectors drive circuit error
Trouble
Failure
q There is error in drive power circuit of injector.
description
Action of con-
troller
q Exhaust gas becomes black.
Problem that
q Combustion becomes irregular.
appears on
machine
q Engine cannot be started.
Related infor-
mation

causes and 1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
standard value
Defective power supply volt-
in normal con- 2 Perform troubleshooting for failure code [CA441].
age system
dition
PC200, 200LC-8E0 (Hybrid) 40-302 3

SEN05248-00 Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA352] Sens Supply 1 Volt Low Error

User code Failure code Sensor power supply 1 voltage low error
Trouble
Failure
q Low voltage was detected in sensor power supply 1 circuit.
description
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

a Disconnect connector with starting switch OFF, then turn starting
switch to ON position and perform troubleshooting.
Disconnect sensor and
wiring harness at right in
Ambient pressure sen-
order and perform oper- AMBAI RPRESURE
sor
Defective sensor or wir- ation to reproduce trou-
1
ing harness ble. If "E" of failure
Probable
code goes off when
causes and
sensor or wiring har-
standard value
ness is disconnected, Engine wiring harness CE01
in normal con-
that sensor or wiring
dition
harness is defective.
Connections in ambient pressure sensor to engine wiring harness to
connector
Defective engine control- If causes 1 and 2 are not detected, engine controller may be defective.
4
ler (Since trouble is in system, troubleshooting cannot be performed.)
40-302 4 PC200, 200LC-8E0 (Hybrid)

Failure code [CA352] Sens Supply 1 Volt Low Error SEN05248-00
Circuit diagram related to sensor power supply 1
PC200, 200LC-8E0 (Hybrid) 40-302 5

SEN05248-00 Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA386] Sens Supply 1 Volt High Error

User code Failure code Sensor power supply 1 voltage high error
Trouble
Failure descrip-
q High voltage was detected in sensor power supply 1 circuit.
tion
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

causes and
standard value
in normal con-
dition
40-302 6 PC200, 200LC-8E0 (Hybrid)

Failure code [CA386] Sens Supply 1 Volt High Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 7

SEN05248-00 Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA428] Water in Fuel Sensor High Error

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

Defective water-in-fuel sen- without turning starting switch to ON position.
1
sor P47(female) Resistance
Between (1) and (2) 10 to 100 kΩ
a Prepare with starting switch to OFF position, then perform trou-
bleshooting without turning starting switch to ON position.
ness
and P47 (male) (1) tance
Wiring harnesses in CE01 (female) (47) to Resis-
tor) Max. 10 Ω
Probable JC02 to P47 (male)(2) tance
causes and a Prepare with starting switch to OFF position, then perform trou-
standard value Short circuit in wiring har- bleshooting without turning starting switch to ON position.
in normal con- 3 ness Wiring harness betweenCE01 (female) (14)
Resis-
dition (with another wiring harness) and each of CE01 (female) pins (With all wir- Min.100 kΩ
tance
Connections in water-in-fuel sensor to engine wiring harness to
connector
Between(14) and(47) 10 to100 kΩ
40-302 8 PC200, 200LC-8E0 (Hybrid)

Failure code [CA428] Water in Fuel Sensor High Error SEN05248-00
Circuit diagram related to water-in-fuel sensor
PC200, 200LC-8E0 (Hybrid) 40-302 9

SEN05248-00 Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA429] Water in Fuel Sensor Low Error

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

Defective water-in-fuel sen-
1 P47(female) Resistance
sor
Between (1) and(2) 10 to 100 kΩ
Between (1) and chassis ground Min.100 kΩ
Ground fault in wiring har- a Prepare with starting switch OFF, then perform troubleshooting
ness without turning starting switch to ON position.
2
(Short circuit with GND cir- Wiring harness between CE01(female) (14) Resis-
Min.100 kΩ
cuit) and P47 (male)(1) tance
Probable without turning starting switch to ON position.
causes and Wiring harness between CE01 (female) (14)
3 ness
standard value and each of CE01 (female) all pins Resis-
in normal con- (With all wiring harness connectors discon- tance
dition nected)
Connections in water-in-fuel sensor to engine wiring harness to
connector
a Prepare with starting switch to OFF position, then perform trou-
bleshooting without turning starting switch to ON position.
Between(14) and(47) 10 to100 kΩ
Min.100 kΩ
ground
40-302 10 PC200, 200LC-8E0 (Hybrid)

Failure code [CA429] Water in Fuel Sensor Low Error SEN05248-00
Circuit diagram related to water-in-fuel sensor
PC200, 200LC-8E0 (Hybrid) 40-302 11

SEN05248-00 Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA435] Eng Oil Press Sw Error

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

Defective engine oil pressure without turning starting switch to ON position.
1
switch OIL PRESURE SWITCH(male) Resistance
Between (1) and body Max. 10 Ω
Disconnection in wiring har- a Prepare with starting switch OFF, then perform troubleshooting
2 (Disconnection in wiring or
defective contact in connec- Max. 10 Ω
and OIL PRESSURE SWITCH (male) (1) tance
tor)
standard value Wiring harness between CE01 (female) (17)
3 ness
in normal con- and each of CE01 (female) pins Resis-
dition (With all wiring harness connectors discon- tance
nected)
Connections in engine oil pressure switch to engine wiring harness
connector
Between(17) and chassis ground Max. 10 Ω
Circuit diagram related to engine oil pressure switch
40-302 12 PC200, 200LC-8E0 (Hybrid)

Failure code [CA435] Eng Oil Press Sw Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 13

SEN05248-00 Failure code [CA441] Battery Voltage Low Error
Failure code [CA441] Battery Voltage Low Error

User code Failure code Battery voltage low error
Trouble
Failure descrip-
q Low voltage was detected in controller power supply circuit.
tion
Action of con-
troller
Problem that
q Engine stops.
appears on
machine
Related infor-
mation

Loose or corroded battery
1 Battery cable may be loosened or corroded. Check it directly.
terminal
a Prepare with starting switch OFF, then keep starting switch OFF
and turn it to START and perform troubleshooting in each case.
2 Low battery voltage Battery (1 piece) Starting switch Voltage
Between (+) and (-) OFF Min. 12 V
terminals START Min. 6.2 V
3 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault. (See cause 6.)
Defective relay for engine position and perform troubleshooting.
4 Replace relays for engine controller power supply (R23, R24) with
controller power supply other relays. If mark E of failure code disappears after reproduction
operation is performed, that relay has defect.
a Prepare with starting switch OFF, then cperform troubleshooting
Disconnection in wiring har- without turning starting switch to ON position.
Wiring harness between F01-19 and R23, Resis-
ness Max. 10 Ω
R24 (female) (3) tance
5 (Disconnection in wiring or Wiring harness between R23, R24 (female) Resis-
defective contact in connec- (5) and CE03 (female) (3) Max. 10 Ω
tance
tor) Wiring harness between CE03 (female) (1) Resis-
Max. 10 Ω
and chassis ground (T12) tance
causes and Between wiring harness between F01-19 and Resis-
ness Min.100 kΩ
standard value 6 R23, R24 (female) (3), and chassis ground tance
(Short circuit with GND cir-
in normal con- Between wiring harness between R23, R24
cuit) Resis-
dition (female) (5) and CE03 (female) (3), and chas- Max. 10 Ω
tance
sis ground
Wiring harness between CE03 (female) (3),
Resis-
and pins of CE03 (female) (1) Min. 100 kΩ
tance
Short circuit in wiring har- (With battery terminal disconnected)
7 ness Wiring harness between CE03 (female) (3),
Resis-
(with another wiring harness) and CE02 (female) all pins Min. 100 kΩ
tance
(With battery terminal disconnected)
Resis-
and CE02 (female) all pins Min. 100 kΩ
tance
(With battery terminal disconnected)
Connections in fuse No. 19 to engine unit wiring harness to engine
controller are suspected. Inspect them directly.
connector
position and start engine and perform troubleshooting in each
case.
CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) and (1)
START Min. 12 V
40-302 14 PC200, 200LC-8E0 (Hybrid)

Failure code [CA441] Battery Voltage Low Error SEN05248-00
Circuit diagram related to engine controller power supply
PC200, 200LC-8E0 (Hybrid) 40-302 15

SEN05248-00 Failure code [CA442] Battery Voltage High Error
Failure code [CA442] Battery Voltage High Error

User code Failure code Battery voltage high error
Trouble
Failure
q High voltage (36 V or higher) was detected in controller power supply circuit.
description
Action of con-
troller
Problem that
appears on q Engine may stop.
machine
Related infor-
mation

1 Low battery voltage
Battery Voltage
Between (+) and (-) terminals Max. 32 V
Probable
causes and
troubleshooting.
standard value
2 Defective alternator E12( (male) Engine speed Voltage
in normal con-
Between (1) and
dition Medium or higher 27.5 to 29.5 V
chassis ground
CE03 (female) Voltage
Between(3) and(1) Max. 32 V
40-302 16 PC200, 200LC-8E0 (Hybrid)

Failure code [CA442] Battery Voltage High Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 17

SEN05248-00 Failure code [CA449] Rail Press Very High Error
Failure code [CA449] Rail Press Very High Error

User code Failure code Common rail pressure very high error
Trouble
Failure descrip-
q High voltage was detected in common rail circuit.
tion
Action of con-
troller
Problem that
q Engine sound becomes large when no or light load is applied.
appears on
machine
q Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pres-
Related infor-
sure)
mation

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
There may be air in low pressure circuit. Check it directly according
to the following procedure.
1) Remove pressure pickup part plug (outlet side) from fuel main fil-
2 Air in low pressure circuit
ter.
2) Operate feed pump of fuel prefilter.
Probable 3) Check pressure pickup plug for leakage of fuel and air.
causes and a For check of fuel return circuit pressure, see Testing and adjust-
standard value Defect in fuel return circuit ing, Checking fuel pressure.
3 Max. 0.02 MPa
in normal con- parts Fuel return circuit Low idle running or
dition pressure cranking {Max. 0.19 kg/cm 2}
Defective common rail pres- Common rail pressure sensor system may be defective. Perform
4
sure sensor troubleshooting for failure codes [CA451] and [CA452].
a For check of leakage through pressure limiter, see Testing and
adjusting, Checking fuel return rate and leakage.
5 Defective pressure limiter
Leakage through
During low idle 0 cc(No leakage)
pressure limiter
6 Defective supply pump If causes 1 to 5 are not detected, supply pump may be defective.
40-302 18 PC200, 200LC-8E0 (Hybrid)

Failure code [CA449] Rail Press Very High Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 19

SEN05248-00 Failure code [CA451] Rail Press Sensor High Error
Failure code [CA451] Rail Press Sensor High Error

User code Failure code Common rail pressure sensor high error
Trouble
Failure
q High voltage was detected in signal circuit of common rail pressure sensor.
description
Action of con-
troller
Problem that
appears on
q Engine speed or output lowers.
machine
q Signal voltage of common rail pressure sensor can be checked with monitoring function.
Related infor-
(Code: Common rail pressure sensor voltage)
mation

Defective sensor power sup- If failure code [CA227] is also displayed, perform troubleshooting for
1
ply 2 line it first.
FUEL RAIL PRESS Voltage
Defective common rail pres-
2 Between(3) and(1) Power supply 4.75 to 5.25 V
sure sensor
3 5V/24V circuit) in wiring har-
Probable ness Voltage Max. 1 V
and FUEL RAIL PRESS (female) (2)
causes and
standard value
in normal con- Short circuit in wiring har- Between wiring harnesses between CE01
dition 4 ness (female) (25) and FUEL RAIL PRESS
Resis-
(with another wiring harness) (female)(2), and between CE01 (female) Min.100 kΩ
tance
(37) and JC01-FUEL RAIL
PRESS(female)(3)
Connections in common rail pressure sensor to engine wiring har-
ness to engine controller may be defective. Check them directly.
connector
CE01 Voltage
Between(37) and(47) Power supply 4.75 to5.25 V
40-302 20 PC200, 200LC-8E0 (Hybrid)

Failure code [CA451] Rail Press Sensor High Error SEN05248-00
Circuit diagram related to common rail pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-302 21

SEN05248-00 Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA452] Rail Press Sensor Low Error

User code Failure code Common rail pressure sensor low error
Trouble
Failure
q Low voltage was detected in signal circuit of common rail pressure sensor.
description
Action of
controller
Problem that
appears on
q Engine speed or output lowers.
machine
q Signal voltage of common rail pressure sensor can be checked with monitoring function.
Related
(Code: 36401 Common rail pressure sensor voltage)
information

Defective sensor power sup- If failure code [CA187] is also displayed, perform troubleshooting for it
1
ply 2 line first.
FUEL RAIL PRESS Voltage
2 Between (3) and(1) Power supply 4.75 to5.25 V
sure sensor
ness
3 Wiring harness between CE01 (female) (25)
Probable and FUEL RAIL PRESS (female) (2), and Min.100 kΩ
cuit) tance
standard a Prepare with starting switch OFF, then perform troubleshooting
value in nor- without turning starting switch to ON position.
mal condition Short circuit in wiring har- Between wiring harnesses between CE01
4 ness (female) (25) and FUEL RAIL PRESS
Resis-
(with another wiring harness) (female) (2), and between CE01 (female) Min.100 kΩ
tance
(47) and JC02 and FUEL RAIL PRESS
(female) (1)
Connections in common rail pressure sensor to engine wiring harness
connector
CE01 Voltage
Between (37) and(47) Power supply 4.75 to 5.25 V
40-302 22 PC200, 200LC-8E0 (Hybrid)

Failure code [CA452] Rail Press Sensor Low Error SEN05248-00
Circuit diagram related to common rail pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-302 23

SEN05248-00 Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA488] Chg Air Temp High Torque Derate

User code Failure code Charge air temperature high torque derate
Trouble
Failure q Temperature signal of boost pressure/temperature sensor exceeded, upper limit of control temper-
description ature.
Action of con-
troller
Problem that
machine
Related infor- q Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature)

The degradation of aftercooler cooling performance is suspected.
Directly check the following points:
Probable Lowering of cooling perfor-
1 q Looseness and damage of fan belt
causes and mance of aftercooler
q Insufficient cooling air
standard value
q Clogging of aftercooler fins
in normal con-
Abnormal rise of turbo- Outlet temperature of turbocharger may be abnormally high. Check
dition 2
charger outlet temperature related parts directly.
Charge temperature sensor system may be defective. Perform
troubleshooting for failure codes [CA153] and [CA154] .
Failure code [CA553] Rail Press High Error

User code Failure code Common rail pressure high error
Trouble
Failure
q High voltage 1 was detected in common rail circuit.
description
Action of
machine mon- q None in particular.
itor
Problem that
q Engine sound becomes large when no or light load is applied.
appears on
machine
Related infor- q Common rail pressure can be checked with monitoring function.(Code: 36400 Common rail pressure)

Connection at ground terminal may be defective. Check following ter-
minals directly.
Probable
Defective connection at q Ground terminal of machine ((–) terminal of battery)
causes and 2
ground terminal q Ground terminal of engine
standard
q Ground terminal of engine controller
value in nor-
q Ground terminal of starting motor
mal condition
Breakage of O-ring of supply
3 O-ring of supply pump actuator may be broken. Check it directly.
pump actuator
4 Perform troubleshooting for failure codes [CA451] and [CA452].
sure sensor system
40-302 24 PC200, 200LC-8E0 (Hybrid)

Failure code [CA559] Rail Press Low Error SEN05248-00
Failure code [CA559] Rail Press Low Error

User code Failure code Common rail pressure low error
Trouble
Failure descrip-
q Low pressure error (1) was detected in common rail circuit.
tion
Action of con-
troller
Problem that q Engine does not start at all or does not start easily.
appears on q Exhaust gas becomes black.
machine q Engine output lowers.
q Common rail pressure can be checked with monitoring function.(Code: 36400 Common rail pres-
Related infor-
sure)
mation

Fuel may be leaking to outside. Check it directly (Check visually
1 Fuel leakage to outside
while running engine at low idle).
a For check of pressure in fuel low pressure circuit, see Testing
and adjusting, Checking fuel pressure.
During cranking 0.3 to1.1 MPa
Defective parts in low pres- (if engine cannot be
2
sure circuit Pressure in low-pres- started) {3.1 to 11.3 kg/cm2}
sure fuel circuit During low idle 0.5 to1.3 MPa
(if engine can be
started) {5.1 to 13.3 kg/cm 2}
a For check of leakage through pressure limiter, see Testing and
adjusting, Checking fuel return rate and leakage.
3 Defective pressure limiter
Probable Leakage through
During low idle 0 cc (No leakage)
causes and pressure limiter
standard value a For check of return rate from injector, see Testing and adjusting,
in normal con- Checking fuel return rate and leakage.
dition During cranking
Defective injector
(if engine cannot be Max. 90 cc/min.
4 (including high pressure pip-
Return rate from started)
ing in cylinder head)
injector During low idle
(if engine can be Max. 180 cc/min.
started)
a For check of return rate from supply pump, see Testing and ad-
justing, Checking fuel return rate and leakage.
During cranking
(if engine cannot be Max. 140 cc/min.
5 Defective supply pump
Return rate from sup- started)
ply pump During low idle
(if engine can be Max. 1,000 cc/min.
started)
Note1: Check the following items for defective parts in low pressure circuit parts.
1) Fuel level
2) Clogging of fuel tank breather
3) Leakage through and clogging of low-pressure fuel piping
4) Clogging of fuel prefilter
5) Clogging of fuel main filter
6) If failure is not solved with no clogging checked, replace the fuel filter with a new one.
PC200, 200LC-8E0 (Hybrid) 40-302 25

SEN05248-00 Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA689] Eng Ne Speed Sensor Error

User code Failure code Engine Ne speed sensor error
Trouble
Failure
q Signal from engine Ne speed sensor are abnormal.
description
Action of
q Continues control with signal from engine Bkup speed sensor.
controller
Problem that q Engine hunts.
appears on q Engine does not start easily.
Related infor-
mation

Defective Ne speed sensor If failure code [CA238] is also displayed, perform troubleshooting
1
power supply line for it first.
CRANK SENSOR Voltage
Defective engine Ne speed sen-
2 Between (1) and (2) Power supply 4.75 to 5.25 V
sor
Breakage or improper clear-
Engine Ne speed sensor may be broken or may have improper
3 ance of engine Ne speed sen-
clearance. Check it directly.
sor
Breakage of rotation sensor
4 Rotation sensor wheel may be broken. Check it directly.
wheel
Disconnection in wiring harness
defective contact in connector) Max. 10 Ω
(27) and CRANK SENSOR (female) (3) tance
Ground fault in wiring harness without turning starting switch ON.
6
Probable (Short circuit with GND circuit) Wiring harness between CE01 (female) Resis-
Min.100 kΩ
causes and (27) and CRANK SENSOR (female) (3) tance
mal condition Wiring harness between CE01 (female)
ness Voltage Max.1 V
(27) and CRANK SENSOR (female) (3)
Between wiring harnesses between CE01
(female) (27) and CRANK SENSOR Resis-
Min.100 kΩ
Short circuit in wiring harness (female) (3) and between CE01 (female) tance
8
(with another wiring harness) (16) and CRANK SENSOR (female)(1)
Between wiring harnesses between CE01
(female) (27) and CRANK SENSOR Resis-
Min.100 kΩ
(female) (3) and between CE01 (female) tance
(48) and CRANK SENSOR (female)(2)
Connections in engine Ne speed sensor to engine wiring harness to
Defective wiring harness con-
nector
Between (16) and
Power supply 4.75 to5.25 V
(48)
40-302 26 PC200, 200LC-8E0 (Hybrid)

Failure code [CA689] Eng Ne Speed Sensor Error SEN05248-00
Circuit diagrams related to engine Ne speed sensor
PC200, 200LC-8E0 (Hybrid) 40-302 27

SEN05248-00 Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error

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

Breakage of engine Ne speed
1 Engine Ne speed sensor may be broken. Check it directly.
sensor
Breakage of engine Bkup speed
2 Engine Bkup speed sensor may be broken. Check it directly.
sensor
Speed sensing wheel on crankshaft side may be installed defec-
tively or broken. Check it according to the following procedure.
Defective installation or break-
1)Set No. 1 piston at compression top dead center (Match stamped
3 age of speed sensing wheel on
mark).
crankshaft side
2)If tip of Ne speed sensor is aligned to center of oblong hole of
speed sensing wheel, it is installed normally.
Probable
Speed sensing ring on camshaft side may be installed defectively
causes and
or broken. Check it according to the following procedure.
standard
Defective installation or break- 1)Set No. 1 piston at compression top dead center (Match stamped
value in nor-
4 age of speed sensing ring on mark).
mal condition
camshaft side 2)Remove Bkup speed sensor.
3)If 2 grooves (1 crest) of speed sensor ring are seen through sen-
sor mounting hole, speed sensor ring is installed normally.
Defective timing of crankshaft Timing of crankshaft and camshaft may be defective. Check it
5
and camshaft directly.
Connection at ground terminal may be defective. Check following
terminals directly.
Defective connection at ground q Ground terminal of machine ((–) terminal of battery)
6
terminal q Ground terminal of engine
q Ground terminal of engine controller
q Ground terminal of starting motor
40-302 28 PC200, 200LC-8E0 (Hybrid)

Failure code [CA731] Eng Bkup Speed Sens Phase Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 29

SEN05248-00 Failure code [CA757] All Continuous Data Lost Error
Failure code [CA757] All Continuous Data Lost Error

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

Loose connection at or cor- Battery terminal connection may be loosened or corroded. Check it
2
roded battery terminal directly.
and turn it to START and perform troubleshooting in each case.
3 Low battery voltage Battery (1 piece) Starting switch Voltage
Between (+) and (–) OFF Min. 12 V
terminals START Min. 6.2 V
4 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.
Defective relay for engine
5 Replace relay (R23, R24) for engine controller with another relay
controller power supply
and perform reproducing operation. If "E" of failure code goes off at
this time, replaced relay is defective.
Probable
causes and
standard value Disconnection in wiring har-
Wiring harness between F01-19 and R23, Resis-
in normal con- ness Max. 10 Ω
dition 6 (Disconnection in wiring or
Wiring harness between R23, R24 (female) Resis-
(5) and CE03 (female) (3) tance
tor)
Max. 10 Ω
and chassis ground (T12) tance
Connections in fuse No. 19 to machine wiring harness to engine
connector
position and start engine and perform troubleshooting in each
case.
CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) and(1)
START Min. 12 V
40-302 30 PC200, 200LC-8E0 (Hybrid)

Failure code [CA757] All Continuous Data Lost Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 31

SEN05248-00 Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA778] Eng Bkup Speed Sensor Error

User code Failure code Engine Bkup speed sensor error
Trouble
Failure descrip-
q Failure was detected in signal from engine Bkup speed sensor.
tion
Action of con-
q Continues control with signal from engine Ne speed sensor.
trolle
Problem that
appears on
machine
Related infor-
mation

Defective sensor power sup- If failure code [CA187] is also displayed, perform troubleshooting
1
ply 2 line for it first.
CAM SENSOR Voltage
Defective engine Bkup
2 Between (1) and(2) Power supply 4.75 to5.25 V
speed sensor
Breakage or improper clear-
Engine Bkup speed sensor may be broken or may have improper
3 ance of engine Bkup speed
clearance. Check it directly.
sensor
Breakage of speed sensing
4 Speed sensing ring may be broken. Check it directly.
ring
Wiring harnesses in CE01 (female) (26) to Resis-
JC03 to CAM SENSOR (female) (3) tance
tor)
ness
6 Between wiring harnesses in CE01(female)
Probable (Short circuit with GND cir- Resis-
(26) to JC03 to CAM SENSOR (female) (3) Min.100 kΩ
causes and cuit) tance
and chassis ground.
standard value
in normal con-
Hot short (Short circuit with position and perform troubleshooting.
dition
7 5V/24V circuit) in wiring har- Between wiring harnesses in CE01(female)
ness (26) to JC03 to CAM SENSOR (female) (3) Voltage Max. 1 V
and chassis ground.
Between wiring harnesses in CE01 (female)
(26) to JC03 to CAM SENSOR (female)(3) Resis-
Short circuit in wiring har- Min.100 kΩ
and in CE01 (female) (37) to JC01 to CAM tance
8 ness
SENSOR(female) (1)
Between wiring harnesses in CE01 (female)
(26) to JC03 to CAM SENSOR (female) (3) Resis-
Min.100 kΩ
and in CE01 (female) (47) to JC02 to CAM tance
SENSOR (female) (2)
Connections in engine Bkup speed sensor to engine wiring harness
connector
Between (37) and
Power supply 4.75 to 5.25 V
(47)
40-302 32 PC200, 200LC-8E0 (Hybrid)

Failure code [CA778] Eng Bkup Speed Sensor Error SEN05248-00
Circuit diagram related to engine Bkup speed sensor
PC200, 200LC-8E0 (Hybrid) 40-302 33

SEN05248-00 Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA1633] KOMNET Datalink Timeout Error

User code Failure code KOMNET Datalink timeout error
Trouble
E0E CA1633 (Engine controller system)
Failure descrip- q Engine controller detected communication error in KOMNET communication circuit between pump
tion controller and machine monitor.
Action of con- q Continues operation in default mode.
Problem that q Machine may not operate normally because information which is exchanged through KOMNET
appears on communication is not transmitted properly.
machine (Trouble phenomenon depends on failed section.)
Related infor-
mation

causes and
standard value
Perform troubleshooting for failure code [DA2RMC].
in normal con-
dition
40-302 34 PC200, 200LC-8E0 (Hybrid)

Failure code [CA2185] Throt Sens Sup Volt High Error SEN05248-00
Failure code [CA2185] Throt Sens Sup Volt High Error

User code Failure code Throttle sensor supply voltage high error
Trouble
Failure descrip-
q High voltage(5.25 V or higher) was detected in throttle sensor power supply circuit.
tion
q If trouble occurs while starting switch is in ON position, controller fixes voltage value to value just
Action of con- before detection of trouble and continues operation.
ation with voltage at 100% value.
Problem that
machine
Related infor-
mation

and CE02 (female) all pins Min.100 kΩ
1 ness tance
(with P20 also disconnected)
Probable Wiring harness between CE02 (female) (22)
Resis-
causes and and CE03 (female) (3) Min.100 kΩ
tance
standard value (with P20 also disconnected)
in normal con- Connections in fuel control dial to machine wiring harness to engine
dition controller may be defective. Check them directly.
connector
If causes 1 and 2 are not detected, engine controller may be defec-
formed.)
PC200, 200LC-8E0 (Hybrid) 40-302 35

SEN05248-00 Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2186] Throt Sens Sup Volt Low Error

User code Failure code Throttle sensor supply low error
Trouble
Failure
q Low voltage was detected in throttle sensor power supply circuit.
description
q If trouble occurs while starting switch is in ON position, controller fixes voltage value to value just be-
Action of con- fore detection of trouble and continues operation.
ation with voltage at 100% value.
Problem that
machine
Related infor-
mation

ness
(female) (22) and P20 (female) (1), and Min.100 kΩ
cuit) tance
chassis ground
Probable
Short circuit in wiring har- without turning starting switch to ON position.
causes and
standard value Resis-
(with another wiring harness) and CE02 (female) all pins Min.100 kΩ
in normal con- tance
(with P20 also disconnected)
dition Connections in fuel control dial to machine wiring harness to engine
connector
If causes 1 to 3 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be performed.)
40-302 36 PC200, 200LC-8E0 (Hybrid)

Failure code [CA2249] Rail Press Very Low Error SEN05248-00
Failure code [CA2249] Rail Press Very Low Error

User code Failure code Common rail pressure very low error
Trouble
Failure descrip-
q Low pressure was detected in common rail circuit.
tion
Action of con-
troller
Problem that q Engine does not start easily.
appears on q Exhaust gas becomes black.
q Common rail pressure can be checked with monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation

causes and
standard value
in normal con-
dition
Failure code [CA2311] IMV Solenoid Error

User code Failure code IMV solenoid error
Trouble
Failure descrip-
q Resistance of supply pump actuator circuit is abnormally high or low.
tion
Action of con-
troller
Problem that
machine
Related infor-
mation

causes and
standard value
Perform troubleshooting for failure code [CA271] and [CA272].
in normal con-
dition
PC200, 200LC-8E0 (Hybrid) 40-302 37

SEN05248-00 Failure code [CA2555] Grid Htr Relay Volt High Error
Failure code [CA2555] Grid Htr Relay Volt High Error

User code Failure code Intake air heater relay voltage high error
Trouble
Failure descrip-
q Disconnection was detected in drive circuit of intake air heater relay.
tion
Action of con-
troller
Problem that
q Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position when engine coolant tem-
mation perature is below –4 °C.

without turning starting switch to ON position. (Troubleshooting
for relay unit)
R18 (male) Resistance
Defective automatic pre- Between (1) and (2) 300 to 600 Ω
1 heater relay (Internal discon- a Prepare with starting switch OFF, then turn starting switch to ON
nection) position and perform troubleshooting. (Troubleshooting by re-
placement)
Replace auto preheater relay (R18) with other relay. If mark E of fail-
ure code disappears after reproduction operation is performed, that
relay has defect.
Probable ness
causes and 2 (Disconnection in wiring or Max. 10 Ω
(40) and R18 (female) (1) tance
standard value defective contact in connec-
in normal condi- tor) Max. 10 Ω
(42) and R18 (female) (2) tance
tion a Prepare with starting switch OFF, then perform troubleshooting
3 ness Between CE02 (female) (40) and each of
Resis-
(with another wiring harness) CE02 (female) pins Min.100 kΩ
tance
(With R18 disconnected)
Connections in automatic preheater relay to machine wiring har-
ness to engine controller may be defective. Check them directly.
connector
Between (40) and (42) 300 to 600 Ω
40-302 38 PC200, 200LC-8E0 (Hybrid)

Failure code [CA2555] Grid Htr Relay Volt High Error SEN05248-00
Circuit diagram related to engine preheater/starting motor/charging system
PC200, 200LC-8E0 (Hybrid) 40-302 39

SEN05248-00 Failure code [CA2556] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt Low Error

User code Failure code Intake air heater relay voltage low error
Trouble
Failure descrip-
q Short circuit was detected in drive circuit of intake air heater relay.
tion
Action of con-
troller
Problem that
q Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position when engine coolant tem-
mation perature is below –4 °C.

without turning starting switch to ON position. (Troubleshooting
for relay unit)
Defective automatic pre- Between (1) and (2) 300 to 600 Ω
1 heater relay (Internal discon- a Prepare with starting switch OFF, then turn starting switch to ON
nection) position and perform troubleshooting. (Troubleshooting by re-
placement)
Replace automatic preheater relay (R18) with another relay and per-
form reproducing operation. If "E" of failure code goes off at this
time, replaced relay is defective.
ness
causes and 2 Between wiring harness between CE02
standard value (female) (40) and R18 (female) (1), and Min.100 kΩ
cuit) tance
in normal con- chassis ground
dition a Prepare with starting switch OFF, then perform troubleshooting
Resis-
(with another wiring harness) and CE02 (female) all pins Min.100 kΩ
tance
(With R18 disconnected)
Connections in automatic preheater relay to machine wiring harness
connector
Between(40) and (42) 300 to 600 Ω
40-302 40 PC200, 200LC-8E0 (Hybrid)

Failure code [CA2556] Grid Htr Relay Volt Low Error SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 41

SEN05248-00 Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D19JKZ] Personal Code Relay Abnormality

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

If the fuse is broken, the circuit probably has a grounding fault, etc.
1 Defective fuse No. 3
(See cause 4)
without turning starting switch to ON position. (Troubleshooting for
relay unit)
Defective personal code Between (1) and (2) (300 to 600 Ω)
2 relay (Internal disconnection a Prepare with starting switch OFF, then turn starting switch to ON
or short circuit) position and perform troubleshooting. (Troubleshooting by re-
placement)
Replace personal code relay (R07) with another relay and perform
reproducing operation. If "E" of failure code goes off at this time,
Probable replaced relay is defective.
standard without turning starting switch to ON position.
ness
value in nor- Wiring harness between F01(3) and R07 Resis-
mal condition (female)(1) tance
Wiring harness between R07 (female) (2) and Resis-
tor) Max. 1 Ω
CM01 (female) (6) tance
Ground fault in wiring har- Between wiring harness between F01(3) and
Resis-
ness R07 (female) (1) wiring harness, and chassis Min. 1 MΩ
4 tance
(Short circuit with GND cir- ground
cuit) Between wiring harness between R07
Resis-
(female) (2) and CM01 (female) (6), and Min. 1 MΩ
tance
chassis ground
If causes 1 to 4 are not detected, machine monitor (KOMTRAX) may
Defective machine monitor
5 be defective. (Since trouble is in system, troubleshooting cannot be
(KOMTRAX section)
performed.)
40-302 42 PC200, 200LC-8E0 (Hybrid)

Failure code [D19JKZ] Personal Code Relay Abnormality SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 43

SEN05248-00 Failure code [D862KA] GPS Antenna Discon
Failure code [D862KA] GPS Antenna Discon

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

causes and
Probable causes are defective GPS antenna, disconnection or short
standard value Defective GPS antenna or
1 circuit in antenna cable, and defective connection of antenna cable
in normal con- antenna cable
connector (GPS).
dition
Configuration drawing
40-302 44 PC200, 200LC-8E0 (Hybrid)

Failure code [D862KA] GPS Antenna Discon SEN05248-00
PC200, 200LC-8E0 (Hybrid) 40-302 45

SEN05248-00 Failure code [DA22KK] Pump Solenoid Power Low Error
Failure code [DA22KK] Pump Solenoid Power Low Error

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

Defective fusible link F04 or If fusible link or fuse is broken, circuit probably has ground fault.
1
fuse No. 2 (See Cause 3.)
a Prepare with starting switch OFF, then carry out troubleshooting
Wiring harness between C02 (female) Resis-
ness Max. 1 Ω
(116), (118), (121) and F01-2 tance
Wiring harness between F01-1A and F04 Resis-
(male) (2) tance
tor)
Wiring harness between F04 (male) (1) and Resis-
Max. 1 Ω
R03 tance
Probable
causes and
standard value
Between wiring harness between C02
in normal con- Resis-
(female) (116)(118)(121) and F01-2, and Min. 1 MΩ
dition Ground fault in wiring harness tance
ground
3 (Short circuit with GND cir-
Between wiring harness between F01-1A
cuit) Resis-
and F04 (male) (2), or circuit branch end, Min. 1 MΩ
tance
and chassis ground
Between wiring harness betweenF04 (male) Resis-
Min. 1 MΩ
(1) and R03, and chassis ground tance
4 Defective pump controller C01(female), C02(female) Voltage
Between C02, (116), (118), (121)
20 to 30 V
and C01(2), (5)
40-302 46 PC200, 200LC-8E0 (Hybrid)

Failure code [DA22KK] Pump Solenoid Power Low Error SEN05248-00
Circuit diagram related to pump controller power supply
PC200, 200LC-8E0 (Hybrid) 40-302 47

SEN05248-00 Failure code [DA25KP] 5V Sensor 1 Power Abnormality
Failure code [DA25KP] 5V Sensor 1 Power Abnormality

Overload alarm monitor non-display specification
User code Failure code 5V sensor power supply output 1 abnormality

Trouble
— DA25KP (Pump controller system)
Failure descrip-
q Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
tion
q Cuts output of 5V sensor power supply output 1 OFF.
Action of control-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
ler
OFF position.
Problem that q Automatic gear shifting function does not work (pump pressure sensor system).
appears on q Auto-decelerator keeps working and is not reset or fine control performance of work equipment is
machine lowered (PPC pressure sensor system).
Related informa-
tion

Bucket CURL PPC pres-
P01
sure sensor
Swing LEFT PPC pres-
P03
sure sensor
Arm IN PPC pressure
P04
Disconnect sensors at right in sensor
Pressure sensor defec- order and perform operation to Bucket DUMP PPC pres-
1 P05
tive (Internal short circuit) reproduce trouble. If "E" of fail- sure sensor
ure code goes off when a sen- Boom RAISE PPC pres-
P06
sor is disconnected, that sensor sure sensor
is defective. Swing RIGHT PPC pres-
P07
sure sensor
F Pump pressure sensor P25
R Pump pressure sensor P26

a Prepare with starting switch to OFF position , then perform trouble-
Probable causes shooting without turning starting switch to ON position.
and standard Between wiring harness in C01 (female) (9) to
value in normal J06 to P01 (female) (3) and chassis ground Resistance Min. 1 MΩ
condition [Bucket CURL PPC pressure sensor system]
Between wiring harness in C01 (female) (9) to
J06 to P03 (female) (3) and chassis ground Resistance Min. 1 MΩ
[Swing LEFT PPC pressure sensor system]
[Arm IN PPC pressure sensor system]
Ground fault in wiring Between wiring harness in C01 (female) (9) to
harness J06 to P05 (female) (3) and chassis ground Resistance Min. 1 MΩ
2
(Short circuit with GND [Bucket DUMP PPC pressure sensor system]
circuit) Between wiring harness in C01 (female) (9) to
[Boom RAISE PPC pressure sensor system]
J06 to P07 (female) (3) and chassi ground Resistance Min. 1 MΩ
[Swing RIGHT PPC pressure sensor system]
[F Pump pressure sensor system]
[R Pump pressure sensor system]
40-302 48 PC200, 200LC-8E0 (Hybrid)

Failure code [DA25KP] 5V Sensor 1 Power Abnormality SEN05248-00

J06 to P01 (female) (3) and chassis ground Voltage Max. 1 V
[Bucket CURL PPC pressure sensor system]
[Swing LEFT PPC pressure sensor system]
[Arm IN PPC pressure sensor system]
Probable causes Hot short (Short circuit
and standard 3 with 24V circuit) in wiring
[Bucket DUMP PPC pressure sensor system]
value in normal harness
condition
[Boom RAISE PPC pressure sensor system]
[Swing RIGHT PPC pressure sensor system]
[F Pump pressure sensor system]
[R Pump pressure sensor system]
If causes 1 to 3 are not detected, pump controller may be defective.
4 Defective pump controller
PC200, 200LC-8E0 (Hybrid) 40-302 49

Circuit diagram related to pump controller 5V sensor power supply output 1 (Overload alarm monitor
non-display specification)
40-302 50 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-302 51

Failure code [DA26KP] 5V Sensor 2 Power Abnormality

User code Failure code 5V sensor power supply output 2 abnormality
Trouble
- DA26KP (Pump controller system)
Failure
q Voltage of 5V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V.
description
q Cut output of 5V sensor power supply output 2 OFF.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to OFF
troller
position.
Problem that
appears on
machine
Action of con-
troller

Ground fault in wiring harness without turning starting switch to ON position.
1 (Short circuit with GND cir- Between wiring harness
Resis-
cuit) betweenC01(female (8) and A08 (female) Max. 1 MΩ
Probable tance
(7), and chassis ground
causes and
Hot short a Prepare with starting switch OFF, then perform troubleshooting
standard value
(Short circuit with 24V circuit) without turning starting switch to ON position.
in normal con-
2 in wiring harness Between wiring harness
dition
betweenC01(female) (8) and A08 (female) Voltage Max. 1 V
If causes 1 and 2 are not detected, pump controller may be defec-
3 Defective pump controller tive. (Since trouble is in system, troubleshooting cannot be per-
formed.)
40-302 52 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-302 53

SEN05248-00 Failure code [DA29KQ] Model Selection Abnormality
Failure code [DA29KQ] Model Selection Abnormality

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

Defective model selection without turning starting switch ON.
connector S30 (female) Resistance
1
(Internal disconnection or Between (1), (2), (4) and (7) ,and
Min. 1 MΩ
short circuit) (8)
ness
Wiring harness between C01 (female) (77) Resis-
and S30 (male) (3) tance
Wiring harnesses in S30 (male) (8) to J05 to Resis-
tor) Max. 1 Ω
chassis ground (T07) tance
Probable
causes and Resis-
(female) (40) and S30 (male) (1), and chas- Min. 1 MΩ
standard value tance
sis ground
in normal con-
Ground fault in wiring har- Between wiring harness between C01
dition Resis-
ness (female) (21) and S30 (male) (2), and chas- Min. 1 MΩ
3 tance
(Short circuit with GND cir- sis ground
cuit) Between wiring harness between C01
Resis-
tance
sis ground
Resis-
tance
sis ground
C01 (female) Resistance
4 Defective pump controller Between (21),(39), (40),(58) and
Min. 1 MΩ
ground
Max. 1 Ω
ground
40-302 54 PC200, 200LC-8E0 (Hybrid)

Failure code [DA29KQ] Model Selection Abnormality SEN05248-00
Circuit diagram related to model selection connector (PC200, 200LC-8)
PC200, 200LC-8E0 (Hybrid) 40-302 55

SEN05248-00
©2009 KOMATSU
All Rights Reserved
40-302 56
SEN05249-00
SEN05249-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
Failure code [DA2RMC] CAN Discon (Pump Con Detected)...................................................................... 4

Failure code [DAF8KB] Short circuit in camera power supply .................................................................... 6
Failure code [DAFGMC] GPS Module Error ............................................................................................... 8
Failure code [DAFRMC] CAN Discon (Monitor Detected) .......................................................................... 10
Failure code [DGH2KB] Hydr Oil Sensor Short .......................................................................................... 12
Failure code [DHPAMA] F Pump Press Sensor Abnormality...................................................................... 14
Failure code [DHPBMA] R Pump Press Sensor Abnormality ..................................................................... 16
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ............................................................ 18
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality........................................................ 20
Failure code [DHS5KK] Travel Speed PPC Sensor Abnormality................................................................ 22
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality....................................................... 24
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality.......................................................... 26
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality .......................................................... 28
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality .................................................... 30
Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Shrt Cir ............................................................. 32
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir .................................................... 33
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir .......................................................... 34
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir ........................................................... 35
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir ....................................................... 36
Failure code [DW43KA] Travel Speed Sol Discon...................................................................................... 38
PC200, 200LC-8E0 (Hybrid) 40-303 1

Failure code [DW43KB] Travel Speed Sol Short ........................................................................................ 40

Failure code [DW45KA] Swing Brake Sol. Valve Open Cir......................................................................... 42
Failure code [DW45KB] Swing Brake Sol. Valve Short Cir ......................................................................... 43
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir................................................................... 44
Failure code [DW91KA] Travel Junction Sol Discon ................................................................................... 46
Failure code [DW91KB] Travel Junction Sol Short ..................................................................................... 48
Failure code [DWK0KA] 2-stage Relief Sol Discon..................................................................................... 50
Failure code [DWK0KB] 2-stage Relief Sol Short ....................................................................................... 52
40-303 2 PC200, 200LC-8E0 (Hybrid)

Shop Manual SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 3

SEN05249-00 Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Failure code [DA2RMC] CAN Discon (Pump Con Detected)

User code Failure code CAN disconnection (Pump controller detected)
Trouble
E0E DA2RMC (Pump controller system)
Failure q Pump controller detected communication error in CAN communication circuit between machine mon-
description itor and engine controller.
Action of con- q Continues operation with information of CAN communication just before detection of error.
Problem that
q Information may not be transmitted normally by CAN communication and machine may not operate
appears on
normally. (Problem depends on failed section.)
machine
Related infor-
mation

Disconnection in wiring har- Wiring harness between CM02 (female) (8),
ness (Disconnection in (9) and C01 (female) (45), or CE02 (female) Resistance Max. 1 Ω
1
wiing or defective contact (46), or K02 (female) (A)
in connector) Wiring harness between CM02 (female) (10)
and C01 (female) (64), or CE02 (female) Resistance Max. 1 Ω
(47), or K02 (female) (B)
Between wiring harness between CM02
(female) (8), (9) or C01 (female) (45), or
Ground fault in wiring har- Resistance Min. 1 MΩ
CE02 (female) (46), or K02 (female) (A), or
2 ness (Short circuit with
N08 (male) (3) and chassis ground
GND circuit)
Possible
(female) (10) and C01 (female) (64), or
causes and Resistance Min. 1 MΩ
CE02 (female) (47), or K02 (female) (B), or
standard value
N08 (male) (10), and chassis ground
in normal state
(female) (8), (9) and C01 (female) (45), or
Hot short Voltage Max. 5.5 V
CE02 (female) (46), or K02 (female) (A), or
3 (Short circuit with 24 V cir-
cuit) in wiring harness
Voltage Max. 5.5 V
Defective CAN terminal
4 resistance (Internal short
K02 (male) Resistance
circuit or disconnection)
Between (A) and (B) 120 ± 12 Ω
40-303 4 PC200, 200LC-8E0 (Hybrid)

Failure code [DA2RMC] CAN Discon (Pump Con Detected) SEN05249-00
Circuit diagram related to CAN communication
PC200, 200LC-8E0 (Hybrid) 40-303 5

SEN05249-00 Failure code [DAF8KB] Short circuit in camera power supply
Failure code [DAF8KB] Short circuit in camera power supply

User code Failure code Short circuit in camera power supply
Trouble
― DAF8KB (Machine monitor system)
Failure q Output power supply voltage (Rating: 8 V) from machine monitor to camera is below 6.0 V or above
description 10 V.
Action of q Cuts output power supply voltage (Rating: 8 V) to camera OFF.
machine moni- q Even if cause of failure disappears, system does not reset itself until starting switch is turned to OFF
tor position.
Problem that
appears on q Camera image is not displayed on monitor screen.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch ON.
mation

a Disconnect camera with starting switch OFF, then turn starting
Defective camera (Internal switch to ON position and perform troubleshooting.
1
short circuit) Disconnect camera and perform failure reproduction operation. If fail-
ure code disappears at this time, camera is defective.
a Disconnect camera with starting switch OFF, then turn starting
Probable Ground fault in wiring har- switch to ON position and perform troubleshooting.
causes and 2 ness (Contact with GND (Disconnect camera and check that it is not defective in advance.)
standard value circuit) Between CM05 (female) (1) and CAMERA
Voltage Min. 6 V
in normal con- (female) (F) wiring harness and ground
dition a Disconnect camera with starting switch OFF, then turn starting
switch to ON position and perform troubleshooting.
Hot short (Contact with 24
3 (Disconnect camera and check that it is not defective in advance.)
V circuit) in wiring harness
Between CM05 (female) (1) and CAMERA
Voltage Max. 10 V
(female) (F) wiring harness and ground
If causes 1 to 3 are not detected, machine monitor may be detective.
4 Defective machine monitor
40-303 6 PC200, 200LC-8E0 (Hybrid)

Failure code [DAF8KB] Short circuit in camera power supply SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 7

SEN05249-00 Failure code [DAFGMC] GPS Module Error
Failure code [DAFGMC] GPS Module Error

User code Failure code GPS module operation error
Trouble
― DAFGMC (KOMTRAX system in machine monitor)
Failure q Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication MO-
description DEM in 50 seconds after KOMTRAX started.
Action of
machine moni-
tor
Problem that
appears on
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position (At least 50 seconds after
mation starting switch is turned to ON position).

causes and
standard value GPS module of machine monitor may be defective. (Since trouble is
in normal con- in system, troubleshooting cannot be performed.)
dition
40-303 8 PC200, 200LC-8E0 (Hybrid)

Failure code [DAFGMC] GPS Module Error SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 9

SEN05249-00 Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [DAFRMC] CAN Discon (Monitor Detected)

User code Failure code CAN disconnection (Monitor detected)
Trouble
E0E DAFRMC (Machine monitor system)
Failure q Machine monitor detected communication error in CAN communication circuit between pump con-
description troller and engine controller.
Action of
machine moni- q If cause of failure disappears, system resets itself.
tor
Problem that
q Information may not be transmitted normally by CAN communication and machine may not operate
appears on
normally. (Problem on failed section.)
machine
Related infor-
mation

Disconnection in wiring har- Wiring harness between CM02 (female) (8)
ness (Disconnection in wiring (9), (9) and C01 (female) (45), or CE02 Resistance Max. 1 Ω
1
or defective contact in con- (female) (46), or K02 (female) (A)
nector) Wiring harness between CM02 (female)
(10) and C01 (female) (64), or CE02 Resistance Max. 1 Ω
(female) (47), or K02 (female) (B)
(female) (8) (9), (9) and C01 (female) (45),
Ground fault in wiring har- Resistance Min. 1 MΩ
or CE02 (female) (46), or K02 (female) (A),
2 ness (Short circuit with GND
or N08 (male) (3), and chassis ground
circuit)
Probable Between wiring harness between CM02
causes and (female) (10) and C01 (female) (64), or
Resistance Min. 1 MΩ
standard value CE02 (female) (47), or K02 (female) (B), or
in normal con- N08 (male) (10), and chassis ground
dition a Prepare with starting switch OFF, then turn starting switch to ON
(female) (8) (9), (9) and C01 (female) (45),
Hot short (Short circuit with Voltage Max. 5.5 V
or CE02 (female) (46), or K02 (female) (A),
3 (24 V circuit) in wiring har-
or N08 (male) (3), and chassis ground
ness
Voltage Max. 5.5 V
4 resistance (Internal short cir-
K02 (male) Resistance
cuit or disconnection)
Between (A) and (B) 120 ± 12 Ω
If causes 1 to 4 are not detected, machine monitor may be defective.
40-303 10 PC200, 200LC-8E0 (Hybrid)

Failure code [DAFRMC] CAN Discon (Monitor Detected) SEN05249-00
Circuit diagram related to CAN communication
PC200, 200LC-8E0 (Hybrid) 40-303 11

SEN05249-00 Failure code [DGH2KB] Hydr Oil Sensor Short
Failure code [DGH2KB] Hydr Oil Sensor Short

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

Defective hydraulic oil tem-
perature sensor
1 P22 (male) Resistance
(Internal disconnection or
Between (1) and (2) 3.5 to 90 kΩ
short circuit)
Between (2) and chassis ground Min. 1 MΩ
Probable
causes and Ground fault in wiring har-
standard value 2 ness
Wiring harness between C01 (female) (29)
in normal con- (Short circuit to GND circuit) Resistance Min. 1 MΩ
and P22 (female) (2), and chassis ground
dition
Between (29) and (46) 3.5 to 90 kΩ
Min. 1 MΩ
ground
Circuit diagram related to hydraulic oil temperature sensor
40-303 12 PC200, 200LC-8E0 (Hybrid)

Failure code [DGH2KB] Hydr Oil Sensor Short SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 13

SEN05249-00 Failure code [DHPAMA] F Pump Press Sensor Abnormality
Failure code [DHPAMA] F Pump Press Sensor Abnormality

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

Defective 5 V sensor power If failure code [DA25KP] is also displayed, perform troubleshooting
1
supply 1 system for it first.
position or start engine and perform troubleshooting in each
case.
Defective F pump pressure P25 Voltage
2 sensor Between (3) and (1) Power supply 4.5 to 5.5 V
(Internal defect) Between (2) and (1) Signal 0.5 to 4.5 V
If voltage is abnormal, replace F pump pressure sensor with R pump
pressure sensor and check failure code. (If "E" of failure code goes
off at this time, F pump pressure sensor is defective.)
Probable Disconnection in wiring har-
causes and ness Resistance Max. 1 Ω
and P25 (female) (1)
standard value 3 (Disconnection in wiring or
in normal con- defective contact in connec- Resistance Max. 1 Ω
dition tor)
Wiring harnesses in C01 (female) (9) to
Resistance Max. 1 Ω
J06 to P25 (female) (3)
ness
4 Between wiring harness between C01
(female) (49) and P25 (female) (2), and Resistance Min. 1 MΩ
cuit)
chassis ground
Hot short (Short circuit to 24
5 Between wiring harness between C01
V circuit) in wiring harness
(female) (49) and P25 (female) (2), and Voltage Max. 4.5 V
chassis ground
40-303 14 PC200, 200LC-8E0 (Hybrid)

Failure code [DHPAMA] F Pump Press Sensor Abnormality SEN05249-00
Circuit diagram related to F pump pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 15

SEN05249-00 Failure code [DHPBMA] R Pump Press Sensor Abnormality
Failure code [DHPBMA] R Pump Press Sensor Abnormality

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

Defective 5 V sensor power If failure code[DA25KP] is also displayed, perform troubleshooting
1
position or start engine and perform troubleshooting in each case.
P26 Voltage
Defective R pump pressure
2 sensor
(Internal defect) If voltage is abnormal, replace R pump pressure sensor with F pump
pressure sensor and check failure code. (If "E" of failure code goes
off at this time, R pump pressure sensor is defective.)
Probable without turning starting switch ON.
causes and Wiring harness between C01 (female) (18)
ness Resistance Max. 1 Ω
standard value and P26 (female) (1)
in normal con- Wiring harness between C01 (female) (68)
defective contact in connec- Resistance Max. 1 Ω
dition and P26 (female) (2)
tor)
Wiring harness in C01 (female) (9) to J06
4 ness
(Short circuit to GND circuit) Resistance Min. 1 MΩ
Hot short (Short circuit to 24 position and perform troubleshooting.
5
V circuit) in wiring harness Wiring harness between C01 (female) (68)
Voltage Max. 4.5 V
40-303 16 PC200, 200LC-8E0 (Hybrid)

Failure code [DHPBMA] R Pump Press Sensor Abnormality SEN05249-00
Circuit diagram related to R pump pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 17

SEN05249-00 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality

User code Failure code Arm curl PPC pressure sensor abnormality
Trouble
― DHS3MA (Pump controller system)
Failure
q Signal voltage of arm curl PPC pressure sensor circuit is below 0.5 V or above 4.5 V.
description
Action of con- q Fixes arm curl PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
q Automatic decelerator cannot be canceled.
appears on
q Arm curl performance lowers.
machine
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will
be broken. Accordingly, take extreme care when checking.
Related infor-
q Arm curl PPC pressure can be checked with monitoring function. (Code: 07200 Arm curl PPC pres-
mation
sure)

Defective 5V sensor power If failure code [DA25KP] is also displayed, perform troubleshooting
1
P04 Voltage
Defective arm curl PPC pres-
2 Between (2) and (1) Signal 0.5 to 4.5 V
sure sensor (Internal defect)
If voltage is abnormal, replace arm curl PPC pressure sensor with
another PPC pressure sensor and check failure code. (If "E" of failure
code goes off at this time, arm curl PPC pressure sensor is defec-
tive.)
Probably
causes and Disconnection in wiring har-
standard ness Resistance Max. 1 Ω
value in nor- 3 (Disconnection in wiring or
mal condition defective contact in connec- Resistance Max. 1 Ω
tor)
Wiring harnesses in C01 (female) (9) to J06
to P04 (female) (3)
4 ness
5
Voltage Max. 4.5 V
40-303 18 PC200, 200LC-8E0 (Hybrid)

Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality SEN05249-00
Circuit diagram related to arm curl PPC pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 19

SEN05249-00 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality

User code Failure code Bucket curl PPC pressure sensor abnormality
Trouble
— DHS4MA (Pump controller system)
Failure descrip-
q Signal voltage of bucket curl PPC pressure sensor circuit is below 0.5 V or above 4.5 V.
tion
Action of con- q Fixes bucket curl PPC pressure at 0 MPa {0 kg/cm 2}and continues control.
Problem that
appears on
q Bucket curl performance lowers.
machine
will be broken. Accordingly, take extreme care when checking.
Related infor-
q Bucket curl PPC pressure can be checked with monitoring function. (Code: 07300 Bucket curl PPC
mation
pressure)
Cause Standard value in normal conditions/Remarks on troubleshooting

Defective 5V sensor power If failure code [DA25KP] is also displayed, perform troubleshooting
1
position or start engine and perform troubleshooting in each
case.
P01 Voltage
Defective bucket curl PPC
2 pressure sensor (Internal
defect)
If voltage is abnormal, replace bucket curl PPC pressure sensor
with another PPC pressure sensor and check failure code. (If "E" of
failure code goes off at this time, bucket curl PPC pressure sensor
is defective.)
standard value Wiring harness between C01 (female) (18)
ness Resistance Max. 1 Ω
in normal con- and P01 (female) (1)
dition Wiring harness between C01 (female) (73)
defective contact in connec- Resistance Max. 1 Ω
tor)
to P01 (female) (3)
4 ness
5
Voltage Max. 1 V
40-303 20 PC200, 200LC-8E0 (Hybrid)

Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality SEN05249-00
Circuit diagram related to bucket curl PPC pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 21

SEN05249-00 Failure code [DHS5KK] Travel Speed PPC Sensor Abnormality
Failure code [DHS5KK] Travel Speed PPC Sensor Abnormality

User code Failure code Travel PPC pressure sensor abnormality
Trouble
E20 DHS5KK (Pump controller system)
Failure descrip-
q Signal voltage of travel PPC pressure sensor is below 0.5 V or above 4.5 V.
tion
Action of con- q Fixes travel PPC pressure at 0 MPa {0 kg/cm 2} and continues control.
Problem that
appears on
q Travel performance is poor.
machine
Related infor-
q Travel PPC pressure can be checked with monitoring function.
mation
(Code: 01882 Travel PPC pressure)
Standard value under normal conditions/Remarks about trouble-

Cause
shooting
Defective 5 V sensor power
1 If failure code [DA26KP] is also displayed, troubleshoot it first.
supply 1 system
a Prepare with starting switch at OFF position, then turn starting
switch to ON position or start engine and troubleshoot.
Y17 Voltage
Defective travel PPC pres-
2 Between (2) and (1) Signal 0.5 to 4.5 V
sure sensor (Internal defect)
If power supply voltage is normal and signal voltage is abnormal,
replace PPC pressure sensor with another one and make judgment
based on the failure code (If failure code "E" goes off, travel PPC
pressure sensor is defective).
a Prepare with starting switch at OFF position, and troubleshoot
Probable
Disconnection in wiring har- Between wiring harness C01 (female) (70)
causes and Resistance Max. 1 Ω
ness and Y11 (female) (1)
standard value 3
(Disconnection or defective Between wiring harness C01 (female) (48)
under normal Resistance Max. 1 Ω
contact in connector) and Y11 (female) (2)
conditions Between wiring harness C01 (female) (8)
and Y11 (female) (3)
a Prepare with starting switch at OFF position, and troubleshoot
Ground fault in wiring har- without turning starting switch to ON position.
4 ness Between wiring harness between C01
(Contact with ground circuit) (female) (48) and Y11 (female) (2), and Resistance Min. 1 MΩ
chassis ground
a Prepare with starting switch at OFF position, then turn starting
Hot short in wiring harness switch to ON position and troubleshoot.
5 (Contact with 5 V or 24 V cir- Between wiring harness between C01
cuit) (female) (48) and P09 (female) (2), and Voltage Max. 4.5 V
chassis ground
If causes 1 to 5 are not detected, the hybrid system controller may
6 Defective pump controller be defective (Since trouble exists in system, troubleshooting cannot
be performed.)
40-303 22 PC200, 200LC-8E0 (Hybrid)

Failure code [DHS5KK] Travel Speed PPC Sensor Abnormality SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 23

SEN05249-00 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality

User code Failure code Boom raise PPC pressure sensor abnormality
Trouble
― DHS8MA (Pump controller system)
Failure
q Signal voltage of boom raise PPC pressure sensor circuit is below 0.5 V or above 4.5 V.
description
Action of con- q Fixes boom raise PPC pressure at 0 MPa {0 kg/cm2}and continues control.
Problem that
appears on
q Boom raise performance lowers.
machine
Related infor-
q Boom raise PPC pressure can be checked with monitoring function. (Code: 07400 Boom raise PPC
mation
pressure)

1
P06 Voltage
Defective boom raise PPC Between (3) and (1) Power supply 4.5 to 5.5 V
2 pressure sensor (Internal Between (2) and (1) Signal 0.5 to 4.5 V
defect) If voltage is abnormal, replace boom raise PPC pressure sensor with
another PPC pressure sensor and check failure code. (If "E" of fail-
ure code goes off at this time, boom raise PPC pressure sensor is
defective.)
Probable
causes and
Disconnection in wiring har- Wiring harness between C01 (female) (18)
standard value Resistance Max. 1 Ω
ness and P06 (female) (1)
in normal con- 3
(Short circuit with GND cir- Wiring harness between C01 (female) (53)
dition Resistance Max. 1 Ω
cuit) and P06 (female) (2)
Wiring harness in C01 (female) (9) to J06 to
P06 (female) (3)
4 ness
5
Voltage Max. 4.5 V
40-303 24 PC200, 200LC-8E0 (Hybrid)

Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality SEN05249-00
Circuit diagram related to boom raise PPC pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 25

SEN05249-00 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality

User code Failure code Swing right PPC pressure sensor abnormality
Trouble
― DHSAMA (Pump controller system)
Failure
q Signal voltage of swing right PPC pressure sensor circuit is below 0.5 V or above 4.5 V.
description
Action of con- q Fixes swing right PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
q Automatic deceleration function and swing holding brake function are not cancelled.
appears on
q Poor operability of swing RH operation.
machine
Related infor-
q Swing right PPC pressure can be checked with monitoring function. (Code: 09200 Swing right PPC
mation
pressure)

1
P07 Voltage
Defective swing right PPC Between (3) and (1) Power supply 4.5 to 5.5 V
2 pressure sensor Between (2) and (1) Signal 0.5 to 4.5 V
(Internal defect) If voltage is abnormal, replace swing right PPC pressure sensor with
code goes off at this time, swing right PPC pressure sensor is defec-
tive.)
Probable
standard value ness Resistance Max. 1 Ω
in normal con- 3 (Disconnection in wiring or
dition defective contact in connec- Resistance Max. 1 Ω
tor)
P07 (female) (3)
4
cuit) and P07 (female) (2), and chassis ground
Hot short (Short circuit to
ness Voltage Max. 4.5 V
40-303 26 PC200, 200LC-8E0 (Hybrid)

Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality SEN05249-00
Circuit diagram related to swing right PPC pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 27

SEN05249-00 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality

User code Failure code Swing left PPC pressure sensor abnormality
Trouble
― DHSBMA (Pump controller system)
Failure
q Signal voltage of swing left PPC pressure sensor circuit is below 0.5 V or above 4.5 V.
description
Action of con- q Fixes swing left PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
q Automatic decelerator and swing holding brake cannot be reset.
appears on
q Swing left performance lowers.
machine
Related infor-
q Swing left PPC pressure can be checked with monitoring function. (Code: 09200 Swing left PPC
mation
pressure)

1
P03 Voltage
Defective swing left PPC Between (3) and (1) Power supply 4.5 to 5.5 V
2 pressure sensor Between (2) and (1) Signal 0.5 to 4.5 V
(Internal defect) If voltage is abnormal, replace swing left PPC pressure sensor with
code goes off at this time, swing left PPC pressure sensor is defec-
tive.)
Probable
in normal con- 3 (Disconnection in wiring or
dition defective contact in connec- Resistance Max. 1 Ω
tor)
P03 (female) (3)
4
cuit) and P03 (female) (2), and chassis ground
40-303 28 PC200, 200LC-8E0 (Hybrid)

Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality SEN05249-00
Circuit diagram related to swing left PPC pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 29

SEN05249-00 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality

User code Failure code Bucket dump PPC pressure sensor abnormality
Trouble
― DHSDMA (Pump controller system)
Contents of
q Signal voltage of bucket dump PPC pressure sensor circuit is below 0.5 V or above 4.5 V.
trouble
Action of con- q Fixes bucket dump PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
appears on
q Bucket dump performance lowers.
machine
Related infor-
q Bucket dump PPC pressure can be checked with monitoring function. (Code: 07301 Bucket dump
mation
PPC pressure)

Defective 5V sensor power If failure code [DA25KP] is also displayed, carry out troubleshooting
1
P05 Voltage
Defective bucket dump PPC Between (3) and (1) Power supply 4.5 to 5.5 V
2 pressure sensor (Internal Between (2) and (1) Signal 0.5 to 4.5 V
defect) If voltage is abnormal, replace bucket dump PPC pressure sensor
with another PPC pressure sensor and check failure code. (If "E" of
failure code goes off at this time, bucket dump PPC pressure sensor
is defective.)
Probable
in normal condi- 3 (Disconnection in wiring or
tion defective contact in connec- Resistance Max. 1 Ω
tor)
to P05 (female) (3)
4 ness
40-303 30 PC200, 200LC-8E0 (Hybrid)

Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality SEN05249-00
Circuit diagram related to bucket dump PPC pressure sensor
PC200, 200LC-8E0 (Hybrid) 40-303 31

SEN05249-00 Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Shrt Cir
Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Shrt Cir
User code Failure code Disconnection or short circuit in HYB Arm IN PPC pressure sensor
Trouble
E09 DHV3KZ (Hybrid system controller)
Related infor- a Since this failure code is related to hybrid system, it is described in "Troubleshooting by failure code
mation (Display of code) (Part 5), Codes related to hybrid system".
40-303 32 PC200, 200LC-8E0 (Hybrid)

Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir SEN05249-00
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir
User code Failure code Disconnection or short circuit in HYB boom LOWER PPC pressure
Trouble sensor
E09 DHV9KZ
(Hybrid system controller)
PC200, 200LC-8E0 (Hybrid) 40-303 33

SEN05249-00 Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir
User code Failure code Disconnection or short circuit in HYB swing RIGHT PPC pressure
Trouble sensor
E09 DHVAKZ
40-303 34 PC200, 200LC-8E0 (Hybrid)

Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir SEN05249-00
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir
User code Failure code Disconnection or short circuit in HYB swing LEFT PPC pressure
Trouble sensor
E09 DHVBKZ
PC200, 200LC-8E0 (Hybrid) 40-303 35

SEN05249-00 Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir
User code Failure code Disconnection or short circuit in HYB Arm OUT PPC pressure sen-
Trouble sor
E09 DHVCKZ
40-303 36 PC200, 200LC-8E0 (Hybrid)

Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 37

SEN05249-00 Failure code [DW43KA] Travel Speed Sol Discon
Failure code [DW43KA] Travel Speed Sol Discon

User code Failure code Travel speed solenoid system disconnection
Trouble
― DW43KA (Pump controller system)
Failure descrip-
q On energizing travel speed shifting solenoid, disconnection was detected in circuit.
tion
Action of con- q None in particular. (Since no current flows, solenoid does not operate.)
Problem that
q Speed is low at High travel speed range (Machine monitor is set to High but actual speed is approx-
appears on
imately Middle).
machine
q Operating condition of travel speed shifting solenoid can be checked with monitoring function.
Related infor-
(Code: 02300 : Solenoid 1)
mation
q Method of reproducing failure code: Start engine, set travel speed to High and Operate travel lever.

Defective travel speed shift-
1 ing solenoid (Internal discon-
V04 (male) Resistance
nection)
Between (1) and (2) 20 to 60 Ω
causes and ness
standard value 2 (Disconnection in wiring or Resistance Max. 1 Ω
and V04 (female) (1)
in normal con- defective contact in connec-
Wiring harness between C02 (female) and
dition tor) Resistance Max. 1 Ω
(115), (117), (120) and V04 (female) (2)
3 Defective pump controller C01 (female) Resistance
Between (87) and (115), (117),
20 to 60 Ω
(120)
40-303 38 PC200, 200LC-8E0 (Hybrid)

Failure code [DW43KA] Travel Speed Sol Discon SEN05249-00
Circuit diagram related to travel speed shifting solenoid
PC200, 200LC-8E0 (Hybrid) 40-303 39

SEN05249-00 Failure code [DW43KB] Travel Speed Sol Short
Failure code [DW43KB] Travel Speed Sol Short

User code Failure code Travel speed solenoid system short
Trouble
― DW43KB (Pump controller system)
Failure descrip-
q On energizing travel speed shifting solenoid, short circuit was detected in circuit.
tion
q Cuts output to travel speed shifting solenoid OFF.
Action of con-
troller
position.
Problem that
q Speed is low at High travel speed range (Machine monitor is set to High but actual speed is approx-
appears on
imately Middle).
machine
q Operating condition of travel speed shifting solenoid can be checked with monitoring function.
Related infor-
mation
q Method of reproducing failure code: Start engine, set travel speed to High and Operate travel lever.

Defective travel speed shift-
1 ing solenoid (Internal discon-
nection)
Min. 1 MΩ
ground
Probable
standard value 2 ness
in normal con- (Short circuit to GND circuit) Resistance Min. 1 MΩ
and V04 (female) (1), and chassis ground
dition a Prepare with starting switch OFF, then perform troubleshooting
3 Defective pump controller Between (87) and (115), (117),
20 to 60 Ω
(120)
Min. 1 MΩ
ground
40-303 40 PC200, 200LC-8E0 (Hybrid)

Failure code [DW43KB] Travel Speed Sol Short SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 41

SEN05249-00 Failure code [DW45KA] Swing Brake Sol. Valve Open Cir
Failure code [DW45KA] Swing Brake Sol. Valve Open Cir
User code Failure code Disconnection of swing brake solenoid system

Trouble
E09 DW45KA (Hybrid system controller)
40-303 42 PC200, 200LC-8E0 (Hybrid)

Failure code [DW45KB] Swing Brake Sol. Valve Short Cir SEN05249-00
Failure code [DW45KB] Swing Brake Sol. Valve Short Cir
User code Failure code Swing Brake Sol Short

Trouble
E09 DW45KB (Hybrid system controller)
PC200, 200LC-8E0 (Hybrid) 40-303 43

SEN05249-00 Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir
User code Failure code Short circuit in swing brake solenoid valve power supply line
Trouble
E09 DW45KY (Hybrid system controller)
40-303 44 PC200, 200LC-8E0 (Hybrid)

Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 45

SEN05249-00 Failure code [DW91KA] Travel Junction Sol Discon
Failure code [DW91KA] Travel Junction Sol Discon

User code Failure code Travel junction solenoid system disconnection
Trouble
― DW91KA (Pump controller system)
Failure descrip-
q When output was made to travel junction solenoid, disconnection was detected in circuit.
tion
Problem that
appears on q Machine is not steered easily during travel.
machine
q Operating condition of travel junction solenoid can be checked with monitoring function.
Related infor-
mation
q Method of reproducing failure code: Start engine and steer machine with right and left travel levers.

Defective travel junction
1 solenoid
(Internal disconnection)
causes and ness
Wiring harness between C02 (female)
(110) and V05 (female) (1)
(115), (117), (120) and V05 (female) (2)
Between (110) and (115), (117),
20 to 60 Ω
(120)
40-303 46 PC200, 200LC-8E0 (Hybrid)

Failure code [DW91KA] Travel Junction Sol Discon SEN05249-00
Circuit diagram related to travel junction solenoid
PC200, 200LC-8E0 (Hybrid) 40-303 47

SEN05249-00 Failure code [DW91KB] Travel Junction Sol Short
Failure code [DW91KB] Travel Junction Sol Short

User code Failure code Travel junction solenoid system short circuit
Trouble
― DW91KB (Pump controller system)
Failure descrip-
q When output was made to travel junction solenoid, short circuit was detected in circuit.
tion
q Cuts output to travel junction solenoid OFF.
Action of con-
troller
position.
Problem that
appears on q Machine is not steered easily during travel.
machine
q Operating condition of travel junction solenoid can be checked with monitoring function.
Related infor-
mation
q Method of reproducing failure code: Start engine and steer machine with right and left travel levers.

Defective travel junction without turning starting switch to ON position.
solenoid V05 (male) Resistance
1
(Internal short circuit or Between (1) and (2) 20 to 60 Ω
ground fault) Between (1) and chassis
Min. 1 MΩ
ground
causes and Ground fault in wiring har- without turning starting switch to ON position.
standard value 2 ness Wiring harness between C02 (female)
in normal condi- (Short circuit to GND circuit) (110) and V05 (female) (1), and chassis Resistance Min. 1 MΩ
tion ground
20 to 60 Ω
(120)
Min. 1 MΩ
ground
40-303 48 PC200, 200LC-8E0 (Hybrid)

Failure code [DW91KB] Travel Junction Sol Short SEN05249-00
Circuit diagram related to travel junction solenoid
PC200, 200LC-8E0 (Hybrid) 40-303 49

SEN05249-00 Failure code [DWK0KA] 2-stage Relief Sol Discon
Failure code [DWK0KA] 2-stage Relief Sol Discon

User code Failure code 2-stage relief solenoid system disconnection
Trouble
― DWK0KA (Pump controller system)
Failure
q When output to 2–stage relief solenoid was cut OFF, disconnection was detected in circuit.
description
Problem that
q Power one-Touch power maximizing function does not work.
appears on
q Travel power is low.
machine
q Operating condition of 2–stage relief solenoid can be checked with monitoring function.
Related infor- (Code: 02300 : Solenoid 1)
mation q Method of reproducing failure code: Turn starting switch to ON position and set machine in mode
other than (L).

Defective 2–stage relief sole- without turning starting switch to ON position.
1
noid (Internal disconnection) V02 (male) Resistance
causes and ness
(109) and V02 (female) (1)
(115), (117), (120 and V02 (female) (2)
Between (109) to (115), (117),
20 to 60 Ω
(120)
40-303 50 PC200, 200LC-8E0 (Hybrid)

Failure code [DWK0KA] 2-stage Relief Sol Discon SEN05249-00
Circuit diagram related to 2-stage relief solenoid
PC200, 200LC-8E0 (Hybrid) 40-303 51

SEN05249-00 Failure code [DWK0KB] 2-stage Relief Sol Short
Failure code [DWK0KB] 2-stage Relief Sol Short

User code Failure code 2-stage relief solenoid system short circuit
Trouble
— DWK0KB (Pump controller system)
Failure
q When output was made to 2-stage relief solenoid, short circuit was detected in circuit.
description
q Cuts output to 2-stage relief solenoid OFF.
Action of con-
troller
position.
Problem that
q One-touch power maximizing function does not work.
appears on
q Travel power is low.
machine
q Operating condition of 2–stage relief solenoid can be checked with monitoring function.
Related infor- (Code: 02300 : Solenoid 1)
mation q Method of reproducing failure code: Turn starting switch to ON position and set machine in working
mode (L).

Defective 2-stage relief sole- without turning starting switch to ON position.
1 noid(Internal short circuit or V02 (male) Resistance
ground fault) Between (1) and (2) 20 to 60 Ω
Between (1) and chassis ground Min. 1 MΩ
Probable
causes and
2 ness Wiring harness between C02 (female)
standard value
(Short circuit to GND circuit) (109) and V02 (female) (1), and chassis Resistance Min. 1 MΩ
in normal con-
ground
dition
20 to 60 Ω
(120)
Min. 1 MΩ
ground
40-303 52 PC200, 200LC-8E0 (Hybrid)

Failure code [DWK0KB] 2-stage Relief Sol Short SEN05249-00
PC200, 200LC-8E0 (Hybrid) 40-303 53

SEN05249-00
©2009 KOMATSU
All Rights Reserved
40-303 54
SEN05250-01
SEN05250-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
Failure code [DXA8KA] PC-EPC (F) Sol Discon......................................................................................... 2

Failure code [DXA8KB] PC-EPC (F) Sol Short ........................................................................................... 4
Failure code [DXA9KA] PC-EPC (R) Sol Discon ........................................................................................ 6
Failure code [DXA9KB] PC-EPC (R) Sol Short........................................................................................... 8
Failure code [DXE0KA] LS-EPC Sol Discon............................................................................................... 10
Failure code [DXE0KB] LS-EPC Sol Short ................................................................................................. 12
Failure code [DXE5KA] Merge-divider Main Sol Discon ............................................................................. 14
Failure code [DXE5KB] Merge-divider Main Sol Short ............................................................................... 16
Failure code [DXE6KA] Merge-divider LS Sol Discon ................................................................................ 18
Failure code [DXE6KB] Merge-divider LS Sol Short................................................................................... 20
Failure code [DY20KA] Wiper Working Abnormality ................................................................................... 22
Failure code [DY20MA] Wiper Parking Abnormality ................................................................................... 24
Failure code [DY2CKA] Washer Drive Discon ............................................................................................ 26
Failure code [DY2CKB] Washer Drive Short............................................................................................... 28
Failure code [DY2DKB] Wiper Drive (For) Short......................................................................................... 30
Failure code [DY2EKB] Wiper Drive (Rev) Short ........................................................................................ 32
PC200, 200LC-8E0 (Hybrid) 40-304 1

SEN05250-01 Failure code [DXA8KA] PC-EPC (F) Sol Discon
Failure code [DXA8KA] PC-EPC (F) Sol Discon

User code Failure code PC-EPC (F) solenoid system disconnection
Trouble
E02 DXA8KA (Pump controller system)
Failure
q On energizing PC-EPC (F) solenoid, disconnection was detected in circuit.
description
Problem that
appears on q If pump load increases, engine speed lowers largely and engine may stall.
machine
q Drive current of PC-EPC (F) solenoid can be checked with monitoring function.
Related infor-
(Code: 01300 PC-EPC solenoid current (F))
mation

Defective PC-EPC (F) sole-
1 noid
Between (1) to (2) 7 to 14 Ω
Emergency pump
Defective emergency pump S25 (male) Resistance
drive switch
2 drive switch (Internal discon-
Normal Max. 1 Ω
nection) Between (3) and (2)
Emergency Min. 1 MΩ
Normal Max. 1 Ω
Probable Between (6) and (5)
causes and
standard
value in nor- Wiring harness between C02 (female) (96) Resis-
mal condition Disconnection in wiring har- Max. 1 Ω
and S25 (female) (3) tance
ness
Wiring harness between S25 (female) (2) and Resis-
3 (Disconnection in wiring or Max. 1 Ω
V11 (female) (1) tance
Wiring harness between C02 (female) (115), Resis-
tor) Max. 1 Ω
(117), (120) and S25 (female) (6) tance
Max. 1 Ω
V11 (female) (2) tance
Between (96) and (115), (117),
7 to 14 Ω
(120)
40-304 2 PC200, 200LC-8E0 (Hybrid)

Failure code [DXA8KA] PC-EPC (F) Sol Discon SEN05250-01
Circuit diagram related to PC-EPC (F) solenoid and PC-EPC (R) solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 3

SEN05250-01 Failure code [DXA8KB] PC-EPC (F) Sol Short
Failure code [DXA8KB] PC-EPC (F) Sol Short

User code Failure code PC-EPC (F) solenoid system short
Trouble
E02 DXA8KB (Pump controller system)
Failure
q On energizing PC-EPC (F) solenoid, short circuit was detected in circuit.
description
q Cuts output to PC-EPC (F) solenoid OFF.
Action of con-
troller
position.
Problem that
machine
q Drive current of PC-EPC (F) solenoid can be checked with monitoring function.
Related infor-
(Code: 01300 PC-EPC solenoid current (F))
mation

Defective PC-EPC (F) sole-
noid
1 V11 (male) Resistance
(Internal short circuit or
Between (1) and (2) 7 to 14 Ω
ground fault)
Between (1) and chassis ground Min. 1 MΩ
Emergency pump
drive switch
2 drive switch (Internal short
Between (2), (3) and
circuit or ground fault) Min. 1 MΩ
(4)
Normal
Probable Between (2), (3) and
Min. 1 MΩ
dition Between wiring harness between C02
(female) (96) and S25 (female) (3) and Resistance Min. 1 MΩ
3 ness
chassis ground
(Contact to ground circuit)
Between wiring harness between S25
(female) (5) and V11 (female) (2) and chas- Resistance Min. 1 MΩ
sis ground
7 to 14 Ω
(120)
Min. 1 MΩ
ground
40-304 4 PC200, 200LC-8E0 (Hybrid)

Failure code [DXA8KB] PC-EPC (F) Sol Short SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 5

SEN05250-01 Failure code [DXA9KA] PC-EPC (R) Sol Discon
Failure code [DXA9KA] PC-EPC (R) Sol Discon

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

Defective PC-EPC (R) sole-
1 noid
Emergency pump
drive switch
2 drive switch (Internal discon-
Normal Max.1 Ω
nection) Between (9) and (8)
Between (12) and Normal Max.1 Ω
Probable
(11) Emergency Min. 1 MΩ
causes and
standard
value in nor- Wiring harness between C02 (female) (104)
mal condition Disconnection in wiring har- Resistance Max.1 Ω
and S25 (female) (9)
ness
Wiring harness between S25 (female) (8)
3 (Disconnection in wiring or Resistance Max.1 Ω
tor) Resistance Max.1 Ω
(115), (117), (120) and S25 (female) (12)
Wiring harness between S25 (female) (11)
Resistance Max.1 Ω
Between (104) and (115), (117),
7 to 14 Ω
(120)
40-304 6 PC200, 200LC-8E0 (Hybrid)

Failure code [DXA9KA] PC-EPC (R) Sol Discon SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 7

SEN05250-01 Failure code [DXA9KB] PC-EPC (R) Sol Short
Failure code [DXA9KB] PC-EPC (R) Sol Short

User code Failure code PC-EPC (R) solenoid system short circuit
Trouble
E02 DXA9KB (Pump controller system)
Failure
q On energizing PC-EPC (R) solenoid, short circuit was detected in circuit.
description
Action of con- q Cuts output to PC-EPC (R) solenoid OFF.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
machine
q Drive current of PC-EPC (R) solenoid can be checked with monitoring function.
Related infor-
(Code: 01302 PC-EPC solenoid current (R))
mation

Defective PC-EPC (R) sole-
noid
1 V12 (male) Resistance
(Internal short circuit or
ground fault)
Emergency pump
drive switch
2 drive switch (Internal short
Between (8), (9) and
circuit or ground fault) Min. 1 MΩ
(10)
Normal
Probable Between (8), (9) and
Min. 1 MΩ
dition Between wiring harness between C02
(female) (104) and S25 (female) (9), and Resistance Min. 1 MΩ
3 ness
chassis ground
(Contact to GND circuit)
Between wiring harness between S25
(female) (8) and V12 (female) (1), and Resistance Min. 1 MΩ
chassis ground
7 to 14 Ω
(120)
Min. 1 MΩ
ground
40-304 8 PC200, 200LC-8E0 (Hybrid)

Failure code [DXA9KB] PC-EPC (R) Sol Short SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 9

SEN05250-01 Failure code [DXE0KA] LS-EPC Sol Discon
Failure code [DXE0KA] LS-EPC Sol Discon

User code Failure code LS-EPC solenoid system disconnection
Trouble
— DXE0KA (Pump controller system)
Failure
q On energizing LS-EPC solenoid, disconnection was detected in circuit.
description
Action of q None in particular. (Since no current flows, solenoid does not operate.)
controller q If cause of failure disappears, system resets itself.
Problem that
appears on q Travel speed is high at Lo and Mi.
machine
q Drive current of LS-EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid current)
mation

Defective LS-EPC solenoid without turning starting switch to ON position.
1
(Internal disconnection) V19 (male) Resistance
causes and ness
standard 2 (Disconnection in wiring or Resistance Max.1 Ω
value in nor- defective contact in connec-
Wiring harness between C02 (female) (115),
mal condition tor) Resistance Max.1 Ω
(117), (120) and V19 (female) (2)
Between (88) and (115), (117),
7 to 14 Ω
(120)
40-304 10 PC200, 200LC-8E0 (Hybrid)

Failure code [DXE0KA] LS-EPC Sol Discon SEN05250-01
Circuit diagram related to LS-EPC solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 11

SEN05250-01 Failure code [DXE0KB] LS-EPC Sol Short
Failure code [DXE0KB] LS-EPC Sol Short

User code Failure code LS-EPC solenoid system short circuit
Trouble
— DXE0KB (Pump controller system)
Failure
q On energizing LS-EPC solenoid, short circuit was detected in circuit.
description
q Cuts output to LS-EPC solenoid OFF.
Action of con-
troller
position.
Problem that
q Travel speed is high at Lo and Mi.
appears on
q Work equipment speed and swing speed are high in economy mode (E).
machine
q Drive current of LS-EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid current)
mation

Defective LS-EPC solenoid without turning starting switch to ON position.
1 (Internal short circuit or V19 (male) Resistance
ground fault) Between (1) and (2) 7 to 14 Ω
Probable
causes and
standard value
(Short circuit to GND circuit) (female) (88) and V19 (female) (1), and Resistance Min. 1 MΩ
in normal con-
chassis ground
dition
7 to 14 Ω
(120)
Min. 1 MΩ
ground
40-304 12 PC200, 200LC-8E0 (Hybrid)

Failure code [DXE0KB] LS-EPC Sol Short SEN05250-01
Circuit diagram related to LS-EPC solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 13

SEN05250-01 Failure code [DXE5KA] Merge-divider Main Sol Discon
Failure code [DXE5KA] Merge-divider Main Sol Discon

User code Failure code Merge-divider main solenoid disconnection
Trouble
Failure
q On energizing merge-divider main EPC solenoid, disconnection was detected in circuit.
description
Problem that
appears on q Single operation speed of work equipment and swing is high in economy mode (E).
machine
q Drive current of merge-divider main EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 merge-divider main solenoid current)
mation

Defective merge-divider
1 main EPC solenoid (Internal
open circuit)
causes and ness
standard value 2 (Disconnection in wiring or Max.1 Ω
and V23 (female) (1) tance
dition tor) Max.1 Ω
(117), (120) and V23 (female) (2) tance
Between (112) and (115), (117),
7 to 14 Ω
(120)
40-304 14 PC200, 200LC-8E0 (Hybrid)

Failure code [DXE5KA] Merge-divider Main Sol Discon SEN05250-01
Circuit diagram related to merge-divider main EPC solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 15

SEN05250-01 Failure code [DXE5KB] Merge-divider Main Sol Short
Failure code [DXE5KB] Merge-divider Main Sol Short

User code Failure code Merge-divider main solenoid short circuit
Trouble
Failure
q On energizing merge-divider main EPC solenoid, short circuit was detected in circuit.
description
q Cuts output to merge-divider main EPC solenoid OFF.
Action of con-
troller
position.
Problem that
machine
q Drive current of merge-divider main EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 merge-divider main EPC solenoid current)
mation

Defective merge-divider without turning starting switch to ON position.
1 main EPC solenoid (Internal V23 (male) Resistance
short circuit or ground fault) Between (1) and (2) 7 to 14 Ω
Probable
causes and
standard value
(Short circuit to GND circuit) (female) (112) and V23 (female) (1), and Resistance Min. 1 MΩ
in normal con-
chassis ground
dition
7 to 14 Ω
(120)
Min. 1 MΩ
ground
40-304 16 PC200, 200LC-8E0 (Hybrid)

Failure code [DXE5KB] Merge-divider Main Sol Short SEN05250-01
Circuit diagram related to merge-divider main EPC solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 17

SEN05250-01 Failure code [DXE6KA] Merge-divider LS Sol Discon
Failure code [DXE6KA] Merge-divider LS Sol Discon

User code Failure code Merge-divider LS solenoid disconnection
Trouble
Failure
q On energizing merge-divider LS EPC solenoid, disconnection was detected in circuit.
description
Action of con- q None in particular (Since no current flows, solenoid does not operate).
Problem that
machine
q Drive current of merge-divider LS EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08001 merge-divider LS solenoid current)
mation

Defective merge-divider LS
1 EPC solenoid (Internal open
circuit)
causes and ness
standard value 2 (Disconnection in wiring or Max. 1 Ω
dition tor) Max. 1 Ω
(117), (120) and V24 (female) (2) tance
Between (89) and (115), (117),
7 to 14 Ω
(120)
40-304 18 PC200, 200LC-8E0 (Hybrid)

Failure code [DXE6KA] Merge-divider LS Sol Discon SEN05250-01
Circuit diagram related to merge-divider LS EPC solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 19

SEN05250-01 Failure code [DXE6KB] Merge-divider LS Sol Short
Failure code [DXE6KB] Merge-divider LS Sol Short

User code Failure code Merge-divider LS solenoid short circuit
Trouble
Failure
q On energizing merge-divider LS EPC solenoid, short circuit was detected in circuit.
description
q Cuts output to merge-divider LS EPC solenoid OFF.
Action of con-
troller
position.
Problem that
machine
q Drive current of merge-divider LS EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 merge-divider LS EPC solenoid current)
mation

Defective merge-divider LS without turning starting switch to ON position.
1 EPC solenoid (Internal short V24 (male) Resistance
circuit or ground fault) Between (1) and (2) 7 to 14 Ω
causes and Ground fault in wiring har- without turning starting switch to ON position.
standard 2 ness Between Wiring harness between C02
Resis-
value in nor- (Short circuit to GND circuit) (female) (89) and V24 (female) (1), and Min. 1 MΩ
tance
mal condition chassis ground
Between (89) and (115), (117),
7 to 14 Ω
(120)
40-304 20 PC200, 200LC-8E0 (Hybrid)

Failure code [DXE6KB] Merge-divider LS Sol Short SEN05250-01
Circuit diagram related to merge-divider LS EPC solenoid
PC200, 200LC-8E0 (Hybrid) 40-304 21

SEN05250-01 Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20KA] Wiper Working Abnormality

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

M05 (female) Wiper blade Resistance
Defective wiper motor Both ends of operat-
1 Max. 1 Ω
(Internal disconnection) ing range
Between (6) and (5)
Other than both ends
Min. 1 MΩ
of operating range
Between (1) and (3) Whole range Max. 20 Ω
without turning starting switch to ON position .
Probable Disconnection in wiring har- Resistance Max. 1 Ω
and M05 (male) (6)
causes and ness
Wiring harness in M05 (female) (5) to J04 to
standard 2 (Disconnection in wiring or Resistance Max. 1 Ω
chassis ground (T05, T06)
value in nor- defective contact in connec-
mal condition tor) Resistance Max. 1 Ω
and M05 (male) (1)
Resistance Max. 1 Ω
– M05 (male) (3)
C01 (female) Wiper blade Resistance
Both ends of operat-
Max. 1 Ω
3 Defective pump controller Between (56) and ing range
chassis ground Other than both ends
Min. 1 MΩ
of operating range
Between (114) and
Whole range Max. 20 Ω
(119)
40-304 22 PC200, 200LC-8E0 (Hybrid)

Failure code [DY20KA] Wiper Working Abnormality SEN05250-01
Circuit diagram related to windshield wiper and window washer
PC200, 200LC-8E0 (Hybrid) 40-304 23

SEN05250-01 Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY20MA] Wiper Parking Abnormality

User code Failure code Wiper resting abnormality
Trouble
— DY20MA (Pump controller system)
Failure
q When windshield wiper rests, P signal for rest area is not input.
description
Action of con- q Cuts output for resting to wiper motor OFF.
Problem that
appears on q Wiper motor does not rest.
machine
q Condition of P contact signal of wiper resting area can be checked with monitoring function.
Related infor- (Code:: 02204 switch 5)
mation q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to
INT/ON .

Defective wiper motor M05 (female) Wiper blade Resistance
1
(Internal disconnection) Storage area Max. 1 Ω
Between (4) and (5)
Working area Min. 1 MΩ
Between (1) and (3) Whole range Max. 20 Ω
Probable Disconnection in wiring har- Resistance Max. 1 Ω
and M05 (male) (4)
causes and ness
Wiring harness in M05 (female) (5) to J04 to
standard value 2 (Disconnection in wiring or Resistance Max. 1 Ω
chassis ground (T05, T06)
Wiring harness between C02( (female)
dition tor) Resistance Max. 1 Ω
(114) and M05 (male) (1)
and M05 (male) (3)
C01 (female) Wiper blade Resistance
3 Defective pump controller Between (75) and Storage area Max. 1 Ω
chassis ground Working area Min. 1 MΩ
Between (114) and
Whole range Max. 20 Ω
(119)
40-304 24 PC200, 200LC-8E0 (Hybrid)

Failure code [DY20MA] Wiper Parking Abnormality SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 25

SEN05250-01 Failure code [DY2CKA] Washer Drive Discon
Failure code [DY2CKA] Washer Drive Discon

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

1 Defective fuse No.4 If fuse is broken, circuit probably has ground fault. (See cause 5.)
Defective washer motor
M06 (male) Resistance
2 (Internal disconnection or
ground fault)
Between (1), (2) and chassis
Min. 1 MΩ
ground
Defective diode array D02 without turning starting switch to ON position.
3
(Internal short circuit) D02 (female) Continuity (Resistance)
Between (3) and (7) No continuity (Min.1 MΩ)
causes and ness
Wiring harness in F01(4) to J03 to M06
standard value 4 (Disconnection in wiring or Resistance Max. 1 Ω
(female) (1)
dition tor) Resistance Max. 1 Ω
M06 (female) (2)
Between wiring harnesses in F01 (4) to J03
to M06 (female) (1), or D02 (female) (3), Resistance Min. 1 MΩ
5 ness
and chassis ground
(Short circuit to GND circuit)
Between wiring harnesses in C01 (female)
(3) to J04 to M06 (female) (2), or D02 Resistance Min. 1 MΩ
(female) (7), and chassis ground
C01 (female) Voltage
Between (3) and chassis ground 20 to 30 V
40-304 26 PC200, 200LC-8E0 (Hybrid)

Failure code [DY2CKA] Washer Drive Discon SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 27

SEN05250-01 Failure code [DY2CKB] Washer Drive Short
Failure code [DY2CKB] Washer Drive Short

User code Failure code Window washer drive system short circuit
Trouble
— DY2CKB (Pump controller system)
Failure q When output to window washer drive system was made (ground circuit was connected), short circuit
description was detected in circuit.
q Cuts output to washer motor OFF.
Action of con-
troller
position.
Problem that
appears on q Window washer does not operate.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and turn washer switch to ON
mation position.

a Prepare with starting switch OFF, and perform troubleshooting
Defective washer motor
M06 (male) Resistance
ground fault)
Between (1), (2) and chassis
Min. 1 MΩ
ground
3
(Internal short circuit) D02 (female) Continuity (Resistance)
Between (3) and (7) No continuity (Min. 1 MΩ)
ness
Wiring harness in F01 (4) to J03 to M06
Possible 4 (Disconnection in wiring or Resistance Max. 1 Ω
(female) (1)
causes and defective contact in connec-
standard tor) Resistance Max. 1 Ω
M06 (female) (2)
value in nor- a Prepare with starting switch OFF, then turn starting switch to ON
mal condition Hot short (Short circuit with
5 24 V circuit) in wiring har-
Wiring harness in C01(3) to M06 (2), to D02
ness Voltage Max. 1 V
Wiring harness in F01 (4) to J03 to M06
(female) (1), or D02 (female) (3) and chassis Resistance Min. 1 Ω
6 ness
ground
(Short circuit to GND circuit)
M06 (female) (2) , or D02(female) (7) and Resistance Min. 1 Ω
chassis ground
C01(female) Voltage
Between (3) and chassis ground 20 to 30 V
40-304 28 PC200, 200LC-8E0 (Hybrid)

Failure code [DY2CKB] Washer Drive Short SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 29

SEN05250-01 Failure code [DY2DKB] Wiper Drive (For) Short
Failure code [DY2DKB] Wiper Drive (For) Short

User code Failure code Wiper motor drive forward system short circult
Trouble
— DY2DKB (Pump controller system)
Failure
q When output to wiper motor drive forward side was made, short circuit was detected in circuit.
description
q Cuts output to wiper motor drive forward side OFF.
Action of con-
troller
position.
Problem that
appears on q Windshield wiper does not operate.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT or
mation ON.

Defective wiper motor without turning starting switch to ON position.
1 (Internal short circuit or M05 (female) Resistance
Probable ground fault) Between (3) and (1) Continuity
causes and Between (3) and chassis ground Min. 1 MΩ
value in nor- Ground fault in wiring har- without turning starting switch to ON position.
mal condition 2 ness Between wiring harness between C02
(Short circuit to GND circuit) (female) (119) and M05 (male) (3), and Resistance Min. 1 MΩ
chassis ground
If causes 1 and 2 are not detected, pump controller may be defective.
40-304 30 PC200, 200LC-8E0 (Hybrid)

Failure code [DY2DKB] Wiper Drive (For) Short SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 31

SEN05250-01 Failure code [DY2EKB] Wiper Drive (Rev) Short
Failure code [DY2EKB] Wiper Drive (Rev) Short

User code Failure code Wiper motor drive reverse system short circuit
Trouble
— DY2EKB (Pump controller system)
Failure
q When output to wiper motor drive reverse side was made, short circuit was detected in circuit.
description
Action of con- q Cuts output to wiper motor drive reverse side OFF.
Problem that
appears on q Windshield wiper does not operate.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and and set wiper switch to
mation INT or ON.

Defective wiper motor
M05 (female) Continuity/Resistance
1 (Internal short circuit or
Between (1) and (3) Continuity
Probable ground fault)
causes and Min. 1 MΩ
ground
standard value
in normal con- Ground fault in wiring har- without turning starting switch to ON position.
dition 2 ness Between wiring harness between C02
(Short circuit to GND circuit) (female) (114) and M05 (male) (1), and Resistance Min. 1 MΩ
chassis ground
If causes 1 and 2 are not detected, pump controller may be defective.
40-304 32 PC200, 200LC-8E0 (Hybrid)

Failure code [DY2EKB] Wiper Drive (Rev) Short SEN05250-01
PC200, 200LC-8E0 (Hybrid) 40-304 33

SEN05250-01
© 2010 KOMATSU
All Rights Reserved
40-304 34
SEN05251-03
SEN05251-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
Precautions related to hybrid machines ...................................................................................................... 4

Common troubleshooting of hybrid components and high voltage wiring (high voltage section)................ 9
Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Short Cir ........................................................... 24
Failure code [DHV9KZ] HYB boom Lower PPC Pr. Sen. Opn/Shrt Cir....................................................... 26
Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt........................................................... 28
Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen Opn/Short Cir. ............................................................ 31
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/Short Cir. ...................................................... 34
Failure code [DW45KA] Swing Brake Sol. Valve Open Cir. ........................................................................ 36
Failure code [DW45KB] Swing Brake Sol. Valve Short Cir. ........................................................................ 40
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir. .................................................................. 42
Failure code [GA01KA] Power Cable Interlock Open Circuit ...................................................................... 44
Failure code [GA02KZ] DC Line Open/Short Circuit ................................................................................... 46
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster ................................................................ 47
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster ................................................................ 48
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster .................................................................. 49
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster .............................................................. 50
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster .................................................................. 51
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster .................................................................. 52
Failure code [GA09KP] Low DC SW Output Volt. After Booster ................................................................. 53
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster................................................................. 54
PC200, 200LC-8E0 (Hybrid) 40-305 1

SEN05251-03
Failure code [GA0BKZ] AC Line Open/Short Circuit................................................................................... 55

Failure code [GA11KK] HYB Cont. Low Supply Voltage ............................................................................. 56
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure............................................................................. 59
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON ................................................................... 60
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF.................................................................. 61
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure................................................................. 62
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure ................................................................ 64
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir ............................................................ 67
Failure code [GA16KK] Low HYB Cont. VDD Suppl. Volt. .......................................................................... 68
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure ................................................................. 69
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit .................................................................. 70
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit ................................................................... 71
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded ....................................................................... 72
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure ................................................................. 73
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt ................................................................ 74
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure ......................................................... 75
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. .......................................................... 76
Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction ................................................................... 76
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation ......................................................... 78
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled ............................................................... 79
Failure code [GA1AKZ] Gen. Mot. Dr. Temp. Sens. Opn/Short Cir. ............................................................ 80
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction .............................................................. 81
Failure code [GA1DMA] Gen. Motro Driver IPM1 Abnormality ................................................................... 82
Failure code [GA1EMA] Gen. Motor Driver IPM 2 Abnormality .................................................................. 83
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure ............................................................... 84
Failure code [GA1FMA] Abnormal Swing Motor Driver............................................................................... 85
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU .......................................................... 86
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure ........................................................ 87
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal .......................................................... 88
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfuuction .............................................................. 89
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded ........................................................ 90
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op. ................................................................. 91
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled............................................................. 92
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. ........................................................ 93
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir. ......................................................... 94
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir......................................................... 95
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir. ............................................................. 96
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir. ............................................................... 97
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat...................................................................... 98
Failure code [GA1PNV] Swg Mot. Driver IPM Ph-U Not Warm up.............................................................. 99
Failure code [GA1QNV] Swg Mot. Driver IPM Ph-V Not Warm Up............................................................. 100
Failure code [GA1RNV] Swng Mot. Driver IPM Ph-W Not Warm Up .......................................................... 101
Failure code [GA1SFS] Contactor Locked .................................................................................................. 102
Failure code [GA1SMC] Contactor Failure.................................................................................................. 103
Failure code [GA1TKG] Capacitor HVPS Abnormal Voltage ...................................................................... 104
Failure code [GA1TKP] Capacitor Low Output Voltage .............................................................................. 105
Failure code [GA1TNS] Capacitor Overheat ............................................................................................... 106
40-305 2 PC200, 200LC-8E0 (Hybrid)

SEN05251-03
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir. ............................................................... 108
Failure code [GA1VFS] Capacitor Contactor Locked.................................................................................. 110
Failure code [GA1VMC] Capacitor Contactor Failure ................................................................................. 112
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. ............................................................. 113
Failure code [GA1YNS] Booster Inductor Overheat ................................................................................... 114
Failure code [GA1YNV] Booster Inductor Not Warming Up........................................................................ 115
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ............................................................ 116
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat ................................................................... 117
Failure code [GA1ZNV] Booster IGBT Temp. Sens. Not Warm Up ............................................................ 118
Failure code [GA21KB] Booster IGBT Short Circuit.................................................................................... 119
Failure code [GA22NS] Booster IGBT Junction Overheat .......................................................................... 120
Failure code [GA60MC] Generator Motor Failure ....................................................................................... 121
Failure code [GA60MD] Gen. Mot. Defective Movement ............................................................................ 122
Failure code [GA60N1] Generator Motor Overrun ...................................................................................... 123
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir............................................................... 124
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat............................................................. 126
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir ........................................................... 127
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir............................................................. 128
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction ............................................................ 129
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir. .......................................................... 130
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir............................................................. 131
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction ............................................................ 132
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir. .......................................................... 133
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir............................................................. 134
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction ............................................................ 135
Failure code [GA70KB] HYB Swing Motor Short Circuit ............................................................................. 136
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion ............................................................. 137
Failure code [GA70NS] HYB Swing Motor Overheat.................................................................................. 138
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. ......................................................... 139
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction............................................................... 141
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op................................................................. 143
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. ............................................................. 145
PC200, 200LC-8E0 (Hybrid) 40-305 3

SEN05251-03 Precautions related to hybrid machines
ters.

high-voltage wiring, "Discharge procedure for capacitor", or 30-102 Testing and adjusting (Part 2), Special
a See the list on "Separate sheet 1" for the monitoring items applied to the troubleshooting of hybrid system
components.
a See "Separate sheet 2" about the check sheet for recording check results when hybrid system compo-
nents have problems.
(Use this check sheet for making inquiries when you contact the Komatsu plant.)
40-305 4 PC200, 200LC-8E0 (Hybrid)

Precautions related to hybrid machines SEN05251-03
List of monitoring items applied to troubleshooting of hybrid system components

(Separate sheet 1)
Motor- Swing Unit
Capac- Rem
No. Monitoring item Code gener- Inverter electric Monitoring item •
itor arks
ator motor Range
Swing LEFT PPC pressure
1 09006 mV
sensor 2 voltage
Swing RIGHT PPC pressure
2 09007 mV
sensor 2 voltage
Arm OUT PPC pressure sen-
3 07602 mV
sor 2 voltage
Arm IN PPC pressure sensor
4 07202 mV
2 voltage
5 Direct current in swing motor 09100 A A A
6 DC current, high-voltage side 09200 V V V
7 Capacitor voltage 09300 V
Voltage at booster low-volt-
8 09400 V
age side
9 Capacitor temperature #1 09301 °C
10 Capacitor temperature #2 09302 °C
11 Booster IGBT temperature 09401 °C
12 Booster inductor temperature 09402 °C
INV film capacitor tempera-
13 09800 °C
ture
14 Swing motor coil temperature 09101 °C
Swing inverter U-phase tem-
15 09500 °C
perature
Swing inverter V-phase tem-
16 09501 °C
perature
Swing inverter W-phase tem-
17 09502 °C
perature
18 Motor-generator temperature 09600 °C
Motor-generator driver tem-
19 09601 °C
perature
Swing Inverter JCT Tempera-
20 09503 °C
ture
ON •
HYB travel buzzer
OFF
ON •
Engine stop relay
OFF
Hybrid system controller relay ON •
21 09700 HYB PPC lock
output OFF
HYB swing holding ON •
brake OFF
ON •
HYB starter operation
OFF
22 Motor-generator speed 09602 r/min
23 Motor-generator torque 09603 Nm
24 Motor-generator shaft output 09604 kW
25 Target motor-generator speed 09605 r/min
Target motor-generator
26 09606 Nm
torque
27 Target capacitor voltage 09303 V
28 Swing lever stroke 42103 %
29 Boom lever stroke 42104 %
30 Arm lever stroke 42105 %
31 Bucket lever stroke 42106 %
PC200, 200LC-8E0 (Hybrid) 40-305 5

Motor- Swing Unit

Capac Rem
No. Monitoring item Code gener- Inverter electric Monitoring item •
itor arks
ator motor Range
Motor-generator speed ON •
control OFF
Motor-generator torque ON •
control OFF
Control output of hybrid sys- Motor-generator servo ON •
32 09701
tem controller ON OFF
ON •
Swing motor servo ON
OFF
Low speed matching ON •
ON OFF
Key SW ON •
Hybrid system controller SW (HYB controller) OFF
33 09702
input ON •
Emergency stop input
OFF
34 Swing motor speed 09102 r/min
35 Swing motor torque 09103 Nm
36 Swing motor shaft output 09104 kW
37 Swing motor target speed 09105 r/min
38 Swing motor torque limit 09106 Nm
Insulation degradation sen-
39 09900 mV
sor voltage
Assembly part number
40 20225
Serial number
41 20417
Program part number
42 20256
Program version
43 20257
40-305 6 PC200, 200LC-8E0 (Hybrid)

Precautions related to hybrid machines SEN05251-03
Check sheet for hybrid system component abnormality

(Separate sheet 2)
Model PC200-8E0 Operation No.
Serial number # Date of testing / /
Engine SAA4D107E-1 Service meter h
Engine serial No. # Operator's name
A. Failure
B. Visual check OK NG
1 Damage of wire and cable

2 Poor connection of connectors
C. Testing on the machine monitor (abnormality record, monitoring) OK NG

3 Checking the error and failure codes
Checking the monitoring information
Testing Mea-
Display item Code condi- Unit Reference value sured OK NG
tions value
Engine speed 01002 r/min 600 – 2,200
Throttle opening 31701 % 0 – 100
DC in swing motor 09100 A ± 400
Capacitor voltage 09300 V 150 – 300
Voltage at booster low-voltage
09400 V 150 – 300
side
Capacitor temperature #1 09301 °C -30 – 65
Capacitor temperature #2 09302 °C -30 – 65
Booster IGBT temperature 09401 °C -30 – 100
Booster inductor temperature 09402 °C -30 – 130
INV film capacitor temperature 09800 °C -30 – 130
Swing motor coil temperature 09101 °C -30 – 160
Swing inverter U-phase tem-
09500 °C -30 – 85
perature
4 Swing inverter V-phase tem- 09501 °C -30 – 85
perature
Swing inverter W-phase tem-
09502 °C -30 – 85
perature
Motor-generator motor tem-
09600 °C -30 – 180
perature
Motor-generator driver tem-
09601 °C -30 – 70
perature
Swing inverter JCT tempera-
09503 °C -30 – 135
ture
Hybrid system controller relay
09700 —
output
Same as engine
Motor-generator speed 09602 r/min
speed
Target motor-generator speed 09605 r/min 600 – 2,500
Target capacitor voltage 09303 V 185 – 298
-100 – 100
Swing lever stroke 42103 % (Zero when lever is
in neutral position)
PC200, 200LC-8E0 (Hybrid) 40-305 7

Mea-
Display item Code Testing conditions Unit Reference value sured OK NG
value
-100 – 100
Boom lever stroke 42104 % (Zero when lever is in
neutral position)
-100 – 100
Arm lever stroke 42105 % (Zero when lever is in
neutral position)
-100 – 100
Bucket lever stroke 42106 % (Zero when lever is in
neutral position)
Control output of hybrid sys-
09701 —
tem controller
Hybrid system controller SW
09702 —
4 input
Swing motor speed 09102 r/min ± 8311
Swing motor target speed 09105 r/min ± 8311
When the key is
turned to the ON
Insulation degradation sen-
09900 position but mV – 4650
sor voltage
before the engine
is started
Assembly part number
20225 — —
Serial number
20417 — 1001 –
Program part number
20256 — 787523R205 –
Program version
20257 — MAIN_080124-R3180 –
40-305 8 PC200, 200LC-8E0 (Hybrid)

Common troubleshooting of hybrid components and high voltage wiring (high voltage section) SEN05251-03
Common troubleshooting of hybrid components and high voltage wiring

(high voltage section)
If it is judged as a result of the troubleshooting that the common troubleshooting of the high voltage section is
necessary, find out the defective portion according to the following procedure.
k Using discharge tool (generator): 796-426-1800, discharge the capacitor in advance.
(For details, see 00-200 Introduction, safety, and basic information, "Handling of hybrid devices and
high-voltage wirings", "Discharge procedure for capacitor" or 30-102 Testing and adjusting (Part 2), Spe-
cial functions of machine monitor, "Discharge of capacitor".)
k After discharging the capacitor, check that both of capacitor charge state LED (3) are turned OFF.
k Even after the capacitor is discharged, 30 V or below charged voltage is still remained in it. Accordingly,
do not work with empty hands. Be sure to insulate your hands before working.
a If HB01 (capacitor portion) is removed, cover the removed connectors (wiring harness and capacitor)
with vinyl sheets etc. to seal from foreign matter.
a Stop the engine before performing troubleshooting.
a Do not apply the tester probes directly to the connectors on the capacitor unit side (female side of HB01)
PC200, 200LC-8E0 (Hybrid) 40-305 9

SEN05251-03 Common troubleshooting of hybrid components and high voltage wiring (high voltage section)
Flow chart of common troubleshooting of high voltage sections
40-305 10 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-305 11

40-305 12 PC200, 200LC-8E0 (Hybrid)

q If the high voltage section seems to be defective as a result of the troubleshooting by failure code,
disconnect the power cable from each component and perform troubleshooting steps 1 – 7 on the
following page.
High voltage components, power cables, and layout drawing of connector
1. Capacitor case
2. Inverter case
3. Capacitor charge state LED
1)Both ON: Outputting high voltage
2)Only right ON: Being charged at high voltage
3)Both OFF: Charge voltage 30 V or below
PC200, 200LC-8E0 (Hybrid) 40-305 13

1. Troubleshooting of capacitor
If the capacitor seems to be defective as a result of the troubleshooting by failure code, perform the following
troubleshooting.

1. Turn starting switch to OFF position.
2. Disconnect power cable connector HC06 of inverter.
(Keep connector HB01 on capacitor side connected)
a Wipe off dirt from capacitor case.
a If measured value does not stabilize, read value 1 minute after.
a It is desirable to measure with a insulation resistance tester.
Probable Between HC06 (DC+) (male) (red of tester)
causes and Deteriorated insulation of Resistance Min. 10 MΩ
1 and capacitor case (black of tester)
standard capacitor system
value under Between HC06 (DC+) (male) (black of
Resistance Min. 10 MΩ
normal tester) and capacitor case (red of tester)
conditions Between HC06 (DC-) (male) (red of tester)
and capacitor case (black of tester)
Between HC06 (DC-) (male) (black of
tester) and capacitor case (red of tester)
If cause 1 is not detected, another high voltage section may be defective.
Then, perform troubleshooting of another high voltage section that seems to be defective.
If abnormality is detected, perform 5. Troubleshooting of capacitor power cable. If result is normal,
replace capacitor.
2.Troubleshooting of electric swing motor
If the electric swing motor seems to be defective as a result of the troubleshooting by failure code, perform the following
troubleshooting.

2. Disconnect power cable connector HC05 of inverter.
a Swing motor has motor coil resistance.
Phase disconnection in Between HC05 (U) (male) and HC05 (V)
1 electric swing motor (male)
system Between HC05 (V) (male) and HC05 (W)
(male)
Between HC05 (W) (male) and HC05 (U)
(male)
Probable
causes and 1. Turn starting switch to OFF position.
standard 2. Disconnect power cable connector HC05 of inverter and power cable
value under connector HB01 of capacitor.
normal a Wipe off dirt from inverter case.
conditions Deteriorated insulation of a If measured value does not stabilize, read value 1 minute after.
2 electric swing motor a It is desirable to measure with a insulation resistance tester.
system a Measurement of only 1 phase of U, V, and W is enough.
Between HC05 (U) (male) (red of tester)
and inverter case (ground) (black of tester)
Between HC05 (U) (male) (black of tester)
and inverter case (ground) (red of tester)
If causes 1 and 2 are not detected, another high voltage section may be defective.
If abnormality is detected, perform 6. Troubleshooting of electric swing motor power cable. If result is
normal, replace electric swing motor.
40-305 14 PC200, 200LC-8E0 (Hybrid)

Circuit diagram related to high voltage
PC200, 200LC-8E0 (Hybrid) 40-305 15

3. Troubleshooting of motor-generator
If the motor-generator seems to be defective as a result of the troubleshooting by failure code, perform the following
troubleshooting.

2. Disconnect power cable connectors HC03 and HC04 of inverter.
a Motor-generator has motor coil resistance.
Between HC03 (A1) (male) and HC04 (A2)
Phase disconnection in Resistance Max. 10 Ω
1 (male)
motor-generator system
Between HC03 (B1) (male) and HC04 (B2)
(male)
Between HC03 (C1) (male) and HC04 (C2)
(male)
2. Disconnect power cable connectors HC03 and HC04 of inverter.
a Measurement of either of connectors HC03 and HC04 is enough.
Between HC03 (A1) (male) and HC03 (B1)
Phase short circuit in Resistance Min. 10 MΩ
2 (male)
motor-generator system
Between HC03 (B1) (male) and HC03 (C1)
(male)
Between HC03 (C1) (male) and HC03 (A1)
(male)
Probable 1. Turn starting switch to OFF position.
causes and
2. Disconnect power cable connectors HC03 and HC04 of inverter
standard value
and power cable connector HB01 of capacitor.
under normal
a Wipe off dirt from inverter case.
conditions
a Measurement of either of connectors HC03 and HC04 is enough.
Between HC03 (A1) (male) (red of tester)
Deteriorated insulation of Between HC03 (A1) (male) (black of tester)
3 Resistance Min. 10 MΩ
motor-generator system and inverter case (ground) (red of tester)
Between HC03 (B1) (male) (red of tester)
Between HC03 (B1) (male) (black of tester)
Between HC03 (C1) (male) (red of tester)
Between HC03 (C1) (male) (black of tester)
If causes 1 – 3 are not detected, another high voltage section may be defective.
If abnormality is detected, perform 7. Troubleshooting of motor-generator power cable. If result is
normal, replace electric motor-generator.
40-305 16 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-305 17

4. Troubleshooting of inverter
If the inverter seems to be defective as a result of the troubleshooting by failure code, perform the following
troubleshooting.

2. Disconnect power cable connectors HC03 – HC06 of inverter and
power cable connector HB01 of capacitor.
a Wipe off dirt from inverter case.
Probable
causes and Between HC06 (DC+) (female) (red of
Deteriorated insulation of Resistance Min. 10 MΩ
standard 1 tester) and inverter case (black of tester)
inverter
value under Between HC06 ((DC+) (female) (black of
normal tester) and inverter case (red of tester)
conditions
Between HC06 (DC-) (female) (red of tester)
and inverter case (black of tester)
Between HC06 (DC-) (female) (black of
tester) and inverter case (red of tester)
If cause 1 is not detected, another high voltage section may be defective.
If there is any abnormality, replace inverter.
5. Troubleshooting of capacitor power cable

If the capacitor power cable seems to be defective as a result of the troubleshooting by failure code, perform the following
troubleshooting.

2. Disconnect power cable connector HC06 of inverter and power cable
connector HB01 of capacitor.
Disconnection in power
1 Between HC06 (DC+) (male) and HB01
cable Resistance Max. 1 Ω
(DC+) (male)
Between HC06 (DC-) (male) and HB01
(DC-) (male)
Probable 2. Disconnect power cable connector HC06 of inverter and power cable
Internal short circuit of
causes and 2 connector HB01 of capacitor.
power cable
standard Between HC06 (DC+) (male) and HC06
value under (DC-) (male)
normal 1. Turn starting switch to OFF position.
conditions 2. Disconnect power cable connector HC06 of inverter and power cable
connector HB01 of capacitor.
a Wipe off dirt from metallic portions of cable housing.
Deteriorated insulation of a If measured value does not stabilize, read value 1 minute after.
3 a It is desirable to measure with a insulation resistance tester.
power cable
Between HC06 (DC+) (male) and metallic
portion of cable housing (part P)
Between HC06 (DC-) (male) and metallic
portion of cable housing (part P)
If any of causes 1 – 3 is detected, replace capacitor power cable.
40-305 18 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-305 19

6. Troubleshooting of electric swing motor power cable

If the electric swing motor power cable seems to be defective as a result of the troubleshooting by failure code, perform
the following troubleshooting.
*: To "keep connector HB01 on capacitor side disconnected" is to leave connector HB01 as it is if it has been
disconnected.

2. Disconnect power cable connector HC05 of inverter and power
cable connector PM02 of electric swing motor.
(Keep connector HB01 on capacitor side disconnected)*
Disconnection in power Between HC05 (U) (male) and PM02 (U)
1 Resistance Max. 1 Ω
cable (male)
Between HC05 (V) (male) and PM02 (V)
(male)
Between HC05 (W) (male) and PM02 (W)
(male)
cable connector PM02 of swing motor.
Probable causes Internal short circuit of Between HC05 (U) (male) and HC05 (V)
and standard power cable (male)
value under Between HC05 (V) (male) and HC05 (W)
normal (male)
conditions Between HC05 (W) (male) and HC05 (U)
(male)
cable connector PM02 of electric swing motor.
Deteriorated insulation a It is desirable to measure with a insulation resistance tester.
3
of power cable Between HC05 (U) (male) and metallic part
of cable housing (part P)
Between HC05 (V) (male) and metallic part
Between HC05 (W) (male) and metallic part
If any of causes 1 – 3 is detected, replace swing motor power cable.
40-305 20 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-305 21

7. Troubleshooting of motor-generator power cable
If the motor-generator power cable seems to be defective as a result of the troubleshooting by failure code, perform the
following troubleshooting.
*: To "keep connector HB01 on capacitor side disconnected" means to leave connector HB01 as it is if it has been
disconnected.

2. Disconnect power cable connectors HC03 and HC04 of inverter and
power cable connectors GM02 and GM03 of motor-generator.
Between HC03 (A1) (male) and GM02 (A1) (male) Resistance Max. 1 Ω
Disconnection in Between HC03 (B1) (male) and GM02 (B1) (male) Resistance Max. 1 Ω
1
power cable
Between HC03 (C1) (male) and GM02 (C1) (male) Resistance Max. 1 Ω
Between HC04 (A2) (male) and GM03 (A2) (male) Resistance Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Resistance Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Resistance Max. 1 Ω
Between HC03 (A1) (male) and HC03 (B2) (male) Resistance Min. 10 MΩ
Internal short
2 circuit of power Between HC03 (B1) (male) and HC03 (C1) (male) Resistance Min. 10 MΩ
cable
Between HC03 (C1) (male) and HC03 (A1) (male) Resistance Min. 10 MΩ
Probable
causes and Between HC04 (A2) (male) and HC04 (B2) (male) Resistance Min. 10 MΩ
standard value Between HC04 (B2) (male) and HC04 (C2) (male) Resistance Min. 10 MΩ
under normal
conditions Between HC04 (C2) (male) and HC04 (A2) (male) Resistance Min. 10 MΩ
Between HC03 (A1) (male) (red of tester) and
metallic portion of cable housing (part P)
Deteriorated
Between HC03 (B1) (male) (red of tester) and
3 insulation of power Resistance Min. 10 MΩ
metallic portion of cable housing (part p)
cable
Between HC03 (C1) (male) (red of tester) and
Between HC04 (A2) (male) (black of tester) and
Between HC04 (B2) (male) (red of tester) and
Between HC04 (C2) (male) (black of tester) and
If any of causes 1 – 3 is detected, replace related motor-generator power cable
40-305 22 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-305 23

SEN05251-03 Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Short Cir
Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Short Cir
User code Failure code Open or short circuit in HYB Arm IN PPC pressure sensor
Failure
E09 DHV3KZ (Hybrid controller system)
Detail of failure q Signal voltage of HYB Arm IN PPC pressure sensor circuit is below 0.3 V or above 4.7 V.
q Controls system by setting Arm IN PPC pressure at 0 MPa {0 kg/cm2}.
Action of con- q Inoperative low speed matching
position.
Problem on
q Disabled low speed matching
machine
Related infor-
q Stroke of Arm IN PPC pressure sensor can be checked with monitoring function.
mation
(Code: 42105 Arm lever stroke)

Defective sensor power sup-
1 If error code [GA13MC] is displayed, troubleshoot it first.
ply system
a Prepare by setting starting switch to OFF position, then start en-
gine and troubleshoot.
HP05 Voltage
Defective Arm OUT PPC Power
Between (3) and (1) 4.5 - 5.5 V
2 pressure sensor supply
(Internal defect) Between (2) and (1) Signal 0.5 - 4.5 V
If the voltage is abnormal, replace the PPC pressure sensor with
another one and make a judgment based on the failure code. (If fail-
ure code "E" goes off, arm OUT PPC pressure sensor is defective.)
Probable shoot without turning starting switch to ON position.
causes and Open circuit in wiring har- Wiring harness between HC02 (female) (31) Resis-
Max. 1 Ω
standard value ness and HP05 (female) (3) tance
3
under normal (Open circuit or defective Wiring harness between HC02 (female) (34) Resis-
Max. 1 Ω
conditions contact in connector) and HP05 (female) (2) tance
Wiring harness between HC02 (female) (62) Resis-
Max. 1 Ω
and HP05 (female) (1) tance
Ground fault in wiring har- shoot without turning starting switch to ON position.
4 ness Between wiring harness (between HC02
Resis-
(Contact with ground circuit) (female) (34) and HP05 (female) (2)) and Min. 1 MΩ
tance
ground
Hot short in wiring harness
5 Between wiring harness (between HC02
(Contact with 24V circuit)
(female) (34) and HP05 (female) (2)) and Voltage Max. 1 V
ground
If causes 1 - 5 are not detected, the hybrid system controller may be
Defective inverter (Hybrid
6 defective (Since trouble exists in system, troubleshooting cannot be
system controller)
performed.)
40-305 24 PC200, 200LC-8E0 (Hybrid)

Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Short Cir SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 25

SEN05251-03 Failure code [DHV9KZ] HYB boom Lower PPC Pr. Sen. Opn/Shrt Cir
Failure code [DHV9KZ] HYB boom Lower PPC Pr. Sen. Opn/Shrt Cir
User code Failure code Open or short circuit in HYB boom LOWER PPC pressure sensor
Failure
E09 DHV9KZ (Hybrid controller system)
Detail of failure q Signal voltage of HYB boom LOWER PPC pressure sensor circuit is below 0.3 V or above 4.7 V.
q Controls system by setting boom LOWER PPC pressure at 0 MPa {0 kg/cm2}.
Action of con- q Inoperative low speed matching
troller q Inoperative hoist matching function
position.
Problem on
q Disabled low speed matching and hoist matching
machine
Related infor-
q Stroke of boom LOWER PPC pressure sensor can be checked with monitoring function.
mation
(Code: 42104 boom lever stroke)

ply system
HP07 Voltage
Power
Defective boom LOWER Between (3) and (1) 4.5 – 5.5 V
supply
2 PPC pressure sensor
(Internal defect) Between (2) and (1) Signal 0.5 – 4.5 V
ure code "E" goes off, boom Lower PPC pressure sensor is defec-
tive.)
standard value Max. 1 Ω
ness and HP07 (female) (3) tance
under normal 3
(Open circuit or defective Wiring harness between HC02 (female) (53) Resis-
conditions Max. 1 Ω
contact in connector) and HP07 (female) (2) tance
Max. 1 Ω
Resis-
tance
ground
(Contact with 24 V circuit)
ground
If causes 1 – 5 are not detected, the hybrid system controller may be
6 defective (Since trouble exists in system, troubleshooting cannot be
system controller)
performed.)
40-305 26 PC200, 200LC-8E0 (Hybrid)

Failure code [DHV9KZ] HYB boom Lower PPC Pr. Sen. Opn/Shrt Cir SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 27

SEN05251-03 Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt.
Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt.
User code Failure code Open or short circuit in HYB swing RIGHT PPC pressure sensor
Failure
E09 DHVAKZ (Hybrid controller system)
q Signal voltage of swing RIGHT PPC pressure sensor for hybrid system is below 0.3 V or above 4.7 V.
q When control lock lever is shifted down, swing RIGHT PPC hydraulic pressure sensor is 0.5 MPa {5
kg/cm 2} or swing RIGHT PPC pressure sensor for hybrid system is 0.5 MPa {5 kg/cm2} and generator
Detail of failure
speed is 500 rpm or more.
q When generator speed is 500 rpm or more, pressure of hybrid swing right PPC pressure sensor is
0.5 MPa {5 kg/cm2} or more higher than pressure of swing PPC right pressure sensor 1.
2
Action of con- q Controls system by setting swing RIGHT PPC pressure at 0 MPa {0 kg/cm }.
q Even if cause of failure disappears,system does not reset itself until starting switch is turned to OFF
troller
position.
q Swinging stops suddenly during right swinging motion. Continues swinging during left swinging mo-
Problem on
tion. After stopping, machine cannot swing to the right.
machine
q Operator cannot control the swinging motion.
a If pressure sensor 5 V circuit (3) and ground circuit (1) are connected reversely, sensor will be broken.
Accordingly, take extreme care when checking.
q Voltage of swing right PPC pressure sensor can be checked with monitoring function.
Related infor-
(Code: 09007 Swing right PPC pressure sensor 2 voltage)
mation
q This failure code may be displayed when communication with pump controller has abnormality. Ac-
cordingly, if [DA2RMC] or [GA14KR] is also displayed, perform troubleshooting for it first.
Cause Standard value in normal condition/ Remarks on troubleshooting

Defective sensor power If error code [DA25KP], [GA13MC] or [GA14KR] is displayed, trouble-
1
supply system shoot it first.
a Prepare by setting starting switch to OFF position ,then start engine
and troubleshoot.
P03 Voltage
Defective swing RIGHT Power
Between (3) and (1) 4.5 – 5.5 V
2 PPC pressure sensor supply
If the voltage is abnormal , replace the PPC pressure sensor with
another one and make a judgment based on the failure code.(If failure
code "E" goes off, swing RIGHT PPC pressure sensor is defective.)
a Prepare by setting starting switch to OFF position ,and troubleshoot
Open circuit in wiring har- Wiring harness between C01 (female) (18)
Probable ness and P07(female) (1)
3
cause and (Open circuit or defective Wiring harness between C01 (female) (72)
standard value contact in connector) and P07 (female) (2)
under normal Wiring harness between C01 (female) (9),
conditions and P07(female) (3) via J06
a Prepare by setting starting switch to OFF position ,and troubleshoot
ness
4 Between wiring harness (between C01
(Contact with ground cir-
(female) (72) and P07 (female) (2) and Resistance Min. 1 MΩ
cuit )
ground
a Prepare by setting starting switch to OFF position ,then turn starting
switch to ON position.
(female) (72) and P07 (female) (2) and Voltage Max. 1 V
ground
When any of causes 1 – 5 is not detected, even if right swing operation
is not performed, if 09002 Swing right PPC pressure displayed by
6 Defective pump controller monitoring function exceeds 0.5 MPa {5 kg/cm 2}, pump controller may
be defective. (Since trouble is in system, troubleshooting cannot be
performed.)
40-305 28 PC200, 200LC-8E0 (Hybrid)

Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt. SEN05251-03
Cause Standard value in normal condition/ Remarks on troubleshooting

a Prepare by setting starting switch to OFF position ,then start en-
gine and troubleshoot..
HP06 Voltage
Power sup-
Defective swing RIGHT Between (3) and (1) 4.5 – 5.5 V
ply
7 PPC pressure sensor
Between (2) and (1) Signal 0.5 – 4.5 V
(Internal defect)
If the voltage is abnormal , replace the PPC pressure sensor with
another one and make a judgment based on the failure code.(If fail-
ure code "E" goes off, swing RIGHT PPC pressure sensor is defec-
tive.)
a Prepare by setting starting switch to OFF position ,and trouble-
Open circuit in wiring har- Wiring harness between HC02 (female) (31) Resis-
Max. 1 Ω
8
Max. 1 Ω
Max. 1 Ω
a Prepare by setting starting switch to OFF position ,and trouble-
Ground fault of wiring har-
ness
(Contact with ground cir- Resis-
(female) (33) and HP06 (female) (2)) and Min. 1 MΩ
cuit ) tance
ground
a Prepare by setting starting switch to OFF position ,then turn start-
Probable
ground
cause and
standard value
under normal
Wiring harness between H16 (female) (7) and Resis-
Disconnection in wiring har- HR06 (female) (1) tance
ness (Disconnection in wir- Wiring harness between HR06 (female) (2) and Resis-
11 Max. 1 Ω
ing or defective contact in HC01 (female) (13) tance
connector) Wiring harness between HC02 (female) (37) Resis-
Max. 1 Ω
and HR06 (female) (5) tance
Wiring harness between HR06 (female) (3) and Resis-
Max. 1 Ω
HC01 (female) (13) tance
Between wiring harness H16 (female) (7) – Resis-
12 ness (contact with ground Min. 1 MΩ
HR06 (female) (1) and ground tance
circuit)
Between wiring harness HC02 (female) (37) – Resis-
Min. 1 MΩ
Defective PPC pressure
without turning starting switch to ON position (troubleshooting of
lock sensing relay (internal
13 unit).
disconnection or short cir-
HR06 (male) Resistance
cuit)
Between (1) and (2) 300 - 600Ω
Defective PPC pressure Terminal PPC lock lever position Voltage
14 lock sensing relay (defec- Between HC02 (37)
Lock Min. 10 V
tive internal contact) and HC01 (13)
Between HC02 (37)
Released (operation side) Max. 2 V
and HC01 (13)
If causes 7– 14 are not detected, the hybrid system controller may be
15 defective (Since trouble exists in system ,troubleshooting cannot be
system controller)
performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 29

SEN05251-03 Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt.
40-305 30 PC200, 200LC-8E0 (Hybrid)

Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen Opn/Short Cir. SEN05251-03
Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen Opn/Short Cir.
User code Failure code Open or short circuit in HYB swing LEFT PPC pressure sensor
Failure
E09 DHVBKZ (Hybrid controller system)
q Signal voltage of swing LEFT PPC pressure sensor for hybrid system is below 0.3 V or above 4.7 V.
q When control lock lever is shifted down, swing LEFT PPC hydraulic pressure sensor is 0.5 MPa {5
kg/cm 2} or swing LEFT PPC pressure sensor for hybrid system is 0.5 MPa {5 kg/cm2} and generator
Detail of failure
speed is 500 rpm or more.
q When generator speed is 500 rpm or more, pressure of hybrid swing right PPC pressure sensor is
0.5 MPa {5 kg/cm2} or more higher than pressure of swing PPC right pressure sensor 1.
2
Action of con- q Controls system by setting swing LEFT PPC pressure at 0 MPa {0 kg/cm }.
troller
position.
q Swinging stops suddenly during left swinging motion. Continues swinging during left swinging mo-
Problem on
tion. After stopping, machine cannot swing to the left.
machine
q Operator cannot control the swinging motion.
a If pressure sensor 5V circuit (3) and ground circuit (1) are connected reversely, sensor will be broken.
Accordingly, take extreme care when checking.
q Voltage of swing left PPC pressure sensor can be checked with monitoring function.
Related infor-
(Code: 09006 Swing left PPC pressure sensor 2 voltage)
mation
q This failure code may be displayed when communication with pump controller has abnormality. Ac-
cordingly, if [DA2RMC] or [GA14KR] is also displayed, perform troubleshooting for it first.

Defective sensor power sup- If error code [DA25KP], [GA13MC] or [GA14KR] is displayed, trou-
1
ply system bleshoot it first.
a Prepare by setting starting switch to OFF position, then start engi-
en and troubleshoot.
P03 Voltage
Power
Defective swing LEFT PPC Between (3) and (1) 4.5 – 5.5 V
supply
2 pressure sensor
(Internal defect)
ure code "E" goes off, swing LEFT PPC pressure sensor is defec-
tive.)
Disconnection in wiring har- Wiring harness between C02 (female) (18) Resis-
Probable Max. 1 Ω
ness and P03 (female) (1) tance
causes and 3
(Disconnection or defective Wiring harness between C02 (female) (16) Resis-
standard value Max. 1 Ω
contact in connector) and P03 (female) (2) tance
under normal Wiring harness between C02 (female) (9), Resis-
J06 and P03 (female) (3) tance
4 ness Between wiring harness (between C01
Resis-
(Contact with ground circuit) (female) (16) and P03 (female) (2)) and Min. 1 MΩ
tance
ground
(female) (16) and P03 (female) (2)) and Voltage Max. 1 V
ground
When any of causes 1 – 5 is not detected, even if left swing opera-
tion is not performed, if 09001 swing left PPC pressure displayed by
6 Defective pump controller monitoring function exceeds 0.5 MPa {5 kg/cm2}, pump controller
may be defective. (Since trouble is in system, troubleshooting can-
not be performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 31

SEN05251-03 Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen Opn/Short Cir.

HP04 Voltage
Power
Defective swing LEFT PPC Between (3) and (1) 4.5 – 5.5 V
supply
7 pressure sensor
(Internal defect)
ure code "E" goes off, swing LEFT PPC pressure sensor is defec-
tive.)
Max. 1 Ω
8
Max. 1 Ω
Max. 1 Ω
Ground fault of wiring har- shoot without turning starting switch to ON position.
Resis-
tance
ground
(female) (43) and HP04 (female) (2)) and Voltage Max. 1V
Probable ground
causes and a Prepare with starting switch OFF, then turn starting switch to ON
standard value position and perform troubleshooting.
under normal Wiring harness between H16 (female) (7) and Resis-
Max. 1 Ω
conditions Disconnection in wiring har- HR06 (female) (1) tance
ness (Disconnection in wiring Wiring harness between HR06 (female) (2) Resis-
11 Max. 1 Ω
or defective contact in con- and HC01 (female) (13) tance
nector) Wiring harness between HC02 (female) (37) Resis-
Max. 1 Ω
and HR06 (female) (5) tance
Wiring harness between HR06 (female) (3) Resis-
Max. 1 Ω
and HC01 (female) (13) tance
Between wiring harness H16 (female) (7) – Resis-
12 ness (contact with ground Min. 1 MΩ
circuit)
Between wiring harness HC02 (female) (37) Resis-
Min. 1 MΩ
– HR06 (female) (5) and ground tance
Defective PPC pressure lock without turning starting switch to ON position (troubleshooting of
13 sensing relay (internal dis- unit).
connection or short circuit) HR06 (male) Resistance
Between (1) and (2) 300 - 600Ω
PPC lock lever posi-
Defective PPC pressure lock Terminal Voltage
tion
14 sensing relay (defective
Between HC02 (37)
internal contact) Lock Min. 10 V
and HC01 (13)
Between HC02 (37) Released (operation
Max. 2 V
and HC01 (13) side)
If causes 7 – 14 are not detected, the hybrid system controller may
15 be defective (Since trouble exists in system, troubleshooting cannot
system controller)
be performed.)
40-305 32 PC200, 200LC-8E0 (Hybrid)

Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen Opn/Short Cir. SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 33

SEN05251-03 Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/Short Cir.
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/Short Cir.
User code Failure code Open or short circuit in HYB Arm OUT PPC pressure sensor
Failure
E09 DHVCKZ (Hybrid controller system)
Detail of failure q Signal voltage of HYB Arm OUT PPC pressure sensor circuit is below 0.3 V or above 4.7 V.
q Controls the system by setting Arm OUT PPC pressure at 0 MPa {0 kg/cm2}.
Action of con- q Low speed matching function does not operate.
position.
Problem on
q Disabled low speed matching
machine
will break. Accordingly, exercise extreme care when checking.
Related infor-
q Stroke of Arm OUT PPC pressure sensor can be checked with monitoring function.
mation
(Code: 42105 Arm lever stroke)

ply system
HP03 Voltage
Defective Arm OUT PPC Power
Between (3) and (1) 4.5 – 5.5 V
2 pressure sensor supply
ure code "E" goes off, Arm OUT PPC pressure sensor is defective.)
Max. 1 Ω
standard value ness and HP03 (female) (3) tance
3
under normal (Open circuit or defective Wiring harness between HC02 (female) (34) Resis-
Max. 1 Ω
conditions contact in connector) and HP03 (female) (2) tance
Max. 1 Ω
Resis-
tance
ground
ground
If causes 1 - 5 are not detected, the hybrid system controller may be
6 defective (Since a trouble exists in the system, troubleshooting can-
system controller)
not be performed.)
40-305 34 PC200, 200LC-8E0 (Hybrid)

Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/Short Cir. SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 35

SEN05251-03 Failure code [DW45KA] Swing Brake Sol. Valve Open Cir.
Failure code [DW45KA] Swing Brake Sol. Valve Open Cir.
User code Failure code Swing holding brake solenoid system open circuit
Failure
E09 DW45KA (Hybrid controller system)
Detail of failure q Open circuit was detected when output to swing holding brake solenoid is turned to OFF.
q Turns output to break solenoid to OFF.
Action of con-
troller
position.
Problem on
q Machine cannot swing upper structure (Swing holding brake cannot be reset).
machine
q If solenoid valve system and wiring harness are normal, machine can swing if turning the swing hold-
ing break release switch to RELEASE position. (However, swing holding brake does not operate
when machine is stopped).
Related infor- q During troubleshooting, turn swing lock switch to OFF position, and turn swing holding brake release
mation switch to RELEASE position.
q The operating condition of swing holding brake solenoid can be checked with monitoring function.
(Code: 09700 Hybrid system controller relay output)

Defective swing holding
1 brake solenoid
Between (1) and (2) 20 – 60 Ω
Defective diode array D01 shoot without turning starting switch to ON position.
2
(Internal disconnection) D01 (male) Digital circuit tester Continuity
Probable
Between (7) and (3) Diode mode Continuity
causes and
standard value
under normal Defective swing lock switch
3 S04 (male) Swing lock switch Continuity
conditions (Internal disconnection)
OFF Max. 1 Ω
Between (3) and (4)
ON Min. 1 MΩ
Defective emergency stop
Emergency stop
4 switch HS01 (Ring terminal) Continuity
switch
OFF Max. 1 Ω
ON Min. 1 MΩ
40-305 36 PC200, 200LC-8E0 (Hybrid)

Failure code [DW45KA] Swing Brake Sol. Valve Open Cir. SEN05251-03

Max. 1 Ω
and D01 (female) (7) tance
Wiring harness between D01 (female) (3) and Resis-
Max. 1 Ω
S04 (female) (3) via J02 tance
Max. 1 Ω
Open circuit in wiring har- HH12 (female) (1) tance
Probable
ness Wiring harness between HH12 (male) (1) and Resis-
causes and 5 Max. 1 Ω
(Open circuit or defective HS01 (22) tance
standard value
contact in connector) Wiring harness between HS01 (21) and Resis-
under normal Max. 1 Ω
HH12 (male) (2) tance
conditions
Wiring harness between HH12 (female) (2) Resis-
Max. 1 Ω
Wiring harness between V03 (female) (2) and Resis-
Max. 1 Ω
C02 (female) (120) tance
Wiring harness between C01 (female) (3) and Resis-
Max. 1 Ω
T04 tance
Defective inverter (Hybrid If causes 1 – 5 are not detected, the hybrid system controller may be
6 system controller) defective (Since a trouble exists in the system, troubleshooting can-
not be performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 37

SEN05251-03 Failure code [DW45KA] Swing Brake Sol. Valve Open Cir.
40-305 38 PC200, 200LC-8E0 (Hybrid)

Failure code [DW45KA] Swing Brake Sol. Valve Open Cir. SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 39

SEN05251-03 Failure code [DW45KB] Swing Brake Sol. Valve Short Cir.
Failure code [DW45KB] Swing Brake Sol. Valve Short Cir.
User code Failure code Short circuit in swing holding brake solenoid system
Failure
(Hybrid controller system)
E09 DW45KB
Detail of failure q Short circuit is detected when output to swing holding brake solenoid is turned to ON.
Action of con-
troller
position.
Problem on
machine
q If solenoid valve system and wiring harness are normal, machine can swing if turning the swing
break release switch to RELEASE position. (However, swing holding brake does not operate when
machine is stopped).
Related infor-
q Turn swing lock switch to OFF position during troubleshooting.
mation
q The operating condition of swing holding brake solenoid can be checked with monitoring function.
(Code 09700: Hybrid system controller relay output)
q Method of reproducing failure code: Turn starting switch to ON position

1 If failure code [GA13MC] is displayed, troubleshoot it first.
ply system
Defective swing holding shoot without turning starting switch to ON position.
2 brake solenoid (Internal short V03 (male) Resistance
circuit or ground fault) Between (1) and (2) 20 – 60 Ω
Probable Between (1) and ground Min. 1 MΩ
causes and a Prepare by setting starting switch to OFF position, and trouble-
standard value shoot without turning starting switch to ON position.
under normal Between wiring harness (between HC01
conditions Resis-
Ground fault wiring harness (female) (8) and D01 (female) (7)) and Min. 1 MΩ
3 tance
(Contact with ground circuit) ground
Between wiring harness (between HC01
Resis-
(female) (8) and V03 (female) (1) via J02) Min. 1 MΩ
tance
and ground
4 be defective (Since a trouble exists in the system, troubleshooting
system controller)
cannot be performed.)
40-305 40 PC200, 200LC-8E0 (Hybrid)

Failure code [DW45KB] Swing Brake Sol. Valve Short Cir. SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 41

SEN05251-03 Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir.
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir.
User code Failure code Short circuit in swing holding brake solenoid valve power line
Failure
E09 DW45KY
Detail of failure q Short circuit is detected when output to swing holding brake solenoid is turned to ON.
Action of con-
troller
OFF position.
Problem on
machine
q If solenoid valve system and wiring harness are normal, machine can swing if turning the swing
holding break release switch to RELEASE position. (However, swing holding brake does not oper-
ate when machine is stopped).
Related infor-
q Turn swing lock switch to OFF position during troubleshooting.
mation
q The operating condition of swing brake solenoid can be checked with monitoring function.
(Code: 09700 Hybrid system controller relay output)

ply system
a Prepare by setting starting switch to OFF position, then turn
Probable starting switch to ON position and troubleshoot.
causes and Between wiring harness (between HC01
standard value Hot short in wiring harness (female) (8) and D01 (female) (7)) and Voltage Max. 1 V
2
under normal (Contact with 24 V circuit) ground
conditions Between wiring harness (between
D01(female) (3) and V03 (female) (1) via Voltage Max. 1 V
J02) and ground
Defective inverter (Hybrid If causes 1 – 2 are not detected, the hybrid system controller may
3 system controller) be defective (Since a trouble exists in the system, troubleshooting
40-305 42 PC200, 200LC-8E0 (Hybrid)

Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir. SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 43

SEN05251-03 Failure code [GA01KA] Power Cable Interlock Open Circuit
Failure code [GA01KA] Power Cable Interlock Open Circuit
User code Failure code Open circuit in power cable interlock circuit
Failure
E09 GA01KA (Hybrid controller system)
q Power cable connectors that connects inverter, motor-generator, capacitor and swing electric motor
Detail of fail- has open circuit.
ure q The cover is removed from the power cable connector of the inverter, generator motor or swing motor.
q Power cable connector is connected upside down.
q Stops swing motor and motor generator control, then turns swing holding brake ON.
Action of con-
troller
position.
Problem on
q Machine cannot swing upper structure.
machine
Related infor-
q If failure code [GA1VFS] is displayed at the same time, the power cable connector HC06 may not be
mation
fitted securely.

Disconnected power cable
1 a Visually check that the power cable connector is disconnected.
connector
Defective fit or failure of
2 Visually check that the power cable connector is fitted securely.
power cable connector
Removed cover from Visually check that cover of connecting part of power cable is mounted
3
power cable connector normally.
Visually check that the mark on power cable connector is on the same
Improper connection of
4 side of the mark on the component to be connected. (See part (a) in the
following figure.)
a Prepare by setting starting switch to OFF position, and troubleshoot
Open circuit in wiring har- without turning starting switch to ON position.
Probable 5 ness (Internal disconnec- a Connect all power cable connectors and troubleshoot.
causes and tion) Wiring harness between HC02 (female) (38) and Resis-
standard Max. 1 Ω
value under a Prepare by setting starting switch to OFF position, and troubleshoot
normal condi- without turning starting switch to ON position.
tions Wiring harness between HC02 (female) (38) and Resis-
Open circuit in wiring har- Max. 1 Ω
PM01 (female) (10) tance
6 ness
Wiring harness between PM01 (female) (9) and Resis-
(Internal disconnection) Max. 1 Ω
GM01 (female) (8) tance
Wiring harness between GM 01 (female) (7) and Resis-
Max. 1 Ω
Ground fault in wiring har- Between wiring harness (between HC02 (female) Resis-
Min. 1 MΩ
ness (38) and PM01 (female) (10)) and ground tance
7
(Contact with ground cir- Between wiring harness (between PM01 (female) Resis-
Min. 1 MΩ
cuit) (9) and GM01 (female) (8)) and ground tance
Between wiring harness (between GM01 (female) Resis-
Min. 1 MΩ
(7) and HC02 (female) (48)) and ground tance
40-305 44 PC200, 200LC-8E0 (Hybrid)

Failure code [GA01KA] Power Cable Interlock Open Circuit SEN05251-03

a Prepare by setting starting switch to OFF position, then turn starting
switch to ON position and troubleshoot.
Between wiring harness (between HC02 (female)
Voltage Max. 1 V
Hot short in wiring harness (38) and PM01 (female) (10)) and ground
8
(Contact with 24V circuit) Between wiring harness (between PM01 (female)
Voltage Max. 1 V
(9) and GM01 (female) (8)) and ground
Between wiring harness (between GM01 (female)
Voltage Max. 1 V
Probable (7) and HC02 (female) (48)) and ground
causes and a Prepare by setting starting switch to OFF position, and troubleshoot
standard Open circuit in wiring of without turning starting switch to ON position.
value under 9 motor-generator a Connect all power cable connectors and troubleshoot.
normal condi- (Internal disconnection) Wiring harness between GM 01 (male) (7) and Resis-
tions Max. 1 Ω
GM01 (male) (8) tance
Open circuit in wiring of without turning starting switch to ON position.
10 swing motor a Connect all power cable connectors and troubleshoot.
(Internal disconnection) Wiring harness between PM 01 (male) (9) and Resis-
Max. 1 Ω
PM01 (male) (10) tance
If causes 1 – 10 are not detected, the hybrid system controller may be
11 defective (Since a trouble exists in the system, troubleshooting cannot
system controller)
be performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 45

SEN05251-03 Failure code [GA02KZ] DC Line Open/Short Circuit
Failure code [GA02KZ] DC Line Open/Short Circuit
User code Failure code Open or short circuit in DC line

Failure
E09 GA02KZ (Hybrid controller system)
Detail of failure q The insulation of cable connecting capacitor and inverter has deteriorated.
q Stops swing motor and motor-generator control, then turns swing holding brake ON.
Action of con-
troller
OFF position.
Problem on q Machine cannot swing upper structure.
machine q Engine speed increases to speed indicated by throttle.
Related infor-
mation

Probable
causes and Defective insulation between
standard value 1 hybrid system components q Visually check that cable is not damaged.
under normal and chassis ground
conditions Defective high voltage sec-
2 Perform high-voltage section common troubleshooting 1 – 7.
tion of hybrid component
40-305 46 PC200, 200LC-8E0 (Hybrid)

Failure code [GA04KG] Abnormal DC HW Volt. Before Booster SEN05251-03
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster
User code Failure code HW source voltage high error in direct current line before boosting
Failure
E09 GA04KG (Hybrid controller system)
Detail of failure q 390 V or higher capacitor voltage is detected by the hardware.

Action of con-
troller
OFF position.
q Capacitor voltage can be checked with monitoring function.
Related infor-
(Code: 09300 Capacitor voltage)
mation

Probable
causes and 1 Defective capacitor Perform high-voltage section common troubleshooting 1.
standard value Defective capacitor power
2 Perform high-voltage section common troubleshooting 5.
under normal cable
conditions Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be
3
system controller) performed.
PC200, 200LC-8E0 (Hybrid) 40-305 47

SEN05251-03 Failure code [GA05KG] Abnormal DC SW Volt. Before Booster
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster
User code Failure code SW source voltage high error in direct current line before boosting
Failure
Detail of failure q 340 V or higher capacitor voltage is detected by the hardware.

Action of con-
troller
position.
Related infor-
mation

Probable
under normal cable
3
40-305 48 PC200, 200LC-8E0 (Hybrid)

Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster SEN05251-03
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster
User code Failure code SW output voltage low error in direct current line before boosting
Failure
E09 GA05KP (Hybrid controller system)
Detail of failure q The 100 V or lower capacitor voltage is detected by the software.
Action of con-
troller
OFF position.
Related infor-
(Code 09300: Capacitor voltage)
mation

Probable
under normal cable
3
PC200, 200LC-8E0 (Hybrid) 40-305 49

SEN05251-03 Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster
User code Failure code Open or short circuit in voltage sensor in direct current line before
Failure boosting
Detail of failure q Abnormality of capacitor voltage sensor in the inverter is detected.
Action of con-
troller
OFF position.
Related infor-
mation
causes and
standard value Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be
under normal 1
conditions
40-305 50 PC200, 200LC-8E0 (Hybrid)

Failure code [GA08KG] Abnormal. DC HW Volt. After Booster SEN05251-03
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster
User code Failure code HW source voltage high error in direct current line after boosting
Failure
Detail of failure q Overvoltage abnormality of power train Is detected by the hardware.

Action of con-
troller
OFF position.
q Voltage of power train can be checked with monitoring function.
Related infor-
(Code: 09200 DC voltage of power train)
mation

Check if swing emergency stop switch was operated in normal
Operation of swing emer- state.
1 gency stop switch If it was operated, turn it to OFF position and turn starting switch to
Probable
(when system is normal) ON position. If failure code is not displayed and abnormal phenom-
causes and
enon does not occur, machine can be operated as it is.
standard value
under normal 2 Defective motor-generator
conditions 3 Defective swing motor
Defective inverter (Hybrid Perform high-voltage section common troubleshooting 1 – 7.
4
system controller)
5 Defective capacitor
PC200, 200LC-8E0 (Hybrid) 40-305 51

SEN05251-03 Failure code [GA09KG] Abnormal. DC SW Volt. After Booster
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster
User code Failure code SW source voltage high error in direct current line after boosting
Failure
Detail of failure q Overvoltage abnormality of power train is detected by the hardware.

Action of con-
troller
OFF position.
Related infor-
mation

1 gency stop switch (when If it was operated, turn it to OFF position and turn starting switch to
Probable
system is normal) ON position. If failure code is not displayed and abnormal phenom-
causes and
enon does not occur, machine can be operated as it is.
standard value
under normal 2 Defective motor-generator
conditions 3 Defective swing motor
Defective inverter (Hybrid Perform high-voltage section common troubleshooting 1 – 7.
4
system controller)
40-305 52 PC200, 200LC-8E0 (Hybrid)

Failure code [GA09KP] Low DC SW Output Volt. After Booster SEN05251-03
Failure code [GA09KP] Low DC SW Output Volt. After Booster
User code Failure code SW output voltage low error in direct current line after boosting
Failure
E09 GA09KP (Hybrid controller system)
Detail of failure q Overvoltage abnormality of power train is detected by the hardware.

Action of con-
troller
OFF position.
Related infor-
mation
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 53

SEN05251-03 Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster
User code Failure code Open or short circuit in voltage sensor in direct current line before
Failure boosting
E09 GA0AKZ (Hybrid controller system)
Detail of failure q Abnormality of capacitor voltage sensor in the inverter is detected.
Action of con-
troller
OFF position.
Related infor-
mation
causes and
under normal 1
conditions
40-305 54 PC200, 200LC-8E0 (Hybrid)

Failure code [GA0BKZ] AC Line Open/Short Circuit SEN05251-03
Failure code [GA0BKZ] AC Line Open/Short Circuit
User code Failure code Open or short circuit in alternate current line
Failure
E09 GA0BKZ (Hybrid controller system)
q The insulation of cable connecting between swing motor or power generating motor and inverter
Detail of failure
has deteriorated.
Action of con-
troller
OFF position.
Related infor-
q Method of reproducing failure code: Start engine and key OFF
mation

Probable
causes and Defective insulation between
standard value 1 hybrid system components q Visually check that cable is not damaged.
under normal and chassis ground
conditions Defective high voltage sec-
2 Perform high-voltage section common troubleshooting 1 – 7.
tion of hybrid component
PC200, 200LC-8E0 (Hybrid) 40-305 55

SEN05251-03 Failure code [GA11KK] HYB Cont. Low Supply Voltage
Failure code [GA11KK] HYB Cont. Low Supply Voltage
User code Failure code HYB system controller source voltage low error
Failure
E09 GA11KK (Hybrid controller system)
Detail of failure q The voltage of hybrid system controller power supply circuit is low.
Action of con- q Stops swing motor and motor-generator control, then turns swing holding brake ON.
Problem on
machine
Related infor-
q This power supply is commonly used for the machine monitor.
mation
q Troubleshooting (E-1)

Loose contact or corrosion of a Battery terminal may be loose or have corroded. Check it direct-
1
battery terminals ly.
Starting switch Voltage
Between positive and
2 Defective battery voltage OFF Min. 12 V
negative terminals
START Min. 6.2 V
3 Defective fuse No. 2 If fuse is broken, circuit probably has ground fault. (See Cause 6)
4 See fuse No. 17. If fuse is broken, circuit probably has ground fault. (See Cause 6)

Wiring harness between F01 to 17 and Resis-

Max. 1 Ω
HH07 (female) (2) tance
Wiring harness between HH07 (male) (2) Resis-
Max. 1 Ω
Probable and HC01 (female) (5), (11) tance
causes and Wiring harness between F01 to 17 and H15 Resis-
Max. 1 Ω
standard value (female) (1) tance
under normal Wiring harness between H15 (male) (1) and Resis-
Max. 1 Ω
conditions starting switch (B) tance
Wiring harness between starting switch Resis-
Max. 1 Ω
Open circuit in wiring har- (ACC) and H15 (male) (5) tance
ness Wiring harness between H15 (male) (5) and Resis-
5 Max. 1 Ω
(Open circuit or defective HH07 (female) (1) tance
contact in connector) Wiring harness between HH07 (male) (1) Resis-
Max. 1 Ω
and HC01 (female) (6), (12) tance
Wiring harness between F01 to 2 and HH07 Resis-
Max. 1 Ω
(female) (4) tance
Wiring harness between HH07 (male) (4) Resis-
Max. 1 Ω
and HC01 (female) (1), (7) tance
Wiring harness between HC01 (female) Resis-
Max. 1 Ω
(13), (19) and HH07 (male) (5) tance
Max. 1 Ω
and ground (T04), (T07) tance
Wiring harness between HC01 (female) Resis-
Max. 1 Ω
(17), (23) and HH07 (male) (3) tance
Max. 1 Ω
and ground (T05), (T06) tance
40-305 56 PC200, 200LC-8E0 (Hybrid)

Failure code [GA11KK] HYB Cont. Low Supply Voltage SEN05251-03

Between wiring harness (between F01 to 17 Resis-
Min. 1 MΩ
and HH07 (female) (2)) and ground tance
Between wiring harness (between HH07
Resis-
(male) (2) and HC01 (female) (5), (11)) and Min. 1 MΩ
tance
ground
Between wiring harness (between F01 to 17 Resis-
Min. 1 MΩ
and H15 (female) (1)) and ground tance
Between wiring harness (between H15
Resis-
(male) (1) and starting switch (B)) and Min. 1 MΩ
tance
Ground fault in wiring har- ground
6 ness (Contact with ground Between wiring harness (between starting
circuit) Resis-
switch (ACC) and H15 (male) (5)) and Min. 1 MΩ
tance
ground
Between wiring harness (between H15
Resis-
(female) (5) and HP07 (female) (1)) and Min. 1 MΩ
tance
ground
Probable Between wiring harness (between HH07
causes and Resis-
(male) (1) and HC01 (female) (6), (12)) and Min. 1 MΩ
standard value tance
ground
under normal
conditions Between wiring harness (F01 to 02 and Resis-
Min. 1 MΩ
HH07 (female) (4)) and ground tance
Between wiring harness (HH07 (male) (4) Resis-
Min. 1 MΩ
and HC01 (female) (1), (7)) and ground tance
Short circuit in wiring har- Between HC01 (female) (1), (5), (6), (7),
7 ness (11), (12) and HC01 (female) (13), (17),
(with another wiring harness) (19), (23) pins Resis-
Max. 1 Ω
tance
(Cables are disconnected form battery ter-
minals.)
Connecting parts between fuse No. 2 and 17, wiring harness and
HH07, between HH07, wiring harness and hybrid system controller
Defective wiring harness may be defective. Check them directly.
8
connector 1. Looseness of connector, breakage of lock, or breakage of seal
2. Corrosion, bending, breakage, push-in, or expansion of pin
3. Moisture or dirt in connector or defective insulation
If causes 1 – 8 are not detected, the inverter (hybrid system control-

Defective inverter (hybrid
9 ler) may be defective (Since a trouble exists in the system, trouble-
system controller)
shooting cannot be performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 57

SEN05251-03 Failure code [GA11KK] HYB Cont. Low Supply Voltage
40-305 58 PC200, 200LC-8E0 (Hybrid)

Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure SEN05251-03
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure
User code Failure code Defective operation of HYB system controller high power supply
Failure
E09 GA12MC (Hybrid controller system)
Defail of failure q Voltage of power train does not drop below the specified level.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
under normal cable
conditions Defective high voltage sec- Since trouble is in system, testing and troubleshooting cannot be
3
tion of hybrid component performed.
PC200, 200LC-8E0 (Hybrid) 40-305 59

SEN05251-03 Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON
User code Failure code HYB system controller high power supply does not increase.
Failure
E09 GA12NK (Hybrid controller system)
Detail of failure q Electrical system in the inverter does not start.

Action of con-
troller
OFF position.
Related infor-
mation

1 Defective capacitor Perform high-voltage section common troubleshooting 1.
Probable
causes and 2 Defective motor-generator Perform high-voltage section common troubleshooting 3.
under normal cable
conditions Defective generator power
cable
Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be
5
40-305 60 PC200, 200LC-8E0 (Hybrid)

Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF SEN05251-03
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF
User code Failure code HYB system controller high power supply does not drop.
Failure
E09 GA12NL (Hybrid controller system)
Detail of failure q Although a certain time has passed, voltage of power train does not drop below the specified level.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and 1 Defective motor-generator Perform high-voltage section common troubleshooting 3.
standard value Defective generator power
under normal cable
3
PC200, 200LC-8E0 (Hybrid) 40-305 61

SEN05251-03 Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure
User code Failure code Defective operation of HYB system controller sensor power supply
Failure
E09 GA13MC (Hybrid controller system)
Detail of failure q Voltage of 5 V sensor power output circuit dropps below 2.5 V or exceeds above 6.0 V.
Action of con- q Turns OFF the 5 V sensor power output.
Problem on q Because swing PPC pressure sensor data is not obtained, machine cannot swing the upper struc-
machine ture.
Related infor-
mation

HP03–07 Voltage
Defective PPC pres-
Between (3) and (1) Power supply 4.5 – 5.5 V
1 sure sensor
(Internal failure) Between (2) and (1) Signal 0.5 – 4.5 V
If the voltage is abnormal, replace the PPC pressure sensor with another
one and make a judgment based on the failure code. (If failure code "E"
goes off, swing RIGHT PPC pressure sensor is defective.)
Wiring harness between HC02 (female) (31) and
HP03 (female) (3), HC02 (female) (31) and
Resis-
HP04 (female) (3), HP05 (female) (3) and HP06 Max. 1 Ω
tance
(female) (3), HP05 (female) (3) and HP07
(female) (3)
Wiring harness between HC02 (female) (53) and Resis-
Max. 1 Ω
Probable Open circuit in wiring HP03 (female) (2) tance
causes and harness Wiring harness between HC02 (female) (43) and Resis-
Max. 1 Ω
standard value 2 (Open circuit or defec- HP04 (female) (2) tance
under normal tive contact in connec- Wiring harness between HC02 (female) (34) and Resis-
Max. 1 Ω
conditions tor) HP05 (female) (2) tance
Max. 1 Ω
HP06 (female) (2) tance
Max. 1 Ω
HP07 (female) (2) tance
Wiring harness between HC02 (female) (62),
(63) and HP03 (female) (1), HP04 (female) (1), Resis-
Max. 1 Ω
HP05 (female) (1), HP06 (female) (1), and HP07 tance
(female) (1)
Between wiring harness (between HC02 Resis-
Min. 1 MΩ
(female) (53) and HP03 (female) (2)) and ground tance
Ground fault in wiring Min. 1 MΩ
3 harness (Contact with
ground circuit) Min. 1 MΩ
Min. 1 MΩ
Min. 1 MΩ
40-305 62 PC200, 200LC-8E0 (Hybrid)

Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure SEN05251-03

Voltage Max. 1 V
(female) (53) and HP03 (female) (2)) and ground
Probable Between wiring harness (between HC02
Hot short in wiring har- Voltage Max. 1 V
causes and (female) (43) and HP04 (female) (2)) and ground
4 ness (Contact with 24V
standard value circuit) Voltage Max. 1 V
under normal
conditions Voltage Max. 1 V
Voltage Max. 1 V
Defective inverter If causes 1 – 4 are not detected, the hybrid system controller may be
5 (Hybrid system control- defective (Since a trouble exists in the system, troubleshooting cannot
ler) be performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 63

SEN05251-03 Failure code [GA14KR] HYB Control. KOMNET Comm. Failure
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure
User code Failure code KOMNET communication error of HYB system controller
Failure
E09 GA14KR (Hybrid controller system)
q Hybrid system controller detects a communication error in CAN communication circuit that is linked
Detail of failure
to the pump controller and engine controller.
Action of con- q Continues to control by using CAN information that was obtained before failure detection.
q Information may not correctly transmitted normally by KOMNET communication and machine may
Problem on
not operate normally.
machine
(Type of trouble depends on failed section.)
Related infor-
mation

Wiring harness between CM02 (female) (8,
9) and C01 (female) (45), CM02 (female) (8,
Resis-
9) and N10 (female) (1), CM02 (female) (8, Max. 1 Ω
tance
9) and CE02 (female) (46), CM02 (female)
Open circuit in wiring har- (8, 9) and K02 (female) (A)
ness Wiring harness between K02 (male) (A) and Resis-
1 Max. 1 Ω
(Open circuit or defective HK02 (female) (A), HCO2 (25) tance
contact in connector) Wiring harness between CM02 (female) (10)
and C01 (female) (64), CM02 (female) (10)
Resis-
and N10 (female) (2), CM02 (female) (10) Max. 1 Ω
tance
and CE02 (female) (47), CM02 (female) (10)
and K02 (female) (B)
Wiring harness between K02 (male) (B) and Resis-
Max. 1 Ω
HK02 (female) (B), HC02 (35) tance
Probable a Prepare by setting starting switch to OFF position, and trouble-
causes and shoot without turning starting switch to ON position.
standard value Between wiring harness (between CM02
under normal (female) (8), (9) and N08 (male) (3), CM02
conditions (female) (8), (9) and C01 (female) (45),
Resis-
CM02 (female) (8), (9) and N10 (female) (1), Min. 1 MΩ
tance
CM02 (female) (8), (9) and CE02 (female)
(46), CM02 (female) (8), (9) and K02
(female) (A)) and ground
Between wiring harness (between K02
Ground fault in wiring har- Resis-
(male) (A) and HK02 (female) (A), HC02 Min. 1 MΩ
2 ness tance
(25)) and ground
(Contact with ground circuit)
Between wiring harness (between CM02
(female) (10) and N08 (male) (10), CM02
(female) (10) and C01 (female) (64), CM02
Resis-
(female) (10) and N10 (female) (2), CM02 Min. 1 MΩ
tance
(female) (10) and CE02 (female) (47), CM02
(female) (10) and K02 (female) (B)) and
ground
Resis-
(male) (B) and HK02 (female) (B), HC02 Min. 1 MΩ
tance
(35)) and ground
40-305 64 PC200, 200LC-8E0 (Hybrid)

Failure code [GA14KR] HYB Control. KOMNET Comm. Failure SEN05251-03

starting switch to ON position and troubleshoot.
Between wiring harness (between CM02
(female) (8), (9) and N08 (male) (3), CM02
(female) (8), (9) and C01 (female) (45),
CM02 (female) (8), (9) and N10 (female) (1), Voltage Max. 5.5 V
CM02 (female) (8), (9) and CE02 (female)
(46), CM02 (female) (8), (9) and K02
(female) (A)) and ground
Hot short in wiring harness (male) (A) and HK02 (female) (A), HC02 Voltage Max. 5.5 V
3
(Contact with 24V circuit) (25)) and ground
Probable Between wiring harness (between CM02
causes and (female) (10) and N08 (male) (10), CM02
standard value (female) (10) and C01 (female) (64), CM02
under normal (female) (10) and N10 (female) (2), CM02 Voltage Max. 5.5 V
conditions (female) (10) and CE02 (female) (47), CM02
(female) (10) and K02 (female) (B)) and
ground
(male) (B) and HK02 (female) (B), HC02 Voltage Max. 5.5 V
(35)) and ground
resistance
4 HK02 (male) Resistance
(Internal short circuit or dis-
connection) Between (A) and (B) 120 ± 12 Ω
5 be defective (Since a trouble exists in the system, troubleshooting
system controller)
PC200, 200LC-8E0 (Hybrid) 40-305 65

SEN05251-03 Failure code [GA14KR] HYB Control. KOMNET Comm. Failure
40-305 66 PC200, 200LC-8E0 (Hybrid)

Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir SEN05251-03
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir
User code Failure code Open or short circuit of HYB controller insulation deterioration sen-
Failure sor
q Sensor failed that detects insulation deterioration of hybrid system components and chassis
Detail of failure
ground.
Action of con-
troller
Problem on
q No current leakage can be detected.
machine
Related infor-
mation
causes and
standard value Defective hybrid system
under normal 1 Perform high-voltage section common troubleshooting 1. - 7.
components
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 67

SEN05251-03 Failure code [GA16KK] Low HYB Cont. VDD Suppl. Volt.
Failure code [GA16KK] Low HYB Cont. VDD Suppl. Volt.
User code Failure code HYB system controller VDD power supply voltage low error
Failure
E09 GA16KK
Detail of failure q Failure of sensor power supply voltage inside inverter is detected.
q Stops swing motor and motor-generator control, then applies swing holding brake.
Action of con-
troller
OFF position.
Related infor-
mation
probable Cause Standard value in normal condition/Remarks on troubleshooting

causes and
under normal 1
conditions
40-305 68 PC200, 200LC-8E0 (Hybrid)

Failure code [GA17KR] Gen. Mot. Drv. Communication Failure SEN05251-03
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure
User code Failure code Communication error of motor-generator driver

Failure
(Hybrid controller system )
E09 GA17KR
Detail of failure q Internal communication failure 2 of inverter is detected by motor-generator controller.
Action of con-
troller
OFF position.
Related infor-
mation
Probable
causes and Cause Standard value in normal condition/Remarks on troubleshooting
standard value
under normal Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be
1
conditions system controller) performed.
PC200, 200LC-8E0 (Hybrid) 40-305 69

SEN05251-03 Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit
User code Failure code Short circuit of motor-generator driver power line
Failure
E09 GA17KY
Detail of failure q Short circuit of power line is detected in motor-generator driver.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
40-305 70 PC200, 200LC-8E0 (Hybrid)

Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit SEN05251-03
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit
User code Failure code Motor-generator driver open/short circuit error

Failure
E09 GA17KZ
Detail of failure q Disconnection or short circuit of motor-generator driver circuit was detected.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 71

SEN05251-03 Failure code [GA17MB] Gen. Mot. Drv. Function Degraded
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded
User code Failure code Reduced performance of motor-generator driver

Failure
E09 GA17MB
Detail of failure q Internal communication failure 1 of inverter is detected by motor-generator controller.
Action of con-
troller
position.
Related infor-
mation

causes and
under normal 1
conditions
40-305 72 PC200, 200LC-8E0 (Hybrid)

Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure SEN05251-03
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure
User code Failure code Defective operation of motor-generator driver excitation power
Failure supply
E09 GA18MC (Hybrid controller system )
Detail of failure q Electrical system in the inverter does not start.

Action of con-
troller
OFF position.
Related infor-
mation

Probable
1 Defective motor-generator Perform high-voltage section common troubleshooting 3.
causes and
under normal 2 Perform high-voltage section common troubleshooting 7.
cable
conditions
3
PC200, 200LC-8E0 (Hybrid) 40-305 73

SEN05251-03 Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt
User code Failure code Motor-generator driver sub-CPU power supply voltage drop
Failure
E09 GA19KK
Detail of failure q Abnormal power supply voltage to motor-generator controller is detected.
Action of control-
ler
OFF position.
Related informa-
tion

Probable causes
and standard
value under nor- Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be
1
mal conditions system controller) performed.
40-305 74 PC200, 200LC-8E0 (Hybrid)

Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure SEN05251-03
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure
User code Failure code Communication failure of motor-generator driver sub-CPU

Failure
E09 GA19KR
Detail of failure q Communication failure is detected in sub-CPU of motor-generator driver.
Action of con-
troller
position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 75

SEN05251-03 Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con.
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con.
User code Failure code Internal failure of motor-generator driver sub-CPU controller
Failure
E09 GA19KT
Detail of failure q Internal communication failure 3 of the inverter is detected by motor-generator controller.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
40-305 76 PC200, 200LC-8E0 (Hybrid)

Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction SEN05251-03
Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction
User code Failure code Malfunction of motor-generator driver sub-CPU

Failure
E09 GA19MA
Detail of failure q Program written in the motor-generator controller is abnormal.
Action of con-
troller
position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 77

SEN05251-03 Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation
User code Failure code Defective operation of motor-generator driver sub-CPU

Failure
E09 GA19MC
Detail of failure q CPU reset of the motor-generator controller occures.
Action of control-
ler
OFF position.
Related informa-
tion

Probable causes
and standard
1
40-305 78 PC200, 200LC-8E0 (Hybrid)

Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled SEN05251-03
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled
User code Failure code Startup failure of motor-generator driver sub-CPU

Failure
E09 GA19NA
q Internal communication initialization failure of the inverter is detected by the motor-generator con-
Detail of failure
troller.
Action of controller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Related informa-
tion

Probable causes
and standard
1
PC200, 200LC-8E0 (Hybrid) 40-305 79

SEN05251-03 Failure code [GA1AKZ] Gen. Mot. Dr. Temp. Sens. Opn/Short Cir.
Failure code [GA1AKZ] Gen. Mot. Dr. Temp. Sens. Opn/Short Cir.
User code Failure code Open or short circuit of temperature sensor of motor-generator
Failure driver
E09 GA1AKZ (Hybrid controller system)
Detail of failure q Open or short circuit of temperature sensor of motor-generator driver is detected.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 80 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction SEN05251-03
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction
User code Failure code Malfunction of motor-generator driver DC voltage sensor

Failure
E09 GA1BMA
Detail of failure q Malfunction of motor-generator driver DC voltage sensor is detected.
q Stops swing motor and motor-generator control, then swing holding brake.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 81

SEN05251-03 Failure code [GA1DMA] Gen. Motro Driver IPM1 Abnormality
Failure code [GA1DMA] Gen. Motro Driver IPM1 Abnormality
User code Failure code Failure of IPM1 motor-generator driver

Failure
E09 GA1DMA
Detail of failure q Failure of IPM1 motor-generator driver is detected.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal cable
3
40-305 82 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1EMA] Gen. Motor Driver IPM 2 Abnormality SEN05251-03
Failure code [GA1EMA] Gen. Motor Driver IPM 2 Abnormality
User code Failure code Abnormality of IPM2 motor-generator driver

Failure
E09 GA1EMA
Detail of failure q Failure of IPM2 motor-generator driver
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal cable
3
PC200, 200LC-8E0 (Hybrid) 40-305 83

SEN05251-03 Failure code [GA1FKR] Swing Mot. Drv. Communication Failure
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure
User code Failure code Communication failure of swing motor driver

Failure
E09 GA1FKR
Detail of failure q Internal communication failure 2 of the inverter is detected by the swing motor controller.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 84 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1FMA] Abnormal Swing Motor Driver SEN05251-03
Failure code [GA1FMA] Abnormal Swing Motor Driver
User code Failure code Failure of swing motor driver

Failure
E09 GA1FMA
Detail of failure q Abnormality of swing motor inverter output circuit is detected.
q Stops swing motor and motor generator control, then applies swing holding brake.
Action of con-
troller
OFF position.
Problem on q Machine cannot swing the upper structure.
Related infor-
mation

Probable
causes and 1 Defective swing motor Perform high-voltage section common troubleshooting 2.
standard value
under normal Defective swing motor
conditions power cable
3
PC200, 200LC-8E0 (Hybrid) 40-305 85

SEN05251-03 Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU
User code Failure code Voltage drop of swing motor driver sub-CPU power supply
Failure
E09 GA1GKK
Detail of failure q Abnormal power supply voltage of swing motor controller power supply is detected.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 86 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure SEN05251-03
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure
User code Failure code Communication failure of swing motor driver sub-CPU
Failure
E09 GA1GKR
Detail of failure q Communication failure is detected in the swing motor driver sub-CPU.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 87

SEN05251-03 Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal
User code Failure code Internal failure of swing motor driver sub-CPU controller
Failure
E09 GA1GKT
Detail of failure q Internal communication failure 3 of inverter is detected by swing motor controller.
q Stops swing motor and motor-generator control, then applies swing holding brake .
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 88 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfuuction SEN05251-03
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfuuction
User code Failure code Malfunction of swing motor driver sub-CPU

Failure
E09 GA1GMA
Detail of failure q Program written in swing motor controller is abnormal.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 89

SEN05251-03 Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded
User code Failure code Startup failure of swing motor driver sub-CPU
failure
E09 GA1GMB
Detail of failure q Internal communication initialization failure of inverter is detected by the swing motor controller.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 90 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op. SEN05251-03
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op.
User code Failure code Defective operation of swing motor driver sub-CPU
Failure
E09 GA1GMC
Detail of failure q CPU reset of swing motor controller has occures.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 91

SEN05251-03 Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled
User code Failure code Performance drop of swing motor driver sub-CPU
Failure
E09 GA1GNA
Detail of failure q Internal communication failure 1 of inverter is detected by swing motor controller.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 92 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. SEN05251-03
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir.
User code Failure code U-phase temperature sensor of swing motor driver open/short cir-
Failure cuit error
E09 GA1HKZ (Hybrid controller system)
Detail of failure q Temperature sensor failure is detected in the U-phase output circuit of swing motor inverter.
Action of con-
troller
OFF position.
q Swing motor coil temperature can be checked with monitoring function.
Related infor-
(Code 09500: Swing inverter U-phase temperature)
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 93

SEN05251-03 Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir.
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir.
User code Failure code V-phase temperature sensor of swing motor driver open/short cir-
Failure cuit error
E09 GA1JKZ (Hybrid controller system)
Detail of failure q Temperature sensor failure is detected in the V-phase output circuit of swing motor inverter.
Action of con-
troller
OFF position.
Related infor-
(Code 09501: Swing inverter V-phase temperature)
mation

causes and
under normal 1
conditions
40-305 94 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir SEN05251-03
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir
User code Failure code W-phase temperature sensor of swing motor driver open/short cir-
Failure cuit error
E09 GA1KKZ (Hybrid controller system)
Detail of failure q Temperature sensor error is detected in the W-phase output circuit of swing motor inverter.
Action of con-
troller
OFF position.
Related infor-
(Code 09502: Swing inverter U-phase temperature)
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 95

SEN05251-03 Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir.
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir.
User code Failure code Swing motor driver current sensor open/short circuit error
Failure
E09 GA1LKZ
Detail of failure q Open/short circuit of swing motor inverter current sensor is detected.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
40-305 96 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir. SEN05251-03
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir.
User code Failure code Swing motor driver current sensor open/short circuit error
Failure
E09 GA1MKZ
Detail of failure q Abnormality of DC voltage sensor of swing motor inverter is detected.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 97

SEN05251-03 Failure code [GA1NNS] Swing Motor Driver IGBT Overheat
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat
User code Failure code Overheat of IGBT swing motor driver

Failure
E09 GA1NNS
q Estimated junction temperature of IGBT swing motor driver (mounted on the inverter) exceeds 135
Detail of failure
°C.
Action of con-
troller
position.
Related infor-
mation
Probable Excessive charging or dis-

1 Check for excessive swinging or swing stop.
causes and charging of capacitor
standard value Defective inverter (Hybrid Check the radiator water level, clogging of radiator fins, and water
under normal 2
system controller) pump operation of hybrid system cooling water circuit.
conditions
Defective inverter (Hybrid Since trouble is in system, testing and troubleshooting cannot be per-
3
system controller) formed.
40-305 98 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1PNV] Swg Mot. Driver IPM Ph-U Not Warm up SEN05251-03
Failure code [GA1PNV] Swg Mot. Driver IPM Ph-U Not Warm up
User code Failure code Failure of U-phase warming up of IPM swing motor driver
Failure
E09 GA1PNV
Detail of failure q U-phase temperature of IPM swing motor driver drops below -35°C.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 99

SEN05251-03 Failure code [GA1QNV] Swg Mot. Driver IPM Ph-V Not Warm Up
Failure code [GA1QNV] Swg Mot. Driver IPM Ph-V Not Warm Up
User code Failure code Failure of V-phase warming up of IPM swing motor driver
Failure
E09 GA1QNV
Detail of failure q V-phase temperature of IPM swing motor driver drops below -35°C.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 100 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1RNV] Swng Mot. Driver IPM Ph-W Not Warm Up SEN05251-03
Failure code [GA1RNV] Swng Mot. Driver IPM Ph-W Not Warm Up
User code Failure code Failure of W-phase warming up of IPM swing motor driver
Failure
E09 GA1RNV
Detail of failure q W-phase temperature of IPM swing motor driver drops below -35°C.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 101

SEN05251-03 Failure code [GA1SFS] Contactor Locked
Failure code [GA1SFS] Contactor Locked
User code Failure code Contactor locked

Failure
E09 GA1SFS
Detail of failure q Contactor inside inverter is molten.
Action of con-
troller
OFF position.
Related infor-
mation

causes and
under normal 1
conditions
40-305 102 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1SMC] Contactor Failure SEN05251-03
Failure code [GA1SMC] Contactor Failure
User code Failure code Defective of contactor operations

Failure
E09 GA1SMC
Detail of failure q Contactor inside inverter cannot be connected.
Action of con-
troller
OFF position.
q Capacitor voltage and booster low voltage can be checked with monitoring function.
Related infor-
(Code 09300: Capacitor voltage; code 09400: Booster low voltage)
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 103

SEN05251-03 Failure code [GA1TKG] Capacitor HVPS Abnormal Voltage
Failure code [GA1TKG] Capacitor HVPS Abnormal Voltage
User code Failure code Abnormality of capacitor high power supply voltage
Failure
E09 GA1TKG
Detail of failure q Capacitor voltage exceeds 335 V.
Action of con-
troller
OFF position.
Related infor-
mation
Probable 1 Defective capacitor Perform high-voltage section common troubleshooting 1.

causes and
under normal 2 Perform high-voltage section common troubleshooting 5.
cable
conditions
3
40-305 104 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1TKP] Capacitor Low Output Voltage SEN05251-03
Failure code [GA1TKP] Capacitor Low Output Voltage
User code Failure code Capacitor output voltage drops

Failure
E09 GA1TKP
Detail of failure q Capacitor voltage drops below 140 V.
Action of con-
troller
OFF position.
Related infor-
mation

Probable
causes and
under normal cable
3
PC200, 200LC-8E0 (Hybrid) 40-305 105

SEN05251-03 Failure code [GA1TNS] Capacitor Overheat
Failure code [GA1TNS] Capacitor Overheat
User code Failure code Capacitor overheat

Failure
E09 GA1TNS
Detail of failure q Capacitor temperature #1 or capacitor temperature #2 exceeds 65°C.
Action of con-
troller
position.
Problem on
machine
q Capacitor temperature #1 and capacitor temperature #2 can be checked with monitoring function.
Related infor-
(Code 09301: Capacitor temperature #1; code 09302: Capacitor temperature #2)
mation

Excessive charging or dis-
charging of capacitor
2. Disconnect connector HP01 and connect T-adapter to male side.
Internal disconnection of
Capacitor temperature sensor #1 Between Resis- 0.1 - 500
2 capacitor temperature sen-
HP01 (male) (4) and (8) tance kΩ
sors #1 or #2
Capacitor temperature sensor #2 Between Resis- 0.1 - 500
HP01 (male) (5) and (8) tance kΩ
Probable 2. Disconnect connectors HC02 and HP01 and connect T-adapters
causes and to female side.
Grounding fault in capacitor
standard value Capacitor temperature sensor #1: Between
temperature sensor #1 wir- Resis-
under normal 3 HC02 (female) (51) or HP01 (female) (4) Min. 1 MΩ
ing harness tance
conditions and ground
(Contact with ground circuit)
Capacitor temperature sensor #2: Between
Resis-
HC02 (female) (61) or HP01 (female) (5) Min. 1 MΩ
tance
and ground
Defective water pump (inter- 2. Disconnect connector HK01 and connect T-adapter to male side.
4
nal disconnection) Resis-
Between HK01 (male) (1) and (2) Min. 1Ω
tance
Check radiator coolant level of coolant circuit of hybrid system, clog-
Defective operation of
5 ging of radiator fins, and operation of water pump. For details, see Y
hybrid system cooling circuit
mode, "Y-11 Capacitor temperature increases abnormally".
40-305 106 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1TNS] Capacitor Overheat SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 107

SEN05251-03 Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir.
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir.
User code Failure code Open or short circuit of capacitor temperature sensor
Failure
E09 GA1UKZ
Detail of failure q Difference between capacitor temperature #1 and capacitor temperature #2 is 20°C or more.
Action of con- q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller OFF position.
Problem on
q None.
machine
Related infor-
(Code 09301: Capacitor temperature #1; code 09302: Capacitor temperature #2)
mation

Defective capacitor tempera- shoot without turning starting switch to ON position.
ture sensor #1 HP01 Resistance
1
short circuit) Between (4) and (12) 0.1 – 500 kΩ
Between (4) and ground Min. 1 MΩ
Defective capacitor tempera- shoot without turning starting switch to ON position.
ture sensor #2 HP01 Resistance
2
short circuit) Between (5) and (12) 0.1 – 500 kΩ
Between (5) and ground Min. 1 MΩ
causes and Wiring harness between HC01 (female) (7) Resis-
Max. 1 Ω
standard value and HP01 (female) (1) tance
Open circuit in wiring har-
under normal
ness Wiring harness between HC01 (female) (20) Resis-
conditions 3 Max. 1 Ω
(Open circuit or defective and HP01 (female) (12) tance
contact in connector)
Max. 1 Ω
Max. 1 Ω
Hot short in the wiring har- starting switch to ON position and troubleshoot.
ness of capacitor tempera-
4
ture sensor #1 (Contact with Between wiring harness (between HC02
24 V circuit) (female) (51) and HP01 (female) (4)) and Voltage Max. 5.5 V
ground
Hot short in the wiring har- starting switch to ON position and troubleshoot.
ness of capacitor tempera-
5
ture sensor #2 (Contact with Between wiring harness (between HC02
24 V circuit) (female) (61) and HP01 (female) (5)) and Voltage Max. 5.5 V
ground
40-305 108 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir. SEN05251-03
Probable Malfunction of cooling circuit Check radiator coolant level of coolant circuit of hybrid system,
6
causes and of hybrid system clogging of radiator fins, and operation of water pump.
standard value
under normal 7 Defective capacitor Perform high-voltage section common troubleshooting 1.
conditions If causes 1 - 5 are not detected, the inverter (hybrid system con-
8 troller) may be defective (Since a trouble exists in the system,
system controller)
troubleshooting cannot be performed.)
PC200, 200LC-8E0 (Hybrid) 40-305 109

SEN05251-03 Failure code [GA1VFS] Capacitor Contactor Locked
Failure code [GA1VFS] Capacitor Contactor Locked
User code Failure code Capacitor contactor locked

Failure
E09 GA1VFS
q Contactor inside of capacitor is molten.
Detail of failure
q Power cable HC06 connector is not fitted securely.
Action of con-
troller
OFF position.
Related infor-
mation
q If failure code [GA01KA] is displayed at the same time, the power cable connector HC06 may not
be fitted securely.

Improper fitting of power Visually check that the power cable HC06 connector is fitted se-
1
cable connector curely.
Visually check that the mark on power cable HC06 connector is on
Improper connection of
2 the same side of the mark (blue) on the component to be connected.
Probable (See part (a) in the following figure.)
causes and a Prepare with starting switch OFF, then turn starting switch ON
standard value and perform troubleshooting.
under normal 3 Between ground and wiring harness
(contact with 24 V circuit) Power
conditions between HC01 (female) (3) and HP01 Max. 1 V
supply
(female) (6)
Before discharging (if capacitor voltage is 30 V or higher), check
4 Defective capacitor capacitor LED through window with power at OFF. If both LEDs
light up, capacitor is defective.
Defective inverter (Hybrid Since this is an internal defect, troubleshooting cannot be per-
5
system controller) formed.
40-305 110 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1VFS] Capacitor Contactor Locked SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 111

SEN05251-03 Failure code [GA1VMC] Capacitor Contactor Failure
Failure code [GA1VMC] Capacitor Contactor Failure
User code Failure code Defective operation of capacitor contactor

Failure
E09 GA1VMC
Detail of failure q Contactor inside of capacitor cannot be connected.
Action of con-
troller
OFF position.
Related infor-
mation

aPrepare with starting switch OFF, then perform
troubleshooting without turning starting switch to ON position.
Probable
Disconnection in wiring har- Wiring harness between HC01 (female) (3) Resis-
Max. 1 Ω
causes and 1 and HC01 (female) (6) CAN tance
ness
standard value
under normal Max. 1 Ω
and HC01 (female) (7) CAN tance
conditions
Since trouble is in system, testing and troubleshooting cannot be
Defective inverter (hybrid performed.
3
controller)
40-305 112 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. SEN05251-03
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ.
User code Failure code Open or short circuit of booster inductor temperature sensor
Failure
E09 GA1XKZ
Detail of failure q Abnormality of booster inductor temperature sensor in the inverter is detected.
Action of con-
troller
OFF position.
q Booster inductor temperature can be checked with monitoring function.
Related infor-
(Code 09402: Booster inductor temperature)
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 113

SEN05251-03 Failure code [GA1YNS] Booster Inductor Overheat
Failure code [GA1YNS] Booster Inductor Overheat
User code Failure code Booster inductor overheat

Failure
E09 GA1YNS
Detail of failure q Temperature of booster inductor inside inverter exceeds 130°C.
Action of con-
troller
position.
Booster inductor temperature can be checked with monitoring function.
q
Related infor-
mation
a See Y-10 of "Troubleshooting for hybrid system (Y mode)" and perform troubleshooting for this failure code.
40-305 114 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1YNV] Booster Inductor Not Warming Up SEN05251-03
Failure code [GA1YNV] Booster Inductor Not Warming Up
User code Failure code Booster inductor is not warmed up.

Failure
E09 GA1YNV
Detail of failure q Temperature of booster inductor inside inverter drops below -35°C.
Action of con-
troller
position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 115

SEN05251-03 Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ.
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ.
User code Failure code Open or short circuit of booster IGBT temperature sensor
Failure
E09 GA1ZKZ
Detail of failure q Abnormality of booster IGBT temperature sensor in inverter is detected.
Action of con-
troller
position.
Related infor-
(Code 09401: Booster IGBT temperature)
mation

Probable
causes and
under normal 1
conditions
40-305 116 PC200, 200LC-8E0 (Hybrid)

Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat SEN05251-03
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat
User code Failure code Booster IGBT temperature sensor overheat

Failure
E09 GA1ZNS
Detail of failure q Temperature of booster IGBT inside the inverter exceeds 100°C.
Action of con-
troller
position.
qBooster inductor temperature can be checked with monitoring function.
Related infor-
mation
PC200, 200LC-8E0 (Hybrid) 40-305 117

SEN05251-03 Failure code [GA1ZNV] Booster IGBT Temp. Sens. Not Warm Up
Failure code [GA1ZNV] Booster IGBT Temp. Sens. Not Warm Up
User code Failure code Booster IGBT temperature sensor is not warmed up.
Failure
E09 GA1ZNV
Detail of failure q Temperature of booster IGBT inside inverter drops below -35°C.
Action of con-
troller
position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
40-305 118 PC200, 200LC-8E0 (Hybrid)

Failure code [GA21KB] Booster IGBT Short Circuit SEN05251-03
Failure code [GA21KB] Booster IGBT Short Circuit
User code Failure code Short circuit of booster IGBT

Failure
E09 GA21KB
Detail of failure q Overcurrent flows through booster IGBT inside inverter.
Action of con-
troller
position.
Related infor-
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 119

SEN05251-03 Failure code [GA22NS] Booster IGBT Junction Overheat
Failure code [GA22NS] Booster IGBT Junction Overheat
User code Failure code Booster IGBT junction overheat

Failure
E09 GA22NS
Detail of failure q Estimated junction temperature of booster IGBT inside inverter exceeds 135°C.
Action of con-
troller
position.
q Swing inverter junction temperature can be checked with monitoring function.
Related infor-
(Code 09503: Swing inverter junction temperature)
mation

Probable Excessive charging or dis-
causes and charging of capacitor
standard value Defective operation of hybrid Check the radiator water level, clogging of radiator fins, and water
2
under normal system cooling circuit pump operation of hybrid system cooling water circuit.
3
40-305 120 PC200, 200LC-8E0 (Hybrid)

Failure code [GA60MC] Generator Motor Failure SEN05251-03
Failure code [GA60MC] Generator Motor Failure
User code Failure code Defective operation of motor-generator

Failure
E09 GA60MC
Detail of failure q Difference between motor-generator and engine speed is 200 rpm or more.
Action of con- q Even if cause of failure disappears, system does not reset itself until starting switch is turned to OFF
troller position.
Problem on
q No power can be generated by the generator motor.
machine
q Motor-generator speed and engine speed can be checked with monitoring function.
Related infor-
(Code 09602: Generator motor speed; code 01002: Engine speed)
mation

1 Defective motor-generator
performed.
Open circuit in wiring har- Max. 1 Ω
and GM01 (female) (2) tance
ness
2
Max. 1 Ω
contact in connector) and GM01 (female) (1) tance
Probable Wiring harness between HC02 (female) (57) Resis-
causes and Max. 1 Ω
standard value a Prepare by setting starting switch to OFF position, and trouble-
under normal shoot without turning starting switch to ON position.
conditions
Resis-
(Contact with ground circuit) (female) (28) and GM01 (female) (2)) and Min. 1 MΩ
tance
ground
(female) (28) and GM01 (female) (2)) and Voltage Max. 20 V
ground
5
PC200, 200LC-8E0 (Hybrid) 40-305 121

SEN05251-03 Failure code [GA60MD] Gen. Mot. Defective Movement
Failure code [GA60MD] Gen. Mot. Defective Movement
User code Failure code Abnormal generator motor speed

Failure
E09 GA60MD
Detail of failure q Abnormal motor-generator speed is detected by measurement with inverter.
q Stop swing motor and motor-generator control, then applies swing holding brake.
Action of con-
troller
position
Related infor-
mation

performed.
Max. 1 Ω
ness and GM01 (female) (2) tance
2
contact in connector) Max. 1 Ω
Probable
standard value
under normal a Prepare by setting starting switch to OFF position, and trouble-
conditions Ground fault of wiring har- shoot without turning starting switch to ON position.
(Contact with ground circuit) (female) (28) and GM01 (female) (2)) and Resis-
Min. 1 MΩ
tance
ground
ground
5
40-305 122 PC200, 200LC-8E0 (Hybrid)

Failure code [GA60N1] Generator Motor Overrun SEN05251-03
Failure code [GA60N1] Generator Motor Overrun
User code Failure code Overrun of motor-generator

Failure
E09 GA60N1
Detail of failure q Overrun of motor-generator is detected.
Action of con-
troller
position.
Related infor-
mation

performed.
Max. 1 Ω
ness and GM01 (female) (2) tance
2
contact in connector) Max. 1 Ω
Probable Max. 1 Ω
causes and
standard value
under normal
conditions 3 ness Between wiring harness (between HC02
Min. 1 MΩ
tance
ground
ground
5
PC200, 200LC-8E0 (Hybrid) 40-305 123

SEN05251-03 Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir.
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir.
User code Failure code Open or short circuit of motor-generator temperature sensor
Fialure
E09 GA61KZ
Detail of failure q Open or short circuit of motor-generator temperature sensor is detected.
Action of con-
troller
position.
Related infor-
mation

Resis-
GM01 Reference value at normal
tance
Resis- Approx.
-40°C
tance 4,200 kΩ
Defective temperature sen- Resis- Approx.
1 10°C
sor of motor-generator 0.5 - tance 210 kΩ
Between (4) and (5)
5,000 kΩ Resis- Approx.
25°C
tance 100 kΩ
Resis- Approx.
40°C
tance 50 kΩ
Between (4) and
Min.1 MΩ
ground
Open circuit in wiring har-
causes and
standard value ness Wiring harness between HC02 (female) (52) Resis-
2 Max. 1 Ω
(Open circuit or defective and GM01 (female) (4) tance
under normal
contact in connector)
conditions Wiring harness between HC02 (female) (41) Resis-
Max. 1 Ω
Min. 1 MΩ
tance
ground
ground
Defective inverter (Hybrid performed.
6
system controller)
40-305 124 PC200, 200LC-8E0 (Hybrid)

Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir. SEN05251-03
PC200, 200LC-8E0 (Hybrid) 40-305 125

SEN05251-03 Failure code [GA61NS] Generator Motor Temp. Sensor Overheat
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat
User code Failure code Motor-generator temperature sensor overheat

Failure
E09 GA61NS
Detail of failure q Temperature of motor-generator exceeds 180°C.
Action of con-
troller
position.
Related infor-
mation
40-305 126 PC200, 200LC-8E0 (Hybrid)

Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir SEN05251-03
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir
User code Failure code Short circuit of A-phase current sensor power line of motor-genera-
Failure tor
E09 GA62KY (Hybrid controller system)
Detail of failure q Overcurrent is detected in A-phase of motor-generator .

Action of con-
troller
position.
Related infor-
mation

Probable 1 Defective motor-generator Perform high-voltage section common troubleshooting 3.
causes and Failure of power cable that
standard value 2 connects between generator Perform high-voltage section common troubleshooting 7.
under normal motor and inverter
conditions
3
PC200, 200LC-8E0 (Hybrid) 40-305 127

SEN05251-03 Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir
User code Failure code Open or short circuit of A-phase current sensor of motor-generator
Failure
E09 GA62KZ
Detail of failure q Open or short circuit is detected in A-phase of motor-generator.
Action of con-
troller
position.
Related infor-
mation

system is normal) ON position. If failure code is not displayed and abnormal phenome-
Probable non does not occur, machine can be operated as it is.
causes and
standard value Failure of power cable that
under normal 2 connects between Perform high-voltage section common troubleshooting 7.
conditions motor-generator and inverter

4
40-305 128 PC200, 200LC-8E0 (Hybrid)

Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction SEN05251-03
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction
User code Failure code Malfunction of motor-generator A-phase current sensor

Failure
E09 GA62MA
Detail of failure q Malfunction of motor-generator A-phase current sensor is detected.
Action of con-
troller
position.
Related infor-
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 129

SEN05251-03 Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir.
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir.
User code Failure code Short circuit of B-phase current sensor power line of motor-genera-
Failure tor
Detail of failure q Overcurrent is detected in B-phase of motor-generator.

Action of con-
troller
position.
Related infor-
mation

standard value 2 connects between Perform high-voltage section common troubleshooting 7.
under normal motor-generator and inverter
conditions
3
40-305 130 PC200, 200LC-8E0 (Hybrid)

Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir SEN05251-03
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir
User code Failure code Open or short circuit of B-phase current sensor of motor-generator
Failure
E09 GA63KZ
Detail of failure q Open or short circuit is detected in B-phase of motor-generator.
Action of con-
troller
position.
Related infor-
mation

Probable enon does not occur, machine can be operated as it is.
causes and

4
PC200, 200LC-8E0 (Hybrid) 40-305 131

SEN05251-03 Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction
User code Failure code Malfunction of motor-generator B-phase current sensor

Failure
E09 GA63MA
Detail of failure q Malfunction of motor-generator B-phase current sensor is detected.
Action of con-
troller
position.
Related infor-
mation

causes and
under normal 1
conditions
40-305 132 PC200, 200LC-8E0 (Hybrid)

Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir. SEN05251-03
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir.
User code Failure code Short circuit of C-phase current sensor power line of motor-genera-
Failure tor
Detail of failure q Overcurren is detected in C-phase of motor-generator.

Action of con-
troller
position.
Related infor-
mation

standard value 2 connects between Perform high-voltage section common troubleshooting 7.
under normal motor-generator and inverter
conditions
3
PC200, 200LC-8E0 (Hybrid) 40-305 133

SEN05251-03 Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir.
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir.
User code Failure code Open or short circuit of C-phase current sensor of motor-generator
Failure
E09 GA64KZ
Detail of failure q Open or short circuit is detected in C-phase of motor-generator.
Action of con-
troller
position.
Related infor-
mation

causes and

4
40-305 134 PC200, 200LC-8E0 (Hybrid)

Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction SEN05251-03
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction
User code Failure code Malfunction of motor-generator C-phase current sensor

Failure
E09 GA64MA
Detail of failure q Malfunction of motor-generator C-phase current sensor is detected.
Action of con-
troller
position.
Related infor-
mation

causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 135

SEN05251-03 Failure code [GA70KB] HYB Swing Motor Short Circuit
Failure code [GA70KB] HYB Swing Motor Short Circuit
User code Failure code Short circuit of HYB system swing motor
Failure
E09 GA70KB
Detail of failure q Short circuit of swing motor is detected.
Action of con-
troller
position.
Related infor-
mation
1 Defective swing motor Perform high-voltage section common troubleshooting 2.

Probable
causes and
under normal 2 connects between swing Perform high-voltage section common troubleshooting 6.
conditions motor and inverter
3
40-305 136 PC200, 200LC-8E0 (Hybrid)

Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion SEN05251-03
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion
User code Failure code Abnormal speed of HYB system swing motor
Failure
E09 GA70MD
Detail of failure q Abnormal swing motor speed is detected by measurement with inverter.
Action of con-
troller
position.
Related infor-
mation

Probable
causes and
under normal 1
conditions
PC200, 200LC-8E0 (Hybrid) 40-305 137

SEN05251-03 Failure code [GA70NS] HYB Swing Motor Overheat
Failure code [GA70NS] HYB Swing Motor Overheat
User code Failure code HYB system swing motor overheat

Faiure
E09 GA70NS
Detail of failure q Swing motor temperature exceeds 160°C.
Action of con-
troller
position.
qSwing motor coil temperature can be checked with monitoring function.
Related infor-
(Code 09101: Swing motor coil temperature)
mation
40-305 138 PC200, 200LC-8E0 (Hybrid)

Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. SEN05251-03
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir.
User code Failure code Open or short circuit of hybrid system swing motor temperature
Failure sensor
Detail of failure q Abnormality of swing motor temperature sensor is detected.

q Stops swing motor and motor-generator control, then applied swing holding brake.
Action of con-
troller
position.
Related infor-
mation
(Code 09101: Swing motor coil temperature)

Resis-
Reference value at normal
tance
Resis- Approx.
-40 °C
tance 4,200 kΩ
Defective temperature sen- Between PM01 Resis- Approx.
1 10 °C
sor of motor-swing (male) (7) and (8) 0.5 - tance 210 kΩ
5,000 kΩ Resis- Approx.
25 °C
tance 100 kΩ
Resis- Approx.
40 °C
tance 50 kΩ
Between PM01
Min. 1 MΩ
(male) (7) and ground
ness Wiring harness between HC02 (female) (42) Resis-
standard value 2 Max. 1 Ω
(Disconnection or defective and PM01 (female) (7) tance
under normal
conditions contact in connector)
Max. 1 Ω
and PM01 (female) (8) tance
(Contact with ground circuit) (female) (42) and PM01 (female) (7)) and Resis- Min.
tance 1 MΩ
ground
starting switch to ON position and troubleshoot.
(female) (42) and PM01 (female) (7)) and Voltage Max. 1 V
ground
5 Defective swing motor
Defective inverter (Hybrid performed.
6
system controller)
PC200, 200LC-8E0 (Hybrid) 40-305 139

SEN05251-03 Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir.
40-305 140 PC200, 200LC-8E0 (Hybrid)

Failure code [GA72MA] HYB Swing Motor Resolver Malfunction SEN05251-03
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction
User code Failure code Malfunction of HYB system swing motor resolver
Failure
E09 GA72MA
Detail of failure q Malfunction of swing motor resolver is detected.
Action of con-
troller
position.
Related infor-
mation

Max. 1 Ω
Open circuit in wiring Max. 1 Ω
harness
1 (Open circuit or defec- Max. 1 Ω
tive contact in connec-
tor) Max. 1 Ω
Max. 1 Ω
Max. 1 Ω
Between wiring harness (between HC02 (female) Resis- Min.
Prabable (29) and PM01 (female) (1)) and ground tance 1 MΩ
causes and Between wiring harness (between HC02 (female) Resis- Min.
Ground fault of wiring (30) and PM01 (female) (3)) and ground tance 1 MΩ
standard value harness
2 Between wiring harness (between HC02 (female) Resis- Min.
under normal (Contact with ground cir- (39) and PM01 (female) (2)) and ground tance 1 MΩ
conditions cuit) Between wiring harness (between HC02 (female) Resis- Min.
(40) and PM01 (female) (5)) and ground tance 1 MΩ
Voltage Max. 1 V
(29) and PM01 (female) (1)) and ground
Voltage Max. 1 V
Hot short in wiring har-
3 ness (Contact with 24 V Voltage Max. 1 V
circuit)
Voltage Max. 1 V
Voltage Max. 1 V
Voltage Max. 1 V
PC200, 200LC-8E0 (Hybrid) 40-305 141

SEN05251-03 Failure code [GA72MA] HYB Swing Motor Resolver Malfunction

Probable 4 Defective swing motor
causes and
Failure of inverter Since trouble is in system, testing and troubleshooting cannot be per-
standard value
5 (Hybrid system control- formed.
under normal
ler)
conditions
40-305 142 PC200, 200LC-8E0 (Hybrid)

Failure code [GA72MC] HYB Swing Motor Resolver Defect Op. SEN05251-03
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op.
User code Failure code Defective operation of HYB system swing motor resolver
Failure
E09 GA72MC
Detail of failure q Defective operation of swing motor resolver is detected.
Action of con-
troller
position.
Related infor-
mation
Max. 1 Ω
Open circuit in wiring Wiring harness between HC02 (female) (30) and Resis-
Max. 1 Ω
harness PM01 (female) (3) tance
1 (Open circuit or defec- Wiring harness between HC02 (female) (39) and Resis-
Max. 1 Ω
tive contact in connec- PM01 (female) (2) tance
tor) Wiring harness between HC02 (female) (40) and Resis-
Max. 1 Ω
Max. 1 Ω
Max. 1 Ω
Probable (29) and PM01 (female) (1)) and ground tance 1 MΩ
causes and Between wiring harness (between HC02 (female) Resis- Min.
Ground fault of wiring (30) and PM01 (female) (3)) and ground tance 1 MΩ
standard value harness
2 Between wiring harness (between HC02 (female) Resis- Min.
under normal (Contact with ground (39) and PM01 (female) (2)) and ground tance 1 MΩ
conditions circuit) Between wiring harness (between HC02 (female) Resis- Min.
Voltage Max. 1 V
Voltage Max. 1 V
Hot short in wiring har- (30) and PM01 (female) (3)) and ground
3 ness (Contact with 24 Between wiring harness (between HC02 (female) Voltage Max. 1 V
V circuit) (39) and PM01 (female) (2)) and ground
Voltage Max. 1 V
Voltage Max. 1 V
Voltage Max. 1 V
PC200, 200LC-8E0 (Hybrid) 40-305 143

SEN05251-03 Failure code [GA72MC] HYB Swing Motor Resolver Defect Op.

Probable 4 Defective swing motor
causes and
standard value Since trouble is in system, testing and troubleshooting cannot be per-
Defective inverter
under normal
5 (Hybrid system control- formed.
conditions
ler)
40-305 144 PC200, 200LC-8E0 (Hybrid)

Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. SEN05251-03
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ.
User code Failure code Open or short circuit of swing motor power cable
Failure
E09 GA81KZ
Detail of failure q Open or short circuit of swing motor power cable is detected.
Action of con-
troller
position.
Related infor-
mation

causes and
under normal 2 connects between swing Perform high-voltage section common troubleshooting 6.
conditions motor and inverter
3 Defective swing motor Perform high-voltage section common troubleshooting 2.

4
PC200, 200LC-8E0 (Hybrid) 40-305 145

SEN05251-03
PC200, 200LC-8E0 (Hybrid) Hydraulic excavator
©2011 KOMATSU
All Rights Reserved
40-305 146
SEN05252-00
SEN05252-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
400 Troubleshooting of electrical system
(E-mode)
Before performing troubleshooting of electrical system .............................................................................. 3

Information in troubleshooting table............................................................................................................ 5
E-1 When starting switch is turned to ON position, machine monitor displays nothing .............................. 6
E-2 When starting switch turned ON (before starting engine), basic check monitor lights up .................... 8
E-3 Engine does not start (Engine does not crank) .................................................................................... 11
E-4 Preheater does not operate.................................................................................................................. 14
E-5 Automatic warm-up system does not operate (in cold season)............................................................ 16
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked ......................... 18
E-7 Caution monitor lights up while engine is running ................................................................................ 20
E-8 Emergency monitor lights up while engine is running .......................................................................... 25
E-9 Engine coolant temperature gauge does not indicate normally ........................................................... 26
E-10 Hydraulic oil temperature gauge does not indicate normally.............................................................. 27
E-11 Fuel level gauge does not indicate normally ...................................................................................... 29
E-12 Contents of display by machine monitor are different from applicable machine ................................ 31
E-13 Some areas of the machine monitor screen are not displayed .......................................................... 32
E-14 Function switch does not work ........................................................................................................... 33
E-15 Auto-deceleration does not operate normally..................................................................................... 34
E-16 Working mode does not change......................................................................................................... 35
PC200, 200LC-8E0 (Hybrid) 40-400 1

400 Troubleshooting of electrical system (E-mode)
E-17 Travel speed does not change ........................................................................................................... 36

E-18 Alarm buzzer cannot be stopped........................................................................................................ 37
E-19 Windshield wiper and window washer do not operate........................................................................ 38
E-20 One-touch power maximizing function does not operate normally ..................................................... 40
E-21 Swing brake does not operate normally ............................................................................................. 43
E-22 Travel alarm does not sound or does not stop sounding.................................................................... 46
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) .................. 48
E-24 While starting switch is in OFF position, service meter is not displayed ............................................ 59
E-25 Machine monitor cannot be set in service mode ................................................................................ 60
E-26 Monitoring function does not display lever control signal normally..................................................... 61
E-27 KOMTRAX system does not operate normally................................................................................... 67
40-400 2 PC200, 200LC-8E0 (Hybrid)

Before performing troubleshooting of electrical system SEN05252-00
Before performing troubleshooting of electrical system
Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power while the starting switch is in the OFF and ON
positions).
a When performing troubleshooting related to the electrical system, you should check the fuses and fusible
links to see if the power is supplied normally.
Type of power Fuse
Fusible link Fuse No. Destination of power
supply capacity
Lamp relay, rear lamp relay, cab lamp relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve [When
1 10 A pump drive switch is operated in emergency]
Swing brake solenoid valve
[When swing brake cancel switch is operated]
Pump controller (Solenoid power supply)
Switch power F04 2 30 A Hybrid controller (solenoid power supply)
supply (60 A) Capacitor (M terminal), Invertor (M terminal)
PPC oil pressure lock solenoid valve
3 10 A Starting motor cut-out relay (PPC lock)
Starting motor cut-out relay (Personal code)
Cigarette lighter
4 10 A
Wind washer motor
5 10 A Horn relay, horn
6 10 A Electrical intake air heater relay
7 10 A Rotary lamp
Switch power F04 8 20 A Right head lamp, working lamp (boom), working lamp (rear)
supply (60 A) Radio
9 10 A
Left knob switch (pump controller input)
10 10 A (Spare)
Air conditioner unit
11 20 A
Air conditioner compressor electromagnetic clutch
12 10 A (Spare)
Switch power F04
13 10 A Head lamp
supply (60 A)
14 10 A Optional power supply (1)
Travel alarm
15 10 A
Optional power supply (2)
Radio (backup power supply)
16 10 A
Room lamp
Starting switch
Constant F05 Machine monitor, Invertor
17 20 A
power supply (30 A) Pump controller
Hybrid controller
18 10 A (Spare)
19 30 A Engine controller
Switch power Starting
20 5A Engine controller (ACC signal), Invertor (ACC signal)
supply switch ACC
PC200, 200LC-8E0 (Hybrid) 40-400 3

SEN05252-00 Before performing troubleshooting of electrical system
Locations of fusible links
Location of fuse box and fuse Nos.
40-400 4 PC200, 200LC-8E0 (Hybrid)

Information in troubleshooting table SEN05252-00

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.
Trouble Trouble which occurred in the machine
Related
Information related to detected trouble or troubleshooting
information
<Contents of description>
q Standard value in normal condition to judge probable causes
q Remarks on judgment
1
<Troubles in wiring harness>
q Disconnection
Connector is connected imperfectly or wiring harness is discon-
nected.
q Ground fault
Wiring harness which is not connected to chassis ground circuit is
in contact with chassis ground circuit.
q Hot short
Wiring harness which is not connected to power source (24 V)
2 circuit is in contact with power source (24 V) circuit.
q Short circuit
Probable Independent wiring harnesses are in contact with each other abnor-
causes and mally.
Probable causes of trouble
standard
(Given numbers are refer-
value in nor-
ence numbers, which do not
mal condi-
indicate priority)
tion <Precautions for troubleshooting>
(1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting,
3 unless otherwise specified.
q If connector No. has no marks of “male” and “female”, dis-
connect connector and insert T-adapters in both male side and
female side.
q If connector No. has marks of “male” and “female”, disconnect
connector and connect T-adapter to only male side or female
side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (-) lead of tester as ex-
plained below for troubleshooting, unless otherwise specified.
4 q Connect positive (+) lead to pin No. or wiring harness entered
on front side.
q Connect negative (-) lead to pin No. or harness entered on rear
side.

This drawing is a part of the circuit diagram related to troubleshoot-
ing.
q Connector No.: Indicates (Model – Number of pins) and (Color).
q “Connector No. and pin No.” from each branching/merging point:
Shows the ends of branch or source of merging within the parts of
the same wiring harness.
q Arrow(io): Roughly shows the location on the machine.
PC200, 200LC-8E0 (Hybrid) 40-400 5

SEN05252-00 E-1 When starting switch is turned to ON position, machine monitor displays nothing
E-1 When starting switch is turned to ON position, machine monitor

displays nothing
Trouble q When starting switch is turned to ON position, machine monitor displays nothing.
q When starting switch is turned to ON position, machine monitor displays KOMATSU logo, screen to
input password (if set), screen to check breaker mode (if set), screen of check before starting, screen
Related
to check working mode and travel speed, and standard screen in order.
information
q When the engine is started, the battery voltage may lower suddenly, depending on the ambient tem-
perature and the condition of the battery.

1 Insufficient battery capacity Electrolyte specific gravity (1
Battery voltage (2pieces)
piece)
Min. 24 V Min. 1.26
Defective fusible link F05 or If fusible link or fuse is broken, circuit probably has ground fault. (See
2
fuse No.17 Cause 5.)
Machine monitor connector may be connected wrongly. Check it
Wrong connection of connec-
3 directly.
tor
(Check mounting bracket plate with connector.)
Wiring harness between battery (–) – chassis Resis-
Max.1Ω
ground tance
Wiring harness between battery (+) – R04 – Resis-
Max.1Ω
F05 (male) (1) tance
Wiring harness between F05 (male) (2) Resis-
ness Max.1Ω
–F01-16D tance
Wiring harness between F01-17 – J06 – Resis-
Probable defective contact in connec- Max.1Ω
CM01 (female) (1)(2) tance
causes and tor)
Wiring harness between CM01 (female) (3)(4) Resis-
standard Max.1Ω
– chassis ground (T05) tance
value in nor-
Wiring harness between F01-17 and H15 Resis-
mal condi- Max.1Ω
(female)(1) tance
tion
Wiring harness between H15 (female) (5), – Resis-
Max.1Ω
J03CM01 (female) (14) tance
a Prepare with starting switch OFF, then troubleshoot without turning
starting switch to ON position.
Between ground and wiring harness between Resis-
Min. 1MΩ
battery (+) – R04 – F05 (male) (1) tance
Min. 1MΩ
Ground fault in wiring harness F05 (male) (2) – F01 - 16D tance
5
(Short circuit with GND circuit) Between ground and wiring harness between Resis-
Min. 1MΩ
F01-17 – J06 – CM01 (female) (1)(2) tance
Between ground and wiringiring harness Resis-
Min. 1MΩ
between F01-17 – H15 (female) (1) tance
Min. 1MΩ
H15 (female) (5) – J03 – CM01 (female) (14) tance
a Prepare with starting switch OFF, then hold starting switch OFF
and ON and perform troubleshooting in each case.
CM01 Starting switch Voltage
Between (1)(2) –
OFF 20 – 30 V
(3)(4)
Between (14) – (3)(4) ON 20 – 30 V
40-400 6 PC200, 200LC-8E0 (Hybrid)

E-1 When starting switch is turned to ON position, machine monitor displays nothing SEN05252-00
Circuit diagram related to machine monitor power supply
PC200, 200LC-8E0 (Hybrid) 40-400 7

SEN05252-00 E-2 When starting switch turned ON (before starting engine), basic check monitor lights up
E-2 When starting switch turned ON (before starting engine), basic check
monitor lights up
Trouble (1) Radiator coolant level monitor lights up red.
q Although radiator coolant level monitor is basic check item, it is also checked while engine is run-
ning.
Related infor-
(If monitor lights up red while engine is running, perform this troubleshooting, too.)
mation
q Condition of radiator coolant level switch signal can be checked by using monitoring function.

Lowering of radiator coolant
Coolant level in radiator sub tank may be low. Check it and add
1 level
coolant if necessary.
Defective radiator coolant Sub-tank coolant
P24 Resistance
2 level switch level
(Internal disconnection) Between FULL and
Max.1Ω
Between (1) – (2) LOW
Probable
Below LOW Min. 1MΩ
causes and
standard value Disconnection in wiring har-
in normal condi- ness
Wiring harness between CM02 (female) (3) Resis-
tion 3 (Disconnection in wiring or Max.1Ω
– P24 (female) (1) tance
Wiring harness between P24 (female) (2) – Resis-
tor) Max.1Ω
Sub-tank coolant
CM02 Voltage
4 Defective machine monitor level
Between FULL and
Between (3) – chas- Max.1 V
LOW
sis ground
Below LOW 20 –30 V
40-400 8 PC200, 200LC-8E0 (Hybrid)

E-2 When starting switch turned ON (before starting engine), basic check monitor lights up SEN05252-00
Circuit diagram related to radiator coolant level switch
PC200, 200LC-8E0 (Hybrid) 40-400 9

SEN05252-00 E-2 When starting switch turned ON (before starting engine), basic check monitor lights up
Trouble (2) Engine oil level monitor lights up red.

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

Lowering of engine oil level
1 Engine oil level may be low. Check it and add oil if necessary.
Defective engine oil level without turning starting switch to ON position.
2 switch P44 Engine oil level Resistance
(Internal disconnection) Between (1) – chas- Between H – L Max.1Ω
Probable
sis ground Below L Min. 1MΩ
causes and
standard
value in nor-
mal condition Wiring harness between CM02 (female) (2) Resis-
defective contact in connec- Max.1Ω
– P44 (female) (1) tance
tor)
4 Defective machine monitor CM02 Engine oil level Voltage
Between (2) – chas- Between H – L Max.1 V
sis ground Below L 20 –30 V
Circuit diagram related to engine oil level switch
40-400 10 PC200, 200LC-8E0 (Hybrid)

E-3 Engine does not start (Engine does not crank) SEN05252-00
E-3 Engine does not start (Engine does not crank)

Trouble q Engine does not start (Engine does not crank).
q Engine starting circuit has following 2 start lock mechanisms.
Related
1) Start lock with password of machine monitor
information
2) Start lock with lock lever

1 Low charge level of battery Electrolyte specific gravity
Battery voltage (2 pieces)
(1 piece)
Min. 24 V Min. 1.26
2 Defective fuse No. 3 If fuse is broken, circuit probably has ground fault. (See cause 10.)
and turn it to START position and perform troubleshooting in each
Defective starting switch case.
3
(Internal disconnection) H15 (male) Starting switch Resistance
OFF Min. 1MΩ
Between (1) – (4)
START Max. 1Ω
Defective lock lever switch
4 S14 (female) Lock lever Resistance
Free Min. 1MΩ
Between (1) – (3)
Lock Max. 1Ω
Defective starting motor cut- without turning starting switch to ON position.
out relay R06 or R07 (Inter- R06 (male), R07 (male) Resistance
5
Probable nal disconnection or short Between (1) – (2) 300 – 600Ω
causes and circuit) Between (3) – (4) Max. 1Ω
standard Between (3) – (5) Min. 1MΩ
value in nor- a Prepare with starting switch OFF (with only terminal C disconnect-
mal condi- ed), then turn starting switch to START position and perform trou-
tion bleshooting.
Safety relay terminal Voltage
Defective starting motor Between B – E Power supply 20 – 30 V
6
safety relay (Internal defect) Between R(R17-2) – E Generation input Max. 1 V
Between S(R17-1) – E Starting input 20 – 30 V
Between C(R18) – E Starting output 20 – 30 V
If power supply, generation input, and starting input are normal but
starting output is not normal, starting motor safety relay is defective.
a Prepare with starting switch OFF, then turn starting switch to
START position and perform troubleshooting.
Starting motor terminals Voltage
Between B (SB) –
Defective starting motor Power supply 20 – 30 V
7 ground
(Internal defect)
Between C (SC) –
Starting input 20 – 30 V
ground
If power supply and starting input are normal but starting motor does
not rotate, starting motor is defective.
a Prepare with starting switch OFF, then turn starting switch to ON po-
sition and perform troubleshooting
Defective alternator (Internal
8 Alternator Voltage
short circuit)
Between L – chassis
Alternator output Max. 1 V
ground
PC200, 200LC-8E0 (Hybrid) 40-400 11

SEN05252-00 E-3 Engine does not start (Engine does not crank)

Wiring harness between H15 (female) (4) – J01 Resis-
Max. 1Ω
– R06 (female) (5) tance
Wiring harness between R06 (female) (3) – Resis-
Max. 1Ω
Wiring harness between R07 (female) (3) – Resis-
Max. 1Ω
Disconnection in wiring har- Wiring harness between starting motor safety Resis-
Max. 1Ω
ness (Disconnection in wiing relay B – heater relay – battery relay B tance
9
or defective contact in con- Wiring harness between starting motor safety Resis-
Max. 1Ω
nector) relay E – chassis ground tance
Wiring harness between starting motor safety Resis-
Max. 1Ω
relay C – starting motor C(SC) tance
Wiring harness between F01-3 – S14 (male) Resis-
Max. 1Ω
(1) tance
Wiring harness between S14 (male) (3) – R06 Resis-
Max. 1Ω
(female) (1) tance
Wiring harness between R06 (female) (2) – J04 Resis-
Probable Max. 1Ω
– chassis ground (T04) tance
causes and
standard
value in nor-
Between ground and wiring harness between
mal condi- Resis-
H15 (female) (4) – J01 – R06 (female) (5) – cir- Min. 1MΩ
tion tance
cuit branch end
Min. 1MΩ
R06 (female) (3) – R07 (female) (4) tance
Min. 1MΩ
Ground fault in wiring har- R07 (female) (3) – R17 (female) (1) tance
10 ness (Short circuit with GND Between ground and wiring harness between
Resis-
circuit) starting motor safety relay B – heater relay – Min. 1MΩ
tance
battery relay B
Resis-
starting motor safety relay C – starting motor C Min. 1MΩ
tance
(SC)
Min. 1MΩ
F01-3 – S14 (male) (1) tance
Min. 1MΩ
S14 (male) (3) – R06(female) (1) tance
Hot short (Short circuit with sition and perform troubleshooting.
11 24 V circuit) in wiring har- Between ground and wiring harness between
ness R17 (female) (2) – alternator L, – circuit branch Voltage Max. 1V
end
40-400 12 PC200, 200LC-8E0 (Hybrid)

E-3 Engine does not start (Engine does not crank) SEN05252-00
PC200, 200LC-8E0 (Hybrid) 40-400 13

SEN05252-00 E-4 Preheater does not operate
E-4 Preheater does not operate

Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up or flash.
q Preheater monitor lights up when starting switch is turned to HEAT position and starts flashing about
30 seconds after to notify completion of preheating (It stops flashing about 10 seconds after).
Related infor- q If engine coolant temperature is below 20 °C, automatic warm-up system operates and preheating
mation monitor lights up for up to 30 seconds.
q Condition of starting switch (preheating) signal can be checked by using the monitoring function.(Code:
04500 Monitor input 1)

and turn it to HEAT position and perform troubleshooting in each
Defective starting switch case.
1
(Internal disconnection) H15 (male) Starting switch Resistance
OFF Min. 1 MΩ
Between (1) – (3)
HEAT Max.1 Ω
Probable
causes and
standard
value in nor- Wiring harness between CM01 (female) (16) –
defective contact in connec- Resistance Max.1 Ω
mal condition J02 – H15 (female) (3)
tor)
a Prepare with starting switch OFF, then keep starting switch in OFF
and turn it to HEAT position and perform troubleshooting in each
case.
CM01 Starting switch Voltage
OFF Max.1 V
Between (16) – ground
HEAT 20 – 30 V
(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become
Trouble
warm.
Related infor- q Check that engine can be turned with starting motor (If engine cannot crank, perform troubleshooting
mation for E-1 Engine does not start (Engine does not crank))

a Prepare with starting switch OFF (with wiring harness connected),
then keep starting switch OFF and turn it to HEAT position and per-
form troubleshooting in each case.
Defective heater relay Heater relay Starting switch Continuity/Resistance
1
(Internal disconnection) Between R15 –
OFF Continuity
ground
Between power sup-
HEAT Max.1Ω
ply terminal – R16
a Prepare with starting switch OFF (with wiring harness connected),
Probable then turn starting switch to HEAT position and perform trouble-
causes and shooting in each case.
standard Defective intake air heater E01 Starting switch Voltage
3
value in nor- (Internal disconnection) Between terminal –
HEAT 20 – 30 V
mal condition ground
If voltage is normal but heater mounting part does not become warm,
intake air heater is defective.
Wiring harness between H15 (female) (3) – Resis-
ness Max.1 Ω
J02 – heater relay R15 tance
Wiring harness between battery relay R03 – Resis-
defective contact in connec- Max.1 Ω
heater relay contact terminal tance
tor)
Wiring harness between heater relay R16 – Resis-
Max.1 Ω
intake air heater E01 tance
40-400 14 PC200, 200LC-8E0 (Hybrid)

E-4 Preheater does not operate SEN05252-00
PC200, 200LC-8E0 (Hybrid) 40-400 15

SEN05252-00 E-5 Automatic warm-up system does not operate (in cold season)
E-5 Automatic warm-up system does not operate (in cold season)
Trouble q Automatic warm-up system does not operate (in cold season).
q When engine coolant temperature is below 30 °C automatic warm-up system raises engine speed to
1,200 rpm.
q If fuel control dial is opened more than 70 % for 3 seconds when starting switch is turned ON position
Related infor-
or after engine is started, automatic warm-up system is turned off. (Automatic warm-up system stops
mation
automatically after operating for 10 minutes.)
q If engine coolant temperature is below 10°C turbocharger protection function operates to keep the
engine speed at low idle.

a Turn starting switch ON or start engine and perform troubleshoot-
ing.
Engine coolant tem- Coolant temperature
Monitoring code
perature level
Probable 105 °C 6 (a: Red)
102 °C 5 (a: Red)
causes and Defective engine coolant tem- 04107
1 100 °C 4 (a: Blue)
standard perature signal system Engine coolant tem-
85 °C 3 (a: Blue)
value in nor- perature
60 °C 2 (a: Blue)
mal condition 30 °C 1 (a: White)
If level of coolant temperature gauge is different from actual coolant
temperature, perform troubleshooting for E-9 Engine coolant temper-
ature gauge does not indicate normally.
If cause 1 is not detected, engine controller may be defective. (Since
trouble is in system, troubleshooting cannot be performed.)
Engine coolant temperature gauge and engine

coolant temperature monitor
40-400 16 PC200, 200LC-8E0 (Hybrid)

E-5 Automatic warm-up system does not operate (in cold season) SEN05252-00
PC200, 200LC-8E0 (Hybrid) 40-400 17

SEN05252-00 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked
E-6 All work equipment, swing, and travel mechanism do not move or
cannot be locked
Trouble (1) All work equipment, swing, and travel mechanism do not move.
Related infor-
mation

2 S14 (female) Lock lever Resistance
Lock Min. 1 MΩ
Between (1) – (2)
Free Max.1 Ω
Defective PPC lock solenoid without turning starting switch to ON position.
3 (Internal disconnection or V01 (male) Resistance
short circuit) Between (1) – (2) 20 – 60 Ω
Between (1) – chassis ground Min. 1 MΩ
Defective assembled-type
4 diode D01
causes and D01 (male) Resistance (Continuitiy)
(Internal short circuit)
standard Between (4) – (8) Min. 1 MΩ (No continuitiy)
value in nor- a Prepare with starting switch OFF, then perform troubleshooting
mal condition without turning starting switch to ON position.
Wiring harness between F01-3 – S14 (male) Resis-
ness Max.1 Ω
(1) tance
Wiring harness between S14 (male) (2) – V01 Resis-
defective contact in connec- Max.1 Ω
(female) (1) tance
tor)
Wiring harness between V01 (female) (2) – Resis-
Max.1 Ω
ness Min. 1 MΩ
6 F01-3 – S14 (male) (1), – circuit branch end tance
cuit) Resis-
S14 (male) (2) – V01 (female) (1), – D01 Min. 1 MΩ
tance
(female) (4)
40-400 18 PC200, 200LC-8E0 (Hybrid)

E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked SEN05252-00
Trouble (2) All work equipment, swing, and travel mechanism cannot be locked.
Related
information

Probable 1 S14 (female) Lock lever Resistance
causes and Lock Min. 1 MΩ
Between (1) – (2)
standard Free Max.1 Ω
value in nor- a Prepare with starting switch OFF, then turn starting switch ON po-
mal condition Hot short sition and perform troubleshooting.
2 (Short circuit with 24 V circuit) Between ground and wiring harness between
in wiring harness S14 (male) (2) – V01 (female) (1), – D01 Voltage Max.1 V
(female) (4)
Circuit diagram related to PPC lock solenoid
PC200, 200LC-8E0 (Hybrid) 40-400 19

SEN05252-00 E-7 Caution monitor lights up while engine is running
E-7 Caution monitor lights up while engine is running

Trouble (1) Charge level monitor lights up red.
Related q Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge voltage)
information q Charge level monitor lights up red at 7.8 V and below.

Defective generation by alter- troubleshooting.
1 nator E12 (male) Engine speed Voltage
(when system is normal) Between (1) – chas-
Medium or higher 27.5 – 29.5 V
sis ground
Probable 2 (Disconnection in wiring or
Wiring harness between CM01 (female) (11) – Resis-
causes and defective contact in connec- Max.1 Ω
J02 – E12 (female) (1) tance
standard tor)
value in nor- a Prepare with starting switch OFF, then perform troubleshooting
mal condition Ground fault in wiring harness without turning starting switch to ON position.
3 (Short circuit with GND cir- Between ground and wiring harness between
Resis-
cuit) CM01 (female) (11) – J02 – E12 (female) (1) – Min. 1 MΩ
tance
circuit branch end
troubleshooting.
4 Defective machine monitor CM02 Engine Voltage
Between (11) –
Running Min. 7.8 V
ground
40-400 20 PC200, 200LC-8E0 (Hybrid)

E-7 Caution monitor lights up while engine is running SEN05252-00
PC200, 200LC-8E0 (Hybrid) 40-400 21

Trouble (2) Fuel level monitor lights up red.

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

Probable
Low fuel level Fuel level may be low (below approximately 41 l). Check it and add
causes and 1
(when system is normal) fuel if necessary.
standard
If cause 1 is not detected, fuel level gauge system may be defective.
value in nor- Defective fuel level gauge
2 Perform troubleshooting for E-11 Fuel level gauge does not indicate
mal condition system
normally.
Trouble (3) Air cleaner clogging monitor lights up red.

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

Clogging of air cleaner Air cleaner may be clogged. Check it, then clean or replace if neces-
1
(when system is normal) sary.
troubleshooting.
P23 (male) Air cleaner Resistance
Defective air cleaner clog- When normal
2 ging switch (Internal discon- (Air intake resis- Max.1 Ω
nection) tance: *1)
Between (1) – (2)
When clogged
(Air intake resis- Min. 1 MΩ
Probable tance: *2)
ness
value in nor- Wiring harness between CM02 (female) (4) – Resis-
3 (Disconnection in wiring or Max.1 Ω
mal condition P23 (female) (1) tance
tor) Max.1 Ω
troubleshooting.
CM02 Air cleaner Voltage
When normal
4 Defective machine monitor (Air intake resis- Max.1 V
Between (4) – chas- tance: *1)
sis ground When clogged
(Air intake resis- 20 – 30 V
tance:*2)
*1: Max. -3,430 Pa {Max. -350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
40-400 22 PC200, 200LC-8E0 (Hybrid)

E-7 Caution monitor lights up while engine is running SEN05252-00
Circuit diagram related to air cleaner clogging switch
PC200, 200LC-8E0 (Hybrid) 40-400 23

Trouble (4) Engine coolant temperature monitor lights up white.

q Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
Related machine monitor through communication system.
information q Engine coolant temperature can be checked by using monitoring function. (Code: 04107 Engine
coolant temperature)

If monitor lights up white, engine coolant temperature may be low
Probable Insufficient warm-up of
(below approximately 30 °C). Warm up engine.
causes and 1 machine
q Lighting up white: Engine coolant temperature is low.
standard (when system is normal)
q Lighting up blue: Engine coolant temperature is proper.
value in nor-
If cause 1 is not detected, engine coolant temperature gauge sys-
mal condition Defective engine coolant
2 tem may be defective. Perform troubleshooting for E-9 Engine
temperature gauge system
coolant temperature gauge does not indicate normally.
Trouble (5) Water separator monitor lights up red.

Related q Condition of signal from water-in-fuel sensor switch can be checked by using monitoring function.
information (Code: 18800 WIF sensor condition)

Probable
Water separator is full
causes and 1 Water separator may be full of water. Check it, then drain if full.
standard
If cause 1 is not detected, water-in-fuel sensor system may be
value in nor- Defective water-in-fuel sen-
2 defective. Perform troubleshooting for failure codes [CA428] and
mal condition sor system
[CA429].
Trouble (6) Hydraulic oil temperature monitor lights up white.

q Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to ma-
Related chine monitor through communication system.
information q Hydraulic oil temperature can be checked by using monitoring function. (Code: 04401 Hydraulic oil
temperature)

Probable If monitor lights up white, hydraulic oil temperature may be low
Insufficient warm-up of
causes and (below about 20 °C). Warm up engine.
1 machine
standard q Lighting up white: Hydraulic oil temperature is low.
value in nor- q Lighting up blue: Hydraulic oil temperature is proper.
mal condi- If cause 1 is not detected, hydraulic oil temperature gauge system
tion 2 may be defective. Perform troubleshooting for E-10 Hydraulic oil
perature gauge system
temperature gauge does not indicate normally.
40-400 24 PC200, 200LC-8E0 (Hybrid)

E-8 Emergency monitor lights up while engine is running SEN05252-00
E-8 Emergency monitor lights up while engine is running

Trouble (1) Engine coolant temperature monitor lights up red.
q Signals of engine coolant temperature sensor are input to engine controller and then transmitted to ma-
information q Engine coolant temperature can be checked by using monitoring function. (Code: 04107 Engine cool-
ant temperature)

If monitor lights up red, engine coolant temperature may be high
Probable (above approximately 102 °C). Cool down engine coolant (Run
Overheating of engine coolant
causes and 1 engine at low idle).
standard q Lighting up red:Engine coolant temperature is high (overheating).
value in nor- q Lighting up blue: Engine coolant temperature is proper.
mal condition If cause 1 is not detected, engine coolant temperature gauge system
Defective engine coolant tem-
2 may be defective. Perform troubleshooting for E-9 Engine coolant
temperature gauge does not indicate normally.
Trouble (2) Hydraulic oil temperature monitor lights up red.

Related infor- chine monitor through communication system.
mation q Hydraulic oil temperature can be checked by using monitoring function. (Code: 04401 Hydraulic oil
temperature)

If monitor lights up red, hydraulic oil temperature may be high (above
Probable approximately 102 °C). Cool down hydraulic oil (Run engine at low
Overheating of hydraulic oil
causes and 1 idle).
standard q Lighting up red: Hydraulic oil temperature is high (overheating).
value in nor- q Lighting up blue: Hydraulic oil temperature is proper.
mal condition If cause 1 is not detected, hydraulic oil temperature gauge system
2 may be defective. Perform troubleshooting for E-10 Hydraulic oil tem-
perature gauge does not indicate normally.
Trouble (3) Engine oil pressure monitor lights up red.

Related infor- q Engine oil pressure switch signal is input to engine controller and then transmitted to machine monitor
mation through communication system.

Probable
Lowering of engine oil pres-
causes and Engine oil pressure may be low. If it is low, perform troubleshooting
1 sure
standard for "S-12 Oil pressure lowers".
value in nor-
Defective engine oil pressure If cause 1 is not detected, engine oil pressure gauge system may be
mal condition 2
switch system defective. Perform troubleshooting for failure code [CA435].
PC200, 200LC-8E0 (Hybrid) 40-400 25

SEN05252-00 E-9 Engine coolant temperature gauge does not indicate normally
E-9 Engine coolant temperature gauge does not indicate normally

(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
information q Engine coolant temperature can be checked by using monitoring function. (Code: 04107 Engine cool-
ant temperature)

Probable
If cause 1 is not detected, engine coolant temperature sensor system
causes and Defective engine coolant tem-
1 may be defective. Perform troubleshooting for failure codes [CA144]
standard perature sensor system
and [CA145].
value in nor-
If cause 1 is not detected, machine monitor may be defective. (Since
mal condition 2 Defective machine monitor
(3) Display of coolant temperature gauge is different from actual engine coolant temperature.
Trouble (4) Display of engine coolant temperature gauge is different from display of engine coolant temperature
monitor.
information q Engine coolant temperature can be checked by using monitoring function.(Code:04107 Engine coolant
temperature)

a Turn starting switch to ON position or start engine and perform
troubleshooting.
Probable Engine coolant tem- Coolant temperature Color of monitor light
causes and perature level (a)
standard 105 °C 6
1 Defective machine monitor Red
value in nor- 102 °C 5
mal condition 100 °C 4
85 °C 3 Blue
60 °C 2
30 °C 1 White
Engine coolant temperature gauge and engine

coolant temperature monitor
40-400 26 PC200, 200LC-8E0 (Hybrid)

E-10 Hydraulic oil temperature gauge does not indicate normally SEN05252-00
E-10 Hydraulic oil temperature gauge does not indicate normally

(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range
Trouble (C).
(2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
temperature

without turning starting switch ON position.
perature sensor
Between (1) – (2) 3.5 – 90 kΩ
short circuit)
ness
Wiring harness between C01 (female) (29) – Resis-
2 (Disconnection in wiring or Max.1 Ω
P22 (female) (2) tance
Probable tor) Max.1 Ω
causes and
a Ground fault in wiring harness
standard Ground fault in wiring harness
3 Between ground and wiring harness between Resis-
value in nor- (Short circuit with GND circuit) Min. 1 MΩ
C01 (female) (29 – P22 (female) (2) tance
mal condition
Hot short
4 (Short circuit with 24 V circuit)
in wiring harness Voltage Max.1 V
C01 (female) (29) – P22 (female) (2)
Between (29) – (46) 3.5 – 90 kΩ
If causes 1 – 5 are not detected, machine monitor may be defective.
Circuit diagram related to hydraulic oil temperature sensor
PC200, 200LC-8E0 (Hybrid) 40-400 27

SEN05252-00 E-10 Hydraulic oil temperature gauge does not indicate normally
(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature moni-
tor.
temperature

a Turn starting switch ON positiion or start engine and perform trou-
Probable bleshooting.
Hydraulic oil tempera- Hydraulic oil tempera- Color of monitor light
causes and
standard ture ture level (a)
105 °C 6
value in nor- 1 Defective machine monitor Red
102 °C 5
mal condi-
100 °C 4
tion
85 °C 3 Blue
40 °C 2
20 °C 1 White
Hydraulic oil temperature gauge and hydraulic

oil temperature monitor
40-400 28 PC200, 200LC-8E0 (Hybrid)

E-11 Fuel level gauge does not indicate normally SEN05252-00
E-11 Fuel level gauge does not indicate normally

(1) While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
(2) While fuel level is low, fuel level gauge does not lower from green range top (F)
Related q Signal voltage of fuel level sensor can be checked by using monitoring function. (Code: 04200 Fuel
information sensor voltage)

Defective fuel level sensor without turning starting switch to ON position.
1 (Internal disconnection or P21 (male) Fuel level Resistance
short circuit) Between (1) – chassis FULL 7–11 Ω
ground EMPTY 85–95 Ω
Probable defective contact in connec- Max. 1 Ω
causes and tor)
standard Ground fault in wiring har- a Prepare with starting switch OFF, then perform troubleshooting
value in nor- ness without turning starting switch to ON position.
3
mal condi- (Short circuit with GND cir- Between ground and wiring harness between Resis-
Min. 1 MΩ
tion cuit) CM01 (female) (9) – P21 (female) (1) tance
sition and perform troubleshooting.
4 24 V circuit) in wiring har-
CM01 (female) (9) – P21 (female) (1)
5 Defective machine monitor CM01 (female) Fuel level Resistance
FULL 7 – 11 Ω
EMPTY 85 – 95 Ω
Circuit diagram related to fuel level sensor
PC200, 200LC-8E0 (Hybrid) 40-400 29

SEN05252-00 E-11 Fuel level gauge does not indicate normally
(3) Display of fuel level gauge is different from actual fuel level.
Trouble
(4) Display of fuel level gauge is different from display of fuel level monitor.
Related q Signal voltage of fuel level sensor can be checked by using monitoring function. (Code: 04200 Fuel
information sensor voltage)

a Turn starting switch to ON position or start engine and perform
troubleshooting.
Probable Reading of fuel level Color of monitor light
Quantity of fuel
causes and gauge (a)
standard 289 l 6
value in nor- 244.5 l 5
mal condition 200 l 4 Blue
100 l 3
60 l 2
41 l 1 Red
Fuel level gauge and fuel level monitor
40-400 30 PC200, 200LC-8E0 (Hybrid)

E-12 Contents of display by machine monitor are different from applicable machine SEN05252-00
E-12 Contents of display by machine monitor are different from appli-

cable machine
Trouble q Contents of display by machine monitor are different from applicable machine
Related infor-
mation

a Turn starting switch ON and perform troubleshooting (by using
Probable monitoring function).
causes and Monitoring code Normal display
1 Defective model code signal
standard 00200 Controller model code PC200-8
value in nor- If display of monitoring is abnormal, perform troubleshooting for failure
mal condition code [DA29KQ].
If causes 1 is not detected, machine monitor may be defective. (Since
PC200, 200LC-8E0 (Hybrid) 40-400 31

SEN05252-00 E-13 Some areas of the machine monitor screen are not displayed
E-13 Some areas of the machine monitor screen are not displayed
Trouble q Some areas of the machine monitor screen are not displayed
q The LCD panel sometimes has black points (points which are not lighted) and bright points (points
Related
which do not go off) for the reason of its characteristics. If the number of the bright points and black
information
points does not exceed 10, those points are not a failure or a defect.

Probable
a Turn starting switch ON and performed troubleshooting.
causes and
Defective machine monitor When following switches are operated, if all LCD panel is lighted up
standard 1
(LCD panel) (all surface becomes white), LCD panel is normal.
value in nor-
q Operation of switches: [4]+[F2] (Press switches simultaneously)
mal condi-
Defective machine moni- If cause 1 is not detected, machine monitor may be defective. (Since
tion 2
tor(body) trouble is in system, troubleshooting cannot be performed.)
40-400 32 PC200, 200LC-8E0 (Hybrid)

E-14 Function switch does not work SEN05252-00
E-14 Function switch does not work

Trouble q Function switch does not work
Related infor- q Condition of signal of function switch can be checked by using monitoring function.
mation (Code: 04503 Monitor function switch)

causes and
standard Machine monitor may be defective.(Since trouble is in system, trou-
value in nor- bleshooting cannot be performed.)
mal condition
PC200, 200LC-8E0 (Hybrid) 40-400 33

SEN05252-00 E-15 Auto-deceleration does not operate normally
E-15 Auto-deceleration does not operate normally

(1) When auto-deceleration switch is operated, auto-deceleration monitor does not light up or does not go
Trouble
off.
Related q Condition of signal of auto-deceleration switch can be checked by using monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)

causes and
standard Machine monitor may be defective.(Since trouble is in system, trou-
mal condition
Trouble (2) Auto-deceleration is not operated or released with lever.

Related q Set speed of auto-deceleration is 1,250 rpm. If fuel control dial is not set above this speed, autodecel-
information eration is not operated or released.

a Start engine and perform troubleshooting (by using monitoring
function).
Monitoring code Item Normal display
Swing
Travel When lever is oper-
01900 Boom LOWER ated: ON
Pressure Switch 1 Boom RAISE When lever is in neu-
Defective PPC pressure sig- Arm IN tral: OFF
1 Arm OUT
nal
Probable Bucket CURL When lever is oper-
causes and 01901 Bucket DUMP ated: ON
standard Pressure Switch 2 When lever is in neu-
Service
value in nor- tral: OFF
mal condition If display of monitoring is abnormal, perform troubleshooting for
"E-26 Monitoring function does not display lever control signal cor-
rectly".
If cause 1 is not detected, machine monitor may be defective.
(Since failure is in it, troubleshooting cannot be performed.)
If cause 1 is not detected, pump controller may be defective. (Since
If cause 1 is not detected, engine controller may be defective. (Since
If cause 1 is not detected, inverter may be defective. (Since trouble is
5 Defective inverter
in system, troubleshooting cannot be performed.)
40-400 34 PC200, 200LC-8E0 (Hybrid)

E-16 Working mode does not change SEN05252-00
E-16 Working mode does not change

Trouble (1) When working mode switch is operated, working mode selection screen is not displayed.
Related infor- q Condition of signal of working mode switch can be checked by using monitoring function.
mation (Code: 04504 Monitor 1st, 2nd line switches)

causes and
standard Machine monitor may be defective. (Since trouble is in system, trou-
mal condition
Trouble (2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related infor-
mation

causes and Machine monitor may be defective. (Since trouble is in system, trou-
standard bleshooting cannot be performed.)
value in nor- Pump controller may be defective
mal condition (Since trouble is in system, troubleshooting cannot be performed.)
PC200, 200LC-8E0 (Hybrid) 40-400 35

SEN05252-00 E-17 Travel speed does not change
E-17 Travel speed does not change

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

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

a Prepare with starting switch OFF, then turn starting switch ON po-
Hot short
Probable sition and perform troubleshooting.
1 (Short circuit with 24 V cir-
causes and Between ground and wiring harness between
cuit) in wiring harness Voltage Max. 1 V
standard C02 (female) (87) – V04 (female) (1)
value in nor- If cause 1 is not detected, machine monitor may be defective.
mal condition (Since trouble is in system, troubleshooting cannot be performed.)
If cause 1 is not detected, pump controller may be defective.
40-400 36 PC200, 200LC-8E0 (Hybrid)

E-18 Alarm buzzer cannot be stopped SEN05252-00
E-18 Alarm buzzer cannot be stopped

Trouble q Alarm buzzer cannot be stopped.
Related infor- q Condition of signal of alarm buzzer cancel switch can be checked by using monitoring function.

causes and
mal condition
PC200, 200LC-8E0 (Hybrid) 40-400 37

SEN05252-00 E-19 Windshield wiper and window washer do not operate
E-19 Windshield wiper and window washer do not operate

Trouble (1) When wiper switch is operated, wiper monitor does not light up or go off.
Related q Condition of wiper switch signal can be checked by using monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)

causes and
mal condition
Trouble (2) When wiper switch is operated, wiper does not operate.
Related q Condition of window rear limit switch signal can be checked by using monitoring function.
information (Code: 02204 Switch 5)

Defective window rear limit W03 (male) Front window Resistance
1 switch When installed to
Min. 1 MΩ
(Internal short circuit) front
Between (1) – (2)
When retracted to
Max. 1 Ω
rear
Defective wiper motor without turning starting switch to ON position.
2
(Internal disconnection) M05 (female) Continuity
Between (1) – (3) Continuity
ness
Probable 3 (Disconnection in wiring or Max. 1 Ω
– M05 (male) (3) tance
causes and defective contact in connec-
standard tor) Max. 1 Ω
– M05 (male) (1) tance
value in nor-
mal condition Ground fault in wiring harness without turning starting switch to ON position.
4 (Short circuit with GND cir- Between ground and wiring harness
Resis-
cuit) between C01 (female) (57) – W03 (female) Min. 1 MΩ
tance
(1)
C01 (female) Front window Resistance
Defective pump controller
When installed to
(Rear limit switch system) Min. 1 MΩ
Between (57) – front
5 ground When retracted to
Max. 1 Ω
rear
Defective pump controller without turning starting switch to ON position.
(Wiper motor system) C02 (female) Continuity
40-400 38 PC200, 200LC-8E0 (Hybrid)

E-19 Windshield wiper and window washer do not operate SEN05252-00
Trouble (3) When window washer switch is operated, window washer does not operate.
Related infor- q Condition of window washer switch signal can be checked by using monitoring function.

causes and
standard value Machine monitor may be defective. (Since trouble is in system,
in normal condi- troubleshooting cannot be performed.)
tion
PC200, 200LC-8E0 (Hybrid) 40-400 39

SEN05252-00 E-20 One-touch power maximizing function does not operate normally
E-20 One-touch power maximizing function does not operate normally

(1)When left knob switch is pressed, one-touch power maximizing monitor is not displayed.
Trouble
(2) When left knob switch is pressed, work equipment power is not increased.
q One-touch power maximizing function does not work when working mode is not power mode (P) or
Related infor- economy mode (E).
mation q Condition of left knob switch signal can be checked by using monitoring function. (Code: 02200 Switch
input 1)

Defective left knob switch
2 S11 (male) Left knob switch Resistance
Release Min. 1 MΩ
Between (1) – (2)
Pressed Max. 1 Ω
ness
Wiring harness between F01-9 – S11 Resis-
(female)(1) tance
Probable defective contact in connec-
Wiring harness between S11 (female) (2) – Resis-
causes and tor) Max. 1 Ω
C01 (female) (41) tance
standard
value in nor- Ground fault in wiring har- without turning starting switch to ON position.
mal condition ness Between ground and wiring harness between Resis-
4 Min. 1 MΩ
(Short circuit with GND cir- F01-9 – S11 (female) (1) tance
cuit) Between ground and wiring harness between Resis-
Min. 1 MΩ
S11 (female) (2) – C01 (female) (41) tance
5 Defective pump controller C01 (female) Left knob switch Resistance
Between (41) – chas- Release Min. 1 MΩ
sis ground Pressed Max. 1 Ω
Machine monitor may be defective. (Since trouble is in system, trou-
bleshooting cannot be performed.)
Circuit diagram related to left knob switch
40-400 40 PC200, 200LC-8E0 (Hybrid)

E-20 One-touch power maximizing function does not operate normally SEN05252-00
Trouble (3) When left knob switch is released, work equipment power does not return to normal level.
Related q Condition of left knob switch signal can be checked by using monitoring function. (Code: 02200 Switch
information input 1)

Probable a Prepare with starting switch OFF, then turn starting switch to ON
Hot short
causes and position and perform troubleshooting.
1 (Short circuit with 24V circuit)
standard Wiring harness between C02 (female) (109) –
in wiring harness Voltage Max. 1 V
value in nor- V02 (female) (1)
mal condition If cause 1 is not detected, pump controller may be defective. (Since
PC200, 200LC-8E0 (Hybrid) 40-400 41

SEN05252-00 E-20 One-touch power maximizing function does not operate normally
40-400 42 PC200, 200LC-8E0 (Hybrid)

E-21 Swing brake does not operate normally SEN05252-00
E-21 Swing brake does not operate normally

Trouble (1) When swing lock switch is operated, swing lock monitor does not light up or go off.
q Condition of swing lock switch signal can be checked by using monitoring function.
Related infor-
(Machine monitor system code: 04502 Monitor input 3)
mation
(Pump controller system code: 02200 Switch input 1)

a Prepare with starting switch OFF, then perform troubleshooting with-
Defective swing lock switch out turning starting switch to ON position.
1 (Internal disconnection or S04 (male) Swing lock switch Resistance
short circuit) OFF Min. 1 MΩ
Between (5) – (6)
ON Max. 1 Ω
out turning starting switch to ON position.
ness
J02 – S04 (female) (5) tance
Wiring harness between S04 (female) (6) – Resis-
J05 – chassis ground (T07) tance
standard
value in nor-
out turning starting switch to ON position.
mal condition Ground fault in wiring harness
3 Between ground and wiring harness between
(Short circuit with GND circuit) Resis-
CM02 (female) (5) – J02 – S04 (female) (5), – Min. 1 MΩ
tance
C01 (female) (19)
4 Defective machine monitor CM02 Swing lock switch Voltage
OFF 20 – 30 V
ON Max. 1 V
Defective emergency stop Resis-
5 D03(3)–H15(12) ON Max. 1 Ω
switch tance
(2) When swing lock switch is turned ON, swing lock does not operate.
Trouble
(Upper structure lowers by its own weight on slope.)
Related infor-
mation

Defective swing lock switch
1 S04 (male) Swing lock switch Resistance
OFF Min. 1 MΩ
Between (3) – (4)
ON Max. 1 Ω
Probable Defective swing brake
Swing Brake
causes and 2 release switch (Internal short S25 (male) Resistance
release switch
standard circuit)
Normal Min. 1 MΩ
value in nor- Between (13) – (14)
Release Max. 1 Ω
mal condition a Prepare with starting switch OFF, then turn starting switch to ON
Hot short (Short circuit with D01 (female) (3) – J02 – S04 (female) (3), – Voltage Max. 1 V
3
24V circuit) in wiring harness S25 (female) (14)
Between ground and wiring harness S04
(female) (4) – V03 (female) (1), – D03 Voltage Max. 1 V
(female) (3)
PC200, 200LC-8E0 (Hybrid) 40-400 43

SEN05252-00 E-21 Swing brake does not operate normally
Trouble (3) Even if swing lock switch is turned to OFF position, swing lock is not released.
Related infor-
mation

1 Defective swing lock switch S04 (male) Swing lock switch Resistance
Bucket DUMP Min. 1 MΩ
Between (3) – (4)
Service Max. 1 Ω
Defective swing brake
Swing Brake
Probable 2 release switch (Internal short S25 (male) Resistance
release switch
causes and circuit)
Normal Min. 1 MΩ
standard Between (13) – (14)
Release Max. 1 Ω
value in nor- a Prepare with starting switch OFF, then turn starting switch ON po-
mal condition sition and perform troubleshooting.
Hot short (Short circuit with D01 (female) (3) – J02 – S04 (female) (3), – Voltage Max. 1 V
3
24 V circuit) in wiring harness S25 (female) (14)
Between ground and wiring harness S04
(female)(4) – V03 (female) (1), – D03 Voltage Max. 1 V
(female) (3)
Defective swing emergency Resis-
4 D03(3) – H15(12) ON Max. 1 Ω
stop switch tance
40-400 44 PC200, 200LC-8E0 (Hybrid)

E-21 Swing brake does not operate normally SEN05252-00
Circuit diagram related to swing brake solenoid
PC200, 200LC-8E0 (Hybrid) 40-400 45

SEN05252-00 E-22 Travel alarm does not sound or does not stop sounding
E-22 Travel alarm does not sound or does not stop sounding
Trouble (1) Alarm does not sound during travel.
Related
information

If the fuse is broken, the circuit probably has a grounding fault, etc.
1 Defective fuse No.15
(See cause 4)
a Start the engine and perform troubleshooting.
When lever is oper-
Defective travel signal sys- 01900 ated: ON
2 Travel
tem Pressure Switch 1 When lever is in neu-
tral: OFF
Probable If display of monitoring is abnormal, perform troubleshooting for E-26
causes and Monitoring function does not display lever control signal normally.
ness
mal condi- Wiring harness between F01-15 – J03 – M14 Resis-
tion (female) (1) tance
Wiring harness between M14 (female) (2) – Resis-
tor Max. 1 Ω
J01(19) – P09 (female) (2) tance
ness
F01-15 – J03 – M14 (female) (1), – circuit Min. 1 MΩ
cuit) tance
branch end
Defective travel alarm
5 If causes 1 – 4 are not detected, travel alarm is defective.
(Internal defect)
Trouble (2) Alarm does not stop sounding while machine is stopped.
Related
information

a Start the engine and perform troubleshooting.
When lever is oper-
Defective travel signal sys- 01900 ated: ON
1 Travel
tem Pressure Switch 1 When lever is in neu-
tral: OFF
If display of monitoring is abnormal, perform troubleshooting for "E-26
Probable
Monitoring function does not display lever control signal normally".
causes and
Defective assembled-type a Prepare with starting switch OFF, then perform troubleshooting
standard
diode D02 without turning starting switch to ON position.
value in nor- 2
(Short circuit with GND cir- D02(male) Continuity
mal condi- Between (4) – (8) Continuity
cuit)
tion
Defective travel hydraulic without turning starting switch to ON position.
3
pressure switch Resis-
Between P09 (male) (1) – (2) Min. 1 MΩ
tance
4
(Short circuit with GND cir- Wiring harness between M14 (female) (2) – Resis-
Min. 1 MΩ
cuit) J01 – P09 (female) (2), – D02 (female) (4) tance
40-400 46 PC200, 200LC-8E0 (Hybrid)

E-22 Travel alarm does not sound or does not stop sounding SEN05252-00
Circuit diagram related to travel alarm and travel PPC oil pressure switch
PC200, 200LC-8E0 (Hybrid) 40-400 47

SEN05252-00 E-23 Air conditioner does not operate normally (including air conditioner abnormality record)
E-23 Air conditioner does not operate normally (including air conditioner
abnormality record)
Trouble (1) When air conditioner switch is operated, air conditioner control screen is not displayed.
Related q Condition of air conditioner switch signal can be checked by using monitoring function.
information (Code: 04505 Monitor 3rd, 4th line switches, 04506 Monitor 5th line switch)
Possible Cause Standard value in normal condition/Remarks on troubleshooting

causes and
mal condition
Trouble (2) When air conditioner switch is operated, air conditioner does not operate at all.
Related
information

1 Defective fuse No.11 If fuse is broken, circuit probably has ground fault, etc. (See cause 4)
If fuse in unit is broken, circuit in unit probably has ground fault. (See
2 Defective fuse in unit
cause 4.)
ness
Wiring harness between F01-11 – fuse in unit
3 (Disconnection in wiring or Resistance Max. 1 Ω
– ACW (wiring side) (6)
Wiring harness between AC W (wiring side)
Probable tor) Resistance Max. 1 Ω
(16) – chassis ground (T07)
causes and
standard Ground fault in wiring har-
value in nor- ness
mal condition (Short circuit with GND cir-
F01-11 – fuse in unit – ACW (wiring side) (6), Resistance Min. 1 MΩ
cuit)
– circuit branch end
Defective air conditioner
5 ACW (wiring side) Voltage
controller
Between (6) – (16) 20 – 30 V
If above voltage is normal, air conditioner controller may be defective.
40-400 48 PC200, 200LC-8E0 (Hybrid)

E-23 Air conditioner does not operate normally (including air conditioner abnormality record) SEN05252-00
Trouble (3) Air does not come out (Air flow is insufficient).
Related infor-
mation

without turning starting switch to ON position (coil side).
Between (1) – (3) 140 – 340 Ω
Defective blower relay
1 a Prepare with starting switch OFF, then turn starting switch to ON po-
sition and perform troubleshooting (contact side).
R20 Air conditioner switch Voltage
Between (4) – chas-
Air blow position 20 – 30 V
sis ground
a Prepare with starting switch OFF, then turn starting switch ON and
perform troubleshooting.
Defective power transistor
2 Fan switch If air flow changes according to
(Internal defect)
Operate in range of Low, operation of fan switch, power tran-
Medium, and High sistor is normal.
Defective blower motor MB (wiring side) Air conditioner switch Voltage
3
(Internal defect) Between (1) – (2) Air blow position 20 – 30 V
If the above voltage is normal and the blower motor does not rotate,
the blower motor is defective.
a Prepare with starting switch OFF, then performt troubleshooting
Wiring harness between F01-11 – fuse in unit
– R20 (female) (1)
Probable Wiring harness between R20 (female) (3) –
causes and ACW (wiring side) (36)
standard Wiring harness between F01-11 –R20
Disconnection in wiring har- Resistance Max. 1 Ω
value in nor- (female) (5)
ness
mal condition 4 Wiring harness between R20 (female) (4) –
(Disconnection in wiring or Resistance Max. 1 Ω
MB (wiring side) (1)
Wiring harness between MB (wiring side) (2) –
tor) Resistance Max. 1 Ω
PTR (wiring side) (3)
Wiring harness between PTR (wiring side) (1)
– chassis ground (T07)
Ground fault in wiring har- R20 (female) (3) – ACW (wiring side) (36)
ness Between ground and wiring harness between
(Short circuit with GND cir- R20 (female) (4) – MB (wiring side) (1)
cuit) Between ground and wiring harness between
MB (wiring side) (2) – PTR (wiring side) (3)
PTR (wiring side) (2) – AC W (wiring side) (8)
If causes 1 – 5 are not detected, air conditioner controller may be
6 defective. (Since trouble is in system, troubleshooting cannot be per-
controller
formed.)
If causes 1 – 5 are not detected, air conditioner system may be defec-
7 tive. See Machine Component Chapter of Shop Manual, Air condi-
system
tioner, Troubleshooting.
PC200, 200LC-8E0 (Hybrid) 40-400 49

Trouble (4) Air is not cooled (Cooling performance is insufficient).

Related infor-
mation

without turning starting switch to ON position (coil side).
Between (1) – (3) 140 – 340 Ω
Defective compressor relay
1 a Prepare with starting switch OFF, then turn starting switch to ON
position and perform troubleshooting (contact side).
R21 Air conditioner switch Voltage
Between (2) – chas-
Cooling position 20 – 30 V
sis ground
Internal air sensor may be defective. Perform troubleshooting for
2 Defective internal air sensor
Abnormality in internal air sensor.
Defective high and low pres- High and low pressure switches may be defective. Perform trouble-
3
sure switches shooting for “Abnormality in refrigerant”.
Defective compressor clutch
4 Compressor clutch may be defective. Check it directly.
(Internal defect)
Defective compressor
5 Compressor may be defective. Check it directly.
(Internal defect)
Probable
causes and
standard Wiring harness between F01-11 – fuse in unit
value in nor- Disconnection in wiring har- Resistance Max. 1 Ω
– R21 (female) (1)
mal condition ness
Wiring harness between R21(female) (3) –
ACW (wiring side) (35)
Wiring harness between F01-11 – R21
(female)(4)
Wiring harness between R21 (female) (2) –
AC02 (female) (1)
ness Between ground and wiring harness between
(Short circuit with GND cir- R21 (female) (3) – AC W (wiring side) (35)
R21 (female) (2) – AC02 (female) (1)
controller
formed.)
If causes 1 – 7 are not detected, air conditioner system may be defec-
9 tive. See Machine Component Chapter of Shop Manual, Air condi-
system
tioner, Troubleshooting.
40-400 50 PC200, 200LC-8E0 (Hybrid)

(5) Air conditioner abnormality record: Communication condition “CAN disconnection”, Communication
Trouble
condition “Abnormal”
q While abnormality in communication is being detected, “CAN disconnection” is displayed.
q If abnormality in communication has been detected and reset, “Abnormality” is displayed.
Related infor-
q If “CAN disconnection” is displayed as communication condition, communication cannot be performed
mation
normally. Accordingly, condition of other monitor is not displayed.
q Method of reproducing abnormality record: Turn starting switch to ON position.

ness
Wiring harness between N10 (female) (2) –
CM02 (female) (8)(9)
Wiring harness between N10 (female) (1) –
CM02 (female) (10)
a Prepare with starting switch OFF, then performtroubleshooting
Ground fault in wiring har- N10 (male) (2) – CM02 (female) (8) (9) – C01
ness (female)(45), – CE02 (female) (46), – K02
2
(Short circuit with GND cir- (female) (A), – N08 (male) (3)
N10 (female) (1) – CM02 (female) (10), – C01
(female) (64), – CE02 (female) (47), – K02
Probable
(female) (B), – N08 (male) (10)
causes and
standard
value in nor- Between ground and wiring harness between
mal condition
N10(male) (2) – CM02 (female) (8) (9) – C01
Voltage Max. 5.5 V
Hot short(Short circuit with24 (female) (45), – CE02 (female) (46), – K02
3
V circuit) in wiring harness (female) (A), – N08(male) (3)
N10 (female) (1) – CM02 (female) (10), – C01
Voltage Max. 5.5 V
(female) (64), – CE02 (female) (47), – K02
(female) (B), – N08 (male) (10)
Defective CAN terminal a Prepare with starting switch OFF, then perform troubleshooting
resistance without turning starting switch to ON position.
4
(Internal short circuit or dis- K02 (male) Resistance
connection) Between (A) – (B) 47 – 67 Ω
controller
formed.)
PC200, 200LC-8E0 (Hybrid) 40-400 51

Trouble (6) Air conditioner abnormality record: Setting condition “Abnormality”

q If setting of air conditioner controller model is different from setting of machine monitor model,
“Abnormality” is displayed.
Related infor-
q If “CAN disconnection” is displayed as communication condition, communication cannot be carried
mation
out normally. Accordingly, this condition is not displayed.
q Method of reproducing abnormality record: Turn starting switch to ON position.

causes and Defective air conditioner con- Air conditioner controller may be defective. (Since trouble is in sys-
1
standard troller tem, troubleshooting cannot be performed.)
value in nor- Machine monitor may be defective. (Since trouble is in system, trou-
mal condition bleshooting cannot be performed.)
Trouble (7) Air conditioner abnormality record: Internal air sensor “Abnormality”
q If “CAN disconnection” is displayed as communication condition, communication cannot be per-
Related infor- formed normally. Accordingly, this condition is not displayed.
mation q Method of reproducing abnormality record: Turn starting switch to ON position + Turn air conditioner
(A/C) switch to ON position.

Defective recirculated air a Prepare with starting switch OFF, then perform troubleshooting
sensor without turning starting switch to ON position.
1
(Internal disconnection or THI (device side) Resistance
short circuit) Between (1) –(2) 300 –430 Ω
ness
Wiring harness between ACW (wiring side) Resis-
(11) – THI (wiring side) (2) tance
Wiring harness between ACW (wiring side) Resis-
(27) – TH I (wiring side) (1) tance
standard
value in nor-
mal condition 3
(Short circuit with GND cir- Between ground and wiring harness between Resis-
Min. 1 MΩ
cuit) ACW (wiring side) (11) – TH I (wiring side) (2) tance
Hot short (Short circuit
4 with24 V circuit) in wiring
harness Voltage Max. 1 V
ACW (wiring side) (11) – TH I (wiring side) (2)
controller
formed.)
40-400 52 PC200, 200LC-8E0 (Hybrid)

Trouble (8) Air conditioner abnormality record: External air sensor "Unused"
q External air sensor is not used in air conditioner system of this machine.
Related infor-
q If “CAN disconnection” is displayed as communication condition, communication cannot be performed
mation
normally. Accordingly, this condition is not displayed.

causes and
standard Since external air sensor is not used in air conditioner system of this
1 Normal display
value in nor- machine, above display is normal
mal condition
Trouble (9) Air conditioner abnormality record: Air flow sensor "Abnormality"
Related formed normally. Accordingly, this condition is not displayed.
information q Method of reproducing abnormality record: Turn starting switch to ON position + Turn air conditioner

Defective air flow sensor
THF (device side) Resistance
short circuit)
Between (1) – (2) 100 – 115 kΩ
ness
(12) – THF (wiring side) (2)
Probable Wiring harness between ACW (wiring side)
causes and (27) – THF (wiring side) (1)
value in nor- 3 ness without turning starting switch to ON position.
mal condition (Short circuit with GND cir- Wiring harness between AC W (wiring side)
cuit) (12) – THF (wiring side) (2)
Hot short (Short circuit position and perform troubleshooting.
4 with24 V circuit) in wiring Between ground and wiring harness
harness between ACW (wiring side) (12) – TH F (wir- Voltage Max. 1 V
ing side) (2)
Defective air conditioner con-
troller
formed.)
PC200, 200LC-8E0 (Hybrid) 40-400 53

Trouble (10) Air conditioner abnormality record: Daylight sensor "Abnormality"


Defective daylight sensor
1 Daylight sensor may be defective.
(Internal defect)
ness
(3) – P31 (female) (1)
(15) – P31 (female) (2)
Ground fault in wiring har- Between ground and wiring harness
Probable
ness between ACW (wiring side) (3) – P31 Resistance Min. 1 MΩ
causes and 3
(Short circuit with GND cir- (female) (1), – circuit branch end
standard
cuit) Between ground and wiring harness
value in nor-
between ACW (wiring side) (15) – P31 Resistance Min. 1 MΩ
mal condition
(female) (2)
Between ground and wiring harness
Hot short (Short circuit with between ACW (wiring side) (3) – P31 Voltage Max. 1 V
4
24V circuit) in wiring harness (female) (1), – circuit branch end
between ACW (wiring side) (15) – P31 Voltage Max. 1 V
(female) (2)
troller
formed.)
40-400 54 PC200, 200LC-8E0 (Hybrid)

Trouble (11) Air conditioner abnormality record: Air outlet damper “Abnormality”

Defective air outlet servo-
1 motor Air outlet servomotor may be defective.
(Internal defect)
Wiring harness between M V1 (wiring side)
(1) – AC W (wiring side) (3)
ness Resistance Max. 1 Ω
defective contact in connec- Resistance Max. 1 Ω
tor)
between MV1 (wiring side) (1) – ACW (wiring Resistance Min. 1 MΩ
side) (3), – circuit branch end
Probable Ground fault in wiring har- Between ground and wiring harness
causes and ness between MV1 (wiring side) (5) – ACW (wiring Resistance Min. 1 MΩ
3
standard (Short circuit with GND cir- side) (9)
value in nor- cuit) Between ground and wiring harness
mal condition between MV1 (wiring side) (6) – ACW (wiring Resistance Min. 1 MΩ
side) (24)
between MV1 (wiring side) (7) – ACW (wiring Resistance Min. 1 MΩ
side) (23)
between MV1 (wiring side) (1) – ACW (wiring Voltage Max. 1 V
4 with24 V circuit) in wiring
side) (9)
harness
side) (24)
side) (23)
troller
formed.)
PC200, 200LC-8E0 (Hybrid) 40-400 55

Trouble (12) Air conditioner abnormality record: A/M damper "Abnormality"


Defective air mix servomotor
1 Air mix servomotor may be defective.
(Internal defect)
Wiring harness between MAM (wiring
side)(1) – AC W (wiring side) (27)
Wiring harness between MAM (wiring side)
ness Resistance Max. 1 Ω
(3) – ACW (wiring side) (3)
defective contact in connec- Resistance Max. 1 Ω
tor)
between MAM (wiring side) (3) – ACW (wiring Resistance Min. 1 MΩ
Ground fault in wiring har- Between ground and wiring harness
Probable
ness between MAM (wiring side) (5) – ACW (wiring Resistance Min. 1 MΩ
causes and 3
(Short circuit with GND cir- side) (2)
standard
value in nor-
mal condition side) (21)
side) (22)
between MAM (wiring side) (3) – ACW (wiring Voltage Max. 1 V
Hot short (Short circuit with between MAM (wiring side) (5) – ACW (wiring Voltage Max. 1 V
4
24V circuit) in wiring harness side) (2)
side) (21)
side) (22)
troller
formed.)
40-400 56 PC200, 200LC-8E0 (Hybrid)

Trouble (13) Air conditioner abnormality record: Refrigerant "Abnormality"


Insufficient refrigerant (gas)
1 Refrigerant (gas) may be insufficient. Check it directly.
Defective high and low pres-
2 sure switches (Internal dis-
P17 (male) Resistance
Probable connection)
Between (1) – (2) Max. 1 Ω
causes and
standard Disconnection in wiring har-
value in nor- ness
Wiring harness between ACW (wiring side)
mal condition 3 (Disconnection in wiring or Resistance Max. 1 Ω
(4) – P17 (female) (1)
Wiring harness between P17 (female) (2) –
chassis ground (T06)
troller
formed)
PC200, 200LC-8E0 (Hybrid) 40-400 57

Circuit diagram related to air conditioner
40-400 58 PC200, 200LC-8E0 (Hybrid)

E-24 While starting switch is in OFF position, service meter is not displayed SEN05252-00
E-24 While starting switch is in OFF position, service meter is not

displayed
Trouble q While starting switch is in OFF position, service meter is not displayed
q While starting switch is in OFF position, if following switches are operated, service meter is displayed
Related infor-
at top center of screen.
mation
Operation of switches: [4] +[1] (Press simultaneously)

Probable When starting switch is turned to ON position, if machine monitor dis-
causes and Defective backup power sup- plays nothing, backup power supply system may be defective. In this
1
standard ply system case, carry out troubleshooting for E-1 When starting switch turned
value in nor- ON, machine monitor displays nothing”.
mal condition If cause 1 is not detected, machine monitor may be defective. (Since
PC200, 200LC-8E0 (Hybrid) 40-400 59

SEN05252-00 E-25 Machine monitor cannot be set in service mode
E-25 Machine monitor cannot be set in service mode

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

causes and
mal condition
40-400 60 PC200, 200LC-8E0 (Hybrid)

E-26 Monitoring function does not display lever control signal normally SEN05252-00
E-26 Monitoring function does not display lever control signal normally
Trouble (1) Monitoring function does not display boom RAISE correctly.
Related infor-
q Monitoring code: 01900 Pressure switch 1
mation

causes and
standard Defective boom RAISE PPC
1 Perform troubleshooting for failure code [DHS8MA].
value in nor- pressure sensor system
mal condition
Trouble (2) Monitoring function does not display arm IN correctly.

Related infor-
mation

causes and
standard Defective arm IN PPC pres-
1 Perform troubleshooting for failure code [DHS3MA].
value in nor- sure sensor system
mal condition
Trouble (3) Monitoring function does not display bucket CURL correctly.
Related infor-
mation

causes and
standard Defective bucket CURL PPC
1 Perform troubleshooting for failure code[ DHS4MA].
mal condition
Trouble (4) Monitoring function does not display bucket DUMP correctly.
Related infor- q Monitoring code: 01901 Pressure switch 2
mation
Probable Cause Standard value in normal state/Remarks on troubleshooting

causes and
standard Defective bucket DUMP PPC
1 Perform troubleshooting for failure code [DHSDMA].
mal condition
PC200, 200LC-8E0 (Hybrid) 40-400 61

SEN05252-00 E-26 Monitoring function does not display lever control signal normally
Trouble (5) Monitoring function does not display boom LOWER correctly.
Related infor-
mation

Defective boom LOWER troubleshooting.
PPC pressure switch (Inter- Right work equipment
nal disconnection or short control lever
circuit) Neutral Min. 1MΩ
Between(1) –(2)
Boom RAISE Max. 1 Ω
ness
Probable Wiring harness between P02 (female) (2) – Resis-
tor) Max. 1 Ω
causes and chassis ground (T10) tance
value in nor- ness without turning starting switch to ON position.
3
mal condition (Short circuit with GND cir- Between ground and wiring harness between Resis-
Min. 1 MΩ
cuit) C01 (female) (14) – P02 (female) (1) tance
4 with24 V circuit) in wiring har-
C01 (female) (14) – P02 (female) (1)
troubleshooting.
Right work equipment
control lever
Between (14) – Neutral Min. 1 MΩ
ground Boom RAISE Max. 1 Ω
Circuit diagram related to boom LOWER PPC pressure switch
40-400 62 PC200, 200LC-8E0 (Hybrid)

Trouble (6) Monitoring function does not display arm OUT correctly.
Related
information

Defective arm OUT PPC troubleshooting.
pressure switch Left work equipment
(Internal disconnection or control lever
short circuit) Neutral Min. 1 MΩ
Between (1) –(2)
Arm OUT Max. 1 Ω
a Prepare with starting switch OFF, then cperform troubleshooting
ness
P08 (female)(1) tance
tor) Max. 1 Ω
Probable chassis ground (T10) tance
ness
value in nor- 3 Between ground and wiring harness
mal condition between C01 (female) (15) – P08 (female) Min. 1 MΩ
cuit) tance
harness between C01 (female) (15) – P08 (female) Voltage Max. 1 V
(1)
troubleshooting.
Left work equipment
control lever
Between (15) – Neutral Min. 1 MΩ
ground Arm OUT Max. 1 Ω
Circuit diagram related to arm OUT PPC pressure switch
PC200, 200LC-8E0 (Hybrid) 40-400 63

Trouble (7) Monitoring function does not display swing correctly.

Related
information

causes and Defective swing RIGHT PPC
1 Perform troubleshooting for failure code [DHSAMA].
standard pressure sensor system
value in nor- Defective swing LEFT PPC
2 Perform troubleshooting for failure code [DHSBMA].
mal state pressure sensor system
Trouble (8) Monitoring function does not display travel normally.

Related infor-
mation

Defective travel PPC pres- troubleshooting.
sure switch P09 (male) Travel lever Resistance
1
(Internal disconnection or Neutral Min. 1 MΩ
short circuit) Between (1) – (2) Travel forward or
Max. 1 Ω
reverse
2
(Internal disconnection) D02 (male) Continuity
Wiring harness between C01 female) (55) – Resis-
ness Max. 1 Ω
D02 (female)(8) tance
Wiring harness between D02 (female) (4) – Resis-
defective contact in connec- Max. 1 Ω
J01 – P09 (female) (2) tance
Probable tor)
mal state Ground fault in wiring har- Between ground and wiring harness
Resis-
ness between C01 (female) (55) – D02 (female) Min. 1 MΩ
4 tance
(Short circuit with GND cir- (8)
Resis-
between D02 (female) (4) – J01 – P09 Min. 1 MΩ
tance
(female) (2) and circuit branch end
harness between C01 (female) (55) – D02 (female) Voltage Max. 1 V
troubleshooting.
C01 (female) Travel lever Continuity
Neutral No continuity
Between (55) –
Travel forward or
ground Continuity
reverse
40-400 64 PC200, 200LC-8E0 (Hybrid)

Circuit diagram related to travel PPC pressure switch and travel alarm
PC200, 200LC-8E0 (Hybrid) 40-400 65

Trouble (9) Monitoring function does not display "travel differential pressure" correctly.
Related infor-
mation

Defective travel steering
troubleshooting.
PPC pressure switch
1 P10 (male) Travel lever Resistance
Neutral Min. 1 MΩ
short circuit) Between(1) – (2)
Only 1 side operated Max. 1 Ω
ness
tor) Max. 1 Ω
Probable
standard ness
3 Between ground and wiring harness
value in nor- (Short circuit with GND cir- Resis-
between C01 (female) (36) – P10 (female) Min. 1 MΩ
mal condition cuit) tance
(2)
harness between C01 (female) (36) – P10 (female) Voltage Max. 1 V
(2)
troubleshooting.
C01 (female) Travel lever Resistance
Neutral Min. 1 MΩ
Between(36) –
Only one side oper-
ground Max. 1 Ω
ated
Circuit diagram related to travel steering PPC pressure switch
40-400 66 PC200, 200LC-8E0 (Hybrid)

E-27 KOMTRAX system does not operate normally SEN05252-00
E-27 KOMTRAX system does not operate normally

Trouble q KOMTRAX system does not operate normally.
q If KOMTRAX system administrator makes request for checking system on machine side for trouble,
Related perform following troubleshooting.
information q Even if KOMTRAX system has trouble, it does not particularly appear on machine.
q Perform all troubleshooting on service menu screen of machine monitor.

a Turn starting switch to ON position and check “Setting condition
or terminal” screen.
1 Defective communication 1
Check item Normal display
Communication start check Completion
a Turn starting switch to ON position and check “Condition of po-
sitioning and communication” screen.
N ###.##.## (Latitude)
Probable 2 Defective GPS
Positioning E ###.##.## (Longitude)
causes and
In positioning
standard
If latitude and longitude are not displayed in 5 minutes on open
value in nor-
patch, notify KOMTRAX service hot line.
mal condi- a Turn starting switch to ON position and check “Condition of po-
tion
Defective communication envi- Check item Normal display
3
ronment Communication Zone level 1 – Zone level 3
If zone level 1 – 3 is not displayed within communication zone of
ORBCOMM, notify KOMTRAX service hot line.
a Turn starting switch to ON position and check “Condition of po-
4 Defective communication 2
Number of items not transmitted 0 - 9 (Normally 0)
a Select “Terminal Status” from “12 Display of a Select “GPS & Communication Status” from
KOMTRAX setting” in the service menu of the “12 Display of KOMTRAX setting” in the service
machine monitor. menu of the machine monitor.
PC200, 200LC-8E0 (Hybrid) 40-400 67

SEN05252-00
©2009 KOMATSU
All Rights Reserved
40-400 68
SEN05253-00
SEN05253-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
500 Troubleshooting of hydraulic and
mechanical system (H-mode)
System diagram of hydraulic and mechanical system ................................................................................ 4

Information in troubleshooting table............................................................................................................ 6
H-1 Speed or power of all work equipment and travel is low ...................................................................... 7
H-2 Engine speed lowers significantly or engine stalls ............................................................................... 8
H-3 All work equipment and travel systems do not work ............................................................................ 9
H-4 Abnormal sound comes out from around hydraulic pump.................................................................... 10
H-5 Auto-decelerator does not operate....................................................................................................... 11
H-6 Fine control performance or response is low ....................................................................................... 12
H-7 Speed or power of boom is low............................................................................................................ 13
H-8 Speed or power of arm is low............................................................................................................... 14
H-9 Speed or power of bucket is low .......................................................................................................... 15
H-10 Work equipment does not move in its single operation...................................................................... 16
H-11 Hydraulic drift of work equipment is large .......................................................................................... 17
H-12 Time lag of work equipment is large .................................................................................................. 18
H-13 When part of work equipment is relieved singly, other parts of work equipment move ..................... 19
H-14 Power maximizing function does not work ......................................................................................... 20
H-15 In compound operation of work equipment, speed of part loaded more is low .................................. 21
H-16 When machine swings and travels simultaneously, travel speed is low ............................................ 22
PC200, 200LC-8E0 (Hybrid) 40-500 1

500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-17 Machine deviates during travel........................................................................................................... 23

H-18 Travel speed is low............................................................................................................................. 24
H-19 Machine is not steered well or steering power is low ......................................................................... 25
H-20 Travel speed does not shift or travel speed is low or high ................................................................. 26
H-21 Travel system does not work (only one side) ..................................................................................... 27
H-22 Upper structure does not swing.......................................................................................................... 28
H-23 Swing acceleration or swing speed of upper structure is low ............................................................. 29
H-24 Upper structure overruns remarkably when it stops swinging............................................................ 30
H-25 Large shock is made when upper structure stops swinging............................................................... 31
H-26 Large sound is made when upper structure stops swinging .............................................................. 32
H-27 Upper structure lowers largely by its own weight ............................................................................... 33
40-500 2 PC200, 200LC-8E0 (Hybrid)

Shop Manual SEN05253-00
PC200, 200LC-8E0 (Hybrid) 40-500 3

SEN05253-00 System diagram of hydraulic and mechanical system
System diagram of hydraulic and mechanical system
40-500 4 PC200, 200LC-8E0 (Hybrid)

System diagram of hydraulic and mechanical system SEN05253-00
a This system diagram is a rough general hydraulic circuit diagram made as reference material for trouble-
shooting of the hydraulic and mechanical systems.
PC200, 200LC-8E0 (Hybrid) 40-500 5

SEN05253-00 Information in troubleshooting table

a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting,
understand that information fully.
Trouble Trouble which occurred in machine
Related
Information related to detected trouble or troubleshooting
information
Cause Standard value/Remarks on troubleshooting
Possible 2
causes and Possible causes of trouble
standard <Contents of description>
(Given numbers are refer-
value for q Standard value to determine possible causes
ence numbers, which do not
judgment q Remarks on judgment
indicate priority)
3
40-500 6 PC200, 200LC-8E0 (Hybrid)

H-1 Speed or power of all work equipment and travel is low SEN05253-00
H-1 Speed or power of all work equipment and travel is low

Trouble q Speed or power of all work equipment and travel is low.
Related
q Carry out all troubleshooting in power mode (P) of working mode.
information

a Prepare with engine stopped, and then run engine at full speed and
carry out troubleshooting.
1 Malfunction of unload valve Control lever Unload pressure
3.5 ± 1.0 MPa
All levers in the neutral position
{36 ± 10 kg/cm2}
Defective adjustment or Left work equipment control lever Main relief pressure
2 malfunction of main relief 33.3 – 36.8 MPa
Arm IN relief
valve {340 – 375 kg/cm2}
If oil pressure does not become normal after adjustment, main relief valve
may have malfunction or internal defect. Check main relief valve directly.
Malfunction of self-reducing Control lever Control circuit source pressure
3
pressure valve 2.84 – 3.43 MPa
All levers in neutral position
{29 – 35 kg/cm2}
low speed and carry out troubleshooting at each speed.
PC-EPC valve output
Engine Control lever
Malfunction of PC-EPC pressure
4 2.9 MPa
valve Low speed
All levers in the neu- {30 kg/cm2}
tral position 0.52 – 0.91 MPa
High speed
Possible {5.3 – 9.3 kg/cm2}
causes and a Prepare with engine stopped, and then run engine at full speed and
standard carry out troubleshooting.
value for Measurement con-
Measured oil pressure Oil pressure ratio
judgment dition
Defective adjustment or
5 Pump discharge pressure Swing lock switch: 1
malfunction of PC valve
ON Approx. 0.6
PC valve output pressure
Arm IN relief (Approx. 3/5)
If oil pressure does not become normal after adjustment, PC valve may
have malfunction or internal defect. Check PC valve directly.
a Prepare with engine stopped, and then run engine at high idle and car-
ry out troubleshooting.
LS-EPC valve output
Travel speed Travel lever
Malfunction of LS-EPC pressure
6 2.9 MPa
valve Lo Neutral
{30 kg/cm2}
0 MPa
Hi Operated
{0 kg/cm2}
Operation of levers and oil pressure ratio
Measured oil pressure Run the track idle
All levers in neutral
Defective adjustment or (Lever operated halfway)
7
malfunction of LS valve Pump discharge pressure 1
Almost same pres-
Approx. 0.6
PC valve output pressure sure
(Approx. 3/5)
If oil pressure does not become normal after adjustment, LS valve may
have malfunction or internal defect. Check LS valve directly.
8 Malfunction of servo piston Servo piston may have malfunction. Check it directly.
Cause may be lowering of performance, malfunction, or internal defect of
9 Defective piston pump
piston pump.
PC200, 200LC-8E0 (Hybrid) 40-500 7

SEN05253-00 H-2 Engine speed lowers significantly or engine stalls
H-2 Engine speed lowers significantly or engine stalls

Trouble q Engine speed lowers significantly or engine stalls.
Related
information

a Prepare with engine stopped, and then run engine at full speed
and carry out troubleshooting.
Left work equipment control lever Main relief pressure
Defective adjustment or mal- 33.3 – 36.8 MPa
1 Arm IN relief
function of main relief valve {340 – 375 kg/cm 2}
If oil pressure does not become normal after adjustment, main relief
valve may have malfunction or internal defect. Check main relief
valve directly.
and low speed and carry out troubleshooting at each speed.
PC-EPC valve output
Engine Control lever
pressure
2 Malfunction of PC-EPC valve 2.9 MPa
Low speed
All levers in the neu- {30 kg/cm2}
tral position 0.52 – 0.91 MPa
High speed
{5.3 – 9.3 kg/cm2}
a Prepare with engine stopped, then run engine at high speed and
Possible carry out troubleshooting.
causes and Measurement condi-
Measured oil pressure Oil pressure ratio
standard tion
value for Defective adjustment or mal- Pump discharge pres-
3 1
judgment function of PC valve sure Swing lock switch: ON
PC valve output pres- Arm IN relief Approx. 0.6
sure (Approx. 3/5)
If oil pressure does not become normal after adjustment, PC valve
may have malfunction or internal defect. Check PC valve directly.
Measured oil pressure All levers in the neu- Run the track idle
(Lever operated half-
Defective adjustment or mal- tral position
4 way)
function of LS valve Pump discharge pres-
1
sure
Almost same pressure
PC valve output pres- Approx. 0.6
sure (Approx. 3/5)
If oil pressure does not become normal after adjustment, LS valve
may have malfunction or internal defect. Check LS valve directly.
Clogging of orifice or filter in Orifices or filters in pump servo devices may be clogged. Check them
5
serve device directly.
40-500 8 PC200, 200LC-8E0 (Hybrid)

H-3 All work equipment and travel systems do not work SEN05253-00
H-3 All work equipment and travel systems do not work

Trouble q All work equipment and travel systems do not work.
Related infor-
mation

PPC lock solenoid valve output
Lock lever
Malfunction of PPC lock sole- pressure
1 0 MPa
noid valve Lock
{0 kg/cm 2}
2.9 MPa
Free
{30 kg/cm2}
Possible a Prepare with engine stopped, and then run engine at full speed
causes and and carry out troubleshooting.
standard Malfunction of self-pressure Control lever Control circuit source pressure
2
value for reducing valve
2.84 – 3.43 MPa
judgment All levers in the neutral position
{29 – 35 kg/cm 2}
Piston pump may have malfunction or internal defect. Check it by fol-
lowing method.
1) Remove plugs from pump discharge pressure pickup ports (F and
3 Defective piston pump R).
2) Crank engine at flywheel (manually).
3) If oil flows out from pump discharge pressure pickup ports, piston
pump is normal.
a Pump shaft may not revolve because of defect in damper. Check
4 Defective damper
damper directly.
PC200, 200LC-8E0 (Hybrid) 40-500 9

SEN05253-00 H-4 Abnormal sound comes out from around hydraulic pump
H-4 Abnormal sound comes out from around hydraulic pump

Trouble q Abnormal sound comes out from around hydraulic pump.
Related
information

1 Lowering of hydraulic oil level Hydraulic oil level may be low. Check it directly.
Possible
causes and 2 Defective hydraulic oil Air may be mixed in hydraulic oil. Check oil directly.
standard Negative pressure may be generated in hydraulic tank because of
3 Clogging of hydraulic tank cap
value for clogged hydraulic tank cap. Check cap directly.
judgment Clogging of hydraulic tank Negative pressure may be generated in suction circuit because of
4
strainer clogged hydraulic tank strainer. Check strainer directly.
5 Defective piston pump Piston pump may have internal defect. Check it directly.
40-500 10 PC200, 200LC-8E0 (Hybrid)

H-5 Auto-decelerator does not operate SEN05253-00
H-5 Auto-decelerator does not operate

Trouble q Auto-decelerator does not operate.
q Carry out this troubleshooting if auto-decelerator does not operate while travel lever is operated.
Related infor- Shuttle valve (in PPC valve) is installed between PPC valve and oil pressure switch of only in travel
mation circuit.

a Prepare with engine stopped, then run engine at high speed and
Possible carry out troubleshooting.
causes and
Travel lever PPC valve output pressure
standard Malfunction of travel PPC
value for 1 0 MPa
valve (shuttle valve) Neutral
judgment {0 kg/cm2}
Forward 2.84 – 3.43 MPa
Reverse {29 – 35 kg/cm2}
PC200, 200LC-8E0 (Hybrid) 40-500 11

SEN05253-00 H-6 Fine control performance or response is low
H-6 Fine control performance or response is low

Trouble q Fine control performance or response is low.
Related
information

LS-EPC valve output
pressure
1 Malfunction of LS-EPC valve Approx. 2.9 MPa
Lo Neutral
{Approx. 30 kg/cm2}
0 MPa
Hi Operated
{0 kg/cm 2}
Orifice of LS circuit (pump – piping – control valve) may be clogged.
Possible 2 Clogging of LS circuit orifice
Check it directly.
causes and
standard
value for
judgment Operation of levers and oil pressure ratio
Measured oil pressure All levers in the neu- Run the track idle
3 way)
function of LS valve Pump discharge pres-
1
sure
Almost same pressure
PC valve output pres- Approx.0.6
sure (Approx. 3/5)
If oil pressure does not become normal after adjustment, LS valve
40-500 12 PC200, 200LC-8E0 (Hybrid)

H-7 Speed or power of boom is low SEN05253-00
H-7 Speed or power of boom is low

Trouble q Speed or power of boom is low.
Related infor-
mation

Right work equipment control
PPC valve output pressure
Malfunction of right PPC lever
1 0 MPa
valve (boom circuit) Neutral
{0 kg/cm2}
Boom raise 2.84 – 3.43 MPa
Boom lower {29 – 35 kg/cm2}
Malfunction of merge-divider Merge-divider main EPC valve may have malfunction. Check it
2
main EPC valve directly.
Malfunction of merge-divider
3 Merge-divider LS-EPC valve may have malfunction. Check it directly.
LS-EPC valve
4 Merge-divider main valve may have malfunction. Check it directly.
main valve
5 Merge-divider LS valve may have malfunction. Check it directly.
LS valve
Malfunction of boom control
Possible 6 Spool of boom control valve may have malfunction. Check it directly.
valve (spool)
causes and Malfunction of boom control
standard Pressure compensation valve of boom control valve may have mal-
7 valve (pressure compensa-
value for function. Check it directly.
tion valve)
judgment Malfunction of boom control Regeneration valve of boom control valve may have malfunction.
8
valve (regeneration valve) Check it directly.
Malfunction of boom control Lock valve of boom control valve may have malfunction. Check it
9
valve (lock valve) directly.
Malfunction or defective seal Safety valve for lock valve may have malfunction or defective seal.
10
of safety valve for lock valve Check it directly.
Malfunction or defective seal
Suction valve of boom control valve may have malfunction or defec-
11 of boom control valve (suction
tive seal. Check it directly.
valve)
Safety-suction valve of boom control valve may have malfunction or
12 of boom control valve
defective seal. Check it directly.
(safety-suction valve)
Malfunction of each control LS shuttle valve of left travel control valve, bucket control valve, or
13
valve (LS shuttle valve) service control valve may have malfunction. Check it directly.
a Prepare with engine stopped,and then run engine at full speed
14 Defective boom cylinder Right work equipment control
Leakage from boom cylinder
lever
Boom raise relief 20 cc/min
PC200, 200LC-8E0 (Hybrid) 40-500 13

SEN05253-00 H-8 Speed or power of arm is low
H-8 Speed or power of arm is low

Trouble q Speed or power of arm is low.
Related
information

Left work equipment control lever PPC valve output pressure
Malfunction of left PPC valve
1 0 MPa
(arm circuit) Neutral
{0 kg/cm 2}
Arm IN 2.84 – 3.43 MPa
Arm OUT {29 – 35 kg/cm 2}
2
LS-EPC valve
main valve
5 Merge-divider LS valve may have malfunction. Check it directly.
LS valve
Malfunction of arm control
6 Spool of arm control valve may have malfunction. Check it directly.
Possible valve (spool)
causes and Malfunction of arm control
Pressure compensation valve of arm control valve may have mal-
standard 7 valve (pressure compensation
function. Check it directly.
value for valve)
judgment Malfunction of arm control Regeneration valve of arm control valve may have malfunction.
8
valve (regeneration valve) Check it directly.
Malfunction of arm control Quick return valve of arm control valve may have malfunction. Check
9
valve (quick return valve) it directly.
Malfunction or defective seal Safety valve for lock valve may have malfunction or defective seal.
10
of safety valve for lock valve Check it directly.
Suction valve of arm control valve may have malfunction or defective
11 of arm control valve (suction
seal. Check it directly.
valve)
Safety-suction valve of arm control valve may have malfunction or
12 of arm control valve
LS shuttle valve of right travel control valve, boom control valve, left
Malfunction of each control
13 travel control valve, bucket control valve, or service control valve may
valve (LS shuttle valve)
have malfunction. Check it directly.
14 Defective arm cylinder Left work equipment control lever Leakage from arm cylinder
Arm IN relief 20 cc/min
40-500 14 PC200, 200LC-8E0 (Hybrid)

H-9 Speed or power of bucket is low SEN05253-00
H-9 Speed or power of bucket is low

Trouble q Speed or power of bucket is low.
Related
information

Right work equipment control
Malfunction of right PPC valve lever
1 0 MPa
(bucket circuit) Neutral
{0 kg/cm2}
Bucket CURL 2.84 – 3.43 MPa
Bucket DUMP {29 – 35 kg/cm2}
Possible Malfunction of bucket control
2 Spool of bucket control valve may have malfunction. Check it directly.
causes and valve (spool)
standard Malfunction of bucket control
Pressure compensation valve of bucket control valve may have mal-
value for 3 valve (pressure compensation
judgment valve)
Safety-suction valve of bucket control valve may have malfunction or
4 of bucket control valve
Malfunction of service control LS shuttle valve of service control valve may have malfunction.
5
valve (LS shuttle valve) Check it directly.
6 Defective bucket cylinder Right work equipment control
Leakage from bucket cylinder
lever
Bucket CURL relief 20 cc/min
PC200, 200LC-8E0 (Hybrid) 40-500 15

SEN05253-00 H-10 Work equipment does not move in its single operation
H-10 Work equipment does not move in its single operation

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

Possible
causes and Work equipment control lever PPC valve output pressure
standard 1 Malfunction of PPC valve 0 MPa
Neutral
value for {0 kg/cm2}
judgment 2.84 – 3.43 MPa
Operated
{29 – 35 kg/cm2}
Malfunction of control valve
2 Spool of control valve may have malfunction. Check it directly.
(spool)
40-500 16 PC200, 200LC-8E0 (Hybrid)

H-11 Hydraulic drift of work equipment is large SEN05253-00
H-11 Hydraulic drift of work equipment is large

Trouble (1) Hydraulic drift of boom is large.
Related
information

Possible
1 Defective boom cylinder Right work equipment control
causes and Leakage from boom cylinder
lever
standard
value for Boom RAISE relief 20 cc/min
judgment Defective seal of boom con- Seal of lock valve of boom control valve may be defective. Check it
2
trol valve (lock valve) directly.
Defective seal of safety valve
3 Seal of safety valve for lock valve may be defective. Check it directly.
for lock valve
Trouble (2) Hydraulic drift of arm is large.

Related
information

1 Defective arm cylinder Left work equipment control lever Leakage from arm cylinder
Arm IN relief 20 cc/min
Possible Defective seal of arm control
causes and 2 Seal of arm control valve spool may be defective. Check it directly.
valve (spool)
standard Defective seal of arm control
value for Seal of pressure compensation valve of arm control valve may be
3 valve (pressure compensation
judgment defective. Check it directly.
valve)
Seal of suction valve of arm control valve may be defective. Check it
Defective seal of arm control directly.
4
valve (suction valve) a This suction valve may be checked by replacing it with another
suction valve and seeing change of condition.
Defective seal of safety valve
5 Seal of safety valve for lock valve may be defective. Check it directly.
for lock valve
Trouble (3) Hydraulic drift of bucket is large.

Related
information

1 Defective bucket cylinder Left work equipment control lever Leakage from bucket cylinder
Bucket CURL relief 20 cc/min
Possible
causes and Defective seal of bucket con-
2 Seal of bucket control valve spool may be defective. Check it directly.
standard trol valve (spool)
value for Defective seal of bucket con-
Seal of pressure compensation valve of bucket control valve may be
judgment 3 trol valve (pressure compen-
defective. Check it directly.
sation valve)
Seal of safety-suction valve of bucket control valve may defective.
Defective seal of bucket con- Check it directly.
4 trol valve (safety-suction a You may replace the safety suction valves of the control valves on
valve) the bottom side and head side with each other and judge from the
change of the phenomenon.
PC200, 200LC-8E0 (Hybrid) 40-500 17

SEN05253-00 H-12 Time lag of work equipment is large
H-12 Time lag of work equipment is large

Trouble q Time lag of work equipment is large.
Related
information

LS-EPC valve output
pressure
1 Malfunction of LS-EPC valve Approx.2.9 MPa
Lo Neutral
{Approx. 30 kg/cm2}
0 MPa
Possible Hi Operated
{0 kg/cm2}
causes and
standard Regeneration valve of control valve may have malfunction. Check it
2 (regeneration valve) [Boom
value for directly.
and arm only]
judgment Safety-suction valve of control valve may have malfunction. Check it
directly.
Malfunction of control valve a This safety-suction valve may be checked by replacing it with
3
(safety-suction valve) safety-suction valve of normal control valve and seeing change of
condition. (Set pressure of safety-suction valve for boom head cir-
cuit is different, however.)
Pressure compensation valve of control valve may have malfunction.
4 (pressure compensation
Check it directly.
valve)
40-500 18 PC200, 200LC-8E0 (Hybrid)

H-13 When part of work equipment is relieved singly, other parts of work equipment move SEN05253-00
H-13 When part of work equipment is relieved singly, other parts of work
equipment move
Trouble q When part of work equipment is relieved singly, other parts of work equipment move.
Related infor-
mation
Possible Cause Standard value/Remarks on troubleshooting

causes and
standard Defective seal of control valve
Seal of pressure compensation valve of control valve on moving side
value for 1 (pressure compensation
may be defective. Check it directly.
judgment valve) on moving side
PC200, 200LC-8E0 (Hybrid) 40-500 19

SEN05253-00 H-14 Power maximizing function does not work
H-14 Power maximizing function does not work

Trouble q Power maximizing function does not work.
Related
information

Possible 2-stage relief solenoid valve out-
causes and Swing lock switch
Malfunction of 2-stage relief put pressure
standard 1 0 MPa
solenoid valve OFF
value for {0 kg/cm 2}
judgment 2.9 MPa
ON
{30 kg/cm2}
Malfunction of main relief
2 Main relief valve may have malfunction. Check it directly.
valve
40-500 20 PC200, 200LC-8E0 (Hybrid)

H-15 In compound operation of work equipment, speed of part loaded more is low SEN05253-00
H-15 In compound operation of work equipment, speed of part loaded

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

Pressure compensation valve of control valve on smaller load side
may have malfunction. Check it directly.
Compound operation Larger load side Smaller load side
Boom RAISE
+ Boom RAISE Arm IN
Possible Arm IN
Boom RAISE
causes and
Malfunction of control valve + Arm OUT Boom RAISE
standard
1 (pressure compensation Arm OUT
value for
valve) on smaller load side Boom RAISE
judgment
+ Boom RAISE Bucket CURL
Bucket CURL
Arm OUT
+ Arm OUT Bucket CURL
Bucket CURL
Boom LOWER
+ Arm OUT Boom LOWER
Arm OUT
PC200, 200LC-8E0 (Hybrid) 40-500 21

SEN05253-00 H-16 When machine swings and travels simultaneously, travel speed is low
H-16 When machine swings and travels simultaneously, travel speed is

low
Trouble q When machine swings and travels simultaneously, travel speed is low.
Related infor- q If speed of single travel operation is also low, carry out troubleshooting for "H-18 Travel speed is low"
mation first.
Possible Cause Standard value/Remarks on troubleshooting

causes and
standard Malfunction of each control LS shuttle valve of left travel control valve or swing control valve may
value for 1
valve (LS shuttle valve) have malfunction. Check it directly.
judgment
40-500 22 PC200, 200LC-8E0 (Hybrid)

H-17 Machine deviates during travel SEN05253-00
H-17 Machine deviates during travel

Trouble q Machine deviates during travel.
Related
information

Malfunction of travel PPC
1 0 MPa
valve Neutral
{0 kg/cm 2}
Malfunction of self-pressure Control lever Control circuit source pressure
2
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Measured oil pres- Run the track idle.
sure All levers in the neu-
3 way)
Possible function of LS valve Pump discharge pres-
causes and 1
sure Almost same pres-
standard PC valve output pressure Approx. 0.6
value for sure (Approx. 3/5)
judgment If oil pressure does not become normal after adjustment, LS valve
Travel junction solenoid valve out-
Travel lever
Malfunction of travel junction put pressure
4 0 MPa
solenoid valve Both sides in the neutral position
{0 kg/cm 2}
2.9 MPa
Either side operated
{30 kg/cm 2}
Malfunction of travel junction
5 Travel junction valve may have malfunction. Check it directly.
valve
Malfunction of travel control
6 Spool of travel control valve may have malfunction. Check it directly.
valve (spool)
7 Defective travel motor Travel lever Leakage from travel motor
Travel relief 27.2 l/min
Final drive may have internal defect. Check it directly.
8 Defective final drive a It may be checked by abnormal sound, abnormal heating, metal
chips in drain oil, etc.
PC200, 200LC-8E0 (Hybrid) 40-500 23

SEN05253-00 H-18 Travel speed is low
H-18 Travel speed is low

Trouble q Travel speed is low.
Related
information

Malfunction of travel PPC
1 0 MPa
valve Neutral
{0 kg/cm2}
Malfunction of self-pressure Control lever Control circuit source pressure
2
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Measured oil pres- LS-EPC valve output
Possible Travel lever
sure pressure
causes and 3 Malfunction of LS-EPC valve Approx. 2.9 MPa
standard Lo Neutral
value for {Approx. 30 kg/cm2}
0 MPa
judgment Hi Operated
{0 kg/cm2}
valve (spool)
Pressure compensation valve of control valve may have malfunction.
Check it directly.
tion valve)
Malfunction of travel control Suction valve of control valve may have malfunction. Check it
6
valve (suction valve) directly.
Malfunction of bucket control LS shuttle valve of bucket control valve may have malfunction.
7
Travel relief 27.2 l/min
40-500 24 PC200, 200LC-8E0 (Hybrid)

H-19 Machine is not steered well or steering power is low SEN05253-00
H-19 Machine is not steered well or steering power is low

Trouble q Machine is not steered well or steering power is low.
Related
information

Travel lever
Malfunction of travel PPC (Steering)
1 0 MPa
valve (steering spool) Both sides in the neutral position
{0 kg/cm 2}
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Travel junction solenoid valve out-
Travel lever
Malfunction of travel junction put pressure
2 0 MPa
solenoid valve Both sides in the neutral position
{0 kg/cm 2}
2.9 MPa
{30 kg/cm 2}
Malfunction of travel junction
3 Travel junction valve may have malfunction. Check it directly.
valve
4
Possible Malfunction of merge-divider
causes and LS-EPC valve
standard Malfunction of merge-divider
value for main valve
judgment 7 Merge-divider LS valve may have malfunction. Check it directly.
LS valve
valve (spool)
Pressure compensation valve of travel control valve may have mal-
tion valve)
Malfunction of travel control Suction valve of travel control valve may have malfunction. Check it
10
Malfunction of bucket control LS shuttle valve of bucket control valve may have malfunction.
11
Defective seal of check valve
Seal of check valve of LS pressure sensing part (control valve side)
12 of LS pressure sensing part
may be defective. Check it directly.
(control valve side)
Seal of safety valve of travel motor may be defective. Check it
directly.
Defective seal of travel motor
13 a You may replace the safety valves of forward and reverse sec-
(safety valve)
tions of the same motor or those of the right and left motors with
each other and judge from the change of the phenomenon.
Seal of check valve of travel motor may be defective. Check it
directly.
14 a You may replace the check valves of forward and reverse sections
(check valve)
of the same motor or those of the right and left motors with each
other and judge from the change of the phenomenon.
PC200, 200LC-8E0 (Hybrid) 40-500 25

SEN05253-00 H-20 Travel speed does not shift or travel speed is low or high
H-20 Travel speed does not shift or travel speed is low or high
Trouble q Travel speed does not shift or travel speed is low or high
Related
information

a Run engine at full speed and carry out troubleshooting (with mon-
itoring function).
Monitoring code:
01500
Lo *663 mA
Mi Operated 424 mA
Hi 0 mA
1 Malfunction of LS-EPC valve
LS-EPC valve output
Possible Travel speed Travel lever
pressure
causes and Approx. 2.9 MPa
standard Lo Neutral
value for {Approx. 30 kg/cm2}
0 MPa
judgment Hi Operated
{0 kg/cm 2}
Travel speed shifting
Travel speed Travel lever solenoid valve output
Malfunction of travel speed pressure
2
shifting solenoid valve 0 MPa
Lo Neutral
{0 kg/cm 2}
Approx. 2.9 MPa
Hi Operated
{Approx. 30 kg/cm2}
Malfunction of travel motor Speed shifting section of travel motor may have malfunction. Check
3
(speed shifting section) it directly.
*: Travel speed Lo can be adjusted with the adjusting function of the machine monitor. Accordingly, if the initial
value has been changed, the measured value varies more or less.
40-500 26 PC200, 200LC-8E0 (Hybrid)

H-21 Travel system does not work (only one side) SEN05253-00
H-21 Travel system does not work (only one side)

Trouble q Travel system does not work (only one side).
Related
information

Defective seal of travel control Seal of suction valve of travel motor may have malfunction. Check it
1
Seal of safety valve of travel motor may have malfunction. Check it
directly.
2 a You may replace the safety valves of forward and reverse sections
(safety valve)
other and judge from the change of the phenomenon.
Seal of check valve of travel motor may have malfunction. Check it
Possible directly.
causes and Defective seal of travel motor
3 a You may replace the check valves of forward and reverse sections
standard (check valve)
value for other and judge from the change of the phenomenon.
judgment Malfunction of travel motor
4 Parking brake of travel motor may have malfunction. Check it directly.
(parking brake)
Travel system relief 27.2 l/min
PC200, 200LC-8E0 (Hybrid) 40-500 27

SEN05253-00 H-22 Upper structure does not swing
H-22 Upper structure does not swing

Trouble (1) Upper structure does not swing in both right and left directions.
Related
q Perform all troubleshooting in power mode (P) of working mode.
information
See "Troubleshooting for hybrid system (Y mode)" and perform troubleshooting since this failure is related to hybrid
system.
Trouble (2) Upper structure swings only in one direction.

Related
information
See "Troubleshooting for hybrid system (Y mode)" and perform troubleshooting since this failure is related to the hybrid
system.
40-500 28 PC200, 200LC-8E0 (Hybrid)

H-23 Swing acceleration or swing speed of upper structure is low SEN05253-00
H-23 Swing acceleration or swing speed of upper structure is low

Trouble (1) Swing acceleration or swing speed of upper structure is low in both right and left directions.
Related
information
system.
Trouble (2) Swing acceleration or swing speed of upper structure is low only in one direction.
Related
information
system.
PC200, 200LC-8E0 (Hybrid) 40-500 29

SEN05253-00 H-24 Upper structure overruns remarkably when it stops swinging
H-24 Upper structure overruns remarkably when it stops swinging

Trouble (1) Upper structure overruns remarkably when it stops swinging in both right and left directions.
Related
information
system.
Trouble (2) Upper structure overruns remarkably when it stops swinging only in one direction.
Related
information
system.
40-500 30 PC200, 200LC-8E0 (Hybrid)

H-25 Large shock is made when upper structure stops swinging SEN05253-00
H-25 Large shock is made when upper structure stops swinging

Trouble q Large shock is made when upper structure stops swinging
Related
information
system.
PC200, 200LC-8E0 (Hybrid) 40-500 31

SEN05253-00 H-26 Large sound is made when upper structure stops swinging
H-26 Large sound is made when upper structure stops swinging

Trouble q Large sound is made when upper structure stops swinging
Related
information
system.
40-500 32 PC200, 200LC-8E0 (Hybrid)

H-27 Upper structure lowers largely by its own weight SEN05253-00
H-27 Upper structure lowers largely by its own weight

Trouble (1) Upper structure lowers largely by its own weight (when parking brake is applied)
q When swing lock switch is turned to ON position or when swing holding brake release switch is set to
Related normal position, swing holding brake is applied and swinging motion of upper structure is stopped with
information disc brake.
system.
Trouble (2) Upper structure lowers largely by its own weight (when parking brake is released).
q When swing holding brake release switch is set to RELEASE position, swing holding brake is released
Related and swinging motion of upper structure is held with swing electric motor. (However, this applies only
information while hybrid system is operating normally)
system.
PC200, 200LC-8E0 (Hybrid) 40-500 33

SEN05253-00
©2009 KOMATSU
All Rights Reserved
40-500 34
SEN05254-01
SEN05254-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
600 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart ........................................................................................................ 2

S-1 Starting performance is poor ................................................................................................................ 6
S-2 Engine does not start ........................................................................................................................... 7
S-3 Engine does not pick up smoothly........................................................................................................ 10
S-4 Engine stops during operations ............................................................................................................ 11
S-5 Engine does not run smoothly .............................................................................................................. 12
S-6 Engine lacks output power ................................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion)................................................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 15
S-9 Oil becomes contaminated early .......................................................................................................... 16
S-10 Fuel consumption is excessive........................................................................................................... 17
S-11 Oil is in coolant (or coolant spurts or coolant level goes down).......................................................... 18
S-12 Oil pressure drops .............................................................................................................................. 19
S-13 Oil level rises (Entry of coolant/fuel) ................................................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ....................................................................... 21
S-15 Abnormal noise is made..................................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................................... 23
PC200, 200LC-8E0 (Hybrid) 40-600 1

SEN05254-01 Method of using troubleshooting chart
Method of using troubleshooting chart
This troubleshooting chart is divided into four sections: Questions, Check items, Causes and Troubleshooting.
First, use the Questions and Check items to select highly probable causes among the Causes. The Questions
and Check items helps to narrows the extent of the probable causes based on the failure symptoms or simple
inspection results without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the
most probable one to make final confirmation according to the troubleshooting procedure.
Questions
Information items to be obtained from the customer or operator. They correspond to A and B in the chart on
the right.
The items in A are basic ones. The information items in B can be obtained from the customer or operator,
depending on their level of the attention to the machine condition.
Check items
Simple checks conducted by the technician to narrow the causes. They correspond to C in the chart on the
right.
Causes
List of items to be narrowed from the questions and checks.
The technician narrows down the probable causes from A, B, and C.
Troubleshooting
Work items to be conducted in order to find out the true cause by verifying the narrowed causes finally in order
from the most probable one by applying troubleshooting tools or direct inspection.
Among the items listed in the [Questions] and [Check items] sections, those related to the [Causes] are
marked withE, Q, and w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q mark
a When narrowing the “causes”, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
40-600 2 PC200, 200LC-8E0 (Hybrid)

Method of using troubleshooting chart SEN05254-01
PC200, 200LC-8E0 (Hybrid) 40-600 3

SEN05254-01 Method of using troubleshooting chart
Example of troubleshooting: Exhaust gas is black (incomplete combustion)

Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Questions] and [Check
items] and found the following three items to be the causal symptoms; [Exhaust gas slowly became black],
[Power slowly became weaker], and [Dust indicator is lighting red].
40-600 4 PC200, 200LC-8E0 (Hybrid)

Method of using troubleshooting chart SEN05254-01
There is a causal relationship between three items in the [Questions] and [Check items] sections and five
items in the [Causes] section.
The method of pinpointing the "cause" from the causal relationship and approaching the "troubleshooting" is
explained according to Step 1 – Step 3 shown below.
PC200, 200LC-8E0 (Hybrid) 40-600 5

SEN05254-01 S-1 Starting performance is poor
S-1 Starting performance is poor
General causes why starting performance is poor Causes

q Defective electrical system
Leaking or clogged fuel piping, entry of air

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

Defective contact of valve & valve seat
Defective alternator (regulator section)

q Insufficient intake of air
Stuck or seized supply pump plunger

q Improper selection of fuel
Defective intake air heater system
Defective or deteriorated battery

a The common rail fuel injection system (CRI) recognizes the fuel injection tim-
Worn piston ring and cylinder

ing electrically. Accordingly, even if the engine is cranked properly, the en-
Clogged air cleaner element
Clogged fuel filter element

gine may not start until the crankshaft rotates 2 turns in the case of the most
disadvantageous condition. This phenomenon does not indicate a trouble,
however.
Defective injector
Check recent repair history
Degree of use of
Operated for long period E E E
Questions temperature
machine
Starting perfor- Became worse gradually Q w w Q
mance Engine starts easily when warm w w
Non-specified fuel is being used Q Q Q
Replacement of filters has not been carried out according to Operation and
w w Q Q
Maintenance Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor
w
does not indicate normally
During operation, charge level monitor indicates abnormal charge w w
Dust indicator is red w
Air breather hole in fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q
Starting motor rotates engine slowly w
Check items
Even if air bleeding plug of fuel filter head is removed, fuel

While engine is w
does not flow out
cranked:
If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, tem-
w
perature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular Q Q w
Engine hunts Q w Q
Blowby gas is excessive w
Inspect air cleaner directly q
When compression pressure is measured, it is found to be low q q
When air bleeding operation for fuel system is performed, air comes out q
Inspect fuel filter, strainer directly q
Remedy
Perform troubleshooting for "Rail Press (Very) Low Error (*1) q

Even when a cylinder is cut out, engine speed does not change q
During pre-heating operation, intake air heater mount is cold q
Is voltage (20 – 30 V) between alternator terminal B and terminal Yes q
E detected with engine at low idle? No q
Specific gravity of electrolyte and voltage of battery are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
Remedy
*1: Displayed failure codes [CA559] and [CA2249]
40-600 6 PC200, 200LC-8E0 (Hybrid)

S-2 Engine does not start SEN05254-01
S-2 Engine does not start
a) Engine does not crank

General causes why engine does not crank
q Internal parts of engine seized Causes
o See “S-4 Engine stops during operations”
Defective starting motor (motor section)

q Defective electrical system
Defective connection of battery cable

q Defective hydraulic pump
Defective or deteriorated battery
Defective starting circuit wiring

Broken flywheel ring gear
Defective hydraulic pump

Defective starting switch
Defective battery relay
Defective safety relay

Questions temperature
Degree of use of
Operated for long period E E
machine
Horn does not sound. Q Q w
Condition of horn when
starting switch is turned
Horn volume is low. w
ON
Battery electrolyte level is low. w

Battery cable terminal is loose w
Q w
Check items
Starting switch is turned ON, but no battery relay operating sound is heard
Starting switch is turned to START, but pinion does not plunge Q Q w
When starting switch is Speed of rotation is low. w
turned to START, start- Abnormal noise is heard w w
ing pinion moves out, Pinion disengages soon w
but: Abnormal noise is heard and engine does not rotate Q Q Q Q
Inspect flywheel ring gear directly q
Carry out troubleshooting in H-mode

Carry out troubleshooting in E-mode
No voltage (20 - 30 V) is deteated between battery relay
q
terminal B and terminal E
When terminal B and termina C of starting switch are
q
Turn starting switch connected, engine starts
Remedy
OFF, connect cable, When terminal B and terminal C at safety relay outlet are
q
and carry out trouble- connected, engine starts
shooting with starting Even if terminal B and terminal C at safety relay outlet q
switch at ON are connected, engine does not start
When safety switch terminal and terminal B of starting

q
motor are connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Rem-
-
-
edy
PC200, 200LC-8E0 (Hybrid) 40-600 7

SEN05254-01 S-2 Engine does not start
b) Engine cranks but no exhaust smoke comes out Causes

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

q Fuel is not being supplied.
q Supply of fuel is extremely small.
q Improper selection of fuel (particularly in winter)

Clogged air breather hole of fuel tank cap
Defective common rail pressure limiter

Seized, abnormally worn feed pump
Stuck, seized supply pump plunger

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

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Degree of use of
Questions
Operated for long period EE

machine
Exhaust smoke suddenly stopped coming out (when starting again). wQww E
Replacement of filters has not been carried out according to Operation and
w E Q
Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole in fuel tank cap is clogged Qw
Rust and water are found when fuel tank is drained QE EE
Check items
When fuel filter is removed, there is no fuel in it w w

Fuel is leaking from fuel piping w
When priming pump is operated, it makes no reaction or it is heavy wQ
Even if air bleeding plug of fuel filter head is removed, fuel
While engine is Q Q w Q
does not flow out
cranked:
If spill hose from injector is disconnected, little fuel spills Q www Q
Inspect fuel filter directly q
Inspect feed pump directly q
Remedy
Carry out troubleshooting for "Rail Press (Very) Low Error (*1)" qq
Carry out troubleshooting for "IMV/PCV1 Short (Open) Error (*2)" q
Inspect overflow valve directly. q
Engine can be started in reduced cylinder mode. q
If pressure limiter return pipe is disconnected, fuel flows out from limiter q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Add

40-600 8 PC200, 200LC-8E0 (Hybrid)

S-2 Engine does not start SEN05254-01
c) Exhaust smoke comes out but engine does not start (Fuel is being Causes
injected)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does not start
q Lack of cranking force due to defective electrical system
Worn valve system (valve, rocker arm, etc.)
Leaking or clogged fuel system, entry of air


Defective intake air heater system

Clogged injector, defective spray
Defective, deteriorated battery
Worn piston ring and cylinder
Use of improper fuel
Clogged fuel filter

Degree of use of
machine
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

Replacement of filters has not been carried out according to Operation
w w
and Maintenance Manual
When engine is preheated or when temperature is low, preheating moni-
w
tor does not indicate proper preheating
Air breather hole in fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
When fuel filter is removed, there is no fuel in it w
When priming pump is operated, it makes no reaction or it is heavy w Q
Check items
Starting motor rotates engine slowly w

When engine is cranked, abnormal sound is generated around cylinder
w
head
Even if air bleeding plug of fuel filter head is removed,
Q w
While engine is fuel does not flow out
cranked: If spill hose from injector is disconnected, little fuel
w
spills
w
Inspect valve system directly q
When compression pressure is measured, it is found to be low q
Remedy
Inspect fuel filter directly q

Carry out troubleshooting for "Rail Press (Very) Low Error (*1)" q
Engine can be started in reduced cylinder mode. q
Coolant temperature gauge does not indicate normally q
During pre-heating operation, intake air heater mount is cold q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
PC200, 200LC-8E0 (Hybrid) 40-600 9

SEN05254-01 S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly
General causes why engine does not pick up smoothly Causes

Seized turbocharger, interference of turbocharger

q Defective condition of fuel spray


Defective contact of valve and valve seat
q Controller is controlling engine in derate mode (limiting injection rate (output) be-
cause of an error in electrical system)

Clogged injector, defective spray
Worn piston ring, cylinder

Improper valve clearance
Clogged fuel filter

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

Non-specified fuel is being used w w w
Replacement of filters has not been carried out according to Operation and Mainte-
w w
nance Manual
Oil must be added more frequently w
Check items
When exhaust manifold is touched immediately after starting engine, temperature

Q w
of some cylinders is low
Color of exhaust Blue under light load w
gas Black wQ w w
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed is normal, but speed suddenly drops when load is applied Q w
Engine hunts Q Q Q
Inspect valve clearance q
Remedy
When turbocharger is rotated by hand, it is found to be heavy q

A cylinder is cut out, but engine speed does not change q
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Remedy
40-600 10 PC200, 200LC-8E0 (Hybrid)

S-4 Engine stops during operations SEN05254-01
S-4 Engine stops during operations
General causes why engine stops during operations Causes

q Seized parts inside engine
Broken auxiliary equipment (pump, compressor, etc.)

q Engine overheating
q Defective hydraulic pump
Broken valve system (valve, rocker arm, etc.)

Broken, seized piston, connecting rod

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

Broken supply pump shaft
Defective hydraulic pump

Broken, seized gear train
Clogged fuel filter

Degree of use
Operated for long period E
of machine
Abnormal noise was heard, it stopped suddenly www w QwQw w
Questions
Condition when Engine overheated and stopped wQ Q

engine stopped Engine stopped slowly w Q
Engine hunted, then stopped wQ QQ
Non-specified fuel is being used QQ Q
w
Fuel level monitor indicates low level (if monitor is installed) w
Check items

Metal particles are found when oil is drained www Q
Does not turn at all ww
When engine is Turns in opposite direction only w
rotated by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine operates, but stops when load is applied to machine w

Carry out troubleshoot-
Inspect piston, connecting rod directly q

Troubleshooting
Inspect crankshaft bearing directly q

ing in H-mode
Inspect gear train directly q

Inspect feed pump directly q
Carry out troubleshooting for “Rail Press (Very) Low Error (*1)” qq
Engine operates when auxiliary equipment (hydraulic pump, compressor,
q
etc.) is removed
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy -
Clean
Clean
Add
PC200, 200LC-8E0 (Hybrid) 40-600 11

SEN05254-01 S-5 Engine does not run smoothly
S-5 Engine does not run smoothly
General causes why engine does not run smoothly Causes

q Air in fuel system
Clogged injector, defective spray (dirt in injector)

q Defective speed sensor (Error at degree that does not generate failure code)
Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness
Clogged fuel filter

Degree of use of
Operated for long period E
machine
Questions
Occurs at a certain speed range Q Q

Occurs at low idle QQQQ Q
Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Operation and Maintenance
w
Manual
Check items

Rust and water are found when fuel tank is drained Q
Troubleshooting

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

*2: Displayed failure code [CA778]
40-600 12 PC200, 200LC-8E0 (Hybrid)

S-6 Engine lacks output power SEN05254-01
S-6 Engine lacks output power
General causes why engine lacks output power Causes

Clogged injector, defective spray (dirt in injector)

Defective command to injector (signal, solenoid)
Defective boost pressure sensor, wiring harness

Defective installation of boost pressure sensor

q Defective spray condition of fuel

q Engine is overheating
o See "S-14 Coolant temperature becomes too high (Overheating)".

q Controller is controlling engine in derate mode
Air leakage from air intake piping

(limiting injection rate (output) because of an error in electrical system)
Leaking, clogged fuel piping

Clogged spill piping

Clogged fuel filter
(air leakage)
Degree of use of machine Operated for long period E E E E
Suddenly Qw Q Q QQ
Questions
Power was lost

Gradually Q Q Q Q Q Q
Non-specified fuel is being used QQQ
w w
Engine oil must be added more frequently Q Q
Dust indicator is red ww
Air breather hole in fuel tank cap is clogged w w
Output power becomes insufficient after short stop of operation w
Color of exhaust gas
Black w w
Blue under light load w
Check items
ww
When engine is cranked, interference sound is generated around turbo-
w
charger
When engine is cranked, abnormal sound is generated around cylinder
w
head
High idle speed is too high Q
High idle speed is normal, but speed suddenly drops when load is applied Q wQQ
Engine does not pick up smoothly and combustion is irregular ww QQ w
Engine hunts QQQ QQ
Blowby gas is excessive w w
Inspect air intake piping directly q
When boost pressure is measured, it is found to be low qqq
Troubleshooting

Inspect fuel piping q
Inspect spill port check valve directly q
Carry out troubleshooting for "Rail Press (Very) Low Error(*1)" q
A cylinder is cut out, but engine speed does not change qq
Inspect boost pressure sensor mount directly q
Carry out troubleshooting for "Chg Air Press Sensor High (Low) Error (*2)" q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Remedy
Clean
Clean

PC200, 200LC-8E0 (Hybrid) 40-600 13

SEN05254-01 S-7 Exhaust smoke is black (incomplete combustion)
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black Causes

Leakage of air between turbocharger and cylinder head

q Defective condition of fuel injection


q Engine is overheating
o See "S-14 Coolant temperature becomes too high (Overheating)".
q Controller is controlling engine in derate mode

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

Improper fuel injection timing

Crushed, clogged muffler
Abnormally worn injector

Clogged, seized injector
Degree of use of Operated for long period E E E E
Suddenly became black w w QQQ
Color of exhaust
Questions
Gradually became black w Q Q

gas
Non-specified fuel is being used QQ
Suddenly w Q QQ
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp worked loose w
Engine is operated in low-temperature mode at normal temperature QQQ
When exhaust manifold is touched immediately after starting engine, tempera-
Check items
Qw
ture of some cylinders is low
When engine is cranked, interference sound is generated around turbocharger w
When engine is cranked, abnormal sound is generated around cylinder head w
Pump relief speed is high (Fuel is injected excessively) Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q QQQ Qw
If spill hose from injector is disconnected, abnormally much fuel spills w
When turbocharger is rotated by hand, it is found to be heavy q
Troubleshooting

When muffler is removed, exhaust sound improves q
Carry out troubleshooting for "Rail Press (Very) Low Error (*1)" q q
Carry out troubleshooting for "Coolant Temp Sens High (Low) Error (*2)" q
Check by using monitoring function qq
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Clean
Remedy

40-600 14 PC200, 200LC-8E0 (Hybrid)

S-8 Oil consumption is excessive (or exhaust smoke is blue) SEN05254-01
S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive Causes

q Abnormal combustion of oil
q Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes continuously)
Turbocharger
q External leakage of oil
q Wear of parts in lubrication system
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
Dust sucked in from intake system
Clogged breather, breather hose

Worn seal on compressor side
Oil leakage from oil drain plug

Worn, damaged rear oil seal
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal on turbine side
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of use of
Questions
Operated for long period EEE E

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

Oil in coolant w
Oil level in damper chamber of applicable machine is high w
Exhaust smoke is blue under light load w w
Amount of blowby Excessive Q Q w w
gas None w
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is found to be dirty abnor-
q
Troubleshooting
mally
Excessive play of turbocharger shaft q q
Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows oil leakage q q
External leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC200, 200LC-8E0 (Hybrid) 40-600 15

SEN05254-01 S-9 Oil becomes contaminated early
S-9 Oil becomes contaminated early
General causes why oil becomes contaminated early Causes

q Entry of exhaust gas into oil due to internal wear
Clogged turbo lubrication oil drain tube

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

q Use of improper oil
Defective oil filter safety valve

q Operation under excessive load

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions
Degree of use of machine Operated for long period EEE

Non-specified fuel is being used Q Q
Metal particles are found when oil is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Check items
Engine oil temperature rises quickly w

Color of exhaust gas
Black w
Excessive Q Q w Q
Amount of blowby gas
None w
Excessive play of turbocharger shaft q
Troubleshooting

Check breather and breather hose directly q
See S- 7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is stuck or broken q
Inspect turbocharger lubrication oil drain tube directly q
Replace
Replace
Replace
Replace
Replace
Remedy -
Clean
Clean
Clean
40-600 16 PC200, 200LC-8E0 (Hybrid)

S-10 Fuel consumption is excessive SEN05254-01
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes

q Leakage of fuel

q Defective condition of fuel injection (improper fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage inside cylinder head cover

Fuel leakage from fuel filter, piping, etc
Defective common rail pressure

Defective supply pump plunger
Defective operation of injector

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

Degree of use of
Questions
Operated for long period EE E

machine
More than that on other machines of same model Q Q Q Q
Condition of fuel
Gradually increased Q Q
consumption
Suddenly increased QQ
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of

w
some cylinders is low
Low idle speed is high Q
Pump relief speed is high Q
Exhaust smoke Black Q Q Q Q
color White Q
Remove and inspect cylinder head cover directly. q
Troubleshooting
Inspect feed pump oil seal directly q

If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting for "Coolant Temp Sens High (Low) Error (*2)" q
Check by using monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

PC200, 200LC-8E0 (Hybrid) 40-600 17

SEN05254-01 S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
General causes why oil is in coolant Cause

q Engine-internal leakage in lubrication system
q Engine-internal leakage in cooling system
Broken cylinder head, head gasket

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

Holes caused by pitting
Degree of use of
Questions
Operated for long period E E

machine
Suddenly increased Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen, oil is milky Q Q w
Troubleshooting Check items
There are excessive air bubbles in radiator, coolant spurts w
Pressure-tightness test of cylinder head shows oil leakage q

Inspect cylinder block directly q q
Pressure-tightness test of oil cooler shows oil leakage Replace q

Replace
Replace
Remedy Replace
40-600 18 PC200, 200LC-8E0 (Hybrid)

S-12 Oil pressure drops SEN05254-01
S-12 Oil pressure drops
General causes why oil pressure drops Causes

q Leakage, clogging, wear of lubricating system
Defective oil level sensor, wiring harness

q Defective oil pressure control
Leaking, crushed, clogged oil piping

q Selection of oil according to the temperature etc. specified in the Operation and Main-
tenance Manual is not observed.
Clogged, broken pipe in oil pan

q Deterioration of oil due to overheating
Clogged strainer in oil pan
Defective regulator valve

Lack of oil in oil pan
Defective oil pump

Coolant/ fuel in oil
Clogged oil filter

Worn bearing
Degree of use of
Questions
machine
Oil pressure monitor indicates low oil pressure Qw
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Mainte-
w
nance Manual
Indicates pressure drop at low idle w
Oil pressure
Indicates pressure drop both at low and high idle Q wwwQ
monitor
Indicates pressure drop on slopes w
(if installed)
w Q
Check items
Sometimes indicates pressure drop

Oil level monitor indicates oil level drop w w
Oil level in oil pan is low w
External engine oil piping is leaking, crushed w
Oil is milky or smells of diesel oil w
Metal particles are found when oil pan is drained w
Metal particles are found in the oil drained from oil filter w Q
Metal particles are found in oil filter q
Troubleshooting
Inspect oil pan strainer, pipe directly qq

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

Valve spring of regulator valve is fatigued, damaged q
Inspect oil filter directly q
If oil level sensor is replaced, oil pressure monitor indicates proper oil level q
Replace
Replace
Correct
Adjust
Remedy -
Clean
Clean
Clean
Clean
Add
PC200, 200LC-8E0 (Hybrid) 40-600 19

SEN05254-01 S-13 Oil level rises (Entry of coolant/fuel)
S-13 Oil level rises (Entry of coolant/fuel)
General causes why oil level rises Causes

q Water in oil (cloudy white)
Defective seal of auxiliary equipment (pump, compressor)

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

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

Broken injector O-ring
Questions
Degree of use of
Operated for long period E EE E
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
Oil in coolant Q QQQ w
Oil smells of diesel fuel w w
Oil is milky Q Q
Check items
When engine is started, drops of water come from muffler Q

When radiator cap is removed and engine is run at low idle, an abnormal number of bub-
w Q
bles appear, or coolant spurts
Exhaust smoke is white Q
Oil level in damper chamber of applicable machine is low w
Oil level in hydraulic tank of applicable machine is low w
Troubleshooting
Remove injector and inspect O-ring q

Inspect cylinder block directly qq
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows oil leakage q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
40-600 20 PC200, 200LC-8E0 (Hybrid)

S-14 Coolant temperature becomes too high (overheating) SEN05254-01
S-14 Coolant temperature becomes too high (overheating)
General causes why coolant temperature becomes too high Causes

q Lack of cooling air (deformation/damage of fan)
q Drop in heat dissipation efficiency
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

q Problem in coolant circulation system
Defective operation of thermostat
Slipping fan belt, worn fan pulley
Rise of hydraulic oil temperature

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

Broken water pump
Lack of coolant
Degree of use of
Operated for long period EE EE
machine
Questions
Condition of Suddenly occurred Qw Q

overheating Always tends to overheat Q ww Q
Coolant temper- Rises quickly Q w
ature gauge
Does not go down below red range w
(if installed)
Radiator coolant level monitor indicates drop of coolant level (if monitor is
w
installed)
Engine oil level has risen and oil is milky wQ
Fan belt tension is low w
When fan belt is turned, it has play w
Milky oil is floating on coolant w
Check items
There are excessive air bubbles in radiator, coolant spurts w

When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard on machine are clogged with dirt or
w w
mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Hydraulic oil temperature enters red range faster than engine coolant temper-
w
ature
Carry out troubleshootinig in H-mode
Inspect cylinder directly q

Inspect oil cooler directly q
Temperature difference between upper and lower tanks of radiator is large q
Troubleshooting
When operation test of thermostat is carried out, it does not open at cracking
q
temperature
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is fount to be normal q

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
―
Add
PC200, 200LC-8E0 (Hybrid) 40-600 21

SEN05254-01 S-15 Abnormal noise is made
S-15 Abnormal noise is made
General causes why abnormal noise is made Causes

q Abnormality due to defective parts
Improper fuel injection timing (abnormality in low coolant tem-

q Abnormal combustion
Deformed cooling fan, loose fan belt, interference of fan belt

q Air sucked in from intake system
Defective inside of muffler (partition board out of position)

a Judge if the noise is an internal noise or an external noise before starting
Leakage of air between turbocharger and cylinder head

troubleshooting.
a The engine is operated in the low-temperature mode while it is not warmed
Interference of turbocharger, seized turbocharger
perature sensor, charge air temperature sensor)

up sufficiently. Accordingly, the engine sound becomes a little larger. This
does not indicate abnormality, however.
a When the engine is accelerated, it is operated in the acceleration mode and
Broken valve system (valve, rocker arm)

its sound becomes a little larger for up to approximately 3 seconds.
Excessive wear of piston ring, cylinder

Improper gear train backlash
Dislocated, seized bushing
Clogged, seized injector

Dirt caught in injector
Degree of use Operated for long period E
Questions
Condition of Gradually occurred Q Q

abnormal noise Sudden occurred Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is heard from turbocharger w
When engine is cranked, abnormal sound is generated around cylinder w w
Check items
When engine is cranked, beat noise is generated around muffler w

wQ
Color of exhaust Blue under light load w
gas Black Qw Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q QQ
When turbocharger is rotated by hand, it is fount to be heavy q
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
A cylinder is cut out, but engine speed does not change qq
Abnormal noise is heard only when engine is cranked q
Perform checking by using monitoring function of machine monitor q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
40-600 22 PC200, 200LC-8E0 (Hybrid)

S-16 Vibration is excessive SEN05254-01
S-16 Vibration is excessive
General causes why vibration is excessive Causes

q Defective parts (abnormal wear, breakage, etc,)
Improper injection timing (Abnormality in coolant

q Misalignment between engine and chassis
Loose engine mounting bolts, broken cushions

q Abnormal combustion
Misalignment between engine and hydraulic

Worn main bearing, connecting rod bearing
a If abnormal noise is made and vibration is excessive, carry out troubleshooting
temper. sensor, charge air temp. sensor)

for "S-15 Abnormal noise is made", too.
Stiff valve system (valve, rocker arm)
Broken output shaft, parts in damper

Improper gear train backlash
Worn camshaft bushing
pump
Degree of use
Questions

of machine
Condition of Suddenly increased. Q Q
vibration Gradually increased. Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
w w
Check items
Metal particles are found when oil pan is drained

Oil pressure is low at low idle Q Q
Vibration occurs at mid-range speed Q Q
Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w Q
Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Check with monitoring function q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
PC200, 200LC-8E0 (Hybrid) 40-600 23

SEN05254-01
©2010 KOMATSU
All Rights Reserved
40-600 24
SEN05270-03
SEN05270-00
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8E0 (Hybrid)

40 Troubleshooting
700 Troubleshooting of Hybrid system
(Y-mode)
Precautions related to hybrid machine........................................................................................................ 2

Y-1 Hybrid monitor does not go off.............................................................................................................. 4
Y-2 Upper structure does not swing ............................................................................................................ 6
Y-3 Swing acceleration or swing speed is low ............................................................................................ 8
Y-4 Upper structure overruns largely after swinging ................................................................................... 9
Y-5 Large shock is made when upper structure stops swinging ................................................................. 10
Y-6 Large abnormal sound is made when upper structure stops swinging................................................. 11
Y-7 Upper structure lowers largely by its own weight.................................................................................. 12
Y-8 Swing electric motor temperature increases abnormally ...................................................................... 13
Y-9 Motor-generator temperature increases abnormally............................................................................. 15
Y-10 Inverter temperature increases abnormally ........................................................................................ 16
Y-11 Capacitor temperature increases abnormally ..................................................................................... 17
PC200, 200LC-8E0 (Hybrid) 40-700 1

700 Troubleshooting of Hybrid system (Y-mode)
SEN05270-03 Precautions related to hybrid machine
Precautions related to hybrid machine
k When testing or adjusting the hybrid machine, ensure that you fully understand the following mat-
ters.

(For details, see 00-200 Introduction, safety, and basic information, Handling of hybrid devices and
high-voltage wiring, "Discharge procedure for capacitor" or 30-102 Testing and adjusting (Part 2), Special
brid devices and high-voltage wiring" before beginning the work on them.
k After discharging the capacitor, confirm that both capacitor charge LEDs (1) are OFF.
k A voltage not exceeding 30V will still remain in the capacitor after the discharging process is com-
pleted. Do not work with bare hands. Always wear insulating gloves.
a For the monitoring items applied to troubleshooting for the hybrid devices, see the list in "Separate sheet
1".
a For the check sheet to record the inspection result when any hybrid device is abnormal, see "Separate
sheet 2".
(Use this check sheet to ask a question of a plant department)
q "Separate sheet 1" and "Separate sheet 2" are in "Troubleshooting by failure code (Part 5)".
40-700 2 PC200, 200LC-8E0 (Hybrid)

Precautions related to hybrid machine SEN05270-03
PC200, 200LC-8E0 (Hybrid) 40-700 3

SEN05270-03 Y-1 Hybrid monitor does not go off
Y-1 Hybrid monitor does not go off
Trouble Hybrid monitor does not go off but keeps lighting.

q Hybrid controller switch input can be checked by using monitoring function.
Related
(Code: 09702 Hybrid controller switch input)
information

If capacitor voltage is below 150 V, run engine at low speed for at
1 Capacitor voltage drop
least 5 minutes.
Swing emergency stop switch

2 Turn swing emergency stop switch OFF.
is ON
3 Defective hybrid system If error of user code E09 is displayed, troubleshoot it first.
Defective assembly of swing Operation section and contact section of swing emergency stop
4
emergency stop switch switch may be coupled defectively. Check them directly.
Swing emergency stop switch may have internal defect. Check it
directly.
Probable Defective swing emergency a Prepare with starting switch OFF, then troubleshoot without turn-
5
causes and stop switch ing starting switch to ON position.
standard Resis-
Between terminals HS01 (11) and HS01 (12) Max. 1 W
value in nor- tance
mal condition a Prepare with starting switch OFF, then troubleshoot without turn-
ing starting switch to ON position.
Wiring harness between terminals HS01 (11) Resis-
Max. 1 W
and HJ02 (female) (12) tance
Wiring harness between terminals HJ02 (11) Resis-
Max. 1 W
Disconnection in wiring har- and HC01 (female) (5)/(11) tance
ness Wiring harness between terminals HJ02 Resis-
6 Max. 1 W
(Disconnection or defective (female) (11) and HH07 (male) (2) tance
contact in connector) Wiring harness between terminals HH07 Resis-
Max. 1 W
(female) (2) and J06 (female) (7) tance
Wiring harness between terminals J06 Resis-
Max. 1 W
(female) (9) and F01-17 tance
Wiring harness between terminals HS01 (12) Resis-
Max. 1 W
and HC02 (female) (27) tance
If causes 1 – 6 are not the cause for the trouble, hybrid controller may
Defective inverter (hybrid con-
7 be defective. (Since trouble is in system, troubleshooting cannot be
troller)
performed.)
40-700 4 PC200, 200LC-8E0 (Hybrid)

Y-1 Hybrid monitor does not go off SEN05270-03
PC200, 200LC-8E0 (Hybrid) 40-700 5

SEN05270-03 Y-2 Upper structure does not swing
Y-2 Upper structure does not swing
Trouble (1) Upper structure swings neither to the right nor left
Related
q Perform all troubleshooting with working mode in power mode (P).
information
a Prepare with engine stopped, then troubleshoot with engine at full
speed.
Malfunction of swing brake Output pressure of swing brake
1 Left work equipment control lever
solenoid valve solenoid valve
Neutral 0 MPa {0 kg/cm2}
Swing LEFT/RIGHT 2.9 MPa {30 kg/cm2}
2 Malfunction of swing brake Swing brake may be malfunctioning. Check it directly.
a Troubleshoot with engine stopped and swing lock switch ON.
Wiring harness between emergency stop Resis-
Probable Defective emergency stop Max. 1 W
3 switch HS01 (11) and (12) tance
causes and switch
Wiring harness between emergency stop Resis-
standard Max. 1 W
switch HS01 (21) and (22) tance
value in nor- Swing machinery may have internal defect. Check it directly.
mal conditon 4 Defective swing machinery * You may judge by abnormal sound, abnormal heating, metallic dust
in drained oil, etc.
Disconnection or short circuit If failure code [DHVAKZ] is displayed, swing RIGHT PPC pressure
5 in swing RIGHT PPC pres- sensor for hybrid system may have disconnection or short circuit.
sure sensor for hybrid system Perform troubleshooting.
Disconnection or short circuit If failure code [DHVBKZ] is displayed, swing LEFT PPC pressure
6 in swing LEFT PPC pressure sensor for hybrid system may have disconnection or short circuit.
sensor for hybrid system Perform troubleshooting.
7 Defective inverter be defective. (Since trouble is in system, troubleshooting cannot be
performed.)
Trouble (2) Upper structure does not swing in only one direction.
Related
information
a Prepare with engine stopped, then troubleshoot with engine at
high idle.
Malfunction of swing PPC Left work equipment control lever PPC valve output pressure
1
Probable valve Neutral 0 MPa {0 kg/cm2}
causes and 2.84 – 3.43 MPa
Swing LEFT/RIGHT
standard {29 – 35 kg/cm2}
value in nor- Disconnection or short circuit If failure code [DHVAKZ] is displayed, swing RIGHT PPC pressure
mal conditon 2 in swing RIGHT PPC pres- sensor for hybrid system may have disconnection or short circuit.
sure sensor for hybrid system Perform troubleshooting.
Disconnection or short circuit If failure code [DHVBKZ] is displayed, swing LEFT PPC pressure
3 in swing LEFT PPC pressure sensor for hybrid system may have disconnection or short circuit.
sensor for hybrid system Perform troubleshooting.
40-700 6 PC200, 200LC-8E0 (Hybrid)

Y-2 Upper structure does not swing SEN05270-03
PC200, 200LC-8E0 (Hybrid) 40-700 7

SEN05270-03 Y-3 Swing acceleration or swing speed is low
Y-3 Swing acceleration or swing speed is low
Trouble (1) Swing acceleration or swing speed is low in both right and left directions
q Capacitor voltage can be checked by using monitoring function.
Related (Code: 09300 Capacitor voltage)
information q Method of reproducing failure code: Turn starting switch to ON position or start engine. Perform all trou-
bleshooting with working mode in power mode (P).
Malfunction of all control LS shuttle valves of all control valves may be malfunctioning. Check
2
valves (LS shuttle valves) them directly.
Swing machinery may have internal defect. Check it directly.
Probable
3 Defective swing machinery * You may judge by abnormal sound, abnormal heating, metallic dust
causes and
in drained oil, etc.
standard
If capacitor voltage decreases much below 200 V each time when
value in nor-
Lowering of capacitor perfor- machine starts normal swing operation (about 90 degrees), capacitor
mal conditon 4
mance function may be lowered. (Since trouble is in system, troubleshooting
5 Defective inverter be defective. (Since trouble is in system, troubleshooting cannot be
performed.)
Trouble (2) Swing acceleration or swing speed is low in only one direction.
Related
information
speed.
Probable Left work equipment control lever PPC valve output pressure
Malfunction of swing PPC
causes and 1
valve Neutral 0 MPa {0 kg/cm2}
standard
2.84 – 3.43 MPa
value in nor- Swing LEFT/RIGHT
mal conditon {29 – 35 kg/cm2}
If cause 1 is not the cause for the trouble, hybrid controller may be
2 Defective inverter defective. (Since trouble is in system, troubleshooting cannot be per-
formed.)
40-700 8 PC200, 200LC-8E0 (Hybrid)

Y-4 Upper structure overruns largely after swinging SEN05270-03
Y-4 Upper structure overruns largely after swinging
Trouble (1) Upper structure overruns largely after swinging in both directions.
Related
information
causes and
standard
value in nor- 1 Defective software Check the version No. of software.
mal conditon
Trouble (2) Upper structure overruns largely after swinging in only one direction.
Related
information

speed.
Output pressure of swing brake
Malfunction of swing PPC Left work equipment control lever
Probable 1 solenoid valve
valve
causes and Neutral 0 MPa {0 kg/cm2}
standard 2.84 – 3.43 MPa
value in nor- Swing LEFT/RIGHT
{29 – 35 kg/cm2}
mal conditon Swing PPC slow return valve may be malfunctioning. Check it
Clogged swing PPC slow directly.
2
return valve * You may judge by exchanging right and left valves and checking
change of phenomenon.
3 Defective software Check the version number of software.
PC200, 200LC-8E0 (Hybrid) 40-700 9

SEN05270-03 Y-5 Large shock is made when upper structure stops swinging
Y-5 Large shock is made when upper structure stops swinging
Trouble q Large shock is caused when upper structure stops swinging.

Related
information

speed.
Output pressure of swing brake
Probable Malfunction of swing PPC Left work equipment control lever
1 solenoid valve
causes and valve
standard Neutral 0 MPa {0 kg/cm2}
value in nor- 2.84 – 3.43 MPa
Swing LEFT/RIGHT
mal conditon {29 – 35 kg/cm2}
Swing PPC slow return valve may be malfunctioning. Check it
Clogged swing PPC slow directly.
2
return valve * You may judge by exchanging right and left valves and checking
change of phenomenon.
40-700 10 PC200, 200LC-8E0 (Hybrid)

Y-6 Large abnormal sound is made when upper structure stops swinging SEN05270-03
Y-6 Large abnormal sound is made when upper structure stops swinging
Trouble q Large abnormal sound is made when upper structure stops swinging in both directions.
Related
information
causes and
standard Swing machinery may have internal defect. Check it directly.
value in nor- 1 Defective swing machinery * You may judge by abnormal sound, abnormal heating, metallic dust
mal conditon in drained oil, etc.
PC200, 200LC-8E0 (Hybrid) 40-700 11

SEN05270-03 Y-7 Upper structure lowers largely by its own weight
Y-7 Upper structure lowers largely by its own weight
Trouble (1) Upper structure lowers largely by its own weight (when swing brake is being applied)
q If swing lock switch is ON or swing brake cancel switch is in normal position, swing brake operates and
Related
upper structure is fixed by disc brake.
information

Probable speed.
causes and Output pressure of swing brake
Malfunction of swing brake Left work equipment control lever
standard 1 solenoid valve
solenoid valve
value in nor- Neutral 0 MPa {0 kg/cm2}
mal conditon
Swing LEFT/RIGHT 2.9 MPa {30 kg/cm2}
Trouble (2) Upper structure lowers largely by its own weight (when swing brake is being released)
q If swing lock switch is ON or swing brake cancel switch is in normal position, swing brake operates
Related
and upper structure is fixed by disc brake.
information
causes and
standard 1 Defective swing motor Swing motor may be malfunctioning. Check it directly.
value in nor- Hybrid controller may be defective.
2 Defective inverter
mal conditon (Since trouble is in system, troubleshooting cannot be performed.)
40-700 12 PC200, 200LC-8E0 (Hybrid)

Y-8 Electric swing motor temperature increases abnormally SEN05270-03
Y-8 Electric swing motor temperature increases abnormally
Symptoms of
q Electric swing motor temperature increases abnormally and error code [GA70NS] is displayed.
failure
q Electric swing motor coil temperature can be checked with monitoring function.
Related
(Code: 09101 Electric swing motor coil temperature)
information
Cause Standard value in normal state and remarks on troubleshooting

Excessive charge and dis-
1 charge of capacitor Check if operator repeated only swing and swing stop operations.
a Prepare by setting starting switch to OFF position, and
Ground fault of wiring harness
troubleshoot without turning starting switch to ON position.
of electric swing motor coil
temperature sensor Resis- Min.
(female) (42) and PM01 (female) (7)) and
(contact with ground circuit) tance 1 MΩ
ground
Lowering of cooling (lubricat-
3 Check oil level with oil level gauge and add oil if oil level is low
ing) oil level
Low quality of cooling (lubri- Cooling (lubricating) oil may contain water, metal dust, etc. Check it
4
cating) oil directly.
a Prepare with engine stopped, then troubleshoot with engine at high
Defective lubricating oil pas- idle.
5 Max. 0.3 MPa
sage in electric swing motor Set all control levers in neutral and mea-
Pressure
sure by using pressure pickup plug. {3.1 kg/cm2}
Clogged cooling (lubricating)
6 Check directly. If clogged, clean.
oil filter
Lubrication pump may have malfunction or internal defect. Check it
according to following procedure.
Possible 1) Disconnect the cooling (lubricating) oil inlet hose of electric swing
causes and 7 Defective lubrication pump motor.
standard
2) Crank the engine with the flywheel (manually).
value in nor-
3) If oil flows out of the disconnected hose, the pump is normal.
mal state
Radiator coolant may have overheated. Perform troubleshooting of
8 Overheat of radiator coolant
"S-14 Coolant temperature is too high (overheat)" in S mode.
If radiator coolant level monitor indicates low level, add coolant
9 Low coolant level
directly to hybrid radiator.
a Prepare with starting switch OFF, then troubleshoot without turning
starting switch to ON position (Set tester in diode mode).
Defective wiring or disconnec-
10 Between CN-HK01 (male) (1) and (2).
tion of water pump
Connect (2) to positive pole, and (1) to Voltage Approx. 0.6 V
negative pole of tester.
Defective water pump impel-
11 Water pump makes unusual noise or vibration.
ler
Air may be accumulated on suction side of water pump. Check
1) Open the radiator cap of the hybrid radiator.
Air accumulated on suction
12 2) Turn the starting switch to the ON position to start the water
side of water pump
pump.
3) If water pump does not make unusual noise or vibration and if
coolant in radiator upper tank flows, pump is normal.
Clogged or crushed hybrid
13 Check hybrid radiator fins directly.
radiator fins
14 Clogged hybrid radiator core Check hybrid radiator core directly.
PC200, 200LC-8E0 (Hybrid) 40-700 13

SEN05270-03 Y-8 Electric swing motor temperature increases abnormally

Defective hybrid radiator cap If coolant flows out of hybrid radiator overflow hose, check hybrid radi-
Possible 15
(pressure valve) ator cap directly.
causes and
Slip of fan belt or wear of fan If dust or dirt is not accumulated in radiator shroud or of undercover,
standard 16
pulley check fan belt and fan pulley directly.
value in nor-
mal state 17 Defective swing electric motor
Since failure is in system, testing and troubleshooting cannot be per-
Defective inverter (hybrid con- formed.
18
troller)
40-700 14 PC200, 200LC-8E0 (Hybrid)

Y-9 Motor-generator temperature increases abnormally SEN05270-03
Y-9 Motor-generator temperature increases abnormally
Symptoms of
q Motor-generator temperature increases abnormally and error code [GA61NS] is displayed.
failure
q Motor-generator temperature can be checked with monitoring function.
Related
(Code: 09600 Motor-generator temperature)
information

1 charge of capacitor (when Check if operator repeated only swing and swing stop operations.
system is normal)
a Prepare by setting starting switch to OFF position, and
Ground fault of wiring harness
troubleshoot without turning starting switch to ON position.
of motor-generator tempera-
ture sensor (contact with Resis- Min.
(female) (52) and GM01 (female) (4)) and
ground circuit) tance 1 MΩ
ground
Lowering of cooling (lubricat-
3 Check oil level with oil level gauge and add oil if oil level is low
ing) oil level
Low quality of cooling (lubri- Cooling (lubricating) oil may contain water, metal dust, etc. Check it di-
4
cating) oil rectly.
Possible a Prepare with engine stopped, then troubleshoot with engine at high
causes and Defective lubricating oil pas- idle.
standard 5 Below 0.6 Mpa
sage in motor-generator Set all control levers in neutral and mea-
value in nor- Pressure
sure by using pressure pickup plug. {6.1 kg/cm2}
mal state Clogged cooling (lubricating)
6 Check directly. If clogged, clean.
oil filter
Lubrication pump may have malfunction or internal defect. Check it
1) Disconnect the cooling (lubricating) oil inlet hose of motor-gener-
7 Defective lubrication pump
ator.
2) Crank the engine with the flywheel (manually).
3) If oil flows out of the disconnected hose, the pump is normal.
Radiator coolant may have overheated. Perform troubleshooting of
8 Overheat of radiator coolant
"S-14 Coolant temperature is too high (overheat)" in S mode.
Since failure is in system, testing and troubleshooting cannot be per-
Defective inverter (hybrid con- formed.
10
troller)
PC200, 200LC-8E0 (Hybrid) 40-700 15

SEN05270-03 Y-10 Inverter temperature increases abnormally
Y-10 Inverter temperature increases abnormally
Symptoms of q Inverter temperature increases abnormally and either or both of error codes [GA1ZNS] and [GA1YNS]
failure are displayed.
q Temperature of booster IGBT and booster inductor of inverter can be checked with monitoring function.
Related
(Code: 09401 Booster IGBT temperature, Code: 09402 Booster inductor temperature)
information

1
charge of capacitor Check if operator repeated only swing and swing stop operations.
2
If radiator coolant level monitor indicates low level, add coolant directly
3 Low coolant level
to hybrid radiator.
a Prepare with starting switch OFF, then troubleshoot without turn-
ing starting switch to ON position (Set tester in diode mode).
4 Between CN-HK01 (male) (1) and (2). Con-
tion of water pump Approx.
nect (2) to positive pole, and (1) to negative Voltage
0.6 V
pole of tester.
Possible 5 Water pump makes unusual noise or vibration.
ler
causes and Air may be accumulated on suction side of water pump. Check
standard according to following procedure.
value in nor-
Air accumulated on suction 1) Open the radiator cap of the hybrid radiator.
mal state 6
side of water pump 2) Turn the key to the ON position to start the water pump.
radiator fins
9
10
Defective inverter (hybrid con- Since failure is in system, testing and troubleshooting cannot be per-
11
troller) formed.
40-700 16 PC200, 200LC-8E0 (Hybrid)

Y-11 Capacitor temperature increases abnormally SEN05270-03
Y-11 Capacitor temperature increases abnormally
Symptoms of
q Capacitor temperature increases abnormally and error code [GA1TNS] is displayed.
failure
Related
(Code: 09301 Capacitor temperature #1, Code: 09302 Capacitor temperature #2)
information

1 charge of capacitor (when Check if operator repeated only swing and swing stop operations.
system is normal)
Ground fault of wiring harness a Prepare with starting switch OFF, then troubleshoot without turn-
of capacitor temperature #1 ing starting switch to ON position.
2
sensor (contact with ground Between HC02 (female) (51) – HP01 (female) Resis-
Min. 1 MW
circuit) (4) wiring harness and ground tance
Ground fault of wiring harness a Prepare with starting switch OFF, then troubleshoot without turn-
of capacitor temperature #2 ing starting switch to ON position.
3
sensor (contact with ground Between HC02 (female) (61) – HP01 (female) Resis-
Min. 1 MW
circuit) (5) wiring harness and ground tance
If radiator coolant level monitor indicates low level, add coolant directly
4 Low coolant level
to hybrid radiator.
a Prepare with starting switch OFF, then troubleshoot without turn-
Possible ing starting switch to ON position (Set tester in diode mode).
5 Between CN-HK01 (male) (1) and (2). Con-
causes and tion of water pump Approx.
nect (2) to positive pole, and (1) to negative Voltage
standard 0.6 V
pole of tester.
value in nor-
mal state 6 Water pump makes unusual noise or vibration.
ler
Air may be accumulated on suction side of water pump. Check
Air accumulated on suction 1) Open the radiator cap of the hybrid radiator.
7
side of water pump 2) Turn the key to the ON position to start the water pump.
radiator fins
10
11
PC200, 200LC-8E0 (Hybrid) 40-700 17

SEN05270-03
PC200, 200LC-8E0 (Hybrid) H
©2012 KOMATSU
All Rights Reserved
Printed in Japan 10-12 (01)
40-700 18

PC200 (LC) - 8E0 SEN05245-02 Hybrid Troubleshooting

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PC200 (LC) - 8E0 SEN05245-02 Hybrid Troubleshooting

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SEN05245-02

PC200, 200LC-8E0 (Hybrid)

Machine model Serial number

Failure code table ....................................................................................................................................... 2

PC200, 200LC-8E0 (Hybrid) 40-100 1

Failure code table

40-100 2 PC200, 200LC-8E0 (Hybrid)

User Device to Document No.

PC200, 200LC-8E0 (Hybrid) 40-100 3

User Device to Document No.

40-100 4 PC200, 200LC-8E0 (Hybrid)

User Device to Document No.

PC200, 200LC-8E0 (Hybrid) 40-100 5

User Device to Document No.

40-100 6 PC200, 200LC-8E0 (Hybrid)

Precautions related to hybrid machines

a Order of items described in table

PC200, 200LC-8E0 (Hybrid) 40-100 7

40-100 8 PC200, 200LC-8E0 (Hybrid)

Locations of fusible links

Location of fuse box and fuse Nos.

PC200, 200LC-8E0 (Hybrid) 40-100 9

Problems that occur when power supply of pump controller is defective

a Green LED of pump controller (a)

40-100 10 PC200, 200LC-8E0 (Hybrid)

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

PC200, 200LC-8E0 (Hybrid) 40-100 11

Problems when controller power supply of hybrid controller (inverter) is defective

Problems when solenoid power supply of hybrid controller (inverter) is defective

40-100 12 PC200, 200LC-8E0 (Hybrid)

a Power supply connector (HC01) of hybrid controller (inverter)

PC200, 200LC-8E0 (Hybrid) 40-100 13

PC200, 200LC-8E0 (Hybrid) Hydraulic excavator

Form No. SEN05245-02

Machine model Serial number

Points to remember when troubleshooting ................................................................................................. 2

PC200, 200LC-8E0 (Hybrid) 40-200 1

Points to remember when troubleshooting

40-200 2 PC200, 200LC-8E0 (Hybrid)

Sequence of events in troubleshooting

PC200, 200LC-8E0 (Hybrid) 40-200 3

Check before troubleshooting

40-200 4 PC200, 200LC-8E0 (Hybrid)

Classification and procedures for troubleshooting

*: Exclusive mode for hybrid model

Procedure for troubleshooting

PC200, 200LC-8E0 (Hybrid) 40-200 5

Precautions related to hybrid machines

40-200 6 PC200, 200LC-8E0 (Hybrid)

Probable problems and troubleshooting No.

PC200, 200LC-8E0 (Hybrid) 40-200 7

40-200 8 PC200, 200LC-8E0 (Hybrid)

Information in troubleshooting table

PC200, 200LC-8E0 (Hybrid) 40-200 9

Related circuit diagram

This drawing is a part of the electric circuit diagram related

40-200 10 PC200, 200LC-8E0 (Hybrid)

Connection table for connector pin numbers

PC200, 200LC-8E0 (Hybrid) 40-200 11

40-200 12 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 13

40-200 14 PC200, 200LC-8E0 (Hybrid)

PC200, 200LC-8E0 (Hybrid) 40-200 15