Shop Pc200 8m0

SEN06109-08
HYDRAULIC PC200 -8M0

EXCAVATOR
PC200LC -8M0
PC220 -8M0
PC220LC -8M0
PC200- 400001
PC200LC- 400001
SERIAL NUMBERS and up
PC220- 100001
PC220LC- 100001
SEN06111-08
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
Machine model Serial number

PC200-8M0 400001 and up
PC200LC-8M0 400001 and up
PC220-8M0 100001 and up
00 Index and foreword 1

100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
PC200, 200LC, 220, 220LC-8M0 00-100 1

100 Index
SEN06111-08 Composition of shop manual
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN06109-08
00 Index and foreword SEN06110-08

100 Index SEN06111-08 q
200 Foreword and general information SEN06112-01
01 Specification SEN06113-00
100 Specification and technical data SEN06114-00
10 Structure, function and maintenance standard SEN06115-03

100 Engine and cooling system SEN06116-00
200 Power train SEN06117-00
300 Undercarriage and frame SEN06118-00
401 Hydraulic system, Part 1 SEN06119-02 q
402 Hydraulic system, Part 2 SEN06120-01
500 Work equipment SEN06122-00
600 Electrical system SEN06123-01
20 Standard value table SEN06124-01

100 Standard service value table SEN06125-01
30 Testing and adjusting SEN06126-01

101 Testing and adjusting, Part 1 SEN06127-00
00-100 2 PC200, 200LC, 220, 220LC-8M0

100 Index
Composition of shop manual SEN06111-08
40 Troubleshooting SEN06130-03
100 Failure code table and fuse locations SEN06131-00
200 General Information on troubleshooting SEN06132-02
301 Troubleshooting by failure code, Part 1 SEN06133-01
400 Troubleshooting of electrical system (E-mode) SEN06138-02
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN06139-01
600 Troubleshooting of engine (S-mode) SEN06140-00
50 Disassembly and assembly SEN06141-04

100 General information on disassembly and assembly SEN06142-01 q
400 Undercarriage and frame SEN06145-02 q
500 Hydraulic system SEN06146-01
700 Cab and its attachments SEN06148-02
80 Appendix SEN06150-00
100 Air conditioner SEN06151-00
90 Diagrams and drawings SEN06152-02

100 Hydraulic diagrams and drawings SEN06153-01
200 Electrical diagrams and drawings SEN06154-02
PC200, 200LC, 220, 220LC-8M0 00-100 3

100 Index
SEN06111-08 Table of contents
Table of contents 1
00 Index and foreword
100 Index SEN06111-08
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
200 Foreword and general information SEN06112-01
Foreword, safety and general information ............................................................................... 2
How to read the shop manual.................................................................................................. 9
Explanation of terms for maintenance standard ...................................................................... 11
Handling equipment of fuel system devices ............................................................................ 13
Handling of intake system parts............................................................................................... 14
Handling of hydraulic equipment ............................................................................................. 15
Method of disconnecting and connectingof push-pull type coupler ......................................... 17
Handling of electrical equipment.............................................................................................. 20
How to read electric wire code................................................................................................. 29
Precautions when performing operation .................................................................................. 32
Practical use of KOMTRAX ..................................................................................................... 35
Standard tightening torque table .............................................................................................. 36
List of abbreviation................................................................................................................... 40
Conversion table...................................................................................................................... 45
01 Specification
100 Specification and technical data SEN06114-00
Specification dimension drawings............................................................................................ 2
Working range diagram ........................................................................................................... 3
Specifications........................................................................................................................... 4
Weight table ............................................................................................................................. 8
Table of fuel, coolant and lubricants ........................................................................................ 12
10 Structure, function and maintenance standard

Engine related parts................................................................................................................. 2
Radiator, oil cooler, aftercooler and fuel cooler........................................................................ 3
Power train............................................................................................................................... 2
Final drive ................................................................................................................................ 4
Swing machinery ..................................................................................................................... 8
Swing circle.............................................................................................................................. 12
Track frame and recoil spring .................................................................................................. 2
Idler.......................................................................................................................................... 4
Carrier roller............................................................................................................................. 6
Track roller ............................................................................................................................... 7
Track shoe ............................................................................................................................... 8
Hydraulic equipment layout drawing........................................................................................ 2
Hydraulic tank and filter ........................................................................................................... 4
Hydraulic pump........................................................................................................................ 6
Pilot oil filter ............................................................................................................................. 28
Control valve............................................................................................................................ 2
CLSS ....................................................................................................................................... 13
Functions and operation by valve ............................................................................................ 17
Swing motor............................................................................................................................. 2
00-100 4 PC200, 200LC, 220, 220LC-8M0

100 Index
Table of contents SEN06111-08
Center swivel joint ................................................................................................................... 10

Travel motor............................................................................................................................. 12
PPC valve................................................................................................................................ 22
Valve control ............................................................................................................................ 42
Solenoid valve ......................................................................................................................... 44
PPC accumulator..................................................................................................................... 46
Return oil filter ......................................................................................................................... 47
Return oil filter with clogging sensor........................................................................................ 48
Attachment circuit selector valve ............................................................................................. 50
Hydraulic cylinder .................................................................................................................... 52
Work equipment ...................................................................................................................... 2
Dimensions of arm................................................................................................................... 10
Dimensions of bucket .............................................................................................................. 12
Engine control.......................................................................................................................... 2
Electrical control system.......................................................................................................... 12
Machine monitor system.......................................................................................................... 35
Sensor ..................................................................................................................................... 56
KOMTRAX system .................................................................................................................. 60
Clogging detection system of additional filter for breaker........................................................ 63
20 Standard value table

100 Standard service value table SEN06125-01
Standard value table for engine related parts .......................................................................... 2
Standard value table for chassis related parts......................................................................... 4
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting ..................................................................... 3
Sketch of special tool............................................................................................................... 7
Testing engine speed............................................................................................................... 8
Testing intake air pressure (boost pressure) ........................................................................... 9
Testing exhaust gas color ........................................................................................................ 10
Adjusting valve clearance........................................................................................................ 11
Testing compression pressure................................................................................................. 13
Testing blowby pressure .......................................................................................................... 16
Testing engine oil pressure...................................................................................................... 17
Handling fuel system parts ...................................................................................................... 18
Releasing residual pressure from fuel system......................................................................... 18
Testing fuel pressure ............................................................................................................... 19
Handling reduced cylinder mode operation ............................................................................. 22
Handling no-injection cranking operation ................................................................................ 22
Testing fuel discharge, return and leak amount....................................................................... 23
Bleeding air from fuel circuit .................................................................................................... 26
Testing fuel circuit for leakage ................................................................................................. 27
Handling controller high voltage circuit .................................................................................... 28
Testing and adjusting air conditioner compressor belt tension ................................................ 29
Replacing alternator belt.......................................................................................................... 30
Testing swing circle bearing clearance .................................................................................... 31
Testing and adjusting track tension ......................................................................................... 32
Testing and adjusting oil pressure in work equipment, swing, and travel circuits .................... 34
Testing control circuit source pressure .................................................................................... 37
Testing and adjusting oil pressure in pump PC control circuit ................................................. 38
Testing and adjusting oil pressure in pump LS control circuit.................................................. 41
Testing solenoid valve output pressure ................................................................................... 46
Testing PPC valve output pressure ......................................................................................... 49
PC200, 200LC, 220, 220LC-8M0 00-100 5

100 Index
Adjusting play of work equipment and swing PPC valves ....................................................... 51

Testing parts which cause hydraulic drift of work equipment ................................................... 52
Releasing remaining pressure from hydraulic circuit ............................................................... 54
Testing oil leakage ................................................................................................................... 55
Bleeding air from each part...................................................................................................... 58
Testing cab tipping stopper ...................................................................................................... 60
Adjusting mirrors...................................................................................................................... 61
Installation and adjustment of mirrors...................................................................................... 62
Angle adjustment of rear view camera .................................................................................... 65
Special functions of machine monitor ...................................................................................... 2
Handling voltage circuit of engine controller ............................................................................ 2
Preparation work for troubleshooting of electrical system ....................................................... 3
Procedure for testing diodes.................................................................................................... 8
Handling battery disconnect switch ......................................................................................... 9
Pm Clinic service ..................................................................................................................... 10
40 Troubleshooting
100 Failure code table and fuse locations SEN06131-00
Failure codes table .................................................................................................................. 2
Fuse locations.......................................................................................................................... 9
200 General Information on troubleshooting SEN06132-02
Symptom and troubleshooting numbers .................................................................................. 2
Sequence of events in troubleshooting.................................................................................... 4
Checks before troubleshooting ................................................................................................ 6
Classification and procedures for troubleshooting................................................................... 8
Symptom and troubleshooting numbers .................................................................................. 10
Information in troubleshooting table......................................................................................... 12
Connector/electrical wiring connection table ........................................................................... 14
Connector list and layout ......................................................................................................... 44
Connection table for connector pin numbers ........................................................................... 54
T- branch box and T- branch adapter table.............................................................................. 90
Troubleshooting method for open circuit in wiring harness of pressure sensor system .......... 93
Failure code [879AKA]............................................................................................................. 3
Failure code [879AKB]............................................................................................................. 3
Failure code [879BKA]............................................................................................................. 3
Failure code [879BKB]............................................................................................................. 3
Failure code [879CKA]............................................................................................................. 3
Failure code [879CKB]............................................................................................................. 3
Failure code [879DKZ]............................................................................................................. 4
Failure code [879EMC] ............................................................................................................ 4
Failure code [879FMC] ............................................................................................................ 4
Failure code [879GKX] ............................................................................................................ 4
Failure code [989L00] .............................................................................................................. 5
Failure code [989M00] ............................................................................................................. 6
Failure code [989N00] ............................................................................................................. 7
Failure code [AA10NX] ............................................................................................................ 8
Failure code [AB00KE] ............................................................................................................ 10
Failure code [B@BAZG] .......................................................................................................... 13
Failure code [B@BAZK]........................................................................................................... 14
Failure code [B@BCNS] .......................................................................................................... 16
Failure code [B@BCZK] .......................................................................................................... 17
Failure code [B@HANS] .......................................................................................................... 19
Failure code [CA111]................................................................................................................ 20
Failure code [CA115] ............................................................................................................... 21
00-100 6 PC200, 200LC, 220, 220LC-8M0

100 Index
Failure code [CA122]............................................................................................................... 22

Failure code [CA123]............................................................................................................... 25
Failure code [CA131]............................................................................................................... 28
Failure code [CA132]............................................................................................................... 31
Failure code [CA144]............................................................................................................... 34
Failure code [CA145]............................................................................................................... 37
Failure code [CA153]............................................................................................................... 40
Failure code [CA154]............................................................................................................... 43
Failure code [CA155]............................................................................................................... 46
Failure code [CA187]............................................................................................................... 47
Failure code [CA221]............................................................................................................... 49
Failure code [CA222]............................................................................................................... 52
Failure code [CA227]............................................................................................................... 55
Failure code [CA234]............................................................................................................... 56
Failure code [CA238]............................................................................................................... 57
Failure code [CA271]............................................................................................................... 59
Failure code [CA272]............................................................................................................... 61
Failure code [CA322]............................................................................................................... 3
Failure code [CA323]............................................................................................................... 6
Failure code [CA324]............................................................................................................... 9
Failure code [CA325]............................................................................................................... 12
Failure code [CA331]............................................................................................................... 15
Failure code [CA332]............................................................................................................... 18
Failure code [CA342]............................................................................................................... 21
Failure code [CA351]............................................................................................................... 22
Failure code [CA352]............................................................................................................... 23
Failure code [CA386]............................................................................................................... 25
Failure code [CA428]............................................................................................................... 26
Failure code [CA429]............................................................................................................... 28
Failure code [CA435]............................................................................................................... 30
Failure code [CA441]............................................................................................................... 32
Failure code [CA442]............................................................................................................... 35
Failure code [CA449]............................................................................................................... 36
Failure code [CA451]............................................................................................................... 38
Failure code [CA452]............................................................................................................... 41
Failure code [CA488]............................................................................................................... 44
Failure code [CA553]............................................................................................................... 45
Failure code [CA559]............................................................................................................... 46
Failure code [CA689]............................................................................................................... 48
Failure code [CA731]............................................................................................................... 51
Failure code [CA757]............................................................................................................... 54
Failure code [CA778]............................................................................................................... 55
Failure code [CA2185]............................................................................................................. 60
Failure code [CA2186]............................................................................................................. 63
Failure code [CA2249]............................................................................................................. 65
Failure code [CA2311] ............................................................................................................. 66
Failure code [CA2555]............................................................................................................. 67
Failure code [CA2556]............................................................................................................. 70
Failure code [D110KB]............................................................................................................. 2
Failure code [D19JKZ]............................................................................................................. 4
Failure code [D811MC] ............................................................................................................ 7
Failure code [D862KA] ............................................................................................................ 8
Failure code [D8AQKR] ........................................................................................................... 9
Failure code [DA22KK] ............................................................................................................ 12
Failure code [DA25KP] ............................................................................................................ 15
Failure code [DA26KP] ............................................................................................................ 18
PC200, 200LC, 220, 220LC-8M0 00-100 7

100 Index
Failure code [DA29KQ]............................................................................................................ 21

Failure code [DA29KQ]............................................................................................................ 24
Failure code [DA2QKR] ........................................................................................................... 26
Failure code [DAF0MB] ........................................................................................................... 29
Failure code [DAF0MC] ........................................................................................................... 29
Failure code [DAF8KB] ............................................................................................................ 30
Failure code [DAF9KQ]............................................................................................................ 32
Failure code [DAFGMC] .......................................................................................................... 33
Failure code [DAFQKR] ........................................................................................................... 34
Failure code [DAZ9KQ]............................................................................................................ 35
Failure code [DAZQKR] ........................................................................................................... 36
Failure code [DB2QKR] ........................................................................................................... 37
Failure code [DGH2KB] ........................................................................................................... 43
Failure code [DHA4KA]............................................................................................................ 45
Failure code [DHPAMA] ........................................................................................................... 46
Failure code [DHPBMA]........................................................................................................... 49
Failure code [DHS3MA] ........................................................................................................... 2
Failure code [DHSAMA]........................................................................................................... 14
Failure code [DHSBMA]........................................................................................................... 17
Failure code [DHSCMA] .......................................................................................................... 20
Failure code [DHSDMA] .......................................................................................................... 23
Failure code [DHSFMA]........................................................................................................... 26
Failure code [DHSGMA] .......................................................................................................... 29
Failure code [DHSHMA] .......................................................................................................... 32
Failure code [DHSJMA] ........................................................................................................... 35
Failure code [DHX1MA] ........................................................................................................... 38
Failure code [DR21KX] ............................................................................................................ 39
Failure code [DR31KX] ............................................................................................................ 41
Failure code [DV20KB] ............................................................................................................ 42
Failure code [DW43KA] ........................................................................................................... 44
Failure code [DW43KB] ........................................................................................................... 46
Failure code [DWA2KA] ........................................................................................................... 2
Failure code [DWA2KB] ........................................................................................................... 4
Failure code [DWK0KA]........................................................................................................... 6
Failure code [DWK0KB]........................................................................................................... 8
Failure code [DWK2KA]........................................................................................................... 10
Failure code [DWK2KB]........................................................................................................... 12
Failure code [DXA8KA]............................................................................................................ 14
Failure code [DXA8KB]............................................................................................................ 17
Failure code [DXA9KA]............................................................................................................ 20
Failure code [DXA9KB]............................................................................................................ 23
Failure code [DXE0KA]............................................................................................................ 26
Failure code [DXE0KB]............................................................................................................ 28
00-100 8 PC200, 200LC, 220, 220LC-8M0

100 Index
Failure code [DY20KA] ............................................................................................................ 42

Failure code [DY20MA] ........................................................................................................... 45
Failure code [DY2CKB] ........................................................................................................... 48
Failure code [DY2DKB] ........................................................................................................... 51
Failure code [DY2EKB]............................................................................................................ 53
400 Troubleshooting of electrical system (E-mode) SEN06138-02
Before troubleshooting for electrical system............................................................................ 3
Information described in troubleshooting table ........................................................................ 5
E-1 Engine does not start (engine does not rotate) ................................................................. 7
E-2 Preheating system does not work..................................................................................... 16
E-3 Machine monitor displays nothing when starting switch is turned to ON position............. 22
E-4 When starting switch is turned to ON position
(with engine stopped), basic check items light up..................................................... 25
E-5 Caution item lights up while the engine is running ............................................................ 26
E-6 Caution item lights up while the engine is running ............................................................ 31
E-7 Fuel gauge does not indicate correct level ....................................................................... 34
E-8 Engine coolant temperature gauge does not indicate correct temperature ...................... 37
E-9 Hydraulic oil temperature gauge does not indicate correct temperature .......................... 39
E-10 Contents of display on machine monitor are different from actual machine model......... 42
E-11 Some areas of machine monitor screen are not displayed ............................................. 44
E-12 Function switch does not work........................................................................................ 44
E-13 Automatic warm-up system does not work (in cold weather).......................................... 45
E-14 Auto-deceleration function does not work properly......................................................... 47
E-15 Working mode does not change ..................................................................................... 49
E-16 Travel speed does not change........................................................................................ 50
E-17 Alarm buzzer does not stop sounding............................................................................. 52
E-18 Service meter is not displayed while starting switch is in OFF position .......................... 52
E-19 Service mode cannot be selected................................................................................... 53
E-20 All work equipment, swing and travel do not work, or lock is not available..................... 54
E-21 Swing parking brake does not work properly .................................................................. 57
E-22 One-touch power maximizing function does not work properly ...................................... 61
E-23 Travel alarm does not sound or does not stop sounding ................................................ 64
E-24 Horn does not sound or does not stop sounding ............................................................ 66
E-25 Wiper or window washer does not operate..................................................................... 70
E-26 "Boom LOWER" is not displayed correctly via monitoring function ................................ 73
E-27 "Arm OUT" is not displayed correctly via monitoring function ......................................... 73
E-28 "Arm IN" is not displayed correctly via monitoring function ............................................. 74
E-29 "Boom RAISE" is not displayed correctly via monitoring function ................................... 74
E-30 "Bucket CURL" is not displayed correctly via monitoring function .................................. 74
E-31 "Bucket DUMP" is not displayed correctly via monitoring function ................................. 75
E-32 "Swing" is not displayed correctly via monitoring function .............................................. 75
E-33 "Travel" is not displayed correctly via monitoring function .............................................. 75
E-34 "Service" is not displayed correctly via monitoring function ............................................ 76
E-35 Attachment hydraulic circuit cannot be changed ............................................................ 79
E-36 KOMTRAX system does not operate normally ............................................................... 80
E-37 Breaker clogging caution lamp lights up when breaker is not used ................................ 82
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN06139-01
System diagram of hydraulic and mechanical system............................................................. 4
Failure mode and cause table ................................................................................................. 6
Information in troubleshooting table ........................................................................................ 8
H-1 All work equipment, swing and travel speed are all slow, or there is no force .................. 9
H-2 Engine speed drops significantly or engine stalls ............................................................. 12
H-3 All work equipment, swing and travel do not work............................................................ 14
H-4 Unusual noise is heard from the vicinity of the hydraulic pump ........................................ 15
H-5 Fine control performance or response is poor .................................................................. 16
H-6 Boom speed is low or power is insufficient ....................................................................... 17
H-7 Arm speed is low or power is insufficient .......................................................................... 21
H-8 Bucket speed is low or power is insufficient ..................................................................... 25
PC200, 200LC, 220, 220LC-8M0 00-100 9

100 Index
H-9 Work equipment does not move in single operation ......................................................... 27

H-10 Hydraulic drift of work equipment is large ....................................................................... 28
H-11 Time lag of work equipment is large................................................................................ 32
H-12 When certain work equipment is relieved hydraulically, other work equipment moves... 33
H-13 One-touch power maximization function does not work ................................................. 34
H-14 When combining operations of work equipment,
equipment subject to heavier loads moves slower.................................................... 35
H-15 Boom RAISE is slow in Swing + Boom RAISE operation ............................................... 36
H-16 When combining swing and travel operations, travel speed drops significantly ............. 37
H-17 Travel deviation is detected ............................................................................................ 38
H-18 Travel speed is slow........................................................................................................ 40
H-19 Machine does not steer well or steering power is low..................................................... 43
H-20 Travel speed does not change, or travel speed is too slow or too fast ........................... 47
H-21 One track does not move................................................................................................ 49
H-22 Machine does not swing ................................................................................................. 51
H-23 Swing acceleration or swing speed is low....................................................................... 54
H-24 Upper structure overruns excessively when it stops swinging ........................................ 57
H-25 Shock is significant when upper structure stops swinging .............................................. 60
H-26 An unusual loud noise is heard when the upper structure stops swinging ..................... 61
H-27 Swing drift on a slope is significant ................................................................................. 62
H-28 Attachment circuit cannot be changed............................................................................ 65
H-29 Oil flow in the attachment circuit cannot be changed...................................................... 66
600 Troubleshooting of engine (S-mode) SEN06140-00
Method of using troubleshooting chart..................................................................................... 2
S-1 Startability is poor .............................................................................................................. 6
S-2 Engine does not start ........................................................................................................ 7
S-3 Engine does not pick up smoothly .................................................................................... 10
S-4 Engine stops during operation .......................................................................................... 11
S-5 Engine runs rough or is unstable ...................................................................................... 12
S-6 Engine lacks 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 (coolant or fuel in oil) ................................................................................ 20
S-14 Coolant temperature rises too high (overheating)........................................................... 21
S-15 Unusual noise is made.................................................................................................... 22
S-16 Vibration is excessive...................................................................................................... 23
50 Disassembly and assembly

100 General information on disassembly and assembly SEN06142-01
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tools list ....................................................................................................................... 7
Sketches of special tools ......................................................................................................... 12
Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of fuel injector assembly .................................................................. 9
Removal and installation of engine front oil seal ..................................................................... 19
Removal and installation of engine rear oil seal ...................................................................... 26
Removal and installation of cylinder head assembly ............................................................... 31
Removal and installation of radiator assembly ........................................................................ 52
Removal and installation of hydraulic oil cooler assembly....................................................... 57
Removal and installation of aftercooler assembly ................................................................... 62
Removal and installation of fuel cooler assembly .................................................................... 67
00-100 10 PC200, 200LC, 220, 220LC-8M0

100 Index
Removal and installation of engine and hydraulic pump assembly ......................................... 70

Removal and installation of final drive assembly ..................................................................... 2
Disassembly and assembly of final drive assembly ................................................................ 7
Removal and installation of swing motor and swing machinery assembly .............................. 27
Disassembly and assembly of swing motor and swing machinery assembly.......................... 33
Removal and installation of swing circle assembly.................................................................. 45
Disassembly and assembly of carrier roller assembly............................................................. 2
Disassembly and assembly of track roller assembly ............................................................... 6
Removal and installation of idler and idler cushion assembly ................................................. 9
Disassembly and assembly of idler ......................................................................................... 12
Disassembly and assembly of idler cushion............................................................................ 17
Removal and installation of sprocket ....................................................................................... 20
Separation and connection of track assembly ......................................................................... 22
Removal and installation of revolving frame assembly............................................................ 28
Removal and installation of counterweight assembly .............................................................. 35
500 Hydraulic system SEN06146-01
Removal and installation of center swivel joint assembly ........................................................ 2
Disassembly and assembly of center swivel joint assembly ................................................... 9
Removal and installation of hydraulic tank assembly .............................................................. 11
Removal and installation of control valve assembly ................................................................ 21
Disassembly and assembly of control valve............................................................................ 38
Removal and installation of hydraulic pump assembly ............................................................ 44
Removal and installation of hydraulic pump input shaft oil seal .............................................. 54
Disassembly and assembly of work equipment PPC valve assembly..................................... 55
Disassembly and assembly of travel PPC valve ..................................................................... 57
Disassembly and assembly of work equipment cylinder ......................................................... 59
Removal and installation of work equipment assembly ........................................................... 2
700 Cab and its attachments SEN06148-02
Removal and installation of operator's cab assembly.............................................................. 2
Removal and installation of operator's cab glass (adhered window glass) ............................. 11
Removal and installation of front window assembly ................................................................ 24
Removal and installation of floor frame assembly ................................................................... 34
Removal and installation of air conditioner unit assembly ....................................................... 44
Removal and installation of machine monitor assembly.......................................................... 2
Removal and installation of engine controller assembly.......................................................... 9
Removal and installation of pump controller assembly ........................................................... 13
Removal and installation of KOMTRAX terminal assembly..................................................... 18
80 Appendix
100 Air conditioner SEN06151-00
Precautions for refrigerant ....................................................................................................... 3
Air conditioner component....................................................................................................... 4
Configuration and function of refrigeration cycle ..................................................................... 6
Outline of refrigeration cycle.................................................................................................... 7
Air conditioner unit................................................................................................................... 9
Air conditioner controller.......................................................................................................... 15
Compressor ............................................................................................................................. 16
Condenser and Modulator ....................................................................................................... 17
Sensor ..................................................................................................................................... 18
Procedure for testing and troubleshooting............................................................................... 20
Circuit diagram and arrangement of connector pins................................................................ 22
System diagram....................................................................................................................... 24
Parts and connectors layout .................................................................................................... 26
PC200, 200LC, 220, 220LC-8M0 00-100 11

100 Index
Testing air leakage (duct)......................................................................................................... 29

Testing with self-diagnosis function ......................................................................................... 31
Testing vent (mode) changeover ............................................................................................. 33
Testing FRESH/RECIRC air changeover................................................................................. 34
Testing sunlight sensor ............................................................................................................ 35
Testing (dual) pressure switch for refrigerant........................................................................... 36
Testing relays........................................................................................................................... 37
Troubleshooting chart 1 ........................................................................................................... 38
Troubleshooting chart 2 ........................................................................................................... 40
Information in troubleshooting table......................................................................................... 42
Failure code list related to air conditioner ................................................................................ 43
Failure code [879AKA] A/C Inner sensor Open Circuit............................................................ 44
Failure code [879AKB] A/C Inner sensor Short Circuit ............................................................ 45
Failure code [879BKA] A/C Outer sensor Open Circuit ........................................................... 46
Failure code [879BKB] A/C Outer sensor Short Circuit ........................................................... 48
Failure code [879CKA] Ventilating sensor Open Circuit .......................................................... 50
Failure code [879CKB] Ventilating sensor Short Circuit .......................................................... 51
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 52
Failure code [879EMC] Ventilating Damper Abnormality......................................................... 54
Failure code [879FMC] Air Mix Damper Abnormality .............................................................. 55
Failure code [879GKX] Refrigerant Abnormality...................................................................... 56
Troubleshooting for power supply and CAN communication system
(Air conditioner does not operate) ........................................................................................... 58
Troubleshooting for compressor and refrigerant system (Air is not cooled) ............................ 60
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ............. 63
Troubleshooting for FRESH/RECIRC air changeover ............................................................. 65
Troubleshooting with gauge pressure...................................................................................... 67
Connection of service tool ....................................................................................................... 69
Precautions for disconnecting and connecting air conditioner piping ...................................... 71
Handling of compressor oil ...................................................................................................... 73
Desiccant replacement procedure ........................................................................................... 75
90 Diagrams and drawings

100 Hydraulic diagrams and drawings SEN06153-01
Symbols in hydraulic circuit diagram ....................................................................................... 2
Hydraulic circuit diagram ......................................................................................................... 5
200 Electrical diagrams and drawings SEN06154-02
Symbols in electric circuit diagram .......................................................................................... 2
Electrical circuit diagram.......................................................................................................... 5
Wiring harness diagram........................................................................................................... 15
00-100 12 PC200, 200LC, 220, 220LC-8M0

100 Index
PC200, 200LC, 220, 220LC-8M0 00-100 13

SEN06111-08
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator

Form No. SEN06111-08
© 2019 KOMATSU
All Rights Reserved
Printed in Japan 03-19 (01)
00-100 14
SEN06112-01
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
00 Index and foreword 1

200 Foreword and general information
Foreword, safety and general information ...................................................................................................... 2
How to read the shop manual ......................................................................................................................... 9
Explanation of terms for maintenance standard ............................................................................................11
Handling equipment of fuel system devices.................................................................................................. 13
Handling of intake system parts .................................................................................................................... 14
Handling of hydraulic equipment................................................................................................................... 15
Method of disconnecting and connectingof push-pull type coupler .............................................................. 17
Handling of electrical equipment................................................................................................................... 20
How to read electric wire code...................................................................................................................... 29
Precautions when performing operation ....................................................................................................... 32
Practical use of KOMTRAX........................................................................................................................... 35
Standard tightening torque table ................................................................................................................... 36
List of abbreviation........................................................................................................................................ 40
Conversion table ........................................................................................................................................... 45
PC200, 200LC, 220, 220LC-8M0 00-200 1

SEN06112-01 Foreword, safety and general information
Foreword, safety and general information 1

Important safety notice
q Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific pur-
pose.
q The symbol mark k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
General precautions q If welding repairs is required, always have a

k Inappropriate handling causes an extreme trained and experienced welder with good
danger. Read and understand what is knowledge of welding perform the work. When
described in the operation and mainte- performing welding work, always wear welding
nance manual before operating the gloves, apron, shielding goggles, cap, etc.
machine. Read and understand what is q Before starting work, warm up your body thor-
described in this manual before starting the oughly to start work under good condition.
work. q Avoid continuing work for long hours and take
q Before performing any greasing or repairs, rests with proper intervals to keep your body in
read all the safety labels stuck to the machine. good condition. Take a rest in a specified safe
For the locations of the safety labels and place.
detailed explanation of precautions, see the
operation and maintenance manual. Safety points
q Locate a place in the repair workshop to keep
1 Good arrangement
the tools and removed parts. Always keep the
tools and parts in their correct places. Always 2 Correct work clothes
keep the work area clean and make sure that 3 Observance of work standard
there is no dirt, water or oil on the floor. Smoke
4 Practice of making and checking signals
only in the areas provided for smoking. Never
smoke while working. Prohibition of operation and handling by
5
q When performing any work, always wear the unlicensed workers
safety shoes and helmet. Do not wear loose 6 Safety check before starting work
work cloths, or clothes with buttons missing. Wearing protective goggles
1. Always wear the protective eyeglasses 7
(for cleaning or grinding work)
when hitting parts with a hammer.
2. Always wear the protective eyeglasses Wearing shielding goggles and protectors
8
(for welding work)
when grinding parts with a grinder, etc.
q When performing any work with two or more 9 Good physical condition and preparation
workers, always agree on the working proce- Precautions against work which you are
dure before starting. While working, always 10
not used to or you are used to too much
keep conversations of the work between your
fellow workers and your self on any step of the
work. During the work, hang the warning tag of Preparation
“UNDER WORKING” in the operator's q Before adding oil or making any repairs, place
compartment. the machine on a firm and level ground, and
q Only qualified workers must perform the work apply the parking brake and chock the wheels
and operation which require license or qualifi- or tracks to prevent the machine from moving.
cation. q Before starting work, lower the work equipment
q Keep the tools in good condition. And learn the (blade, ripper, bucket, etc.) to the ground. If it is
correct way to use the tools, and use the not possible to lower the equipment to the
proper ones among them. Before starting the ground, insert the lock pin or use blocks to pre-
work, thoroughly check the tools, forklift truck, vent the work equipment from falling. And be
service car, etc. sure to lock all the work equipment control
levers and hang a warning tag on them.
00-200 2 PC200, 200LC, 220, 220LC-8M0

Foreword, safety and general information SEN06112-01
q When performing the disassembling or assem- q When removing the part which is under internal
bling work, support the machine securely with pressure or reaction force of the spring, always
blocks, jacks, or stands before starting the leave two bolts in diagonal positions. Loosen
work. those two bolts gradually and alternately and
q Remove all of mud and oil from the steps or release the pressure, then, remove the part.
other places used to get on and off the q When removing the part, be careful not to
machine completely. Always use the handrails, break or damage the electrical wiring. The
ladders of steps when getting on or off the damaged wiring may cause electrical fires.
machine. Never jump on or off the machine. q When removing piping, prevent the fuel or oil
When the scaffold is not provided, use steps or from spilling out. If any fuel or oil drips onto the
stepladder to secure your footing. floor, wipe it off immediately. Fuel or oil on the
floor can cause you to slip and can even cause
Precautions during work fires.
q For the machine equipped with the battery dis- q As a general rule, do not use gasoline to wash
connect switch, check that the system operat- parts. Do not use gasoline to clean the electri-
ing lamp is turned off before starting the work. cal parts, in particular.
Then, turn the battery disconnect switch to the q Reinstall the parts removed to their original
OFF (Q) position and remove the switch key. places. Replace the damaged parts and the
For the machine not equipped with the battery parts which must not be used with new ones.
disconnect switch, remove the cable from the When installing the hoses and wiring har-
battery before starting the work. Be sure to nesses, be careful that they are not damaged
remove the negative end (-) of the battery by contacting with other parts when the
cable first. machine is operated.
q Release the remaining pressure in the circuits q When connecting the high pressure hoses and
completely before the work when the parts in tubes, make sure that they are not twisted. The
the circuits of oil, fuel, coolant and air are dis- damaged high pressure hoses and tubes are
connected or removed. When the cap of the oil very dangerous when they are installed. So, be
filter, drain plug or oil pressure pickup plug is extremely careful when connecting the high
removed, loose them slowly to prevent the oil pressure pipings. In addition, check that their
from spurting out. connections are correct.
q When removing or installing the checking plug q When assembling or installing the parts, be
or the piping in the fuel circuit, wait 30 seconds sure to tighten the bolts to the specified torque.
or longer after the engine is shut down and When installing the protective parts such as
start the work after the remaining pressure is guards, or the parts which vibrate violently or
released from the fuel circuit. rotate at high speeds, be sure to check that
q Immediately after the engine is shut down, the they are installed correctly.
coolant and oil in the circuits are hot. Be care- q When aligning two holes, never insert your fin-
ful not to get scalded by the hot coolant and oil. gers or hand into the holes. Align the holes
Start the work after checking that the coolant with care so that your fingers are not caught in
and oil are cooled down sufficiently. the hole.
q Start the work after the engine is shut down. Be q When measuring hydraulic pressure, check
sure to shut down the engine when working on that the measuring tools are correctly installed.
or around the rotating parts in particular. When q Pay attention to safety when removing and
checking the machine without shutting down installing the tracks of the track type machines.
the engine (measuring oil pressure, engine When removing the track, it separates sud-
speed, oil or coolant temperature), take denly. The workers should not stand at either
extreme care not to get caught in the rotating end of the track.
parts or the working equipment. q If the engine is operated for a long time in a
q The hoist or crane must be used to sling the closed place which is not ventilated well, you
components weighing 25 kg or heavier. Check may suffer from gas poisoning. Accordingly,
the slings (wire rope, nylon sling, chain and open the windows and doors to ventilate the
hook) for damage before the work. Use the place well.
slings with ample capacity and install them to
the proper places. Operate the hoist or crane
slowly to prevent the component from hitting
any other part. Do not work with any part still
raised by the hoist or crane.
PC200, 200LC, 220, 220LC-8M0 00-200 3

Precautions for slinging work and making sig-

nals
q Only one appointed worker must make signals
and co-worker must communicate with each
other frequently. The appointed signaler must
make specified signals clearly at the place
where the signaler is well seen from the opera-
tor's seat and where the signaler can
see the working condition easily. The signaler
must always stand in front of the load and
guide the operator safely.
1. Do not stand under the load.
2. Do not step on the load.
q Check the slings before starting sling work.
q Keep putting on the gloves during sling work. q When installing wire ropes to an angular load,
(Put on the leather gloves, if available.) apply pads to protect the wire ropes. If the
q Measure the weight of the load by the eye and load is slippery, apply proper material to pre-
check its center of gravity. vent the wire rope from slipping.
q Use the proper sling according to the weight of q Use the specified eye bolts and fix wire ropes,
the load and method of slinging. If too thick chains, etc. to them with shackles, etc.
wire ropes are used to sling a light load, the q Apply wire ropes to the middle portion of the
load may slip and fall. hook.
q Do not sling a load with one wire rope only. If a Slinging near the tip of the hook may
do so, the load may rotate or the sling gets cause the rope to slip off the hook during
loose and the sling may slip off. Install two or hoisting. The hook has the maximum
more wire ropes symmetrically. strength at the middle part.
k Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
q Hanging angle must be 60 degrees or smaller
as a rule.
q When hanging a heavy load (25kg or heavier),
the hanging angle of the rope must be nar-
rower than that of the hook.
a When slinging a load with two ropes or
more, the larger the hanging angle is, the
larger the tension of each rope. The figure
bellow shows the variation of allowable
load in kN {kg} when hoisting is made with
two ropes, each of which is allowed to q Do not use twisted or kinked wire ropes.
sling up to 9.8 kN {1000kg} a load verti- q When slinging up a load, observe the follow-
cally, at various hanging angles. When the ing.
two ropes sling a load vertically, up to19.6 1. Wind up the rope slowly until the wire rope
kN {2000 kg} of total weight can be sus- tensions. When putting your hands on the
pended. This weight is reduced to 9.8 kN wire ropes, do not grasp them but press
{1000 kg} when the two ropes make a them down from above. If you grasp them,
hanging angle of 120 degrees. If the two your fingers may be caught.
ropes sling a 19.6 kN {2000 kg} load at a 2. After the wire ropes are stretched, stop
hanging angle of 150 degrees, each rope the crane and check the condition of the
is subjected to a force as large as 39.2 kN slung load, wire ropes, and pads.
{4000 kg}. 3. If the load is unstable or the wire rope or
chains are twisted, lower the load and lift it
up again.
4. Do not lift up the load at an angle.
q When lowering a load, pay attention to the fol-
lowing.
00-200 4 PC200, 200LC, 220, 220LC-8M0

1. When lifting down a load, stop it temporar- q After finishing the work, stop the hoist at the
ily at 30 cm above the floor, and then specified position and raise the hook to at least
lower it slowly. two meters above the floor. Do not leave the
2. Check that the load is stable, and then sling attached to the hook.
remove the sling.
3. Remove kinks and dirt from the wire ropes Selecting wire ropes
and chains used for the sling work, and q Select adequate ropes depending on the
put them in the specified place. weight of the parts to be hoisted, referring to
the table below
Precautions for using mobile crane Wire ropes (standard “Z” twist ropes without galva-
a Read the Operation and Maintenance Manual nizing) (JIS G3525, Type 6x37-A)
of the crane carefully in advance and operate
the crane safely. Nominal
Allowable load
diameter of rope
Precautions for using overhead traveling crane mm kN ton
k The hoist or crane must be used to sling 10 8.8 0.9
the components weighing 25 kg or heavier. 12 12.7 1.3
A part weighing 25 kg or heavier in “disas- 14 17.3 1.7
sembly and assembly” section is indicated 16 22.6 2.3
with the symbol of 4. 18 28.6 2.9
20 35.3 3.6
q Before starting work, check the wire ropes,
25 55.3 5.6
brake, clutch, controller, rails, over winding
30 79.6 8.1
prevention device, ground fault circuit inter-
rupter for electric shock prevention, crane colli- 40 141.6 14.4
sio n pr even tion d evice , an d en erg izing 50 221.6 22.6
warning lamp, and check the following safety 60 318.3 32.4
items.
q Observe the signals for sling work. a The allowable load is calculated as one sixth of
q Operate the hoist at a safe place. the breaking load of the rope to be used
q Be sure to check the directions of the direction (safety coefficient: 6).
indication plate (north, south, east and west)
and the operating button. Precautions for disconnecting and connecting
q Do not sling a load at an angle. Do not move hoses and tubes in air conditioner circuit
the crane while the slung load is swinging.
q Do not raise or lower a load while the crane is Disconnection
k When replacing the air conditioner unit, air
moving longitudinally or laterally.
q Do not drag a sling.
conditioner compressor, condenser or
q When lifting up a load, stop it just after it leaves
receiver drier, etc., collect the refrigerant
the ground and check safety, and then lift it up.
(air conditioner gas: R134a) from the air
q Consider the travel route in advance and lift up
conditioner circuit before disconnecting
a load to a safe height.
the air conditioner hoses.
q Place the control switch in a position where it
a Ask a qualified person for collecting, adding
will not be an obstacle to work and passage.
and filling operations of the refrigerant (air con-
q After operating the hoist, do not swing the con-
ditioner gas: R134a).
trol switch.
a Never release the refrigerant (air conditioner
q Remember the position of the main switch so
gas: R134a) to the atmosphere.
k If refrigerant gas (air conditioner gas:
that you can turn off the power immediately in
an emergency. R134a) gets in your eyes, you may lose
q Shut down the main switch when the hoist
your sight. And if it touches your skin, you
stops because of a blackout. When turning on
may suffer from frostbite. Put on protective
a switch which is turned OFF by the ground
eyeglasses, gloves and working cloth with
fault circuit interrupter for electric shock pre-
long sleeves while collecting the refrigerant
vention, check that the devices related to that
or filling the air conditioner circuit with the
switch are not in operating condition.
refrigerant.
q If you find an obstacle around the hoist, stop
the operation.
PC200, 200LC, 220, 220LC-8M0 00-200 5

q When loosening the nuts fixing air conditioner

hoses and tubes, be sure to use two wrenches;
use one wrench to fix and use the other one to
loosen the nut.
Connection
q When installing the hose for the air conditioner
circuit, take care not to allow invasion of dirt,
dusts and water into the hose.
q Check that the O-rings are fitted to the joints
when connecting the air conditioner piping.
q Once an O-ring is used, it is deformed and
deteriorated. Accordingly, do not reuse it.
q When removing the O-rings, use a soft tool so
that the piping is not damaged. For tightening torques, see “Others”, “Precau-
q Check that the O-ring is not damaged or deteri- tions for disconnection and connection of air
orated. conditioner piping”.
q Apply compressor oil for refrigerant (R134a) to
the O-ring.
a However, do not apply oil to the threaded
portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL ZXL100PG (equivalent to
SYSTEMS PAG46)
SANDEN SP-10
q When tightening nuts of the air conditioner

hoses and tubes, be sure to use two wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
a Example of fitting of O-ring
q An O-ring is fitted to every joint of the air
conditioner piping.
00-200 6 PC200, 200LC, 220, 220LC-8M0

Fire prevention q When performing grinding or welding work

Action if fire occurs on the machine, move any flammable
q Turn the starting switch to the OFF position to materials to a safe place before starting.
shutdown the engine.
q Use the handrails and steps to get off the
machine.
q Do not jump off the machine. You may fall or
suffer serious injury.
q The fume generated by a fire contains harm-
ful materials which have a bad influence on a
human body when they are sucked.
Don't breathe a fume.
q After a fire, there may be harmful compounds
left. If it touches your skin it may have a bad
influence on your body.
Be sure to wear rubber gloves when handle
the materials left after the fire.
The material of the gloves, which is recom-
mended is polychloroprene (Neoprene) or
polyvinyl chloride (in the lower temperature
environment).
When wearing cotton-work-gloves, wear rub-
ber gloves under them.
Prevent fire
q Fire caused by fuel, oil, coolant or window
washer fluid
Do not bring any flame or fire close to flamma-
ble substances such as fuel, oil, coolant or
window washer fluid.There is danger that they
may catch fire. Always observe the following. q Fire caused by accumulation or attachment
q Do not smoke or use any flame near fuel of flammable material
or other flammable substances. q Remove any dry leaves, chips, pieces of
q Shut down the engine before adding fuel. paper, coal dust, or any other flammable
q Do not leave the machine when adding materials accumulated or attached to or
fuel or oil. around the engine exhaust manifold, muf-
q Tighten all the fuel and oil caps securely. fler, or battery, or on the undercovers.
q Be careful not to spill fuel on overheated q To prevent fires from being caught,
surfaces or on parts of the electrical sys- remove any flammable materials such as
tem. dry leaves, chips, pieces of paper, coal
q After adding fuel or oil, wipe up any spilled dust, or any other flammable materials
fuel or oil. accumulated around the cooling system
q Put greasy rags and other flammable (radiator, oil cooler) or on the undercover.
materials into a safe container to maintain
safety at the workplace. q Fire coming from electric wiring
q When washing parts with oil, use a non- Short circuits in the electrical system can
flammable oil. Do not use diesel oil or gas- cause fire. Always observe the following.
oline.There is danger that they may catch q Keep all the electric wiring connections
fire. clean and securely tightened.
q Do not weld or use a cutting torch to cut q Check the wiring every day for looseness
any pipes or tubes that contain flammable or damage. Reconnect any loose connec-
liquids. tors or refasten wiring clamps. Repair or
q Determine well-ventilated areas for storing replace any damaged wiring.
oil and fuel. Keep the oil and fuel in the
specified place and do not allow unauthor-
ized persons to enter.
PC200, 200LC, 220, 220LC-8M0 00-200 7

q Fire caused by piping Dispose of waste materials

Check that all the clamps for the hoses and To prevent pollution, pay full attention to the way to
tubes, guards, and cushions are securely fixed dispose of waste materials.
in position. q Always put the oil and coolant drained from the
If they are loose, they may vibrate during oper- machine in containers. Never drain the oil and
ation and rub against other parts.There is dan- coolant directly onto the ground or dump into
ger that this may lead to damage to the hoses the sewage system, rivers, the sea, or lakes.
and cause high-pressure oil to spurt out, lead- q Observe the related laws and regulations when
ing to fire and serious personal injury or death. disposing of harmful objects such as oil, fuel,
coolant, solvent, filters, and batteries.
q Fire around the machine due to highly
heated exhaust gas
This machine is equipped with KDPF
(Komatsu Diesel Particulate Filter).
KDPF is a system for purifying soot in exhaust
gas. The exhaust gas discharged during the
purification process (regeneration) can be
higher temperature than that of existing mod-
els. Do not bring any flammable material close
to the outlet of the exhaust pipe.
q If there are thatched houses, dry leaves or
pieces of paper around the job site, set the
system to the “Regeneration Disable”
before starting operation to prevent fire
hazard of highly heated exhaust gas Some kinds of rubber and plastics may produce
caused by KDPF regeneration. poisonous gas harmful to human body when they
See the operation and maintenance man- are burned.
ual for the setting procedure. q As for rubber, plastics, or parts (hoses, cables,
and wiring harnesses, etc.) which contain
q Explosion caused by lighting equipment those materials, ask the industrial waste treat-
q When checking fuel, oil, battery electro- ment firms for their disposals in accordance
lyte, or coolant, always use lighting equip- with the local regulations.
ment with anti-explosion specifications.
q When taking the electrical power for the
lighting equipment from the machine itself,
follow the instructions in the operation and
maintenance manual.
00-200 8 PC200, 200LC, 220, 220LC-8M0

How to read the shop manual SEN06112-01
How to read the shop manual 1
q Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
q Materials and specifications are subject to change without notice.
q The shop manuals are available for “Machine part” and “Engine part”. For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual

q This shop manual describes the technical information required for the services performed in a work-
shop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword

q This section includes the index, foreword, safety and basic information.
01. Specification
q This section explains the specifications of the machine.
10. Structure, function and maintenance standard

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

q The standard values for a new machine and trouble shooting are described. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting

q This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
q This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly

q This section explains the procedures for removing, installing, disassembling, and assembling each part
or component and the special tools for the works as well as precautions for doing them safely. In addi-
tion, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for
the works are also explained.
80. Appendix
q The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings

q This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-
to-date information before you start any work.
Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition table.
PC200, 200LC, 220, 220LC-8M0 00-200 9

SEN06112-01 How to read the shop manual
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is increased by
1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol Item Remarks
k
The special safety precautions required for performing work are
Safety
described.
The special technical precautions or other precautions for preserving
a Caution
standards required when performing work are described.
The weight of part or component and the cautions required when
4
Weight selecting hoisting wire or when working posture is important are
described.
3
Tightening The tightening torques that require special attention during assembly
torque work are described.
2
The places to be coated with adhesives, etc. during assembling are
Coat
indicated.
5
The places to which oil is supplied and the quantity of the oil are indi-
Oil, coolant
cated.
6
The places from which oil is drained and quantity of the oil are indi-
Drain
cated.
Unit
q In this shop manual, the units are indicated with International System of units (SI).
q For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.
00-200 10 PC200, 200LC, 220, 220LC-8M0

Explanation of terms for maintenance standard SEN06112-01
Explanation of terms for maintenance standard 1

q The chapter of maintenance standard shows judgement criteria to determine the products to be
replaced or to be reused. The judgement criteria are described by using the following terms.
Standard dimension and tolerance q When some parts are repaired, the value of
q To be accurate, the finished dimension of a performance/function is set to the standard
part is slightly different from one to another. value.
q To specify the finished dimension of a part, a
certain dimension is set for the part and an
allowable difference from that dimension is
indicated.
q The above dimension set is called the “stan-
dard dimension” and the range of difference
from the standard dimension is called the “tol-
erance”.
q The standard dimension and tolerance are
indicated by attaching the symbols of + or -
and a number on the right side of the standard
dimension.
Example:
Standard dimension Tolerance
–0.022
120
–0.126
q The tolerance may be indicated in the text and

a table as “standard dimension (upper limit of
tolerance/lower limit of tolerance).”
Example: 120(-0.022/-0.126)
q Usually, the dimension of a hole and the
dimension of a shaft to be inserted into the
hole are indicated by the same standard
dimension and different tolerances of the hole
and shaft. The tightness of fit is decided by the
tolerance.
q Indication of dimension of rotating shaft and
Standard interference
hole and their related drawing.
q When the diameter of a hole of a part shown in
the given standard dimension and tolerance
Example:
table is smaller than that of the shaft to be
Standard Tolerance inserted, the difference between those diame-
dimension Shaft Hole ters is called the “interference”.
–0.030 +0.046 q Subtract the maximum dimension of the hole
60
–0.076 +0 from the minimum dimension of the shaft and
call it (A). Subtract the minimum dimension of
Standard clearance and standard value the hole from the maximum dimension of the
q The clearance made when new parts are shaft and call it (B). The range between (A)
assembled is called the standard clearance, and (B) is the “standard interference”.
which is indicated by the range from the mini- q After repairing or replacing some parts, mea-
mum clearance to the maximum clearance. sure the dimension of their hole and shaft and
q When some parts are repaired, the clearance check that the interference is in the standard
is generally adjusted to the standard clear- range.
ance.
q The values indicating performance and func-
tion of new products or equivalent are called
the “standard value”, which is indicated by a
range or a target value.
PC200, 200LC, 220, 220LC-8M0 00-200 11

SEN06112-01 Explanation of terms for maintenance standard
Repair limit and allowable value or allowable

dimension
q The dimensions of parts change because of
the wear or deformation while they are used.
When the dimension changes exceeding cer-
tain value, the parts can not be used any lon-
ger. This value is called “repair limit”.
q If a part is worn to the repair limit, it must be
replaced or repaired.
q The performance and function of the products
lower while they are used. When the value of
the performance and function lowers exceed-
ing a certain limit and it influences the opera-
tion etc., this value is called the allowable
value or allowable dimension.
q A product whose dimension is out of the allow-
able value, must be repaired. However, since
the allowable values are generally estimated
through various tests or experiences in most
cases, the judgement must be made in consid-
eration of the operating condition and cus-
tomer’s requirement.
Allowable clearance
q Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
“allowable clearance”.
q If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.
Allowable interference
q The allowable maximum interference between
the hole of a part and the shaft of another part
to be assembled is called the “allowable inter-
ference”.
q The allowable interference shows the repair
limit of the part of smaller tolerance.
q The parts whose interferences are out of the
allowable interference must be replaced or
repaired.
00-200 12 PC200, 200LC, 220, 220LC-8M0

Handling equipment of fuel system devices SEN06112-01
Handling equipment of fuel system devices 1

q The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump
and nozzle. If foreign material enters this sys-
tem, it may cause a failure. Use special care to
prevent entry of the foreign material when ser-
vicing the fuel system.
Use care for working environment

q Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
q Plug the pipes and the openings of the compo-
nents which are removed with the caps, tapes,
vinyl bags, etc. to prevent foreign material from
entering. Never perform repair works under the
condition that the openings are left as they are
or plugged with cloths as foreign material may
enter or environment may be polluted by the oil
leaked. Do not discard the waste oil some-
where or other. Hand it over to your customer
for disposal, or dispose it by yourself.
How to clean parts when dirt is stuck .

q If any dirt or dust sticks the parts of the fuel
system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge

q Be sure to use the Komatsu genuine fuel filter
cartridge.
q The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump
and nozzle. In order to prevent foreign material
from entering this system, the filter employs a
specially high performance of filter element. If
a filter element other than the genuine one is
used, the fuel system may have a failure.
Accordingly, never use such a filter element.
PC200, 200LC, 220, 220LC-8M0 00-200 13

SEN06112-01 Handling of intake system parts
Handling of intake system parts 1

Be careful of working environment
q Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
q Plug the pipes and the openings of the compo-
nents which are removed, with the caps, tapes,
vinyl bags, etc. to prevent foreign material from
entering. Never perform repair works under the
condition that the openings are left open or
plugged with rag since foreign material may
enter.
00-200 14 PC200, 200LC, 220, 220LC-8M0

Handling of hydraulic equipment SEN06112-01
Handling of hydraulic equipment 1

q With the increase in pressure and precision of
the hydraulic components, the most common
cause of a failure is dirt (foreign material) in the
hydraulic circuit. Therefore, the special care
must be taken when adding hydraulic oil,or
w h en d i s a s s em b l i ng o r a s s e m bl i n g t h e
hydraulic components.
Be careful of working environment

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

q When disassembly or maintenance work of Preventing intrusion of foreign materials during
the hydraulic is performed in the field, there is refilling operations.
danger of dust entering the components. It is
q Care must be taken when adding hydraulic oil
also difficult to check the performance of the
so that foreign material does not enter. Keep
components after repairs, so it is desirable to
the oil filler port and the area around it, oil sup-
use the component exchange service. The dis-
ply pump and oil container clean. If an oil
assembly and assembly of the hydraulic com-
cleaning device is used, it is possible to
ponents must be performed in the specially
remove the dirt that is collected during storage.
arranged dustproof workshop and the perfor-
It is a surer means.
mance test of the components must be per-
formed with the special testing equipment.
Replacing hydraulic oil while its temperature is

Sealing openings high
q Plug the pipes and the openings of the compo- q When the hydraulic oil is warm, it flows easily.
nents which are removed with the caps, tapes, In addition, sludge can also be drained from
vinyl bags, etc. to prevent foreign material from the circuit together with the oil. So, it is better
entering. Never leave the openings of the to change the hydraulic oil while it is warm.
pipes and hoses without being covered or When changing the hydraulic oil, the old oil
plugged with cloth as foreign material may must be drained as much as possible. (Drain
enter them or environment may be polluted by the oil not only from the hydraulic tank, but also
the oil leaked. Do not discard the waste oil from the filter housing and the drain plug hole
somewhere or other. Hand it over to your cus- in the circuit.) If the old oil is left in the system,
tomer for disposal, or dispose it by yourself. the contaminant and sludge in the oil mix with
the new oil and shorten the life of the new
hydraulic oil.
PC200, 200LC, 220, 220LC-8M0 00-200 15

SEN06112-01 Handling of hydraulic equipment
Flushing operations
q After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.
Cleaning operations
q After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil cir-
cuit. The oil cleaning equipment can remove
the ultra fine (approximately 3 Œºm) particles
that the filter built in the hydraulic equipment
can not remove. So, it is an extremely effective
device.
00-200 16 PC200, 200LC, 220, 220LC-8M0

Method of disconnecting and connectingof push-pull type SEN06112-01
Method of disconnecting and connectingof push-pull type coupler 1

k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1
Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it
mating adapter (3). (Fig. 1) in mating adapter (3) aligning them with each
a It can be pushed in by approximately other. (Fig. 4)
3.5mm. a Do not hold rubber cap part (4).
a Do not hold rubber cap portion (4). 2. After inserting the hose fitting in the adapter on
2. While pushing hose joint (2) into adapter (3), the other side perfectly, pull it back to check
push rubber cap (4) against adapter (3) until the connecting condition. (Fig.4)
“click” is heard. (Fig. 2) a When the hose fitting is pulled back, the
3. Hold hose adapter (1) or hose (5) and pull it rubber cap will move toward the hose,
out. (Fig. 3) however, it is not a problem.
a Since some hydraulic oil flows out, pre-
pare an oil container.
PC200, 200LC, 220, 220LC-8M0 00-200 17

SEN06112-01 Method of disconnecting and connectingof push-pull type
Type 2
1. While holding the fitting, push body (7) in 1. While holding the fitting, push body (7) in
straight until sliding prevention ring (6) hits straight until sliding prevention ring (6) hits
contact surface (a) at the hexagonal part on contact surface (a) at the hexagonal part on
the male side. (Fig. 6) the male side to connect it. (Fig. 9)
2. While keeping the condition of Step 1, turn
lever (8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)
00-200 18 PC200, 200LC, 220, 220LC-8M0

Method of disconnecting and connectingof push-pull type SEN06112-01
Type 3
1. While holding the fitting, push body (9) in 1. While holding the fitting, push body (9) in
straight until sliding prevention ring (8) hits straight until sliding prevention ring (8) hits
contact surface (b) at the hexagonal portion on contact surface (a) at the hexagonal portion on
the male side. (Fig. 10) the male side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface
(b) of the hexagonal portion on the male side.
(Fig. 11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig.
12)
PC200, 200LC, 220, 220LC-8M0 00-200 19

SEN06112-01 Handling of electrical equipment
Handling of electrical equipment 1

q To maintain the performance of the machine over a long period, and to prevent failures or troubles
before they occur, correct “operation”, “maintenance and inspection” “troubleshooting”, and “repairs”
must be performed. This section deals particularly with correct repair procedures for mechatronics com-
ponents and is aimed at improving the quality of repairs. For this purpose, it describes the working pro-
cedures in “Handling of electrical equipment”.
Precautions for handling electric equipment

Handling wiring harnesses and connectors
q Wiring harnesses consist of wires connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wires.
q Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely Defective crimping or soldering of connectors
careful when handling the wiring harnesses. q The pins of the male and female connectors
are attached to wires by crimping or soldering.
If excessive force is applied to the wire, the
joining area may become loose, which may
result in a defective connection or breakage.
Main failures occurring in wiring harness

Defective contact of connectors (defective con-
tact between male and female connectors)
q Problems with defective contact are likely to
occur because the male connector is not prop- Disconnections in wiring
erly inserted into the female connector,or q If the wiring harness is pulled to disconnect the
b ecau se one or bot h of conn ecto rs a re connector, or the components are lifted with a
deformed or the position is not correctly crane while the wiring harness is still con-
aligned, or because there is corrosion or oxi- nected, or a heavy object hits the wiring har-
dization of the contact surfaces. The corroded ness, the crimping of the connector may
or oxidized contact surfaces may become separate, or the soldering may be damaged, or
shiny again (and contact may become normal) the wiring harness may be broken.
by connecting and disconnecting the connec-
tors approximately ten times.
00-200 20 PC200, 200LC, 220, 220LC-8M0

Handling of electrical equipment SEN06112-01
Oil, mud or dirt stuck to connector

q If any oil or grease is stuck to the connector
and an oil film is formed on the mating surface
of the male and female pins, the oil prevents
electricity from passing through, resulting in
defective contact. If any oil or grease, mud or
dirt is stuck to the connector, wipe it off with a
dry cloth or blow it with compressed air and
spray it with electrical contact restorer.
a When wiping the joint portion of the con-
nector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed
air, it causes the contacts to become dirt-
ier. So, remove the oil and water from the
High-pressure water entering connector
compressed air completely before clean-
q The connector is designed to make it difficult ing the connector with the compressed air.
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to spray water over
the connector.
The connector is designed to prevent water
from entering, but once water does enter, it is
difficult to drain it. If water should get into the
connector, the pins will be short-circuited by
the water. So if any water gets in, immediately
dry the connector or take other appropriate
action before passing electricity through it.
Removing, installing, and drying connectors

and wiring harnesses
Disconnecting connectors
1. Hold the connectors when disconnecting.
q Disconnect connectors by holding the
connector bodies. For the connectors held
by a screw, loosen the screw fully, then
hold the male and female connectors with
each hand respectively and pull them
apart horizontally. For the connectors with
lock stopper, press down the stopper with
your thumb and pull the connectors apart.
Entry of water, mud or dirt when disconnecting a Never pull the connector with one
a connector hand.
q If any water, mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is discon-
nected. Before disconnecting the connector,
wipe off any stuck water or dirt by using a
piece of dry cloth or blow it with compressed
air.
PC200, 200LC, 220, 220LC-8M0 00-200 21

a If the machine is left disassembled for

a long time, it is particularly easy for
improper contact to occur, so always
cover the connector.
2. When removing from clips

q Both of the connector and clip have stop-
pers, which are engaged with each other
when the connector is connected.
Connecting connectors
1. Check the connector visually.
q Check that there is no oil, dirt or water
stick to the connector pins (joint portion).
q Check that the connector pins are free
from deformation, defective contact, corro-
sion, or damage.
q Check that external surfaces of the con-
nectors are free from damage or break-
age.
a If any oil, water or dirt is stuck to the con-
nector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
connector and the inside of the wiring har-
ness with a dryer. But be careful not to
q When removing a connector from a clip,
make it too hot as it causes short circuit.
pull the connector in a parallel direction to
a If there is any damage or breakage,
the clip for removing stoppers.
replace the connector.
a If the connector is pried up and down
2. Fix the connector securely.
or to the right and left, the housing
q Align the connectors correctly, and fit them
may break.
securely. For the connectors with the lock
stopper, push in the connectors until
“click” is heard.
3. Action to take after removing connectors

q After removing the connector, cover it with
the vinyl bag to prevent entry of dust,
3. Correct the protrusion of the boot and mis-
dirt,oil or water in the contact portion.
alignment of the wiring harness
00-200 22 PC200, 200LC, 220, 220LC-8M0

q For connectors fitted with the boot, correct Connection

any extrusion of the boot. In addition, if the 1. Push in female connector (2) horizontally until
wiring harness or the clamp is out of the the lock clicks. (Arrow: x)
position, put it in its original position. 2. Since locks (a) and (b) may not be set com-
a If the connector cannot be corrected pletely, push in female connector (2) with curv-
easily, remove the clamp and adjust ing movement until the locks are set normally.
the position. (Arrow: x, y, and z)
a Lock (a) in the figure is pulled down (not
set completely), and lock (b) is set com-
pletely.
q If the connector clamp is removed, be

sure to return it to its original position. And
check that it is securely installed.
Drying wiring harness
q If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing by
using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness.
If water gets directly on the connector, do as
follows.
1. Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in
the air may cause defective contact of the
conditioner, remove oil and water in the air
Deutsch connector (DT8-pin, DT12-pin) before starting air blow.
Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).
PC200, 200LC, 220, 220LC-8M0 00-200 23

2. Dry the inside of the connector with a dryer. Handling of connectors used on engine
If water gets inside the connector, use a dryer Slide, lock type (Type 1) (FRAMATOME-3,
to dry the connector. FRAMATOME-2)
a Hot air from the dryer can be used, but
Disconnection
regulate the time to use hot air in order to
1. Slide lock (L1) to the right.
prevent the connector or related parts
2. While pressing lock (L2), pull out connector (1)
from becoming too hot, as it causes defor-
toward you.
mation or damage to the connector.
a In the case that even if lock (L2) is
pressed, connector (1) cannot be pulled
out toward you unless part A floats, float
part A with a small flat-head screwdriver
while pressing lock (L2), and then pull out
connector (1) toward you.
3. Perform a continuity test on the connector.After

drying, leave the wiring harness disconnected
and perform a continuity test to check for any
short circuits between pins caused by water.
a After the connector is completely dried,
blow the contact restorer and reassemble
Connection
them.
1. Insert the connector securely until a click is
heard.
Slide, lock type (Type 2) (FRAMATOME-24)

Disconnection
1. Slide down lock (red) (L1).
00-200 24 PC200, 200LC, 220, 220LC-8M0

2. While pressing lock (L2), pull out connector Connection

(1). 1. Insert the connector securely until a click is
heard.
Push lock type (1) (BOSCH-3)

Disconnection
1. While pressing lock (C), pull out connector (3)
in the direction of the arrow.
q 114 series
a Lock (L2) is located in the back of connec-

tor (1).
q 107 series
Connection
heard.
Pull lock type (PACKARD-2)

Disconnection
1. Disconnect the connector (2) by pulling lock a If the lock is located on the underside, use
(B) (on the wiring harness side) of connector flat-head screwdriver [1] since you cannot
(2) outward. insert your fingers.
While pushing up lock (C) of the connector
with flat-head screwdriver [1], pull out con-
nector (3) in the direction of the arrow.
PC200, 200LC, 220, 220LC-8M0 00-200 25

Connection Example) Injection pressure control valve of

1. Insert the connector securely until a click is supply pump: PCV (SUMITOMO-2)
heard.
Push lock type (2) (SUMITOMO-4)

Disconnection
1. While pressing lock (C), pull out connector (4)
Connection
heard.
Example) Speed sensor of supply pump: G

(SUMITOMO-3)
a Pull the connector straight up.
Push lock type (3) (AMP-3)

Disconnection
1. While pressing lock (E), pull out connector (5)
Example) Fuel pressure sensor in common
rail: PFUEL etc (AMP-3)
Connection
heard.
00-200 26 PC200, 200LC, 220, 220LC-8M0

Turn-housing type (Round green connector) Handling controller

(CANNON-4) q The electronic circuits for control including the
Disconnection microcomputers are assembled in the control-
1. Turn housing (H1) in the direction of the arrow. ler. These electronic circuits in the controller
a Unlock the connector by turning housing must be handled with care as they control the
(H1). When the lock is release the housing machine.
is felt tight to turn. q Do not place objects on top of the controller.
2. Pull out housing (H1) in the direction of the
arrow.
a Housing (H1) is left on the wiring harness
side.
q Cover the control connectors with tape or a

vinyl bag. Never touch the connector contacts.
q During rainy weather, do not leave the control-
ler in a place where it is exposed to rain.
q Do not place the controller on oil, water, or soil,
Connection or in a place that can be heated to a high tem-
1. Insert the connector to the end while aligning perature even for a short period of time.
its grove to the other. (Place it on a suitable dry stand.)
2. Turn housing (H1) in the direction of the arrow
until it “clicks”.
q Precautions when performing arc welding

When performing arc welding on the machine
body, disconnect all the wiring harness con-
nectors connected to the controller. Put the arc
welding ground to the place close to the weld-
ing point.
PC200, 200LC, 220, 220LC-8M0 00-200 27

Precautions for troubleshooting electrical cir-

cuits
q Be sure to turn the starting switch to the “OFF”
position before disconnecting or connecting
the connectors.
q Before performing troubleshooting, check all
the related connectors for loose connection.
a Check the related connectors for their per-
formance by disconnecting and connect-
ing them several times.
q Be sure to connect all the disconnected con-
nectors before proceeding to the next step.
a If the starting switch is turned to the “ON”
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
q When performing the troubleshooting for the
c i r c u i t ( m e a s u r e m e n t o f v o l ta g e , r e s i s -
tance,continuity, current, etc.), shake the
related wiring harnesses and connectors sev-
eral times and check that the multimeter read-
ing does not change.
a If there is any value change on the multim-
eter, there may be a defective contact in
the circuit.
00-200 28 PC200, 200LC, 220, 220LC-8M0

How to read electric wire code SEN06112-01
How to read electric wire code 1

q In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by sym-
bols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not indi-
cated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.
Type, symbol, and material

q AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular com-
pressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the
coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Tempera-
Sym-
Type Conductor Material ture range Example of use
bol
(°C) in use
Low-voltage
For large current wiring
wire for AV
(nominal No. 5 and above)
automobile
Thin-cover
low-voltage
General wiring
wire for AVS
(nominal No. 3 and lower)
automobile Annealed Soft polyvinyl chloride –30 to +60
(Type 1) copper
Thin-cover for elec-
low-voltage tric appli- For mid- to small-size
wire for CAVS ance excavators
automobile (nominal No. 1.25 and lower)
Type 2
Heat-resis-
(Safety factor:
tant low-volt- Heat-resistant crosslinked
AEX –50 to +110 Wiring at high-temperature
age wire for polyethylene
place
automobile
PC200, 200LC, 220, 220LC-8M0 00-200 29

SEN06112-01 How to read electric wire code
Dimension
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5

Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor Cross-
sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
Coating D
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –

AV Standard – – – – – – – 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor Cross-
sectional area 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
Coating D
AVS Standard – – – – – – – – –
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
7/round 11/round 16/round
strands/Diam- – – –
compression compression compression
eter of strand
Conductor Cross-
sectional area – 0.56 – 0.88 – 1.29
(mm2)
d (approx.) – 0.9 – 1.1 – 1.4
Coating D
CAVS Standard – 1.6 – 1.8 – 2.1
a “f” of nominal No. denotes flexible”.
00-200 30 PC200, 200LC, 220, 220LC-8M0

How to read electric wire code SEN06112-01
Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
a Remarks: In a color code consisting of two colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is “Green” and marking is “White”.
Types of circuits and color codes
Type of wire AVS, AV, CAVS AEX

Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Appendix Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
PC200, 200LC, 220, 220LC-8M0 00-200 31

SEN06112-01 Precautions when performing operation
Precautions when performing operation 1

q When performing “removal or installation” and “disassembly or assembly” of the components, observe
the following general cautions.
Precautions for removal work

q If the coolant contains antifreeze, dispose of it correctly as chemicals. Do not drain the coolant to the
sewage rashly.
q After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
q When draining oil, prepare a container with sufficient capacity.
q Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Attach the tags to wires and hoses to show their installing positions to prevent any mistake when install-
ing.
q Check the number and thickness of the shims, and keep them in a safe place.
q When hoisting the components, prepare the slings with sufficient strength.
q When using forcing screws to remove any component, tighten the forcing screws uniformly and alter-
nately.
q Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
a Precautions when handling piping during disassembly
Use the plugs indicated below for the pipes disconnected at the disassembly.
Face seal type hoses and tubes

Nominal No. Plug (nut end) Sleeve nut (elbow end)
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
Split flange type hoses and tubes

Nominal No. Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
00-200 32 PC200, 200LC, 220, 220LC-8M0

Precautions when performing operation SEN06112-01
If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal No. Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
Precautions for installation work

q Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
q Install the hoses without twist and interference, and securely fasten the clamps located in-between if
they are.
q Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When applying adhesive, clean and degrease the part, and apply two to three drops of adhesive to the
threaded portion.
q When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure
that the surface is free from dirt or damage.
q Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
q Coat the rotating parts and sliding parts with engine oil.
q Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
q After installing the snap ring, check that the snap ring is settled in the ring groove completely.
q When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then
connect them securely.
q Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of
the eyes and the hook.
q When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening
on one side.
a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such
as the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air
bleeding of the hydraulic circuit according to the following procedure.
1. Start and run the engine at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately
100 mm before the stroke end four to five times.
PC200, 200LC, 220, 220LC-8M0 00-200 33

SEN06112-01 Precautions when performing operation
3. Operate the hydraulic cylinder three to four times to the end of its stroke.
a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.
Precautions at the time of completing work

Refilling of coolant, oil and grease
q When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the
coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the pip-
ing, and add the coolant to the specified level again.
q When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu
recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to
the specified level again.
q If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after
rebuilding the parts, by referring to “Testing and adjusting”.
q Supply the specified amount of grease to the work equipment parts.
Check of installed condition of cylinder heads and manifolds

q Check the cylinder head and intake and exhaust manifold mountings for looseness.
q If any bolt is loose, retighten it.
a For the tightening torques, see the “Disassembly and assembly”.
Check of engine piping for damage and looseness

Check the piping for damage, the mounting bolts and nuts for looseness, and the
Intake and exhaust
joints for air suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the part.
Cooling system joints for water leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the part.
Fuel system joints for fuel leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check of KDPF or muffler and exhaust pipe for damage and looseness
q Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If
any part is damaged, replace it.
q Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting
parts for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function

q Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.If any
unusual noise is heard, repair KDPF or muffler, referring to “Troubleshooting” and “Disassembly and
assembly”.
00-200 34 PC200, 200LC, 220, 220LC-8M0

Practical use of KOMTRAX SEN06112-01
Practical use of KOMTRAX 1

KOMTRAX system transmits various machine information by use of the radio communication and
KOMTRAX operator can refer this information in the office and provide various services to the customers.
When KOMTRAX is installed on the machine, the machine information can be checked through the
KOMTRAX system and the testing and troubleshooting can be performed efficiently.
(KOMTRAX may not be installed on the machine in some countries or areas.)
Merit of using KOMTRAX

q The working place of the machine can be checked in the map on PC.
q Operation information such as service meter reading, operating hours, fuel consumption, occurred cau-
tion and failure code can be checked.
q The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic
oil filter, hydraulic oil and engine oil can be checked.
q The information of machine working condition (idling time, traveling time, digging time, relieving time,
etc.) can be checked and the machine operating condition can be presumed with these information.
q Various reports such as “Fuel saving operation support”, “Summary of operation”, etc. can be generated
and utilized as an advice tool for the user and operator.
How to use KOMTRAX practically

With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc.
through KOMTRAX.
2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed
failure code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority fail-
ure code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed fail-
ure code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits
for the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the
replacement work to the customer.
3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading.
How to operate KOMTRAX

For the operating method of each screen of KOMTRAX, see “KOMTRAX basic operation manual”.
PC200, 200LC, 220, 220LC-8M0 00-200 35

SEN06112-01 Standard tightening torque table
Standard tightening torque table 1

Table of tightening torque for bolts and nuts
Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.
1. The following table applies to the bolts in Fig. A.
Thread
Width across flats Tightening torque
diameter
(mm) (mm) (Nm) (kgm)
6 10 (10) 11.8 to 14.7 1.2 to 1.5
8 13 (12) 27 to 34 2.8 to 3.5
10 17 (14) 59 to 74 6.0 to 7.5
12 19 (17) 98 to 123 10.0 to 12.5
14 22 157 to 196 16 to 20
16 24 245 to 309 25 to 31.5
18 27 343 to 427 35 to 43.5
20 30 490 to 608 50 to 62
22 32 662 to 829 67.5 to 84.5
24 36 824 to 1,030 84 to 105
27 41 1,180 to 1,470 120 to 150
30 46 1,520 to 1,910 155 to 195
33 50 1,960 to 2,450 200 to 250
36 55 2,450 to 3,040 250 to 310
39 60 2,890 to 3,630 295 to 370
a Values with ( ) in the “Width across flats” column are for (*) marked bolt (flange bolt) shown in Fig.
A.
2. The following table applies to the bolts in Fig. B.
Thread
Width across flats Tightening torque
diameter
6 10 5.9 to 9.8 0.6 to 1.0
8 12 13.7 to 23.5 1.4 to 2.4
10 14 34.3 to 46.1 3.5 to 4.7
12 17 74.5 to 90.2 7.6 to 9.2
Fig. A Fig. B
a Values with parentheses are applied to the width across flats of (*) marked bolts (flanged bolts)
00-200 36 PC200, 200LC, 220, 220LC-8M0

Standard tightening torque table SEN06112-01
Table of tightening torque for split flanged bolts

a Unless otherwise specified, tighten the split flange bolt to the torque shown in the table below.
Thread diameter Width across flats Tightening torque

10 14 59 to 74 6.0 to 7.5
12 17 98 to 123 10.0 to 12.5
16 22 235 to 285 23.5 to 29.5
Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.
Thread diameter Width across flats Tightening torque (Nm {kgm})

Nominal No.
(mm) mm Range Target
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
– 18 59 to 98 {6.0 to10.0} 78 {8.0}
03,04 20 Varies depending 84 to 132 {8.5 to13.5} 103 {10.5}
on type of connec-
05,06 24 tor. 128 to 186 {13.0 to19.0} 157 {16.0}
10,12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.
Nominal Thread diameter Width across flats Tightening torque (Nm {kgm})
No. (mm) mm Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.81 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 { 9.5 to 12.5} 107.8 {11.0}
33 33 – 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 – 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 – 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
PC200, 200LC, 220, 220LC-8M0 00-200 37

SEN06112-01 Standard tightening torque table
Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a The table is applied to the threads coated with engine oil (wet threads)
Tightening torque (Nm {kgm}) Taper seal Face seal

Width
Nominal Nominal No. –
across Thread root
No. of Thread size threads per
flats Range Target diameter
hose (mm) inch, type of
(mm) (reference)
thread
34 to 54 { 3.5 to 5.5} 44 { 4.5} – 9/16-18UN 14.3
02 19
34 to 63 { 3.5 to 6.5} 44 { 4.5} 14 – –
22 54 to 93 { 5.5 to 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 to 98 { 6.0 to 10.0} 78 { 8.0} 18 – –
04 27 84 to 132 { 8.5 to 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 – –
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 – –
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 – –
Table of tightening torque for face seal joints

a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).
Outer Width Tightening torque (Nm {kgm}) Face seal

diameter across Nominal No. – Thread root
of pipe flats Range Target threads per inch, diameter
(mm) (mm) type of thread (Reference)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 {27} 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16-16UN 20.6
15 {16} 30 {32} 60 to 68 {6.1 to 6.8} 64 {6.5} 1-14UN 25.4
22 {20} 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
00-200 38 PC200, 200LC, 220, 220LC-8M0

Standard tightening torque table SEN06112-01
Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114
series engines to the torques shown in the following table.
Thread diameter Tightening torque

(mm) (Nm) (kgm)
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
Tightening torque table for I-joints on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric I-joints used on the 102, 107 and 114 series engines to
the torque shown in the following table.
Thread size Tightening torque

(mm) (Nm) (kgm)
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
Tightening torque table for tapered screws on 102,107 and 114 series engines
a Unless otherwise specified, tighten the tapered inch thread screws used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Material In cast iron or steel In aluminum

Tightening torque Tightening torque
Thread diameter (inch)
(Nm) (kgm) (Nm) (kgm)
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
PC200, 200LC, 220, 220LC-8M0 00-200 39

SEN06112-01 List of abbreviation
List of abbreviation 1
q This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, com-
ponents, and functions whose meaning is not immediately clear. The spelling is given in full with an out-
line of the meaning.
q Abbreviations that are used in general society may not be included.
q Special abbreviations which appear infrequently are noted in the text(marked wit a).
q This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text
of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the shop manual

Purpose of use (major
Abbrevia-
Full Spelling applicable machine (*), Explanation
tion
or equipment/device)
Function with which when the tires skid (wheels
Anti-skid Brake Travel and brake (HD, stop rotating), the brakes are released, and when
ABS
System HM) the wheels start to rotate, the brakes are applied
again.
Automatic Idling
AISS Engine Automatic setting function of idling speed
Setting System
Function that a lever can perform the steering
Advanced
operations, shifting gear speed operation and
AJSS Joystick Steering Steering (WA)
changing direction operation instead of a steering
System
wheel.
Automatic
Function that the retarder works automatically with
Retarder Travel and brake (HD,
ARAC a certain braking force when the accelerator pedal
Accelerator HM)
is released while the machine travels downhill.
Control
Function that the retarder works automatically with
Automatic a certain braking force so that the machine travels
Travel and brake (HD,
ARSC Retarder Speed with the speed not exceeding the speed set by the
HM)
Control operator when the accelerator pedal is released
while the machine travels downhill.
Function with which, when the rear wheels spin on
Automatic Spin Travel and brake (HD, soft ground surfaces, this function automatically
ASR
Regulator HM) uses the optimum braking force to drive both
wheels.
A device that can be fixed onto a machine in order
ATT Attachment Work equipment
to enable it to do different jobs.
Valve that bypasses part of the brake cooling oil to
Brake cooling oil
BCV Brake (HD) reduce the load on the hydraulic pump when the
control valve
retarder is not being used.
Controller Area Communication and One of communication standards that is used in
CAN
Network electronic control the network on the machine
Crankcase Regulator valve that is installed to the KCCV
CDR Depression Engine ventilator It is not used independently and
Regulator described CDR valve.
Closed-center System that can simultaneously actuate multiple
CLSS Load Sensing Oil pressure actuators regardless of the load (provides better
System combined operation comparing to OLSS).
Function to maintain optimum fuel injection
Common Rail amount and fuel injection timing by using engine
CRI Engine
Injection controller to perform electronic control of supply
pump, common rail, and injector.
00-200 40 PC200, 200LC, 220, 220LC-8M0

List of abbreviation SEN06112-01

Abbrevia-
tion
Electronic control device that uses the signals
Electronic Control Electronic control from the sensors on the machine to indicate the
ECM
Module system optimum actuation to the actuators . (Same as
ECU)
Proportional electromagnetic valve that gradually
Electronic Control Transmission (D, HD,
ECMV increases oil pressure to engage clutch and
Modulation Valve WA, etc.)
reduces transmission shock.
Electronically
System that ensures smooth high-speed travel by
Controlled
ECSS Travel (WA) using hydraulic spring effect of accumulator to
Suspension
absorb vibration of machine during travel
System
Electronic control device that uses the signals
Electronic Control Electronic control from the sensors on the machine to indicate the
ECU
Unit system optimum actuation to the actuators. (Same as
ECM)
Function to recirculate part of exhaust gas to
Exhaust Gas combustion chamber in order to reduce
EGR Engine
Recirculation combustion temperature and to control emission
of NOx.
Equipment System that allows data (filter, oil replacement
Management interval, malfunctions on machine, failure code,
EMMS Machine monitor
Monitoring and failure history) from each sensor on the
System machine to be checked on monitor.
Electromagnetic
Electromagnetic proportional control Mechanism
EPC Proportional Oil pressure
that actuator works in proportion to current
Control
Falling Object Structure that protects operator's head from falling
FOPS Protective Cab and canopy objects. (Structure to protect operator)
Structure Performance standardized in ISO 3449
Forward-Neutral-
F-N-R Operation Forward - NEUTRAL - REVERSE
Reverse
Communication Global Positioning System Satellite positioning
Global Positioning
GPS (KOMTRAX system that is used to determine the current
System
§KOMTRAX Plus) location on the earth
Steering function that uses a combination of
Hydrostatic hydraulic motor and bevel shaft to control
HSS Steering (D)
Steering System difference in travel speed of right and left tracks to
turn machine without using steering clutch.
Hydraulic transmission system that uses a
Hydro Static
HST Transmission (D, WA) combination of hydraulic pump and hydraulic
Transmission
motor to shift gear steplessly without using gears.
Valve that adjusts fuel intake amount at inlet port
Inlet Metering
IMA Engine of pump in order to control fuel discharge amount
Actuator
of supply pump. Same meaning as IMV
Valve adjusting fuel intake amount at inlet port of
Inlet Metering
IMV Engine pump in order to control fuel discharge amount of
Valve
supply pump. Described IMV (IMA)
Komatsu Closed This mechanism separates oil in blowby gas and
KCCV Crankcase Engine returns it to the intake side to afterburn it there. It
Ventilation primarily consists of filters.
PC200, 200LC, 220, 220LC-8M0 00-200 41


Abbrevia-
tion
Komatsu
This filter is used to capture soot in exhaust gas.
KCSF Catalyzed Soot Engine
It is built in to KDPF.
Filter
Komatsu Diesel The catalyst used for purifying exhaust gas.
KDOC Engine
Oxidation Catalyst It is built in to KDPF.
This component with built-in KDOC (catalyst) and
Komatsu Diesel KCSF purifies exhaust gas. Part building in (soot-
KDPF Engine
Particulate Filter capturing filter)
It is installed in place of the currently used muffler.
Function that recovers the drive force of the
wheels by braking automatically with the optimum
Komatsu Traction Travel and brake (HM
KTCS force and at the same time activates the inter-axle
Control System system)
differential lock when the wheels idle while the
machine travels on the soft ground road.
Liquid Display Image display equipment such as
Liquid Crystal
LCD Machine monitor the monitor which assembles in the liquid crystal
Display
element.
Light Emitting Diode Semi-conductor element that
Light Emitting
LED Electronic parts emits light when the voltage is applied in the
Diode
normal direction.
Local Interconnect Communication and One of communication standards that is used in
LIN
Network electronic control the network on the machine
Function that detects differential pressure of pump
LS Load Sensing Oil pressure
and controls discharge amount according to load.
Low Voltage
Communication and One of communication standards that is used in
LVDS Differential
electronic control the network on the machine
Signaling
It means the intake air flow of the engine. It is not
used independently but used together with the
MAF Mass Air Flow Engine
sensor. The mass air flow sensor may be called
MAF sensor.
Multimedia Service that allows transmission and reception of
MMS Messaging Communication short messages consisting of characters or voice
Service or images between cell phones.
Device actuated to open electric or hydraulic
NC Normally Closed Electric and hydraulic
circuits that are normally closed if not actuated.
Device actuated to close electric or hydraulic
NO Normally Open Electric and hydraulic
circuits that are normally open if not actuated.
Open-center Load Hydraulic system that can operate multiple
OLSS Oil pressure
Sensing System actuators at the same time, regardless of the load.
Pressure
PC Oil pressure A function used to correct oil pressure.
Compensation
System in which a controller instantly analyses
Palm command data from each lever, pedal, and dial, and
PCCS Steering (D)
control system performs optimum electronic control of the engine
and transmission.
Valve installed at inlet port of pump to adjust fuel
Pre-stroke Control
PCV Engine intake amount in order to control fuel discharge
Valve
amount of supply pump.
Proportional Proportional pressure control Mechanism that
PPC Oil pressure
Pressure Control actuator works in proportion to hydraulic pressure
00-200 42 PC200, 200LC, 220, 220LC-8M0

List of abbreviation SEN06112-01

Abbrevia-
tion
Piston Pump and Oil pressure
PPM Piston pump and motor.
Motor (D, PC, etc.)
PTO Power Take Off Power transmission Power take-off mechanism
Power Tilt and Function that performs hydraulic control of the tilt
PTP Work equipment (D)
power Pitch dozer and pitch of the bulldozer blade.
Structure that protects operator fastening seat belt
Roll-Over from being crushed when machine tips over
ROPS Protective Cab and canopy (Structure to protect operator when machine tips
Structure over)
Performance standardized in ISO 3471
Abbreviation for “International system of units”
International unit
SI Unit Unit system that is employed worldwide, and “one
system
unit against one factor”
Actuator that moves a part with a movable iron
SOL Solenoid Electric core in the coil (solenoid), which is moved by
energizing the coil.
TWV Two Way Valve Hydraulic and electric Solenoid valve that switches the direction of flow.
*1: Code for applicable machine family

D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out

A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
PC200, 200LC, 220, 220LC-8M0 00-200 43

Abbreviation Actual word spelled out

OPT
Option (if equipped)
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
00-200 44 PC200, 200LC, 220, 220LC-8M0

Conversion table SEN06112-01
Conversion table 1
Method of using the conversion table
q The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches

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

1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to
the left) to get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm =
21.65 in.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
PC200, 200LC, 220, 220LC-8M0 00-200 45

SEN06112-01 Conversion table
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
l to U.S. Gallons
1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
00-200 46 PC200, 200LC, 220, 220LC-8M0

l to U.K. Gallons
1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
PC200, 200LC, 220, 220LC-8M0 00-200 47

SEN06112-01 Conversion table
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
00-200 48 PC200, 200LC, 220, 220LC-8M0

Temperature
Conversion of Fahrenheit to Celsius
q A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
q When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahr-
enheit temperatures and read the corresponding Celsius temperature in the column at the left.
q When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Cel-
sius values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
PC200, 200LC, 220, 220LC-8M0 00-200 49

SEN06112-01

© 2018 KOMATSU
All Rights Reserved
00-200 50
SEN06114-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
01 Specification 1
100 Specification and technical data
Specification dimension drawings ................................................................................................................... 2
Working range diagram................................................................................................................................... 3
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 8
Table of fuel, coolant and lubricants.............................................................................................................. 12
PC200, 200LC, 220, 220LC-8M0 01-100 1

SEN06114-00 Specification dimension drawings
Specification dimension drawings 1
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0

Check item Unit PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
A Overall length mm 9,425 9,425 9,885 9,885
B Overall height mm 3,040 3,040 3,185 3,185
C Overall width mm 2,800 3,080 2,980 3,280
D Shoe width mm 600 700 600 700
E Cab height mm 3,040 3,040 3,055 3,055
F Tail swing radius mm 2,750 2,750 2,940 2,940
G Overall track length mm 4,070 4,450 4,260 4,640
Length of track on
H mm 3,275 3,655 3,460 3,845
ground
Min. ground length mm 440 440 440 440
01-100 2 PC200, 200LC, 220, 220LC-8M0

Working range diagram SEN06114-00
Working range diagram 1

Check item Unit PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
A Max. digging reach mm 9,875 9,875 10,180 10,180
B Max. digging depth mm 6,620 6,620 6,920 6,920
C Max. digging height mm 10,000 10,000 10,000 10,000
Max. vertical wall dig-
D mm 5,980 5,980 6,010 6,010
ging depth
E Max. dumping height mm 7,110 7,110 7,035 7,035
F Min. dumping height mm 2,645 2,645 2,530 2,530
Max. digging reach at
G mm 9,700 9,700 10,020 10,020
ground level
PC200, 200LC, 220, 220LC-8M0 01-100 3

SEN06114-00 Specifications
Specifications 1
PC200-8M0, PC200LC-8M0
Machine model PC200-8M0 PC200LC-8M0
Serial number 400001 and up
3
Bucket capacity m 0.8 0.8
Operating weight kg 19,900 21,100
Max. digging depth mm 6,620 6,620
Working range
Max. vertical wall digging depth mm 5,980 5,980

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

Max. digging force (when power max. 138.3 {14,100} 138.3 {14,100}
kN {kg}
function is turned on) (149.1 {15,200}) (149.1 {15,200})
Swing speed min-1 {rpm} 12.4 {12.4} 12.4 {12.4}
Swing operation max. slope angle degree 25 25
Travel speed km/h Lo: 3.0 Mi: 4.1 Hi: 5.5 Lo: 3.0 Mi: 4.1 Hi: 5.5
Gradability degree 35 35
2
Ground pressure (Standard shoe) kPa {kg/cm } 46.1 {0.47} 37.3{0.38}
Overall length mm 9,425 9,425
Overall width mm 2,800 3,080
Overall crawler width mm 2,800 3,080
Overall height (During transportation) (*) mm 3,040 3,040
Machine overall height (*) mm 3,040 3,040
Ground clearance of upper structure
mm 1,085 1,085
bottom
Dimensions
Min. ground clearance mm 440 440

Tail swing radius mm 2,750 2,750
Work equipment min. swing radius mm 3,040 3,040
Top height at min. swing radius of
mm 8,005 8,005
work equipment
Length of track on ground mm 3,275 3,655
Track gauge mm 2,200 2,380
Cab height mm 2,390 2,390
Width of standard shoe mm 600 700
*: Grouser height (26 mm) included.
01-100 4 PC200, 200LC, 220, 220LC-8M0

Specifications SEN06114-00

Model SAA6D107E-1
4-cycle, water-cooled in-line, direct injection with
Type
turbocharger and air-cooled aftercooler
Number of cylinders – bore x stroke mm 6 – 107 x 124
Piston displacement l {cc} 6.69 {6,690}
Rated hosepower
• SAE J1995 [gross] 110 {147} / 2000 {2000}
kW {HP}/
• ISO 14396 110 {147} / 2000 {2000}
Performance
min-1 {rpm}
Engine
• ISO 9249/SAE J1349 [net] 103 {138} / 2000 {2000}

Nm {kgm} /
Max. torque 602 {61.4} / 1,500 {1,500}
min-1 {rpm}
Max. speed with no load min-1 {rpm} 2,060 {2,060}
-1
Min. speed with no load min {rpm} 1,050 {1,050}
Min. fuel consumption ratio g/kWh{g/HPh} 215 {155}
Starting motor 24 V, 4.5 kW
Alternator 24 V, 35 A
Battery 12 V, 110 Ah x 2
Radiator type CF90-4
Carrier roller 2 on one side
Undercarriage
Track roller 7 on one side 9 on one side
Assembly-type triple grosser Assembly-type triple grosser

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

Control Hydraulic
pump
Discharge l/min Piston: 219.5 x 2

Set pressure MPa {kg/cm2} Piston: 37.2 {380}
Type and number 6-spool type: 1
valve
Operating method Hydraulic
HMV120, piston type: 2

Travel motor
Hydraulic
(with brake valve and parking brake)

motor
Hydraulic system
KMF125ABE-6, piston type: 1

Swing motor KMF125AB-6, piston type: 1 (*3)
(with safety valve and parking brake)
Boom (*1) Arm (*1) (*2) Bucket
Hydraulic cylinder
Double-acting Double-acting Double-acting

Type
piston piston piston
Cylinder inner diameter mm 120 135 115
Piston rod diameter mm 85 95 80
Stroke mm 1,334.5 1,490 1,120
Max. distance between pins mm 3,204.5 3,565 2,800
Min. distance between pins mm 1,870 2,075 1,680
Hydraulic tank Box-shaped sealed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler CF91-1 (Air-cooling type)
*1: Cushion is provided on the head side
*2: Cushion is provided on the bottom side
*3: Asian specification
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of
an independent engine. While, net denotes the value measured of an engine under the condition essentially the
same as that when it is installed on machine.
PC200, 200LC, 220, 220LC-8M0 01-100 5

SEN06114-00 Specifications
PC220-8M0, PC220LC-8M0
3
Bucket capacity m 1.0 1.0
Operating weight kg 23,200 24,600
Max. digging depth mm 6,920 6,920
Working range
Max. vertical wall digging depth mm 6,010 6,010

Max. digging radius mm 10,180 10,180
Max. reach at ground level mm 10,020 10,020
Max. digging height mm 10,000 10,000
Performance
Max. dumping height mm 7,035 7,035

Max. digging force (when power max. 158.9 {16,200} 158.9 {16,200}
kN {kg}
function is turned on) (171.6 {17,500}) (171.6 {17,500})
Swing speed min-1 {rpm} 11.7 {11.7} 11.7 {11.7}
Swing operation max. slope angle degree 25 25
Travel speed km/h Lo: 3.1 Mi: 4.2 Hi: 5.5 Lo: 3.1 Mi: 4.2 Hi: 5.5
Gradability degree 35 35
2
Ground pressure (Standard shoe) kPa {kg/cm } 51 {0.52} 42.2 {0.43}
Overall length mm 9,885 9,885
Overall width mm 2,980 3,280
Overall crawler width mm 2,980 3,280
Overall height (During transportation) (*) mm 3,185 3,185
Machine overall height (*) mm 3,055 3,055
Ground clearance of upper structure
mm 1,100 1,100
bottom
Dimensions
Min. ground clearance mm 440 440

Tail swing radius mm 2,940 2,940
Work equipment min. swing radius mm 3,450 3,450
Top height at min. swing radius of
mm 8,110 8,110
work equipment
Length of track on ground mm 3,460 3,845
Track gauge mm 2,380 2,580
Cab height mm 2,405 2,405
Width of standard shoe mm 600 700
*: Grouser height (26 mm) included.
01-100 6 PC200, 200LC, 220, 220LC-8M0

Specifications SEN06114-00

Model SAA6D107E-1
4-cycle, water-cooled in-line, direct injection with
Type
turbocharger and air-cooled aftercooler
Number of cylinders – bore x stroke mm 6 – 107 x 124
Piston displacement l {cc} 6.69 {6,690}
Rated hosepower
• SAE J1995 [gross] 129 {173} / 2000 {2000}
kW {HP}/
• ISO 14396 129 {173} / 2000 {2000}
Performance
min-1 {rpm}
Engine
• ISO 9249/SAE J1349 [net] 123 {164} / 2000 {2000}

Nm {kgm} /
Max. torque 690 {70.4} / 1,500 {1,500}
min-1 {rpm}
Max. speed with no load min-1 {rpm} 2,160 {2,160}
Min. speed with no load min-1 {rpm} 1,060 {1,060}
Min. fuel consumption ratio g/kWh{g/HPh} 215 {153}
Starting motor 24 V, 4.5 kW
Alternator 24 V, 35 A
Battery 12 V, 110 Ah x 2
Radiator type CF90-4
Carrier roller 2 on one side
Undercarriage
Track roller 8 on one side 10 on one side
Assembly-type triple grosser Assembly-type triple grosser

Track shoe
47 on one side 51 on one side
Type and numbers HPV95+95, Variable displacement piston type: 2

Control Hydraulic
pump
Discharge l/min Piston: 219.5 x 2

Set pressure MPa {kg/cm2} Piston: 37.2 {380}
Type and number 6-spool type: 1
valve
Operating method Hydraulic
HMV120, piston type: 2

Travel motor
Hydraulic
(with brake valve and parking brake)

motor
Hydraulic system
KMF125ABE-6, piston type: 1

Swing motor KMF125AB-6, piston type: 1 (*3)
(with safety valve and parking brake)
Boom (*1) Arm (*1) (*2) Bucket
Hydraulic cylinder
Double-acting Double-acting Double-acting

Type
piston piston piston
Cylinder inner diameter mm 130 190 130
Piston rod diameter mm 90 80 90
Stroke mm 1,335 1,635 1,020
Max. distance between pins mm 3,205 2,235 2,625
Min. distance between pins mm 1,870 3,870 1,605
Hydraulic tank Box-shaped sealed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler CF91-1 (Air-cooling type)
*1: Cushion is provided on the head side
*2: Cushion is provided on the bottom side
*3: Asian specification
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of
an independent engine. While, net denotes the value measured of an engine under the condition essentially the
same as that when it is installed on machine.
PC200, 200LC, 220, 220LC-8M0 01-100 7

SEN06114-00 Weight table
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
PC200-8M0, PC200LC-8M0
Unit: kg
Engine assembly 733 733
• Engine 575 575
• Damper 6 6
• Hydraulic pump 152 152
Radiator and oil cooler assembly 115 115
Hydraulic tank and filter assembly (not including hydraulic oil) 131 131
Fuel tank assembly (not including fuel) 141 141
Revolving frame 1,721 1,721
Cab 480 480
Operator’s seat 35 35
Counterweight 3,735 3,735
Swing machinery 174 174
Control valve 235 235
Swing motor 51.5 51.5
Travel motor 93 x 2 93 x 2
Center swivel joint 36 36
Track frame assembly (not including piping) 4,264 4,862
• Track frame 2,260 2,649
• Swing circle 273 273
• Idler 101 x 2 101 x 2
• Idler cushion 118 x 2 129 x 2
• Carrier roller 14 x 4 14 x 4
• Track roller 36 x 14 36 x 18
• Final drive (including travel motor) 330 x 2 330 x 2
Track shoe assembly
• Standard triple shoe (600 mm) 1,215 x 2 1,325 x 2
• Wide triple shoe (800 mm) 1,530 x 2 1,670 x 2
• Road liner (Rubber pad type) (600 mm) 1,470 x 2 1,600 x 2
01-100 8 PC200, 200LC, 220, 220LC-8M0

Weight table SEN06114-00
Unit: kg
Boom assembly 1,541 1,541
Arm assembly 794 794
Bucket assembly 633 633
Boom cylinder assembly 176 x 2 176 x 2
Arm cylinder assembly 228 228
Bucket cylinder assembly 137 137
Link (large) assembly 83 83
Link (small) assembly 22 x 2 22 x 2
Boom pin 42 + 8 x 2 + 28 + 10 + 26 42 + 8 x 2 + 28 + 10 + 26
Arm pin 12 + 8 12 + 8
Bucket pin 20 x 2 20 x 2
Link pin 13 x 2 13 x 2
PC200, 200LC, 220, 220LC-8M0 01-100 9

SEN06114-00 Weight table
PC220-8M0, PC220LC-8M0
Unit: kg
Engine assembly 733 733
• Engine 575 575
• Damper 6 6
• Hydraulic pump 152 152
Radiator and oil cooler assembly 115 115
Hydraulic tank and filter assembly (not including hydraulic oil) 131 131
Fuel tank assembly (not including fuel) 141 141
Revolving frame 2,023 2,023
Cab 480 480
Operator’s seat 35 35
Counterweight 5,056 5,056
Swing machinery 218 218
Control valve 235 235
Swing motor 51.5 51.5
Travel motor 93 x 2 93 x 2
Center swivel joint 36 36
Track frame assembly (not including piping) 4,785 5,411
• Track frame 2,573 3,080
• Swing circle 293 293
• Idler 101 x 2 101 x 2
• Idler cushion 129 x 2 129 x 2
• Carrier roller 14 x 4 14 x 4
• Track roller 36 x 14 36 x 18
• Final drive (including travel motor) 350 x 2 350 x 2
Track shoe assembly
• Wide triple shoe (800 mm) 1,600 x 2 1,735 x 2
• Road liner (Rubber pad type) (600 mm) 1,535 x 2 —
01-100 10 PC200, 200LC, 220, 220LC-8M0

Weight table SEN06114-00
Unit: kg
Boom assembly 1,947 1,947
Arm assembly 950 950
Bucket assembly 722 722
Boom cylinder assembly 203 x 2 203 x 2
Arm cylinder assembly 269 269
Bucket cylinder assembly 167 167
Link (large) assembly 78 78
Link (small) assembly 22 x 2 22 x 2
Boom pin 51 + 8 x 2 + 31 + 10 + 26 51 + 8 x 2 + 31 + 10 + 26
Arm pin 12 + 10 12 + 10
Bucket pin 20 x 2 20 x 2
Link pin 17 x 2 17 x 2
PC200, 200LC, 220, 220LC-8M0 01-100 11

SEN06114-00 Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants 1

a For details of the notes (Notes 1, Note 2...) in the table, see Operation and Maintenance Manual.
01-100 12 PC200, 200LC, 220, 220LC-8M0

Table of fuel, coolant and lubricants SEN06114-00
Unit: l
PC200, 200LC-8M0 PC220, 220LC-8M0
Refilling points
Specified capacity Refill capacity Specified capacity Refill capacity
Engine oil pan 25.4 23.1 25.4 23.1
Swing machinery case 7.1 6.5 8.2 7.2
Final drive case (each of right and left) 3.8 3.6 5.4 5.0
Damper case 0.65 0.65 0.65 0.65
Hydraulic oil system 237 135 244 135
Fuel tank 400 — 400 —
Cooling system 20.3 20.3 19.9 19.9
PC200, 200LC, 220, 220LC-8M0 01-100 13

SEN06114-00

© 2012 KOMATSU
All Rights Reserved
01-100 14
SEN06116-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
10 Structure, function and

maintenance standard 1
100 Engine and cooling system
Engine related parts ............................................................................................................................. 2
Radiator, oil cooler, aftercooler and fuel cooler .................................................................................... 3
PC200, 200LC, 220, 220LC-8M0 10-100 1

SEN06116-00 Engine related parts
Engine related parts 1
1. Drive plate Outline

2. Torsion spring A damper assembly is wet type.
3. Stopper pin Oil capacity: 0.65 l
4. Friction plate
5. Muffler
6. Rear engine mount
7. Front engine mount
8. Damper assembly
10-100 2 PC200, 200LC, 220, 220LC-8M0

Radiator, oil cooler, aftercooler and fuel cooler SEN06116-00
Radiator, oil cooler, aftercooler and fuel cooler 1
1. Radiator Specifications
2. Oil cooler Radiator : CF90-4
3. Aftercooler Oil cooler : CF91-1
4. Fuel cooler Aftercooler : Aluminum wave type
5. Reservoir tank Fuel cooler : Drawn cup type
6. Fan
7. Shroud
8. Radiator cap
9. Radiator inlet hose
10. Net
11. Radiator outlet hose
PC200, 200LC, 220, 220LC-8M0 10-100 3

SEN06116-00

© 2012 KOMATSU
All Rights Reserved
10-100 4
SEN06117-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

200 Power train
Power train ........................................................................................................................................... 2
Final drive............................................................................................................................................. 4
Swing machinery.................................................................................................................................. 8
Swing circle ........................................................................................................................................ 12
PC200, 200LC, 220, 220LC-8M0 10-200 1

200 Power train
SEN06117-00 Power train
Power train 1
1. Idler
2. Center swivel joint
3. Control valve
4. Final drive
5. Travel motor (HMV120)
6. Hydraulic pump (HPV95 + 95)
7. Engine (SAA6D107E-1)
8. Travel speed solenoid valve
9. Swing brake solenoid valve
10. Swing motor (KMF125ABE-6)
11. Swing machinery
12. Swing circle
10-200 2 PC200, 200LC, 220, 220LC-8M0

200 Power train
Power train SEN06117-00
PC200, 200LC, 220, 220LC-8M0 10-200 3

200 Power train
SEN06117-00 Final drive
Final drive 1
PC200-8M0, PC200LC-8M0
10-200 4 PC200, 200LC, 220, 220LC-8M0

200 Power train
Final drive SEN06117-00
1. Level plug
2. No. 1 planetary gear (No. of teeth: 42)
3. Drain plug
4. No. 1 sun gear shaft (No. of teeth: 10)
5. No. 2 sun gear (No. of teeth: 21)
6. No. 1 planetary carrier
7. Cover
8. Ring gear (No. of teeth: 95)
10. Ring nut
11. Hub
12. Sprocket
13. Floating seal
14. Travel motor
Specifications
Reduction ratio: – ((10 + 95)/10) x ((21 + 95)/21) + 1 = –57.000
Unit: mm
No. Check item Criteria Remedy
Backlash between travel motor Standard clearance Allowable clearance
16
and No.2 planetary carrier 0.06 to 0.25 1.00
Backlash between No. 2 plane-
17 0.17 to 0.57 1.10
tary gear and ring gear
18 0.15 to 0.49 —
tary gear and No. 2 sun gear
Backlash between No. 1 plane- Replace
19 0.17 to 0.57 1.10
20 tary gear and No. 1 sun gear 0.14 to 0.46 1.00
shaft
21 0.38 to 0.66 1.00
tary carrier and No. 2 sun gear
Amount of wear on sprocket
22 Repair limit: 6 Rebuild by build-
tooth
up welding or
Standard dimension Repair limit
23 Width of sprocket tooth replace
71 68
PC200, 200LC, 220, 220LC-8M0 10-200 5

200 Power train
SEN06117-00 Final drive
PC220-8M0, PC220LC-8M0
10-200 6 PC200, 200LC, 220, 220LC-8M0

200 Power train
Final drive SEN06117-00
1. Level plug
3. Drain plug
4. No. 1 sun gear shaft (No. of teeth: 10)
5. No. 2 sun gear (No. of teeth: 21)
7. Cover
9. Gear hub (No. of teeth: 95)
10. Sprocket
11. Floating seal
12. Travel motor
Specifications
Reduction ratio: – ((10 + 95)/10) x ((21 + 95)/21) + 1 = –57.000
Unit: mm
Backlash between travel motor Standard clearance Allowable clearance
14
and No.2 planetary carrier 0.13 to 0.47 1.00
15 0.17 to 0.57 1.10
16 0.06 to 0.25 —
tary gear and No. 2 sun gear
Backlash between No. 1 plane- Replace
17 0.14 to 0.46 1.00
18 tary gear and No. 1 sun gear 0.16 to 0.56 1.10
shaft
19 0.38 to 0.66 1.00
Amount of wear on sprocket
20 Repair limit: 6 Rebuild by build-
tooth
up welding or
21 Width of sprocket tooth replace
71 68
PC200, 200LC, 220, 220LC-8M0 10-200 7

200 Power train
SEN06117-00 Swing machinery
Swing machinery 1
PC200-8M0, PC200LC-8M0
10-200 8 PC200, 200LC, 220, 220LC-8M0

200 Power train
Swing machinery SEN06117-00
1. Drain plug
2. Swing pinion (No. of teeth: 13)
4. No. 2 planetary gear
5. No. 2 sun gear
8. No. 1 sun gear
9. Swing motor
10. Oil level gauge
11. Ring gear
12. Case
Specifications
Reduction ratio: ((17 + 58)/17) x ((18 + 58)/18) = 18.627
Unit: mm
Backlash between swing motor Standard clearance Allowable clearance
13
shaft and No. 1 sun gear 0.18 to 0.28 —
Backlash between No. 1 sun
14 0.16 to 0.50 1.00
gear and No.1 planetary gear
15 0.18 to 0.59 1.10
16 0.39 to 0.71 1.20
17 0.16 to 0.50 0.90
Replace
18 0.18 to 0.59 1.00
19 0.07 to 0.23 —
tary carrier and swing pinion
Backlash between swing pinion
20 0.22 to 1.32 2.00
and swing circle
Clearance between plate and
21 0.66 to 1.14 —
No. 2 planetary carrier
Clearance between No. 2 sun
22 1.66 to 2.94 —
gear and plate
Standard dimension Repair limit Apply hard
Wear of swing pinion surface
23 chrome plating or
contacting with oil seal ø125 (0/ – 0.100) — replace
PC200, 200LC, 220, 220LC-8M0 10-200 9

200 Power train
SEN06117-00 Swing machinery
PC220-8M0, PC220LC-8M0
10-200 10 PC200, 200LC, 220, 220LC-8M0

200 Power train
Swing machinery SEN06117-00
1. Drain plug
2. Swing pinion (No. of teeth: 13)
4. No. 2 sun gear
8. No. 1 sun gear
9. Swing motor
10. Oil level gauge
11. Ring gear
12. Case
Specifications
Reduction ratio: ((17 + 58)/17) x ((14 + 58)/14) = 22.689
Unit: mm
Backlash between swing motor Standard clearance Allowable clearance
13
shaft and No. 1 sun gear 0.18 to 0.28 —
14 0.16 to 0.50 1.00
15 0.18 to 0.59 1.10
16 0.35 to 0.64 1.20
17 0.12 to 0.44 0.90
Replace
18 0.16 to 0.56 1.00
19 0.08 to 0.23 —
tary carrier and swing pinion
Backlash between swing pinion
20 0.23 to 1.37 2.00
and swing circle
Clearance between plate and
21 0.58 to 1.62 —
No. 2 planetary carrier
Clearance between No. 2 sun
22 2.56 to 3.84 —
gear and plate
Standard dimension Repair limit Apply hard
Wear of swing pinion surface
23 chrome plating or
contacting with oil seal ø125 (0/ – 0.100) — replace
PC200, 200LC, 220, 220LC-8M0 10-200 11

200 Power train
SEN06117-00 Swing circle
Swing circle 1
PC200-8M0, PC200LC-8M0
1. Swing circle inner race (No. of teeth: 96) Specifications

2. Ball Reduction ratio: –96/13 = –7.385
3. Swing circle outer race Amount of filled grease: 14.6 l (G2-LI)
a. Inner race soft zone “S“ position

b. Outer race soft zone “S“ position
Unit: mm
Axial clearance of bearing Standard clearance Allowable clearance
4 Replace
(when mounted on chassis) 0.5 to 1.6 3.2
10-200 12 PC200, 200LC, 220, 220LC-8M0

200 Power train
Swing circle SEN06117-00
PC220-8M0, PC220LC-8M0
1. Swing circle inner race (No. of teeth: 92) Specifications

2. Ball Reduction ratio: –92/13 = –7.077
3. Swing circle outer race Amount of filled grease: 15.8 l (G2-LI)
a. Inner race soft zone “S“ position

b. Outer race soft zone “S“ position
Unit: mm
Axial clearance of bearing Standard clearance Allowable clearance
4 Replace
(when mounted on chassis) 0.5 to 1.6 3.2
PC200, 200LC, 220, 220LC-8M0 10-200 13

SEN06117-00

© 2012 KOMATSU
All Rights Reserved
10-200 14
SEN06118-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

300 Undercarriage and frame
Track frame and recoil spring............................................................................................................... 2
Idler ...................................................................................................................................................... 4
Carrier roller ......................................................................................................................................... 6
Track roller ........................................................................................................................................... 7
Track shoe............................................................................................................................................ 8
PC200, 200LC, 220, 220LC-8M0 10-300 1

SEN06118-00 Track frame and recoil spring
Track frame and recoil spring 1
1. Idler q The dimensions and the number of track roll-

2. Track frame ers depend on the model, but the basic struc-
3. Carrier roller ture is not different.
4. Final drive q Number of track rollers
5. Track roller
6. Track shoe Model Q'ty (One side)
7. Center guard
PC200-8M0 7
8. Front guard
PC220-8M0 8
PC200LC-8M0 9
PC220LC-8M0 10
10-300 2 PC200, 200LC, 220, 220LC-8M0

Track frame and recoil spring SEN06118-00
Standard shoe
Models
PC200-8M0 PC220-8M0 PC200LC-8M0 PC220LC-8M0
Item
Shoe width (mm) 600 600 700 700
Link pitch (mm) 190 190 190 190
Q'ty (One side) 45 47 49 51
Unit: mm
Standard dimen-
Tolerance Repair limit
sion
Vertical width of +3
9 Track frame 107 111
idler guide –1
Rebuild by
Idler support 105 ±0.5 103 build-up weld-
ing or replace
+4
Horizontal Track frame 250 255
–1
10 width of idler
guide Idler support 247.4 — 245.4

Free length Load at Load at
Installed
× Outside installed Free length installed
length
diameter length length
11 Recoil spring 109.3 kN 87.4 kN Replace
PC200-8M0 503 × 231 389 480
{11,150 kg} {8,920 kg}
PC200LC-8M0
126.5 kN 101 kN
PC220-8M0 561 × 237 433 535
{12,900 kg} {10,300 kg}
PC220LC-8M0
PC200, 200LC, 220, 220LC-8M0 10-300 3

SEN06118-00 Idler
Idler 1
10-300 4 PC200, 200LC, 220, 220LC-8M0

Idler SEN06118-00
Unit: mm
1 Outside diameter of protrusion
538 —
2 Outside diameter of tread 500 488
Rebuild by build-
3 Thickness of tread 26 20 up welding or
replace
4 Difference of tread 19 25
5 Total width 159 —
6 Width of tread 37.5 —
Standard Tolerance Standard Allowable
Clearance between shaft and dimension Shaft Hole clearance clearance
7
bushing
–0.250 +0.164 0.176 to
65 —
–0.350 –0.074 0.514
Interference between idler and dimension Shaft Hole interference interference Replace bushing
8
bushing
+0.108 –0.032 0.040 to
72 —
+0.008 –0.062 0.170
Clearance between bushing Standard clearance Clearance limit
9 and support (Sum of clearance
at both sides) 0.5 to 1.0 —
PC200, 200LC, 220, 220LC-8M0 10-300 5

SEN06118-00 Carrier roller
Carrier roller 1
Unit: mm
1 Outside diameter of flange
143 —
2 Outside diameter of tread 120 106
3 Width of tread 43 —
4 Thickness of tread 23 16
5 Width of flange 14 —
6 Replace
bushing –0.170 +0.301 0.338 to
40 —
–0.190 +0.168 0.491
Interference between roller and dimension Shaft Hole interference interference
7
bushing +0.061 0 0.016 to
47 —
+0.016 –0.040 0.101
Standard clearance Allowable clearance
8 Axial clearance of roller
0.44 to 0.76 —
10-300 6 PC200, 200LC, 220, 220LC-8M0

Track roller SEN06118-00
Track roller 1
Unit: mm
1 Outside diameter of flange
188 —
2 Outside diameter of tread 156 144 Rebuild by build-
3 Thickness of tread 44.5 38.5 up welding or
4 Total width 225 — replace
5 Width of tread 44.5 —

6 Width of flange 25.5 —
7
bushing –0.215 +0.195 0.215 to
60 —
–0.315 0 0.510
Replace bushing
Interference between roller and dimension Shaft Hole interference interference
8
bushing +0.153 +0.030 0.023 to
67 —
+0.053 0 0.153
Clearance between bushing and Standard clearance Allowable clearance
9 collar Replace
(Sum of clearance at both sides) 0.5 to 1.0 —
PC200, 200LC, 220, 220LC-8M0 10-300 7

SEN06118-00 Track shoe
Track shoe 1
a P portion shows the link of bushing press fitting

end.
*1. Triple grouser shoe

*2. Road liner
*3. Swamp shoe
*4. Flat shoe
10-300 8 PC200, 200LC, 220, 220LC-8M0

Track shoe SEN06118-00
Unit: mm
1 Link pitch
190.3 193.3
Turn 180 deg. or
Standard dimension Turning limit
2 Outside diameter of bushing replace
59.4 54.4
3 Thickness of bushing metal 10.4 5.4
4 Link height
105 97 Repair or
replace
Thickness of link metal
5 28.5 20.5
(bushing press-fitting portion)
6 160.4
7 Shoe bolt pitch 124.4
8 62
Inside
9 84.8
width
Overall
10 Link 45.4
width
Tread
11 39.6
width
Regular 2.5 Adjust or replace
12 Protrusion of pin
Master 2.5
Protrusion of bush- Regular 4.85
13
ing Master 0.0
Overall length of Regular 212
14
pin Master 212
Overall length of Regular 138.5
15
bushing Master 128.7
16 Thickness of spacer —
17 Bushing 88.2 to 245 kN {9 to 25 ton}
18 Regular pin 127.4 to 274.4 kN {13 to 28 ton}
Press-fitting force —
19
Master pin 78.4 to 147 kN {8 to 15 ton}
(*)
* Dry type track link
PC200, 200LC, 220, 220LC-8M0 10-300 9

Unit: mm
Tightening torque (Nm {kgm}) Retightening angle (deg.)
Triple grouser 490 ± 49
a. Regular 120 ± 10
shoe {50 ± 5}
link
Road liner 549 ± 59
Shoe bolt — Retighten
20 (Rubber pad type) {56 ± 6}
Tightening torque Retightening angle Lower limit torque
b. Master (Nm {kgm}) (deg.) (Nm {kgm})
link
— — —
No. of shoes (each side) PC200-8M0: 45 PC200LC-8M0: 49 —
Standard dimen- Tolerance Standard
Interference between bushing sion Shaft Hole interference
21
and link
+0.434 +0.074
59 0.320 to 0.434
+0.394 0
Interference between regular +0.222 –0.138
22 38 0.300 to 0.422
pin and link +0.162 –0.200
Standard dimen- Tolerance Standard clear-
Clearance between regular pin sion Shaft Hole ance
23
and bushing
+0.222 +0.902
38 0.180 to 0.740 Adjust or replace
+0.162 +0.402
24 Interference between master sion Shaft Hole interference
(*) pin and link
+0.280 +0.062
37.8 0.188 to 0.280
+0.250 0
25 Clearance between master pin sion Shaft Hole clearance
(*) and bushing
–0.150 +0.902
38 0.552 to 1.252
–0.350 +0.402
* Dry type track link
10-300 10 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 10-300 11

Triple grouser shoe
Swamp shoe
Road liner
10-300 12 PC200, 200LC, 220, 220LC-8M0

Unit: mm
1 Height
26 16
10
2 Thickness
(*) 8.5
3 Length of base 26
4 Length of base 19
5 Length at tip 20 Rebuild by build-
up welding or
6 Length at tip 14 replace
7 Length at tip 19
8 Thickness 36 26
(*) 34.5 24.5
9 Height 102.5 90.5
10 Thickness 17 5
11 Height 70 Replace
*: PC200-8M0, PC200LC-8M0: 600 mm width shoe
PC200, 200LC, 220, 220LC-8M0 10-300 13

SEN06118-00

© 2012 KOMATSU
All Rights Reserved
10-300 14
SEN06119-02
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

401 Hydraulic system, Part 1
Hydraulic equipment layout drawing .................................................................................................... 2
Hydraulic tank and filter........................................................................................................................ 4
Hydraulic pump .................................................................................................................................... 6
Pilot oil filter........................................................................................................................................ 28
PC200, 200LC, 220, 220LC-8M0 10-401 1

SEN06119-02 Hydraulic equipment layout drawing
Hydraulic equipment layout

drawing 1
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic oil filter
6. R.H. travel motor
7. Swing motor
8. Hydraulic pump
9. Control valve
10. Oil cooler
11. L.H. travel motor
12. L.H. PPC valve
13. Lock lever
14. Center swivel joint
15. R.H. PPC valve
16. Travel PPC valve
17. Attachment PPC valve
18. Accumulator
19. Solenoid valve assembly
19A. PPC lock solenoid valve
19B. 2-stage relief solenoid valve
19C. Swing brake solenoid valve
19D. Travel speed solenoid valve
19E. Travel junction solenoid valve
19F. ATT selector solenoid valve
10-401 2 PC200, 200LC, 220, 220LC-8M0

Hydraulic equipment layout drawing SEN06119-02
PC200, 200LC, 220, 220LC-8M0 10-401 3

SEN06119-02 Hydraulic tank and filter
Hydraulic tank and filter 1
1. Hydraulic tank Specifications

2. Oil filler port cap Tank capacity : 190 l
3. Filter element Amount of oil inside tank : 135 l
4. Strainer
5. Bypass valve Pressure valve
6. Suction strainer Relief cracking pressure:
7. Sight gauge 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2}
8. Breather Suction cracking pressure:
0 to 0.49 kPa {0 to 0.005 kg/cm2}
Bypass valve set pressure:
150 ± 30 kPa {1.5 ± 0.3 kg/cm2}
10-401 4 PC200, 200LC, 220, 220LC-8M0

Hydraulic tank and filter SEN06119-02
Hydraulic tank oil filler cap Hydraulic tank breather

Structure Structure

1: Bottom plate 1: Nut

2: Gasket 2: Cover
3: Filter element
Function 4: Case
Prevention of pressure rise in hydraulic tank 5: Valve assembly
While the hydraulic circuit is in operation, the pres- 6: Body
sure in the hydraulic tank increases as the oil level
and the temperature in the hydraulic tank rise cor- Function
responding to the operation of the hydraulic cylin- Prevention of negative pressure in hydraulic tank
ders. When the pressure in the tank exceeds the Since the hydraulic tank is pressurized and sealed,
set pressure, bottom plate (1) is pushed up to if the oil level in it decreases, negative pressure is
release the pressure in the tank and prevent pres- generated in it. At this time, valve assembly (5) is
sure rise. opened by the differential pressure from the ambi-
(Set pressure of exhaust valve: 16.7 ± 6.86 kPa ent pressure, and ambient pressure is transmitted
{0.17 ± 0.07 kg/cm2} ) into the tank to prevent generation of negative pres-
sure in the tank.
(Set pressure of intake valve: Max. 0.002 MPa
{0.02 kg/cm2})
PC200, 200LC, 220, 220LC-8M0 10-401 5

SEN06119-02 Hydraulic pump
Hydraulic pump 1
Type: HPV95+95
10-401 6 PC200, 200LC, 220, 220LC-8M0

Hydraulic pump SEN06119-02
Outline
q This pump consists of 2 variable capacity
swash plate piston pumps, PC valve, LS valve,
and EPC valve.
IMF : Front PC mode selector current

IMR : Rear PC mode selector current
ISIG : LS set pressure selector current
PAF : Front pump discharge port
PAR : Rear pump discharge port
PBF : Pump pressure input port
PD1F : Case drain port
PD1R : Air bleeder
PD2F : Drain plug
PD2R : Drain plug
PENF : Front control pressure detection port
PENR : Rear control pressure detection port
PEPC : EPC basic pressure port
PEPCC : EPC basic pressure detection port
PFC : Front pump discharge pressure detection
port
PLSF : Front load pressure input port
PLSFC : Front load pressure detection port
PLSR : Rear load pressure input port
PLSRC : Rear load pressure detection port
PMF : Front PC mode selector pressure detec-
tion port
PMR : Rear PC mode selector pressure detec-
tion port
PRC : Rear pump discharge pressure detection
port
PS : Pump suction port
PSIG : LS set selector pressure detection port
1. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. LS-EPC valve
6. PC-EPC valve
PC200, 200LC, 220, 220LC-8M0 10-401 7

1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. Servo piston
13. PC valve
10-401 8 PC200, 200LC, 220, 220LC-8M0

Function q Piston (6) carries out relative movement in the

q The pump converts the engine rotation trans- axial direction inside each cylinder chamber of
mitted to its shaft to oil pressure and delivers cylinder block (7).
pressurized oil corresponding to the load. q Cylinder block (7) seals the pressurized oil to
q It is possible to change the discharge amount valve plate (8) and carries out relative rotation.
by changing the swash plate angle. q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
Structure q The oil inside the respective cylinder chambers
q Cylinder block (7) is supported to shaft (1) by of cylinder block (7) is suctioned and dis-
spline (14). charged through valve plate (8).
q Shaft (1) is supported by front and rear bear-
ings (15).
q Tip of piston (6) is shaped as a concave ball
and shoe (5) is caulked to it to form one unit.
q Piston (6) and shoe (5) constitute the spherical
bearing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) conducts high pressure oil to
the cylinder surface (B) with cradle (2), which
is secured to the case, and forms a static pres-
sure bearing when it slides.
PC200, 200LC, 220, 220LC-8M0 10-401 9

Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between
along cylindrical surface (B), so angle (a) volumes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
th e axia l d ir ection of cylinde r bloc k ( 7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q (a) is named the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
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q With center line (X) of rocker cam (4) at a

swash plate angle (a) in relation to the axial
direction of cylinder block (7), flat surface (A)
acts as a cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) suctions and discharges the
oil by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
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10-401 10 PC200, 200LC, 220, 220LC-8M0

Control of discharge
q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
becomes larger and pump discharge (Q)
increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
PC200, 200LC, 220, 220LC-8M0 10-401 11

1. LS valve
PA : Pump port 1. Sleeve

PDP : Drain port 2. Piston
PLP : LS control pressure output port 3. Spool
PLS : LS pressure input port 4. Spring
PP : Pump port 5. Sheet
PPL : Control pressure input port 6. Sleeve
PSIG : LS mode selector pilot port 7. Plug
8. Locknut
Function
q The LS (load sensing) valve detects the load
and controls the discharge amount.
q This valve controls main pump discharge (Q)
according to differential pressure (dPLS)[= PP
— PLS], called the LS differential pressure (the
difference between main pump pressure PP
and control valve outlet port pressure PLS).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional
solenoid valve enter this valve.
q The relationship between the LS differential
pressure between the main pump pressure
(PP) and LS pressure (PLS) (dPLS) [= (PP) —
(PLS)] and the pump discharge (Q) changes
as shown in the diagram according to LS
selector current (ISIG) of the LS-EPC valve.
q If (ISIG) changes from 0 to 1A, setting force
the spring changes, too. As the result, the
specified median of the pump discharge vol-
ume switching point changes as shown in the
diagram. It will change in the range of 0.27 to
1.7 MPa {2.78 to 17.75 kg/cm2}.
10-401 12 PC200, 200LC, 220, 220LC-8M0

Operation
1) When the control valve is situated at neutral
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q The LS valve is a 3-way selector valve, with q Spool (6) is pushed to the right, and port (C)
pressure (PLS) (LS pressure) from the outlet and port (D) will be connected.
port of the control valve brought to spring q Pump pressure (PP) is conducted to the larger
chamber (B), and main pump discharge pres- diameter end from the port (K).
sure (PP) brought to port (H) of sleeve (8). q The same pump pressure (PP) is conducted to
q Magnitude of the force resulting from this LS the smaller diameter end from the port (J).
pressure (PLS), force of spring (4) and the q According to the difference in the areas on
pump discharge pressure (self pressure) (PP) servo piston (12), the pressure moves in such
determine the position of spool (6). that the swash plate angle may be minimized.
q However, magnitude of the output pressure
(PSIG) (called the LS selector pressure) of the
EPC valve for the LS valve entering port (G)
also changes the position of spool (6). (Setting
force of the spring is changed)
q Before the engine is started, servo piston (12)
is pushed to the left. (See the figure)
q If the control lever is at the neutral position
when the engine is started, LS pressure (PLS)
will be set to 0 MPa {0 kg/cm2}. (It is intercon-
nected to the drain circuit through the control
valve spool)
PC200, 200LC, 220, 220LC-8M0 10-401 13

2) Action for the direction of maximizing the pump discharge
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q When the difference between the main pump q If the output pressure of the EPC valve for the
pressure (PP) and LS pressure (PLS), in other LS valve enters port (G), rightward force is
w o r d s , L S d i ffe r e n t i a l p r e s s u r e ( dP L S) generated on piston (7).
becomes smaller (for example, when the area q If piston (7) is pushed to the right, setting force
of opening of the control valve becomes larger of spring (4) is weakened, changing the LS dif-
and pump pressure PP drops), spool (6) is ferential pressure (dPLS) [Difference between
pushed to the left by the combined force of LS oil pressures (PLS) and (PP)] when ports (D)
pressure (PLS) and the force of spring (4). and (E) of spool (6) are connected.
q When spool (6) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K)
becomes drain pressure (PT). (The operation
of the PC valve is explained later.)
q The pressure at the large diameter end of
servo piston (12) becomes drain pressure
(PT), and pump pressure (PP) enters port (J)
at the small diameter end, so servo piston (12)
is pushed to the left side. Therefore, the swash
plate is moved in the direction to make the dis-
charge amount larger.
10-401 14 PC200, 200LC, 220, 220LC-8M0

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

becomes larger (for example, when the area of
opening of the control valve becomes smaller
and pump pressure (PP) rises) because of the
rightward move (it reduces discharge amount)
of servo piston (12), pump pressure (PP)
pushes spool (6) to the right.
q When spool (6) moves, main pump pressure
(PP) flows from port (C) to port (D) and from
port (K), it enters the large diameter end of the
piston.
q Main pump pressure (PP) also enters port (J)
of the small diameter end of the piston, but
because of the difference in area between the
large diameter end and the small diameter end
on servo piston (12), it is pushed to the right.
As the result, the servo piston (12) moves into
the direction of reducing the swash plate
angle.
q As LS selector pressure (PSIG) is input to port
(G), setting force of spring (4) is reduced.
PC200, 200LC, 220, 220LC-8M0 10-401 15

4) When servo piston is balanced
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q Let us take the area receiving the pressure at q Force of spring (4) is adjusted in such that the
the large diameter end of the piston as (A1), position of the balanced stop of this spool (6)
the area receiving the pressure at the small may be determined when (PP) — (PLS) = 1.7
diameter end as (A0), and the pressure flowing MPa{17.75 kg/cm2} at the median of the speci-
into the large diameter end of the piston as fied value.
(PEN). q If (PSIG) [Output pressure of LS-EPC valve, 0
q If the main pump pressure (PP) of the LS valve to 2.9 MPa {0 to 30 kg/cm2}] is input to port (G),
and the combined force of spring (4) and LS the position of the balanced stop is changed in
pressure (PLS) are balanced, and the relation- the range of (PP) — (PLS) = 1.7 to 0.27 MPa
ship is (A0) x (PP) = (A1) x (PEN), servo piston {17.75 to 2.78 kg/cm2} in proportion to (PSIG)
(12) will stop in that position. pressure.
q The swash plate of the pump will be held at the
intermediate position. [Spool (6) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q At this point, the relationship between the pres-
sure receiving areas across servo piston (12)
is (A0) : (A1) = 3 : 5, so the pressure applied
across the piston when it is balanced becomes
(PP) : (PEN) C 5 : 3.
10-401 16 PC200, 200LC, 220, 220LC-8M0

2. PC valve
PA : Pump port 1. Plug

PA2 : Pump pressure pilot port 2. Servo piston assembly
PDP : Drain port 3. Pin
PM : Mode selector pressure pilot port 4. Spool
PPL : Control pressure output port (to LS valve) 5. Retainer
6. Sheet
7. Cover
8. Wiring
Function
q When the pump discharge pressure (PP1) q If the engine speed goes below the specified
(self-pressure) and (PP2) (other pump pres- value because of increased load, the controller
sure) are high, the PC valve controls the pump sends a command current to PC-EPC valve
so that the volume of oil beyond the discharge solenoid in order to reduce the slope angle in
pressure-based specific flowrate may not be proportion to reduction in the engine speed.
conducted however you may increase the con-
trol valve stroke. Namely it is intended at con-
trolling the horse power for the pumps so that it
may not exceed the engine hose power.
q If the pump discharge pressure increases due
to increased load during operation, this valve
decreases the pump discharge.
q And if the pump discharge pressure goes low,
it increases the pump discharge.
q In this case, relation between the mean dis-
charge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and the pump discharge (Q)
will become as shown in the diagram if the
relation is represented as the parameter the
current value (X) to be given to PC-EPC valve
solenoid.
q The controller continues counting the actual
engine speed.
q If the engine speed is slowed down due to
increased load, the controller reduces the
pump discharge to recover the speed.
PC200, 200LC, 220, 220LC-8M0 10-401 17

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

q Command current (X) is being sent to PC-EPC a Other pump's pressure denotes the pressure
valve solenoid (1) from the pump controller. of the pump situated on the opposite side.
q This command current acts on PC-EPC valve For the front pump pressure, the other pump's
to output the signal pressure in order to modify pressure is that of the rear pump.
the force pushing piston (2). And for the rear pump pressure, the other
q Spool (3) stops at a position where the com- pump's pressure is that of the front pump.
bined spool-pushing force is balanced by the
setting force of springs (4) and (6) as well as
the pump pressures (PP1) (self-pressure) and
(PP2) (another pump's pressure).
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The size of command current (X) is determined
by the nature of the operation (lever opera-
tion), the selected working mode, and the set
value and actual value of the engine speed.
10-401 18 PC200, 200LC, 220, 220LC-8M0

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Action of spring
q Load of springs (4) and (6) on the PC valve is q Self pressure (PP1) enters port (B) and the
determined by the swash plate position. small diameter end of servo piston (9), and
q As servo piston (9) moves to right, spring (6) is other pump pressure (PP2) enters port (A).
retracted. q When pump pressures (PP1) and (PP2) are
q If the servo piston moves further, it will be con- small, spool (3) will be positioned in the left
tacted again seat (5) and spring (6) will be side.
fixed. q Port (C) and (D) are connected, and the pres-
q After that, spring (4) alone will operate. sure entering the LS valve becomes drain
q The spring load is changed by servo piston (9) pressure (PT).
as it extends or compresses springs (4) and q If port (E) and port (G) of the LS valve are con-
(6). nected, the pressure entering the large diame-
The spring load changes as the servo piston ter end of the piston from port (J) becomes
(9) extends and contracts the springs (4) and drain pressure (PT), and servo piston (9)
(6). moves to the left side.
q If the command current (X) to PC-EPC valve q The pump discharge will be set to the increas-
solenoid (1) changes, so does the force pushing trend.
ing piston (2). q Accompanied with move of servo piston (9),
q Spring load of springs (4) and (6) is also springs (4) and (6) will be expanded and the
affected by the command current (X) to PC- spring force becomes weaker.
EPC valve solenoid.
q Port (C) of the PC valve is connected to port
(E) of the LS valve.
PC200, 200LC, 220, 220LC-8M0 10-401 19

q As the spring force is weakened, spool (3)

moves to the right, the connecting between
port (C) and port (D) is shut off and the pump
discharge pressure ports (B) and (C) are con-
nected.
q As a result, the pressure on port (C) rises and
the pressure on the large diameter end of the
piston also rises. Thus, the leftward move of
servo piston (9) is stopped.
q Servo piston (9) stop position (= Pump dis-
charge) is decided by the position where the
pushing force generated from the pressures
(PP1) and (PP2) applied to spool (3), the push-
ing force of the solenoid in PC-EPC valve gen-
erates and the pushing force of springs (4) and
(6) are balanced.
10-401 20 PC200, 200LC, 220, 220LC-8M0

(2) When load on actuator is large and pump discharge pressure is high
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Outline q When servo piston (9) moves to the right,

q When the load is large and pump discharge springs (4) and (6) are compressed and push
pressures (PP1) and (PP2) are high, the force back spool (3).
pushing spool (3) to the right becomes larger q When spool (3) moves to the left, the opening
and spool (3) will be moved to the position of port (C) and port (D) becomes larger.
shown in above figure. q As a result, the pressure on port (C) (= J) is
q Part of the pressure to be conducted from port decreased and the rightward move servo pis-
(C) to LS valve flows from port (B) to port (C) ton (9) is stopped.
and (D) through LS valve. At the end of this q The position in which servo piston (9) stops at
flow, level of this pressure becomes approxi- this time is further to the right than the position
mately half of the main pump pressure (PP2). when pump pressures (PP1) and (PP2) are
low.
Operation q The relationship between the average pump
q When port (E) and port (G) of the LS valve are pressure (PP1 + PP2)/2 and servo piston (9) in
connected, this pressure from port (J) enters terms of their positions can be represented by
the large diameter end of servo piston (9), the broken line in the figure springs (4) and (6)
stopping servo piston (9). form the double springs.
q If main pump pressure (PP2) increases further
and spool (3) moves further to the right, main
pump pressure (PP1) flows to port (C) and acts
to make the pump discharge the minimum.
PC200, 200LC, 220, 220LC-8M0 10-401 21

q The relationship between the average pump

pressure (PP1 + PP2)/2 and average pump
discharge (Q) becomes as shown below.
q If command voltage (X) sent to PC-EPC valve

solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/
2, and pump discharge (Q) is proportional to
the force of the PC-EPC valve solenoid and
moves in parallel.
q Namely, the force of PC-EPC valve solenoid
(1) is added to the pushing force to the right
because of the pump pressure applied to the
spool (3), so the relationship between the aver-
age pump pressure (PP1 + PP2)/2 and the
pump discharge (Q) moves from (A) to (B) as
the command current (X) is increased.
10-401 22 PC200, 200LC, 220, 220LC-8M0

2) As the emergency pump drive switch is turned on due to failure on the pump
controller
(1) When the main pump is under light load
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q If there is a failure in the pump controller, the q Since the pressure on the small diameter end
emergency pump drive switch is turned on to of the piston large, servo piston (9) moves in
hand the control to the resistor side. the direction to make the discharge amount
q In this case, the power is directly supplied from larger.
the battery. The current, however, is too large
as is, so the resistor is set in between to con-
trol the current flowing to PC-EPC valve sole-
noid (1).
q The current becomes constant, so the force
pushing piston (2) is also constant.
q If the main pump pressures (PP1) and (PP2)
are low, the combined force of the pump pres-
sure and the PC-EPC valve solenoid (1) is
weaker than the spring set force, so spool (3)
is balanced at a position to the left.
q The port (C) is connected to the drain pressure
of the port (D), and the large diameter end of
the servo piston (9) also becomes the drain
pressure (PT) through the LS valve.
PC200, 200LC, 220, 220LC-8M0 10-401 23

(2) When the main pump is under heavy load
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q If the emergency pump drive switch is turned q The curve resulting when the emergency pump
on in the same way as in above, the command drive switch is ON is situated further to the left
current (X) sent to PC-EPC valve solenoid (1) (B) than when the pump controller is normal
becomes constant. (A).
q For this reason, the force of piston (2) pushing
spool (3) is constant.
q If main pump pressures (PP1) and (PP2)
increase, spool (3) moves further to the right
than when the main pump load is light, and is
balanced at the position in the figure above.
q In this case, the pressure from port (B) flows to
port (C), so servo piston (9) moves to the right
(smaller pump discharge) and stops at a posi-
tion to the further to the right then when the
load on the pump is light.
q When the emergency pump drive switch is
turned on, too, the pump pressure (PP) and
pump discharge (Q) have a relationship as
shown with the curve in the figure correspond-
ing to the current sent to the PC-EPC valve
solenoid through the resistor.
10-401 24 PC200, 200LC, 220, 220LC-8M0

3. LS (PC)-EPC valve
C : To LS (PC) valve
P : From self-pressure reducing valve
T : To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
PC200, 200LC, 220, 220LC-8M0 10-401 25

Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1) When signal current is 0 (coil is de-
tion. energized)
q When it receives signal current (i) from the q When there is no signal current flowing from
controller, it generates the EPC output pres- the controller to coil (2), coil (2) is de-ener-
sure in proportion to the size of the signal, and gized.
outputs it to the LS (PC) valve. q Spool (5) is pushed to the left by spring (4).
q Port (P) closes and the pressurized oil from the
self pressure reducing valve does not flow to
the LS (PC) valve.
q The pressurized oil from the LS (PC) valve is
drained to the tank through port (C) and port
(T).
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10-401 26 PC200, 200LC, 220, 220LC-8M0

2) When signal current is very small 3) When signal current is maximum

(coil is energized) (coil is energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressure on port (C) increases and the force to q Spool (5) is pushed toward right side by rod
act on spool (5) surface and the spring load on (6).
spring (4) become larger than the propulsion q The maximum volume of pressurized oil is
force of plunger (7). conducted from port (P) to port (C), increasing
q Spool (5) is pushed to the left, and port (P) is the circuit pressure across EPC valve and LS
shut off from port (C). (PC) valve to the maximum level.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves up and down so that the pro- not flow to the tank.
pulsion force of plunger (7) may be balanced
with pressure of port (C) + spring load of spring
(4).
q The circuit pressure between the EPC valve
and the LS (PC) valve is controlled in propor-
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PC200, 200LC, 220, 220LC-8M0 10-401 27

SEN06119-02 Pilot oil filter
Pilot oil filter 1

For breaker
1. Filter Specifications
2. Case Rated pressure : 6.57 MPa {67 kg/cm2}
3. Head cover Flow rate : 16 l/min.
4. Relief valve Relief valve cracking pressure
: 0.15 MPa {1.5 kg/cm2}
Filter mesh size : 6 mm
Filtering area : 450 cm2
10-401 28 PC200, 200LC, 220, 220LC-8M0

Pilot oil filter SEN06119-02
PC200, 200LC, 220, 220LC-8M0 10-401 29

SEN06119-02

© 2019 KOMATSU
All Rights Reserved
10-401 30
SEN06120-01
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

Control valve ........................................................................................................................................ 2
CLSS.................................................................................................................................................. 13
Functions and operation by valve ...................................................................................................... 17
PC200, 200LC, 220, 220LC-8M0 10-402 1

SEN06120-01 Control valve
Control valve 1
a In this section, only the 7-spool valve (6-spool valve + service valve) is shown.
10-402 2 PC200, 200LC, 220, 220LC-8M0

Control valve SEN06120-01
A1: To bucket cylinder head PX1: From 2-stage relief solenoid valve
A2: To L.H. travel motor PX2: From 2-stage relief solenoid valve
A3: To boom cylinder bottom T: To hydraulic tank
A4: To swing motor T1: To hydraulic tank
A5: To R.H. travel motor TS: To hydraulic tank
A6: To arm cylinder head TSW: From swing motor
A-1: To attachment IS1: Pump merge-divider EPC valve (for main
ATT: From attachment spool) drive signal
B1: To bucket cylinder bottom IS2: Pump merge-divider EPC valve (for LS
B2: To L.H. travel motor spool) drive signal
B3: To boom cylinder head IS3: Variable back pressure solenoid valve drive
B4: To swing motor signal
B5: To R.H. travel motor 1. Variable back pressure valve
B6: To arm cylinder bottom 2. Variable back pressure solenoid valve
B-1: To attachment 3. Pump merge-divider EPC valve (for LS spool)
BP1: From LS select solenoid valve 4. Pump merge-divider EPC valve (for main
BP5: From attachment selector solenoid valve spool)
C: To oil cooler 5. Arm hydraulic drift prevention valve (if
P1: From R.H. work equipment PPC valve equipped)
(bucket DUMP) 6. Boom hydraulic drift prevention valve
P2: From R.H. work equipment PPC valve 7. Service valve
(bucket CURL) 8. Cover A
P3: From travel PPC valve (L.H. travel 9. 7-spool valve
REVERSE) 10. Arm quick return valve
P4: From travel PPC valve (L.H. travel FOR- 11. Cover B
WARD) 12. Merge-divider valve
P5: From R.H. work equipment PPC valve
(boom RAISE)
P6: From R.H. work equipment PPC valve
(boom LOWER)
P7: From L.H. work equipment PPC valve
(swing RIGHT)
P8: From L.H. work equipment PPC valve
(swing LEFT)
P9: From travel PPC valve (R.H. travel
REVERSE)
P10: From travel PPC valve (R.H. travel FOR-
WARD)
P11: From L.H. work equipment PPC valve (arm
OUT)
P12: From L.H. work equipment PPC valve (arm
IN)
P-1: From R.H. attachment PPC valve
P-2: From R.H. attachment PPC valve
PLS1: To rear pump LS valve
PLS2: To front pump LS valve
PLSC: LS pressure pickup port
PP1: From rear pump
PP2: From front pump
PP1S: Front pump oil pressure sensor mounting
port
PPC: Pilot source pressure pickup port
PP2S: Rear pump oil pressure sensor mounting
port
PPS2: To front pump LS valve
PR: To solenoid valve, PPC valve, and EPC
valve
PST: From travel junction solenoid valve
PC200, 200LC, 220, 220LC-8M0 10-402 3

10-402 4 PC200, 200LC, 220, 220LC-8M0

1. Pressure compensation valve (arm OUT) 12. Pressure compensation valve (R.H. travel
2. Pressure compensation valve (R.H. travel FORWARD)
REVERSE) 13. Pressure compensation valve (arm IN)
3. Pressure compensation valve (swing RIGHT) 14. Main relief valve
4. Pressure compensation valve (boom RAISE) 15. Unload valve
5. Pressure compensation valve (L.H. travel 16. Main relief valve
REVERSE) 17. Spool (service)
6. Pressure compensation valve (bucket DUMP) 18. Spool (bucket)
7. Pressure compensation valve (service) 19. Spool (L.H. travel)
8. Pressure compensation valve (bucket CURL) 20. Spool (boom)
9. Pressure compensation valve (L.H. travel 21. Spool (swing)
FORWARD) 22. Spool (R.H. travel)
10. Pressure compensation valve (boom LOWER) 23. Spool (arm)
11. Pressure compensation valve (swing LEFT)
Unit: mm
Free length x Load at Load at
Installed
Outside diame- installed Free length installed
24 Spool return spring length
ter length length
407 N 326 N
55.2 x 34.4 51.2 — If damaged or
{41.5 kg} {33.2 kg}
deformed,
393 N 315 N replace spring.
25 Spool return spring 54.5 x 34.8 51.2 —
{40.1 kg} {32.1 kg}
375 N 300 N
{38.2 kg} {30.6 kg}
421 N 336 N
{42.9 kg} {34.3 kg}
PC200, 200LC, 220, 220LC-8M0 10-402 5

10-402 6 PC200, 200LC, 220, 220LC-8M0

1. Suction valve (arm OUT) 11. Suction valve (R.H. travel FORWARD)
2. Suction valve (R.H. travel REVERSE) 12. Suction safety valve (arm IN)
3. Suction valve (boom RAISE) 13. LS shuttle valve (arm)
4. Suction valve (L.H. travel REVERSE) 14. LS shuttle valve (R.H. travel)
5. Suction safety valve (bucket DUMP) 15. LS selector valve
6. Suction safety valve (service) 16. LS shuttle valve (boom)
7. 2-stage suction safety valve (service) 17. LS shuttle valve (L.H. travel)
8. Suction safety valve (bucket CURL) 18. LS shuttle valve (bucket)
9. Suction valve (L.H. travel FORWARD) 19. LS shuttle valve (service)
10. Suction safety valve (boom LOWER) 20. LS check valve
Unit: mm
Installed
21 Suction valve spring length If damaged or
ter length length
deformed,
5.5 N 4.4 N replace spring.
46.8 x 7.5 40.6 —
{0.56 kg} {0.45 kg}
1.5 N 1.2 N
22 Check valve spring 11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg}
PC200, 200LC, 220, 220LC-8M0 10-402 7

10-402 8 PC200, 200LC, 220, 220LC-8M0

1. Unload valve R.H. travel valve

2. Suction safety valve for hydraulic drift preven- 14. LS shuttle valve
tion valve (boom “RAISE” and arm “OUT”) 15. Pressure compensation valve (FORWARD)
3. Main relief valve 16. Spool
4. Variable back pressure valve 17. Suction valve (FORWARD)
18. Suction valve (REVERSE)
Arm valve 19. Pressure compensation valve (REVERSE)
5. LS shuttle valve
6. Arm quick return valve Swing valve
7. Pressure compensation valve (IN) 20. LS selector valve
8. Spool 21. Pressure compensation valve (L.H.)
9. Suction safety valve (IN) 22. Spool
10. Cooler check valve 23. Pressure compensation valve (R.H.)
11. Regeneration circuit check valve
12. Suction valve (OUT)
13. Pressure compensation valve (OUT)
Unit: mm
Installed
24 Check valve return spring length
ter length length
14.7 N 11.8 N
59.3 x 14.4 43 —
{1.5 kg} {1.2 kg}
13.7 N 11 N
25 Check valve spring 33.8 x 6 29 — If damaged or
{1.4 kg} {1.12 kg}
deformed,
170 N 135 N replace spring.
26 Piston return spring 60.2 x 20 36 —
{17.3 kg} {13.8 kg}
5.9 N 4.71 N
{0.6 kg} {0.48 kg}
157 N 126 N
28 Piston return spring 88.2 x 28.4 65 —
{16 kg} {12.8 kg}
36.1 N 28.8 N
29 Piston return spring 18.0 x 9.3 13.4 —
{3.68 kg} {2.94 kg}
PC200, 200LC, 220, 220LC-8M0 10-402 9

10-402 10 PC200, 200LC, 220, 220LC-8M0

1. Return spring L.H. travel valve

2. Merge-divider valve (for LS) 15. Merge-divider valve (travel junction valve)
3. Valve (sequence valve) 16. Return spring
4. Spring (sequence valve) 17. LS shuttle valve
5. Merge-divider valve (main) 18. Pressure compensation valve (FORWARD)
6. Return spring 19. Spool
20. Suction valve (FORWARD)
Boom valve 21. Suction valve (REVERSE)
7. Boom hydraulic drift prevention valve 22. Pressure compensation valve (REVERSE)
8. LS shuttle valve
9. Pressure compensation valve (LOWER) Bucket valve
10. Spool 23. LS shuttle valve
11. Suction safety valve (LOWER) 24. Pressure compensation valve (CURL)
12. Regeneration circuit check valve 25. Spool
13. Suction valve (RAISE) 26. Suction safety valve (CURL)
14. Pressure compensation valve (RAISE) 27. Suction safety valve (DUMP)
28. Pressure compensation valve (DUMP)
Unit: mm
Installed
29 Spool return spring length
ter length length
121 N 96.5 N
36.4 x 21.8 33.0 —
{12.3 kg} {9.84 kg}
250 N 200 N
{25.5 kg} {20.4 kg}
If damaged or
178 N 142 N
31 Spool return spring 64.5 x 32.3 63.0 — deformed,
{18.1 kg} {14.5 kg}
replace spring.
35.3 N 28.2 N
{3.6 kg} {2.88 kg}
13.7 N 11.0 N
{1.4 kg} {1.12 kg}
5.9 N 4.71 N
34 Piston return spring 31.5 x 10.3 19.5 —
{0.6 kg} {0.48 kg}
50.0 N 40.0 N
35 Piston return spring 30.7 x 20.5 23 —
{5.1 kg} {4.08 kg}
PC200, 200LC, 220, 220LC-8M0 10-402 11

1. LS shuttle valve Structure

2. Pressure compensation valve q The control valves of the following types are
3. Spool set.
4. 2-stage suction safety valve 6-spool valve (without service valve)
5. Suction safety valve 7-spool valve (6-spool valve with service valve)
6. Unload valve q This control valve consists of a 6-spool valve
7. Main relief valve (unit type) and a set of service valve. A merge-
8. LS bypass plug divider valve, a variable back pressure valve
and a boom hydraulic drift prevention valve are
installed to it.
q Since all the valves are assembled together
with connecting bolts and their passes are con-
nected to each other inside the assembly, the
assembly is compact and easy to maintain.
q With one spool provided for one work equip-
ment, this control valve is simple in structure.
10-402 12 PC200, 200LC, 220, 220LC-8M0

CLSS SEN06120-01
CLSS 1
CLSS: Abbreviation for Closed center Load Sensing System
Structure of CLSS
CLSS: Abbreviation for Closed center Load Sensing System
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Features Configuration
q Fine control not influenced by load q CLSS consists of variable capacity piston
q Control performance that allows digging even pump, control valve, and actuators.
when fine control operation is turned on q The main pump consists of pump itself, PC
q Ease of combined operation enabled by the valve and LS valve.
flow divider function that is determined by the
opening areas of spools during combined
operations
q Energy saving by variable pump control
PC200, 200LC, 220, 220LC-8M0 10-402 13

SEN06120-01 CLSS
Basic principle q If it becomes higher than the set pressure

Pump swash plate angle control (when the actuator load pressure is low), the
q The pump swash plate angle (pump discharge) pump swash plate angle shifts toward the mini-
is controlled so that LS differential pressure mum position.
(dPLS), which is the difference between pump
discharge pressure (PP) and LS pressure LS differential pressure (dPLS) and pump
(PLS)) (load pressure of actuator) at control swash plate angle
valve outlet, is constant.
q [LS differential pressure (dPLS) = Pump dis-
charge pressure (PP) - LS pressure (PLS)]
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q The pump swash plate angle shifts toward the

maximum position if LS differential pressure
(dPLS) is lower than the set pressure of the LS
valve (when the actuator load pressure is
high).
10-402 14 PC200, 200LC, 220, 220LC-8M0

CLSS SEN06120-01
Pressure compensation control
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q A pressure compensation valve is installed to the outlet port side of each control valve to balance the
load pressure.
q When actuators are operated in combination, the pressure difference (dP) between the upstream (inlet
port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of
the load (pressure).
q The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.
PC200, 200LC, 220, 220LC-8M0 10-402 15

SEN06120-01 CLSS
System diagram
a The illustration shows the state when actuator (7) is relieved at the stroke end in the merge mode.

*
1. Front pump 9. LS circuit

2. Rear pump 10. Tank circuit
3. Main relief valve 11. Valve
4. Unload valve 12. Spring
5. Merge-divider valve 13. LS bypass plug
6. Control valve 14. LS valve
7. Actuator 15. PC valve
8. Pump circuit
10-402 16 PC200, 200LC, 220, 220LC-8M0

Functions and operation by valve SEN06120-01
Functions and operation by valve 1

Hydraulic circuit diagram and name of valves
PC200, 200LC, 220, 220LC-8M0 10-402 17

SEN06120-01 Functions and operation by valve
1. Arm valve 33. Main relief valve (for arm, R.H. travel, and
2. R.H. travel valve swing circuits)
3. Swing valve Set pressure:
4. Boom valve 35.4 ± 0.3 MPa {360.5 ± 3 kg/cm2}
5. L.H. travel valve When one-touch power max. switch is set
6. Bucket valve to ON position:
7. Service valve 38.0 ± 0.3 MPa {387 ± 3 kg/cm2}
8. Spool (arm) 34. Unload valve (for boom, L.H. travel, bucket,
9. Spool (R.H. travel) and attachment circuits)
10. Spool (swing) Cracking pressure:
11. Spool (boom) 2.5 ± 0.5 MPa {26 ± 5 kg/cm2}
12. Spool (L.H. travel) 35. Unload valve (for arm, R.H. travel, and swing
13. Spool (bucket) circuits)
14. Spool (service) Cracking pressure:
15. Pressure compensation valve 2.5 ± 0.5 MPa {26 ± 5 kg/cm2}
16. Suction valve 36. Suction safety valve
17. Check valve (for boom regeneration circuit) Set pressure:
18. Check valve (for arm regeneration circuit) 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}
19. Pump merge-divider EPC valve (for LS spool) 37. Suction safety valve
20. Pump merge-divider EPC valve (for main Set pressure:
spool) 38.9 ± 0.5 MPa {397 ± 5 kg/cm2}
21. LS shuttle valve 38. Suction safety valve
22. LS bypass plug Set pressure:
23. LS selector valve 31.4 ± 0.5 MPa {320 ± 5 kg/cm2}
24. Merge-divider valve 39. Suction 2-stage safety valve
25. Arm quick return valve 1st stage set pressure:
26. Self-pressure reducing valve 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}
27. Travel junction valve 2nd stage set pressure:
28. Variable back pressure valve 20.6 ± 0.5 MPa {210 ± 5 kg/cm2}
29. Variable back pressure solenoid valve 40. Suction safety valve for hydraulic drift preven-
30. Cooler check valve tion valve
31. Boom hydraulic drift prevention valve Set pressure:
32. Main relief valve (for boom, L.H. travel, bucket, 38.9 ± 0.5 MPa {397 ± 5 kg/cm2}
and attachment circuits)
Set pressure:
35.4 ± 0.3 MPa {360.5 ± 3 kg/cm2}
When one-touch power max. switch is set
to ON position:
38.0 ± 0.3 MPa {387 ± 3 kg/cm2}
10-402 18 PC200, 200LC, 220, 220LC-8M0

Unload valve

E
D F *
1. LS circuit
2. Valve
3. Pump circuit
4. Tank circuit
5. Spring
Function
q When all control valves are at HOLD, this valve q During operation (when a given work is done
serves to drain as same amount of oil as the within the discharge available with the mini-
pump discharge with swash plate angle at the mum swash plate angle), the discharge pres-
minimum. sure corresponding to the minimum pump
q The pump pressure becomes the pressure cor- swash plate angle is set to LS pressure + P1
responding to the set load of spring (5) in the pressure.
valve (referred to as P1). q The LS differential pressure (dPLS) with the
q Since LS pressure is drained from LS bypass swash plate angle at the minimum becomes
valve, LS pressure C tank pressure C 0 MPa {0 P1 pressure.
kg/cm2}.
Operation
q Pressure of pump circuit (3) is received by the
end of valve (2).
q Since the control valve is in NEUTRAL posi-
tion, pressure of LS circuit (1) is 0 MPa {0 kg/
cm2}.
q Pressurized oil of pump circuit (3) stops at
valve (2), and the pressure rises as no relief is
available.
q If this pressure grows larger than the force of
spring (5), valve (2) moves to the left.
q Ports (b) and (c) are interconnected, and the
pump pressurized oil flows to tank circuit (4).
q The pressurized oil of LS circuit (1) passes
from orifice (a) through port (c) and is drained
to tank circuit (4).
q When this valve is actuated, the LS pressure
becomes nearly equal to the tank pressure.
q Since the pump discharge pressure - LS circuit
pressure during unloading is larger than pump
LS control pressure, the signal is output to min-
imize the pump swash plate angle.
PC200, 200LC, 220, 220LC-8M0 10-402 19

Operation of relief valve

q When cylinder reaches its stroke end, main
relief valve opens.
q Pump discharge (Q) is relieved to the tank.
(For details, see “System diagram” of “Struc-
ture of CLSS”.)
q Since the pump discharge pressure (PP) and
LS pressure (PLS) do not flow neither to the
upstream nor downstream, they become
approximately the same and LS differential
pressure (dPLS) becomes 0 MPa {0 kg/cm2}.
q As LS differential pressure (dPLS) is lower
than the LS set pressure of LS valve, LS valve
operates to make the pump swash plate angle
maximum.
q Mechanically, operation of PC valve has prior-
ity over that of LS valve.
q The pump is maintained at the minimum swash
plate angle due to PC valve cut-off function.
10-402 20 PC200, 200LC, 220, 220LC-8M0

Introduction of LS pressure
LS: Abbreviation for Load Sensing
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1. Main pump
2. Main spool
3. Pressure compensation valve
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function Operation
q The upstream pressure (spool meter-in down- q When main spool (2) is operated, the pump
stream pressure) of pressure compensation pressure is transmitted to port (c) through lead-
valve (3) is transmitted and led to LS shuttle ing hole (a) and is led to LS circuit.
valve (7) as LS pressure. q When the pump pressures rises to reach the
q Connected to actuator port (B) through valve load pressure of port (B), check valve (5)
(4), and makes LS pressure C actuator load opens and the pressurized oil flows.
pressure.
q In main spool (2), leading hole (a) with a small
diameter also acts as an orifice.
q LS pressure works as source pressure when
closing unload vale while control lever is oper-
ated, and this pressure also functions as oper-
ating pressure when pressure compensation
valve is compensated.
PC200, 200LC, 220, 220LC-8M0 10-402 21

LS bypass plug
LS: Abbreviation for Load Sensing
D E

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1. Main pump
2. Main spool
4. LS shuttle valve
5. LS bypass plug
6. LS circuit
Function
q This valve relieves the residual pressure in LS
pressure circuit (6) from orifices (a) and (b).
q Slows down the rising rate of LS pressure to
prevent a sudden change of hydraulic pres-
sure.
q Depending on the bypass flow from LS bypass
plug (5), pressure loss is generated due to the
circuit resistance from orifice (c) of main spool
(2) to LS shuttle valve (4).
q Effective LS differential pressure drops to
improve a dynamic stability of the actuator.
10-402 22 PC200, 200LC, 220, 220LC-8M0

Pressure compensation valve

When the work equipment is operated independently and the load pressure is the maximum
(When the load pressure is higher than other work equipment during a combined operation)
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1. Main pump 4. Piston

2. Valve 5. Spring
3. 3.Shuttle valve 6. LS shuttle valve
Function
q Pressure compensation valve works as the
load check valve.
q If the pump pressure (LS pressure) is lower
than the load pressure at port (c), shuttle valve
(3) in pressure compensation valve piston (4)
interconnects spring chamber (E) and port (C).
q The force of spring (5) operates piston (4) and
valve (2) to the closing direction.
Integrated pressure compensation valve

q When a high peak pressure or continuous and
repetitive peak pressure (as in breaker opera-
tion) is generated in the actuator circuit, valve
(2) may collide with valve chamber seat (C),
producing high stress in the parts.
q To prevent this, a pressure compensation
valve with integrated valve (2) and piston (4) is
used.
q With this machine, this valve is adopted for the
travel valve, bucket valve (cylinder bottom),
and the service valve.
PC200, 200LC, 220, 220LC-8M0 10-402 23

When compensated
(When the load pressure is lower than other work equipment during a combined operation)
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Function
q The pressure compensation valve closes by
the LS pressure of port (D), and the spool
meter-in downstream pressure of port (B)
becomes equivalent to the maximum pressure
of other work equipment.
q Since the spool meter-in upstream pressure of
port (A) is the pump pressure, the spool meter-
in differential pressure [upstream pressure port
(A) pressure] - downstream pressure [port (B)
pressure] becomes equivalent to all the spools
in operation.
q Pump flow is divided according to the ratio of
the meter-in opening areas.
Operation
q Spring chamber (E) is interconnected to port
(D).
q Piston (4) and valve (2) are moved in the clos-
ing direction (to the right) by the LS circuit
pressure of port (F) from other work equip-
ment.
q Valve upstream pressure (= spool meter-in
downstream pressure) of port (B) is controlled
with the LS pressure.
10-402 24 PC200, 200LC, 220, 220LC-8M0

Area ratio of pressure compensation valve
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Function
q The state of division changes according to the area ratio of pressure compensation portions (A1) and
(A2). Area ratio = (A2)/(A1)
q When the area ratio is equal to 1: As the spool meter-in downstream pressure is equal to the maximum
load pressure, the oil flow is divided in the ratio as same as the opening area ratio.
q When the area ratio is more than 1: As the spool meter-in downstream pressure is higher than the max-
imum load pressure, the oil flow to the compensated side is divided in a ratio lower than the opening
area ratio.
q When the area ratio is below 1: As the spool meter-in downstream pressure is lower than the maximum
load pressure, the oil flow to the compensated side is divided in a ratio higher than the opening area
ratio.
PC200, 200LC, 220, 220LC-8M0 10-402 25

Shuttle valve in pressure compensation valve

When holding pressure at port (A) becomes higher than LS pressure in spring chamber (B)
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1. Main pump
2. Valve
3. Shuttle valve
4. Piston
Operation
q Shuttle valve (3) is pressed to the right side by the pressure of port (A). As a result, port (A) is discon-
nected from port (C).
q Holding pressure at port (A) is transmitted to the spring chamber (B) to push piston (4) to the left so that
piston (4) is not separated from valve (2).
10-402 26 PC200, 200LC, 220, 220LC-8M0

When traveling
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Structure
q Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve
without shuttle valve (5) is adopted.
PC200, 200LC, 220, 220LC-8M0 10-402 27

Boom regeneration circuit

When cylinder head pressure is lower than bottom pressure (hydraulic drift, etc.)
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1. Main pump
2. Boom valve spool
4. Suction safety valve
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
q The regeneration circuit is installed across the cylinder bottom and cylinder head to increase flow to the
cylinder head when the boom is lowered.
Operation
q When the cylinder head pressure is lower than the bottom pressure, some of pressurized oil (A) from
the cylinder bottom flows to drain circuit (B) from the notch of boom spool (2).
q The remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder bot-
tom through circuit (D).
q Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
10-402 28 PC200, 200LC, 220, 220LC-8M0

When cylinder head pressure is higher than bottom pressure (digging operation, etc.)
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Function
q Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom
to the head.
PC200, 200LC, 220, 220LC-8M0 10-402 29

Arm regeneration circuit

When cylinder head pressure is higher than bottom pressure
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1. Main pump
2. Arm valve spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
q The regeneration circuit installed between the cylinder head and cylinder bottom increases the oil flow-
ing to the cylinder bottom (pump discharge + regeneration flow) during arm IN operation in order to
accelerate the cylinder.
Operation
q When the cylinder head pressure is higher than the bottom pressure, part of pressurized oil (A) from the
cylinder head flows to drain circuit (B) through the notch of arm spool (2).
q The remaining oil flows to the regeneration circuit (C), opens check valve (6), and flows to the cylinder
bottom through circuit (D).
q Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
10-402 30 PC200, 200LC, 220, 220LC-8M0

When cylinder head pressure is lower than bottom pressure
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Function
q Check valve (6) installed to regeneration circuit (C) closes and shuts off the oil flowing from the cylinder
head to the bottom.
PC200, 200LC, 220, 220LC-8M0 10-402 31

Merge-divider valve
When oil flowing from two pumps are merged [pump merge-divider valve changeover signals (IS1)
and (IS2) are OFF]
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1. Main spool
2. Spring
3. LS spool
4. Spring
5. LS circuit (for bucket valve)
6. LS circuit (for bucket valve)
7. LS circuit (for arm valve)
8. LS circuit (for arm valve)
9. Pump merge-divider EPC valve (for main spool changeover)
10. Pump merge-divider EPC valve (for LS spool changeover)
Function Operation
q This valve merges the pressurized oil (P1) and q Since drive signal (IS1) of the EPC valve for
(P2) from the two pumps or divides them the main spool is OFF, the output pressure of
(enables them to flow to respective control the pump merge-divider EPC valve is 0 MPa {0
valve groups). kg/cm2}.
q This valve merges or divides LS circuit pres- q Main spool (1) is pressed to the right by spring
sures as well. (2). As a result, ports (E) and (F) are intercon-
nected.
10-402 32 PC200, 200LC, 220, 220LC-8M0

q Pressurized oil (P1) and (P2) discharged from

the two pumps merge at ports (E) and (F), and
flow to the control valve which requires the oil.
q Since drive signal (IS2) of the EPC valve for
LS spool (3) is also OFF, LS spool (3) is
pressed to the right by spring (4). As a result,
ports (A) and (B) are interconnected and ports
(B) and (C) are interconnected.
q The LS pressures transmitted from respective
control valve spools through LS circuits (5), (6),
(7), and (8) are transmitted to all the pressure
compensation valves.
PC200, 200LC, 220, 220LC-8M0 10-402 33

When oil flowing from two pumps are divided [pump merge-divider valve changeover signals (IS1)
and (IS2) are ON]
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q Since drive signal (IS1) of the main spool is ON, main spool (1) is moved to the left by the output pres-
sure from the pump merge-divider EPC valve. As a result, port (E) is disconnected from port (F).
q The pressurized oil from the two pumps are sent to respective control valve groups.
Pressure P1: To bucket, left travel, boom
Pressure P2: To swing, right travel, arm
q When drive signal (IS2) of the EPC valve for LS spool (3) becomes ON, LS spool (3) is also moved to
the left by the output pressure from the pump merge-divider EPC valve. As a result, ports (A) and (C)
are interconnected, and other ports remain disconnected from each other.
q The LS pressures transmitted from respective control valve spools through LS circuits (5), (6), (7), and
(8) are transmitted to respective control valves.
10-402 34 PC200, 200LC, 220, 220LC-8M0

LS selector valve Operation

LS: Abbreviation for Load Sensing When pilot pressure (BP) is shut off
q Since pilot pressure (BP) is shut off, piston (3)
is pressed to the left by force of spring (2).
q If the swing lever is moved, swing LS pressure
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(P1) passing through swing spool (5) enters
port (A).
q Swing LS pressure (P1) presses valve (1) to
the left, and port (A) and port (B) are intercon-
%3 nected.
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3 port (A) to LS shuttle valve (8) through port (B).
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pressure (BP) moves piston (3) to the right
a The illustration shows the condition when the against the force of spring (2).
combined operation of swing and R.H. travel is q When piston (3) moves to the right, valve (1)
performed. [When pilot pressure (BP) is sup- disconnects ports (A) and (B).
plied] q Since ports (A) and (B) are disconnected,
1. Valve swing LS pressure (P1) is not transmitted to LS
2. Spring shuttle valve (8).
3. Piston q Swing LS pressure (P1) cannot affect other LS
4. Piston circuits, even if it rises.
5. Swing valve spool
6. R.H. travel valve spool
7. Arm valve spool
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9. LS circuit
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q This valve prevents the high LS pressure of the ࠕ21ࠖ
swing valve from entering the LS circuits of

work equipment valves when the swing and
work equipment are in combined operation.
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PC200, 200LC, 220, 220LC-8M0 10-402 35

Self-pressure reducing valve

Function
q This valve serves to reduce the discharge
pressure of main pump and provide it for sole-
noid valves, EPC valves, etc. for use as the
control pressure.
Operation
When engine is stopped
q Poppet (11) is pressed against the seat by
spring (12), so port (PR) is disconnected from
port (TS).
q Valve (14) is pressed to the left by spring (13),
so port (P2) is disconnected from (TS).
q Valve (7) is pressed to the left by spring (8), so
port (P2) is disconnected from port (A2).
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10-402 36 PC200, 200LC, 220, 220LC-8M0

When load pressure (P2) is low When load pressure (P2) is high
a When all control levers are in NEUTRAL posi- q As load pressure (A2) increases with the dig-
tion, or when load pressure (A2) is lower than ging operation, etc, the pump discharge
output pressure (PR) of the self-pressure increases accordingly.
reducing valve q Pressure (P2) increases, and [Force (Area fd
x Pressure P2] becomes larger than [Force of
q Force of spring (8) and the force exerted by the spring (8) + Force (Area fd x Pressure PR)].
pressure (PR) (0 MPa {0 kg/cm 2 }, when As a result, valve (7) moves fully to the right.
engine is stopped), are applied to valve (7) in q Since the area of the opening between ports
the direction to disconnect the circuit ports (P2) (P2) and (A2) increases, the passage resis-
and (A2). tance reduces, reducing the engine horse-
q When the pressurized oil flows in from port power loss.
(P2), valve (7) balances at a position where q When pressure (PR) rises above the set pres-
[Force (Area fd x Pressure P2) = Force of sure, poppet (11) opens.
spring (8) + Force (Area fd x Pressure PR)] q The pressurized oil flows from port (PR) to ori-
holds. fice (a) in spool (14), then flows to seal drain
q The opening of valve (7) is adjusted so that port (TS) from the opening of poppet (11).
pressure (P2) remains at a constant level q Differential pressure generated across orifice
higher than pressure (PR). (a) in spool (14) moves spool (14) in the direc-
q When pressure (PR) rises above the set pres- tion that the spool closes the opening between
sure, poppet (11) opens. ports (P2) and (PR).
q The pressurized oil flows from port (PR) to ori- q Pressure (P2) is reduced to a constant pres-
fice (a) in spool (14), then flows to seal drain sure (the set pressure) by the opening and
port (TS) from the opening of poppet (11). supplied for use as pressure (PR).
q Differential pressure generated across orifice
(a) in spool (14) moves spool (14) in the direc-
tion that the spool closes the opening between
ports (P2) and (PR).
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PC200, 200LC, 220, 220LC-8M0 10-402 37

When abnormally high pressure is generated

q If pressure (PR) of the self-pressure reducing
valve becomes abnormally high, ball (16) con-
tracts spring (15) and separates from the seat.
q This allows the pressurized oil to flow to drain
port (TS) from port (PR), lowering pressure
(PR).
q As a result, components such as PPC valves
and solenoid valves are protected from abnor-
mally high pressure.
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10-402 38 PC200, 200LC, 220, 220LC-8M0

Travel junction valve

Function
q When travel control lever is operated for straight-travel, travel junction valve does not receive the pilot
pressure (PST) from travel junction solenoid valve, thus right and left travel circuits interconnect each
other, and equal amount of oil is supplied to right and left travel motors to secure straight-travel ability.
q When travel control lever is operated for turning, travel junction valve receives the pilot pressure (PST)
from travel junction solenoid valve, thus right and left travel circuits are shut off each other, and indepen-
dent amount of oil is supplied to right and left travel motors to secure turning ability.
PC200, 200LC, 220, 220LC-8M0 10-402 39

Operation
When pilot pressure (PST) is shut off (travel junction)
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q If pilot pressure (PST) from the travel junction solenoid valve is shut off, travel junction spool (2) is
pressed back towards right by the force of spring (1). As a result, ports (PTL) and (PTR) are intercon-
nected.
q If the oil flow rates to the R.H. and L.H. travel motors become different from each other, the oil flows
through the opening of travel junction spool (2) from port of higher pressure side to port of lower pres-
sure side supplying the difference of oil to the lower pressure side so that the oil flow rates to both
motors will be equalized.
10-402 40 PC200, 200LC, 220, 220LC-8M0

When pilot pressure (PST) is supplied (travel independent)
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q When pilot pressure (PST) from the travel junction solenoid valve is supplied, travel junction spool (2)
compresses spring (1) to the left side and ports (PTL) and (PTR) are disconnected.
q The oil flow rate to both right and left motors becomes independent.
PC200, 200LC, 220, 220LC-8M0 10-402 41

Travel PPC shuttle valve

PPC: Abbreviation for Proportional Pressure Control
Function
q If boom RAISE, arm IN or OUT, bucket CURL or DUMP operation is performed when the machine is
traveling up a steep, the pilot pressure from the travel PPC valve serves to restrict the travel of respec-
tive spools of boom, arm and bucket valves so that the oil flow rates to respective cylinders are
restricted.
q To limit the travel of the boom, arm or bucket spool, the pilot pressure from the travel PPC valve passes
through the internal circuit of respective control valves and acts on the spool.
Operation
When travel levers are in NEUTRAL

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q The oil in the stroke limiting signal chamber (a) passes through orifices (5) and (6) of respective pistons
(3) and (4) build in the travel spring case, and then is drained through the travel PPC valve.
q When boom RAISE (or arm IN or OUT, bucket CURL or DUMP) operation is performed, spool (1) moves
to the left until it contacts the end face of spring case (2) (st0).
10-402 42 PC200, 200LC, 220, 220LC-8M0

When travel lever is operated

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q If the right travel lever is moved to REVERSE (or FORWARD) position, the pilot pressure from the travel
PPC valve moves spool (7) to the left (or right).
q Spool (7) pushes piston (3) and orifice (5) is closed. As a result, stroke limiting signal chamber (a) and
the drain circuit from the travel PPC valve are disconnected.
q At this time, the pilot pressure from the travel PPC valve passes through orifice (6) of piston (4), acts on
the left end of piston (8) and pushes piston (8) to the right.
q When boom RAISE (or arm IN or OUT, bucket CURL or DUMP) operation is performed, spool (1) moves
to the left.
q Maximum travel of the spool is limited to (st1) that has reduction in travel by the amount of movement
(st2) of piston (8) to the right.
PC200, 200LC, 220, 220LC-8M0 10-402 43

Boom hydraulic drift prevention valve

Function
q While boom is not operated by the right work equipment control lever, the hydraulic drift prevention
valve prevents pressurized oil to leak from boom cylinder bottom through spool (1) to prevent the boom
from drifting hydraulically.
Operation
In boom “RAISE” operation
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q When operating boom “RAISE”, the pressurized oil from the control valve exerts a left-hand force on the
right side of ring-shaped area (S), of which outside diameter is poppet (5) diameter (d1) and of which
inside diameter is seat diameter (d2).
q The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
q As a result, the pressurized oil from the control valve passes through the opening of poppet (5) and
flows to the boom cylinder bottom.
10-402 44 PC200, 200LC, 220, 220LC-8M0

In boom “NEUTRAL” operation
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q When the boom is operated to “NEUTRAL” position, the pressurized oil flowing inside poppet (5)
through orifice (a) of poppet (5) is stopped by pilot piston (2).
q The holding pressure of boom cylinder bottom exerts a right-hand force on the left side of ring-shaped
area (S), of which outside diameter is poppet (5) diameter (d1) and of which inside diameter is seat
diameter (d2).
q The combined force of right-hand force on area (S) and the spring force of spring (4) moves poppet (5)
to the right.
q The circuit from control valve to boom cylinder bottom shuts off, then the oil pressure of the boom cylin-
der bottom side is kept.
PC200, 200LC, 220, 220LC-8M0 10-402 45

In boom “LOWER” operation
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q When operating boom “LOWER”, the pilot pressure from the PPC valve pushes pilot piston (2).
q The pressurized oil of the boom cylinder bottom flows from orifice (c) to drain port (T) through orifice (a)
and chamber (b).
q Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b)
drops.
q As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
q As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control
valve.
10-402 46 PC200, 200LC, 220, 220LC-8M0

Arm hydraulic drift prevention valve

(if equipped)
Function
q While arm is not operated by the left work equipment control lever, the hydraulic drift prevention valve
prevents pressurized oil to leak from arm cylinder head through spool (1) to prevent the arm from drifting
hydraulically.
Operation
In arm “OUT” operation
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q During arm “OUT” operation, the pressurized oil from the control valve exerts a left-hand force on the
right side of area (S) of ring-shaped surface, of which outside diameter is equal to diameter (d1) of pop-
pet (5) and of which inside diameter is equal to seat diameter (d2).
q The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
q As a result, pressurized oil from the control valve flows to the arm cylinder head through the opening of
poppet (5).
PC200, 200LC, 220, 220LC-8M0 10-402 47

In arm “NEUTRAL” operation
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q When the arm is operated to “NEUTRAL” position, the pressurized oil flowing inside poppet (5) through
orifice (a) of poppet (5) is stopped by pilot piston (2).
q The holding pressure of arm cylinder head exerts a right-hand force on the left side of ring-shaped area
(S), of which outside diameter is equal to diameter (d1) of poppet (5) and of which inside diameter is
equal to seat diameter (d2).
q The combined force of right-hand force on area (S) and the reaction force of spring (4) moves poppet (5)
to the right.
q The circuit from control valve to arm cylinder head shuts off, then the oil pressure of the arm cylinder
head side is kept.
10-402 48 PC200, 200LC, 220, 220LC-8M0

In arm “IN” operation
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q When arm is operated “IN”, the pilot pressure from the PPC valve pushes pilot piston (2).
q The pressurized oil of the arm cylinder head flows from orifice (c) to drain port (T) through orifice (a) and
chamber (b).
q Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b)
drops.
q As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
q As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control
valve.
PC200, 200LC, 220, 220LC-8M0 10-402 49

Suction safety valve for hydraulic drift prevention valve

Operation when abnormally high pressure is generated
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q If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port
(B) opens check valve (6) to actuate safety valve (3).
q When the arm hydraulic drift prevention valve (optional) is installed to the arm cylinder head circuit, the
pressurized oil of the boom cylinder bottom circuit pressure or arm cylinder head circuit pressure, which-
ever has higher pressure, opens check valve (6) or (6A) to actuate safety valve (3).
10-402 50 PC200, 200LC, 220, 220LC-8M0

Arm quick return valve
Function
q Large amount of oil is returned from the cylinder bottom when arm OUT operation is performed.
q The valve reduces this pressure loss.
Operation
In arm “OUT” operation
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q In arm “OUT” operation, the pilot pressure from the PPC valve pushes pilot piston (1).
q The pressurized oil in chamber (b) inside the valve is drained through orifice (c).
q The pressurized oil of the arm cylinder bottom side flows from orifice (c) to drain port (T) through orifice
(a) and chamber (b).
q Chamber (b) and drain port (T) are interconnected, and the pressure of chamber (b) drops.
q If the pressure in chamber (b) drops lower than that of port (A), the force exerted on the pressure receiv-
ing surface of [Area (S2) of fd2 (surface of seat diameter)] on the port (A) side exceeds the combined
force of the force exerted on the pressure receiving surface [Area (S1) of fd1] on the chamber (b) side
of valve (2) and the spring force.
q The result is, (Force exerted on surface of fd2 > Force exerted on surface of fd1 + Force of spring).
q Valve (2) is pressed to the right and pressurized oil flows from port (A) to port (B).
q The pressurized oil of the arm cylinder bottom side is drained directly to the tank from port (B).
PC200, 200LC, 220, 220LC-8M0 10-402 51

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q When the arm is operated from arm “OUT” to “NEUTRAL, the pilot pressure from PPC valve is shut off.
q The pressurized oil that flows in through orifice (a) in valve (2) and is drained, is stopped by pilot piston
(1).
q The holding pressure of the arm cylinder bottom side exerts a left-hand force on the right side of ring-
shaped surface, whose area is equal to the area of (S2 - S1) of valve (2).
q The combined force of the force exerted on the ring-shaped surface and the spring force of the spring
(3) moves valve (2) to the left and shuts off port (A) and port (B).
10-402 52 PC200, 200LC, 220, 220LC-8M0

Variable back pressure valve When engine is running (during swing or travel
operation)
Function q The pressurized oil (PR) from self-pressure
q This valve creates back pressure in the drain reducing valve (1) flows to variable back pres-
circuit to prevent cavitation caused by negative sure solenoid valve (3).
pressure in each actuator circuit (motors, cylin- q Since drive signal (IS3) of variable back pres-
ders, etc.). sure solenoid valve (3) is “OFF”, pressurized
q In order to reduce output loss, this valve oil (PR) is flown to spring chamber (C) of vari-
reduces the back pressure in the drain circuit able back pressure valve (4).
when any operation other than the travel and q Pressurized oil (PR) transmitted to spring
swing is performed. chamber (C) exerts a force on the left end face
of valve (6) (surface of fd), and it pushes valve
Operation (6) to the right as a combined force with the
When engine is stopped reaction force of spring (5).
q Pressurized oil is not supplied from the main q Pressure (PA) of drain circuit (A) of the control
pump to self-pressure reducing valve (1). valve acts on the right end face of valve (6)
q No oil pressure is transmitted from variable (surface of fd1) to push valve (6) to the left.
back pressure solenoid valve (3) to spring q Valve (6) balances at a position where it cre-
chamber (C), and valve (6) is pressed to the ates back pressure (PA) determined as fol-
right by the reaction force of spring (5). lows; PA = (Area of surface fd) x Pressure
q Drain circuit (A) of the control valve is intercon- (PR) + Reaction force of spring (5) / Area of
nected to port (T) through orifice (b) of valve surface fd1
(6). q Accordingly, the oil flow rate from drain circuit
(A) of the control valve to port (T) is limited. In
other words, the set pressure of variable back
pressure valve (4) is adjusted.
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PC200, 200LC, 220, 220LC-8M0 10-402 53

When engine is running (other than swing or

travel operation)
q The pressurized oil from self-pressure reduc-
ing valve (1) flows to variable back pressure
solenoid valve (3).
q Since drive signal (IS3) of variable back pres-
sure solenoid valve (3) is “ON”, the pressur-
ized oil (PR) from self-pressure reducing valve
(1) flown to spring chamber (C) of variable
back pressure valve (4) is drained through
variable back pressure solenoid valve (3).
q Only the reaction force of spring (5) pushes
valve (6) to the right.
q Pressure (PA) of drain circuit (A) of the control
valve acts on the right end face of valve (6)
(surface of fd1) to push valve (6) to the left.
q Valve (6) balances at a position where it cre-
ates back pressure (PA) determined as fol-
lows; PA = Reaction force of spring (5) / Area
of surface fd1
q Accordingly, the oil flow rate from drain circuit
(A) of the control valve to port (T) is limited. In
other words, the set pressure of variable back
pressure valve (4) is adjusted.
&

3$
76 7 $ G
,6 35

*
10-402 54 PC200, 200LC, 220, 220LC-8M0

Main relief valve
1. Spring
2. Poppet
Function
q This valve has two selectable settings for its set pressure.
q If the extra power is necessary, this valve is set to the high-pressure setting when pilot pressure (P) is
applied to it from the 2-stage relief solenoid valve.
q The relief valve set pressure is determined by the load at installed length of spring (1). (1st stage set
pressure)
q When the 1st stage set pressure is set correctly, the 2nd stage set pressure does not need to be set.
Setting the 1st stage set pressure completes the setting of the 2nd stage set pressure.
Operation
When pilot pressure (P) is shut off (low pressure setting)
q The set pressure is determined by the load at installed length of spring (1).
When pilot pressure (P) is supplied (high pressure setting)

q The load at installed length of spring (1) is added with the force exerted by pilot pressure (P) applied to
the area of diameter (d1) of poppet (2), raising the set pressure to higher level.
PC200, 200LC, 220, 220LC-8M0 10-402 55

2-stage suction-safety valve

[Installed to port (B) of the service valve]
1. Spring
2. Piston
3. Spring
4. Holder
Function
q This valve has two settings for its set pressure.
q This valve is set to the low-pressure setting when the pilot pressure is applied to it from the attachment
circuit selector solenoid valve.
q ON/OFF of the pilot pressure changes the set pressure according to the type of the installed attachment
(breaker, crusher, etc.).
q The set pressure of this valve is determined by the load at installed length of spring (1). (High-pressure
side)
q The set pressure of the low-pressure setting is determined by the travel of the piston.
10-402 56 PC200, 200LC, 220, 220LC-8M0

Operation When pilot pressure (P) is supplied (low pres-

When pilot pressure (P) is shut off (high pressure setting)
sure setting) q When pilot pressure (P) is supplied, the pilot
q Since pilot pressure (P) is shut off, piston (2) is pressure is transmitted to part (A) through pas-
pressed to the left by force of spring (3). [Load sage (B).
at installed length of spring (1) < Load at q The pilot pressure acts on the pressure receiv-
installed length of spring (3).] ing diameter at part (A) [(d1) — (d2)] of piston
q The load at installed length of spring (1) (2).
becomes maximum, inducing high-pressure q Piston (2) compresses spring (3) by receiving
setting. pilot pressure and moves to the right until it
q Passage (B) is interconnected to the drain cir- contacts holder (4).
cuit via passage (C) and chamber (D). q Since spring (1) is expanded and reducing its
load at installed length, the set pressure is low-
ered.
q The amount of pressurized oil for stroke of pis-
%
ton (2) is drained from passage (C) via cham-
ber (D) .
3
$ %
' & 6WURNH

3
*
G G
' &
*
PC200, 200LC, 220, 220LC-8M0 10-402 57

SEN06120-01

© 2018 KOMATSU
All Rights Reserved
10-402 58
SEN06121-02
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

Swing motor ......................................................................................................................................... 2
Center swivel joint .............................................................................................................................. 10
Travel motor ....................................................................................................................................... 12
PPC valve .......................................................................................................................................... 22
Valve control....................................................................................................................................... 42
Solenoid valve.................................................................................................................................... 44
PPC accumulator ............................................................................................................................... 46
Return oil filter .................................................................................................................................... 47
Return oil filter with clogging sensor .................................................................................................. 48
Attachment circuit selector valve........................................................................................................ 50
Hydraulic cylinder............................................................................................................................... 52
PC200, 200LC, 220, 220LC-8M0 10-403 1

SEN06121-02 Swing motor
Swing motor 1
Type: KMF125ABE-6
B: From swing brake solenoid valve Specifications

MA: From control valve (swing RIGHT)
MB: From control valve (swing LEFT) Models PC200-8M0, PC220-8M0,
Item PC200LC-8M0 PC220LC-8M0
S: From control valve
T: To tank Type KMF125ABE-6
1. Reverse prevention valve Theoretical displacement 125 cm3/rev
2. Safety valve Safety valve set pressure 28.4 MPa {290 kg/cm2}
Rated engine speed 1,694 rpm 1,879 rpm
Brake release pressure 1.4 MPa {14 kg/cm2}
10-403 2 PC200, 200LC, 220, 220LC-8M0

Swing motor SEN06121-02
PC200, 200LC, 220, 220LC-8M0 10-403 3

1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10. Cylinder block
11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Shuttle valve
Unit: mm
Standard size Repair limit
Free length x Installation Installation Installation

Free length
Outside diameter length load load
16 Check valve spring If damaged or
3.43 N 2.74 N
57.2 x 20.0 30.9 — deformed, replace
{0.35 kg} {0.27 kg}
spring.
13.7 N 11.0 N
17 Shuttle valve spring 16.4 x 8.9 11.5
{1.4 kg}
—
{1.12 kg}
10-403 4 PC200, 200LC, 220, 220LC-8M0

Model: KMF125AB-6 (For Asian specification)
B: From swing holding brake solenoid valve Specifications

MA: From control valve (swing RIGHT)
MB: From control valve (swing LEFT) Models PC200-8M0, PC220-8M0,
Item PC200LC-8M0 PC220LC-8M0
S: From control valve
T: To hydraulic tank Model KMF125AB-6
1. Safety valve Theoretical displacement 125 cm3/rev
Safety valve set pressure 28.4 MPa {290 kg/cm2}
Rated engine speed 1,694 rpm 1,879 rpm
Brake release pressure 1.4 MPa {14 kg/cm2}
PC200, 200LC, 220, 220LC-8M0 10-403 5

10-403 6 PC200, 200LC, 220, 220LC-8M0

1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10. Cylinder block
11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Shuttle valve
Unit: mm
Load at Load at
Free length x Installed
installed Free length installed
Outside diameter length
16 Check valve spring length length
If damaged or
3.43 N 2.74 N deformed, replace
57.2 x 20.0 30.9 —
{0.35 kg} {0.27 kg} spring.
13.7 N 11.0 N
17 Shuttle valve spring 16.4 x 8.9 11.5
{1.4 kg}
—
{1.12 kg}
PC200, 200LC, 220, 220LC-8M0 10-403 7

Swing holding brake
1. When solenoid valve is de-energized 2. When solenoid valve is energized
Operation Operation
q As the swing holding brake is de-energized, q As the swing brake solenoid valve is ener-
the pressurized oil from the self pressure gized, the valve is switched.
reducing valve is shut off. q The pressurized oil from the self pressure
q Port (B) is connected to tank circuit (T). reducing valve is conducted brake chamber (a)
q Brake piston (7) is pushed down by brake through port (B).
spring (1). q After entering chamber (a), the pressurized oil
q Disc (5) and plate (6) are pushed together, and compresses brake spring (1) and pushes
the brake is applied. brake piston (7) up.
q Disc (5) is separated from plate (6), releasing
the brake.
7
6HOISUHVVXUH
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UHGXFLQJYDOYH
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0
+\GUDXOLFSXPS
6ZLQJEUDNH
VROHQRLGYDOYH 0 6ZLQJEUDNH
+\GUDXOLFSXPS VROHQRLGYDOYH

%
%
DD

*
*
10-403 8 PC200, 200LC, 220, 220LC-8M0

Relief valve portion
Outline 2 When swing is stopped

q The relief valve portion consists of check q When the swing control lever is returned to
valves (2) and (3), shuttle valves (4) and (5), neutral, the supply of pressurized oil from the
and relief valve (1). pump to port (MA) is stopped.
q The pressurized oil from the motor outlet can't
Function return to the tank since the returning circuit to
q When the machine is in the swing holding the tank is closed from control valve (6). Thus,
mode, control valve (6) closes the motor outlet pressure on port (MB) increases.
circuit, but the motor rotation is continued by q Rotation resistance is generated on the motor
inertial force. and hence the brake starts working.
q The motor output, therefore, is abnormally q Shuttle valve (4) is pressed as pressure on
increased, resulting in damaging the motor. port (MB) goes above port (MA).
q In order to prevent the motor damages, the q The pressure on chamber (C) is increased to
relief valve relieves the abnormally high pres- the set pres sure of relief valve (1) and
sure to port (S) from the motor outlet side becomes the same as that of port (MB).
(high-pressure side) of the motor. q A high braking torque works on the motor,
thereby stopping the motor.
Operation q When relief valve (1) is being actuated, the
1 When starting swing relieved pressurized oil and the pressurized oil
q When the swing control lever is operated to the from port (S) are fed to port (MA) through
right- swing, the pressurized oil from the pump is check valve (3).
supplied to port (MA) through control valve (6). q Above prevents cavitation on port (MA).
q The pressure on port (MA) rises, the starting
torque is generated in the motor, and the motor )URPSRUW6
starts to rotate.
q The pressurized oil from the outlet port of the
motor passes from port (MB) through the con-
trol valve (6) and returns to the tank.

)URPSRUW6
&

0% 0$

&

*
0% 0$

*
PC200, 200LC, 220, 220LC-8M0 10-403 9

SEN06121-02 Center swivel joint
Center swivel joint 1
A1 : To L.H. travel motor port (PB) 1. Cover

A2 : From control valve (L.H. travel FORWARD port) 2. Slipper seal
B1 : To L.H. travel motor [Port (PA)] 3. Rotor
B2 : From control valve (L.H. travel REVERSE port) 4. Dust seal
C1 : To R.H. travel motor [Port (PA)] 5. 5. O-ring
C2 : From control valve (R.H. travel FORWARD port) 6. 6. Cover
D1 : To R.H. travel motor [port (PB)] 7. Shaft
D2 : From control valve (R.H. travel REVERSE port)
E1 : To L.H. and R.H. travel motor [port (P)]
E2 : From travel speed increase solenoid valve
DR1 : From L.H. and R.H. travel motor [port (T)]
DR2 : To hydraulic tank 1.
10-403 10 PC200, 200LC, 220, 220LC-8M0

Center swivel joint SEN06121-02
Unit: mm
Standard dimension Standard clearance Allowable clearance
8 Clearance between rotor and shaft Replace
80 0.056 to 0.105 0.111
PC200, 200LC, 220, 220LC-8M0 10-403 11

SEN06121-02 Travel motor
Travel motor 1
L.H. travel motor

PA : From control valve (L.H. travel FORWARD port)
PB : From control valve (L.H. travel REVERSE port)
R.H. travel motor
PA : From control valve (R.H. travel REVERSE port)
PB : From control valve (R.H. travel FORWARD port)
P : From travel speed increase solenoid valve
T : To hydraulic tank
B : Plug (Brake release pressure port)
MA : MA pressure pickup port
MB : MB pressure pickup port
10-403 12 PC200, 200LC, 220, 220LC-8M0

Travel motor SEN06121-02
PC200, 200LC, 220, 220LC-8M0 10-403 13

1. Regulator piston
2. Regulator valve
3. Motor case
5. Check valve
6. Rocker cam
7. Retainer guide
8. Output shaft
9. Pin
10. Retainer
11. Piston
12. Cylinder block
13. Valve plate
14. Counterbalance valve spool
15. Ring
16. Brake piston
17. Plate
18. Disc
19. Ball retainer
Unit: mm
Load at Load at
Outside diameter length
20 Check valve spring length length
7.16 N 5.69 N
32.5 x 6.5 24.2 —
{0.73 kg} {0.58 kg}
If damaged or
2.55 N 2.06 N deformed, replace
21 Check valve spring 13.0 x 6.5 8.5
{0.26 kg}
—
{0.21 kg} spring.
411 N 328 N
22 Spool return spring 58.4 x 30 42.6
{41.9 kg}
—
{33.5 kg}
54.9 N 43.9 N
23 Regulator valve spring 21.5 x 11.1 17.1
{5.6 kg}
—
{4.48 kg}
Specifications
Model HMV120
Min. 82
Theoretical discharge (cm3/rev)
Max. 106.2
Rated pressure: MPa {kg/cm } 2
37.3 {380}
Min. 2,689
Rated speed (rpm)
Max. 1,275
Brake release pressure (MPa {kg/cm2}) 1.18 {12}
Travel speed changeover pressure (MPa {kg/cm }) 2
0.78 {8.0}
10-403 14 PC200, 200LC, 220, 220LC-8M0

Operation of motor
1) At slow speed (motor swash plate angle at maximum)
D 3
7UDYHOVSHHGVROHQRLG
YDOYHGHHQHUJL]HG

E

6HOISUHVVXUH
7UDYHOYDOYH
UHGXFLQJYDOYH
F
*
q As the solenoid valve is de-energized, the pilot q The combined force of the piston propulsion
pressurized oil from the self pressure reducing forces works as the moment of inclining rocker
valve does not flow to port (P). cam (4) toward the maximum swash plate
q Regulator valve (9) is pushed to the right by angle.
spring (10). q The pressurized oil at regulator piston (15)
q Pressurized oil being conducted from the con- passes through orifice (c) of regulator valve (9)
trol valve to end cover (8) by pressing check and is drained to the motor case.
valve (22) is shut off by regulator valve (9). q Rocker cam (4) is inclined in the maximum
q Fulcrum (a) of rocker cam (4) is eccentric to swash plate angle direction. The motor capac-
the working point (b) of the combined force of ity becomes maximum, turning on the low
the propulsion force of cylinder (6). speed travel.
PC200, 200LC, 220, 220LC-8M0 10-403 15

2) At high speed (motor swash plate angle at minimum)
7UDYHOVSHHG
VROHQRLGYDOYH
3 HQHUJL]HG

6HOISUHVVXUH
7UDYHOYDOYH
UHGXFLQJYDOYH
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*
q As the solenoid valve is energized, the pilot

pressurized oil from the self pressure reducing
valve flows to port (P).
q Regulator valve (9) is pushed to the left.
q The pressurized oil from the control valve
passes through passage (d) in regulator valve
(9) and enters regulator piston (15).
q Regulator piston (15) is pushed to the right.
q Rocker cam (4) is inclined in the minimum
swash plate angle direction. The motor capac-
ity becomes minimum, turning on the high
speed travel.
10-403 16 PC200, 200LC, 220, 220LC-8M0

Operation of parking brake
1) When starting travel

7UDYHOYDOYH
H
*
q As the travel lever is operated, pressurized oil

from the pump activates counterbalance valve
spool (19), opening the parking brake circuit.
q The pressurized oil is conducted to chamber
(e) of brake piston (12) and compresses spring
(11), pushing piston (12) toward left.
q Since the pushing force to plate (13) and disc
(14) disappears, plate (13) is separated from
disc (14) and the brake is released.
PC200, 200LC, 220, 220LC-8M0 10-403 17

2) When travel is stopped

7UDYHOYDOYH
I H
*
q As the travel lever is placed in neutral, counter-

balance valve spool (19) returns to the neutral
position and closing the parking brake circuit.
q The pressurized oil in chamber (e) of brake
piston (12) passes through orifice (f) of brake
piston (12) and is drained to the motor case.
q Brake piston (12) is pushed to the right by
spring (11).
q Plate (13) and disc (14) are pushed together,
and the brake is applied.
q As brake piston (12) returns, flow of pressur-
ized oil is reduced with slow return valve (22).
q The time delay will be set to activate the brake
only after the machine has stopped.
10-403 18 PC200, 200LC, 220, 220LC-8M0

Brake valve Operation when pressurized oil is supplied

q The brake valve consists of suction safety q Operating the travel lever conducts the pres-
valve (18A) and counterbalance valve (18). surized oil from the control valve to port (PA).
q Functions and operations of respective compo- q The pressurized oil push-opens suction safety
nents shall conform to the following. valve (18A) and then flows to motor outlet port
(MB) through motor inlet port (MA).
1) Counterbalance valve and check valve q The motor outlet side is closed by suction
safety valve (18B) and spool (19), so the pres-
Function sure at the supply side rises.
q When traveling downhill, the machine travel
speed tends to get faster than the motor
(engine) speed because of the downward force
generated from its own weight.
q If the machine travels with the engine at low
speed, the motor may rotate without load,
causing the machine to run away; resulting in a
very dangerous situation. 7UDYHOYDOYH
q These valves are used to prevent above by
controlling the machine to travel according to 3$ 3% %
the engine speed (pump discharge).
$
7UDYHOYDOYH
0$ 0%
3$ 3%
$
*

0$ 0%
*
PC200, 200LC, 220, 220LC-8M0 10-403 19

q The pressurized oil on the supply side flows to Operation of brake during travelling downhill
chamber (S1) through orifice (E1) and orifice q If indication of the machine runaway is sensed
(E2) of the spool (19). while travelling downhill, the motor will be
q As the pressure in chamber (S1) goes above caused to rotate without load to decrease the
the spool selector pressure, spool (19) is inlet side oil pressure.
pushed toward right. q Pressure in chamber (S1) is released through
q Port (MB) and port (PB) are connected, open- orifices (E1) and (E2).
ing the motor outlet port side and starting the q As the pressure in chamber (S1) goes below
motor rotating. the spool selector pressure, spool (19) is
returned to the left by spring (20) and outlet
port (MB) is throttled.
q The pressure at the outlet port side rises, gen-
erating rotation resistance on the motor to pre-
vent the machine from running away.
q The spool moves to a position where the pres-
sure on outlet port (MB) can be balanced
7UDYHOYDOYH against the machine's own weight and the inlet
port pressure.
3$ 3%
q Oil flow from the outlet circuit is reduced to
ensure the travel speed corresponded to the
pump discharge.

6
7UDYHOYDOYH
0$ 0%
3$ 3%
( (
* 6
0$ 0%
( (
*
10-403 20 PC200, 200LC, 220, 220LC-8M0

2) Safety valve q When the pressure rises above the set pressure
of the suction safety valve, poppet (1) opens.
Function q The pressurized oil passes through notch (A1)
of spool (19) into chamber (MA) of the circuit at
q As long as the machine travel is stopped (or it
the opposite side.
is travelling downhill), the counterbalance q At the time of counterclockwise rotation, it
valve closes the inlet and outlet circuits of the makes reverse operation of clockwise rotation.
motor.
q Since the motor is rotated by inertial force,
pressure in the motor outlet port side is abnor-
mally increased, potentially resulting in dam-
ages on the motor and piping.
q The safety valve releases this abnormal pres-
sure to the inlet port side of the motor in order
to prevent damages to the equipment.
Operation
(1) When travel is stopped
(or when travelling downhill) (Right swing)
q Reduction of the pressure at motor inlet (PA)
decreases the pressure in chamber (S1). (2) When starting travel
q When it drops beyond the spool switching (or when traveling at a constant speed)
pressure, spool (19) is returned to the left by
q As the travel lever is operated, the pressurized
spring (20), reducing the pressure at outlet
oil from the pump moves spool (19) toward right.
passage (B1).
q The passage to the suction safety valve func-
q The motor tries to continue rotation resorting to
tions as a circuit which passes through notch
inertial force, thus pressure on the outlet port
(B2) of spool (19), producing large differential
(MB) is increased.
pressure.
q The pump pressure rises, providing a large
tractional force to the valve.
7UDYHOYDOYH
3$ 3%
7UDYHOYDOYH
3$ 3% %
$
6
6

0$ 0%
$ %
0$ 0%
%
*
*
PC200, 200LC, 220, 220LC-8M0 10-403 21

SEN06121-02 PPC valve
PPC valve 1
Work equipment and swing PPC valve 1
P: From self pressure reducing valve

P1: L.H. PPC valve: Arm OUT port/R.H. PPC valve: Boom LOWER port
P2: L.H. PPC valve: Arm IN port/R.H. PPC valve: Boom RAISE port
P3: L.H. PPC valve: Swing LEFT port/R.H. PPC valve: Bucket CURL port
P4: L.H. PPC valve: Swing RIGHT port/R.H. PPC valve: Bucket DUMP port
T: To hydraulic tank
10-403 22 PC200, 200LC, 220, 220LC-8M0

PPC valve SEN06121-02
PC200, 200LC, 220, 220LC-8M0 10-403 23

1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter
Unit: mm

Installed
Centering spring x Outside installed Free length installed
10 (for ports P3 and P4) diameter
length
length length
If damaged or
17.7 N 14.1 N
42.5 x 15.5 34.0 — deformed,
{1.80 kg} {1.44 kg}
replace spring.
Centering spring 29.4 N 23.5 N
11 (for ports P1 and P2) 44.5 x 15.5 34.0
{3.0 kg}
—
{2.40 kg}
16.7 N 13.3 N
12 Metering spring 26.5 x 8.15 24.9
{1.70 kg}
—
{1.36 kg}
10-403 24 PC200, 200LC, 220, 220LC-8M0

Operation q The relationship of the position of spool (1) and

body (10) [fine control hole (f) is in the middle
1. When in neutral between drain chamber (D) and pump pres-
q Ports (A) and (B) of the control valve and ports sure chamber (PP)] does not change until
(P1) and (P2) of the PPC valve are connected retainer (9) contacts spool (1).
to drain chamber (D) through fine control hole q Metering spring (2) contracts in proportion to
(f) in spool (1). the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
the stroke of the control lever.
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
(same as pressure at port (P1)) and the force
of the return spring of the control valve spool
are balanced.
'
I I
7
3

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3 3
UHGXFLQJYDOYH '

I 7
$ &RQWUROYDOYH %
6HOISUHVVXUH
3 3 33
*
UHGXFLQJYDOYH

2. During fine control $ &RQWUROYDOYH %

(Neutral o fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down. *
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1) through fine control
hole (f).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced
with the pressure at port (P1).
PC200, 200LC, 220, 220LC-8M0 10-403 25

3. During fine control 4. At full stroke

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

'
I 7
3
6HOISUHVVXUH 33
UHGXFLQJYDOYH 3 3

$ &RQWUROYDOYH %

'
I 7
*
I
6HOISUHVVXUH 33
UHGXFLQJYDOYH 3 3
$ &RQWUROYDOYH %
*
10-403 26 PC200, 200LC, 220, 220LC-8M0

Travel PPC valve 1

PPC: Abbreviation for Proportional Pressure Control
P : From self-pressure reducing valve

P1 : To control valve (L.H. travel REVERSE port)
P2 : To control valve (L.H. travel FORWARD port)
P3 : To control valve (R.H. travel REVERSE port)
P4 : To control valve (R.H. travel FORWARD port)
T : To hydraulic tank
PC200, 200LC, 220, 220LC-8M0 10-403 27

1. Plate
2. Case
3. Piston
4. Seal
5. Spool
6. Damper
10-403 28 PC200, 200LC, 220, 220LC-8M0

Unit: mm

Installed
x Outside installed Free length installed
7 Centering spring diameter
length
length length If damaged or
deformed,
108 N 86.3 N replace spring.
48.6 x 15.5 32.5 —
{11.0 kg} {8.8 kg}
16.7 N 13.3 N
{1.7 kg}
—
{1.36 kg}
PC200, 200LC, 220, 220LC-8M0 10-403 29

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

(Neutral o fine control) *
q When piston (4) is pushed by lever (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1) through fine control
hole (f).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
10-403 30 PC200, 200LC, 220, 220LC-8M0

3) During fine control 4) At full stroke

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

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PC200, 200LC, 220, 220LC-8M0 10-403 31

Service PPC valve (with EPC valve) 1
a For the details of operation, see the paragraph of “Work equipment swing PPC valve.”
10-403 32 PC200, 200LC, 220, 220LC-8M0


P1: To service valve
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. EPC valve
Unit: mm

Load at Load at
8 Centering spring Outside diameter length
deformed, replace
125 N 100 N spring.
33.9 x 15.3 28.4 —
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
{1.70 kg}
—
{1.36 kg}
PC200, 200LC, 220, 220LC-8M0 10-403 33

1. EPC valve
C: To control valve 2. Spool

P: From self pressure reducing valve 3. Push pin
T: To hydraulic tank 4. Coil
5. Plunger
1. Body 6. Connector
Unit: mm

Load at Load at If damaged or
Installed
Free length installed Free length installed deformed, replace
7 Return spring length
length length PPC valve assem-
bly.
3.1 N 2.5 N
9.5 8.4 —
{0.32 kg} {0.26 kg}
10-403 34 PC200, 200LC, 220, 220LC-8M0

Function
q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion.
q When it receives signal current (i) from the pump controller, it generates the EPC output pressure in pro-
portion to the size of the signal, and outputs it to the control valve.
PC200, 200LC, 220, 220LC-8M0 10-403 35

Operation
1) When signal current is 0 (coil is de-energized)

q When there is no signal current flowing from the controller to coil (4), coil (4) is de-energized.
q Spool (2) is pushed to the left by spring (3).
q Port (C) closes and the pressurized oil from the front pump does not flow to the control valve.
q The pressurized oil from the control valve is drained to the tank through port (C) and port (T).
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10-403 36 PC200, 200LC, 220, 220LC-8M0

2) When signal current is very small (coil is energized)

q When a very small signal current flows to coil (4), coil (4) is energized, and a propulsion force is gener-
ated on the right side of plunger (5).
q Push pin (6) pushes spool (2) to the right, and pressurized oil flows from port (P) to port (C).
q Pressures on port (C) increases and the force to act on surface (a) of spool (2) and the spring load on
spring (3) become larger than the propulsion force of plunger (5).
q Spool (2) is pushed to the left, port (P) is shut off from port (C) and ports (C) and (T) are connected.
q Spool (2) moves so that the propulsion force of plunger (5) may be balance with pressure of port (C) +
spring load of spring (3).
q The circuit pressure between the EPC valve and the control valve is controlled in proportion to the size
of the signal current.
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PC200, 200LC, 220, 220LC-8M0 10-403 37

3) When signal current is maximum (coil is energized)

q As the signal current flows to coil (4), coil (4) is energized.
q When this happens, the signal current is at its maximum, so the propulsion force of plunger (5) is also at
its maximum.
q Spool (2) is pushed to the left by push pin (6).
q The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit
pressure across EPC valve and the control valve to the maximum level.
q Since port (T) is closed, pressurized oil does not flow to the hydraulic tank.
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10-403 38 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 10-403 39

Service PPC valve 1
a For the details of operation, see the paragraph of “Work equipment and swing PPC valve“.
10-403 40 PC200, 200LC, 220, 220LC-8M0


1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
Unit: mm

Load at Load at
7 Centering spring Outside diameter length
deformed, replace
125 N 100 N spring.
33.9 x 15.3 28.4 —
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
{1.70 kg}
—
{1.36 kg}
PC200, 200LC, 220, 220LC-8M0 10-403 41

SEN06121-02 Valve control
Valve control 1
10-403 42 PC200, 200LC, 220, 220LC-8M0

Valve control SEN06121-02
1. Travel PPC valve

2. Service PPC valve
3. Service pedal
4. L.H. travel lever
5. R.H. travel lever
6. R.H. PPC valve
7. R.H. work equipment control lever
8. Solenoid block
9. Accumulator
10. Control valve
11. Hydraulic pump
12. Junction box
13. L.H. work equipment control lever
14. L.H. PPC valve
Lever positions
A. Neutral
B. Boom “RAISE”
C. Boom “LOWER”
D. Bucket “DUMP”
E. Bucket “CURL”
F. Neutral
G. Arm “IN”
H. Arm “OUT”
J. Swing “RIGHT”
K. Swing “LEFT”
L. Neutral
M. Travel “REVERSE”
N. Travel “FORWARD”
PC200, 200LC, 220, 220LC-8M0 10-403 43

SEN06121-02 Solenoid valve
Solenoid valve 1
PPC lock, travel junction, ATT selector, travel speed, swing brake, and 2-stage relief solenoid valves
10-403 44 PC200, 200LC, 220, 220LC-8M0

Solenoid valve SEN06121-02
1. PPC lock solenoid valve When solenoid is energized

2. 2-stage relief solenoid valve q As the signal current flows from the controller
3. Swing brake solenoid valve to solenoid (9), solenoid (9) is energized.
4. Travel speed solenoid valve Accordingly, spool (10) is pushed to the right.
5. Travel junction solenoid valve This operation flows the pressurized oil from
6. ATT selector solenoid valve the main pump, through port (P), via inside
7. Connector spool (10), to port (A), and eventually to the
8. Moving core actuator.
9. Coil At the same time, port (T) closes, the oil does
10. Spool not flow to the tank.
11. Block
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T: To tank
A1: To PPC valve
A2: To main valve (2-stage relief valve)
A3: To swing motor
A4: To L.H. and R.H. travel motors
A5: To main valve (Travel junction valve)
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ACC: To accumulator *
Operation
When solenoid is de-energized
q Since the signal current does not flow from the
controller, solenoid (9) is de-energized.
For this reason, spool (10) is pushed to the left
by spring (12).
Since port (P) is closed to port (A), pressurized
oil from the main pump does not flow to the
actuator.
At this time, the oil from the actuator is drained
through ports (A) and (T) into the tank.
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PC200, 200LC, 220, 220LC-8M0 10-403 45

SEN06121-02 PPC accumulator
PPC accumulator 1
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Gas capacity: 300 cc (for PPC)
10-403 46 PC200, 200LC, 220, 220LC-8M0

Return oil filter SEN06121-02
Return oil filter 1

For breaker
1. Drain plug Specifications

2. Filter Rated pressure: 6.9 MPa {70 kg/cm2}
3. Case Flow rate: 200 l/min
4. Head cover Relief valve cracking pressure:
5. Relief valve 0.34 ± 0.05 MPa {3.5 ± 0.5 kg/cm2}
Filter mesh size: 6 mm
Filtering area: 4,570 cm2
PC200, 200LC, 220, 220LC-8M0 10-403 47

SEN06121-02 Return oil filter with clogging sensor
Return oil filter with clogging sensor 1

For breaker
1. Drain plug Specifications

2. Filter Rated pressure: 6.9 MPa {70 kg/cm2}
3. Case Flow rate: 200 l/min
4. Head cover Relief valve cracking pressure:
5. Relief valve 0.34 ± 0.05 MPa {3.5 ± 0.5 kg/cm2}
6. Sensor Filtration degree:6 mm
Filtering area: 4,570 cm2
Sensor operating pressure:
0.24 ± 0.02 MPa {2.4 ± 0.2 kg/cm2}
Sensor tightening torque: 58.8 to 78.5 Nm
10-403 48 PC200, 200LC, 220, 220LC-8M0

Return oil filter with clogging sensor SEN06121-02
PC200, 200LC, 220, 220LC-8M0 10-403 49

SEN06121-02 Attachment circuit selector valve
Attachment circuit selector valve 1
ACC: To accumulator
ATT: To attachment
P1: From attachment selector solenoid valve
TS: To hydraulic tank
V: To control valve
1. Spool
Unit: mm

Load at Load at
Free length x Installed If damaged or
2 Spool return spring Outside diameter length
length length
deformed, replace
spring.
834 N 667 N
132 x 29 114.5 —
{85.0 kg} {68.0 kg}
10-403 50 PC200, 200LC, 220, 220LC-8M0

Attachment circuit selector valve SEN06121-02
Function 2. When breaker is installed

q When a breaker is installed, the return oil from q Pilot pressure from the attachment circuit
the breaker does not pass through the main selector solenoid valve contracts spring (2),
valve, but returns directly to the hydraulic tank. and spool (1) moves to the right to the stroke
q When other attachments (crusher, etc.) are end.
installed, the attachment and the main valve q Ports (ATT) and (V) are shut off and ports
are interconnected. (ATT) and (T) are interconnected.
q Pressurized oil returning from the breaker
Operation returns directly to the hydraulic tank through
port (T) without passing through the control
1. When attachment other than breaker valve.
is installed
q Spool (1) is pressed to the left by the force of
spring (2).
q Ports (ATT) and (V) are interconnected and
ports (ATT) and (T) are shut off. Attachment is
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PC200, 200LC, 220, 220LC-8M0 10-403 51

SEN06121-02 Hydraulic cylinder
Hydraulic cylinder 1
PC200-8M0 and PC200LC-8M0
Boom cylinder
Arm cylinder
Bucket cylinder
10-403 52 PC200, 200LC, 220, 220LC-8M0

Hydraulic cylinder SEN06121-02
Unit: mm
Standard Tolerance Standard Clearance

Cylinder
size Shaft Hole clearance limit
–0.036 +0.222 0.083 to

Boom 85 0.412
Clearance between pis- –0.090 +0.047 0.312
1 Replace bushing
ton rod and bushing
–0.036 +0.222 0.083 to
Arm 95 0.412
–0.090 +0.047 0.312
–0.030 +0.258 0.078 to
Bucket 80 0.434
–0.076 +0.048 0.334
100 hours greasing maintenance specification

Unit: mm
–0.030 +0.457 0.400 to
Boom 80 1.0
–0.060 +0.370 0.517
Clearance between pis-
–0.030 +0.457 0.400 to
2 ton rod support shaft Arm 80 1.0
–0.076 +0.370 0.533
and bushing
–0.030 +0.424 0.380 to
Bucket 70 1.0
–0.060 +0.350 0.484 Replace pin or
–0.030 +0.424 0.380 to bushing
Boom 70 1.0
–0.060 +0.350 0.484
Clearance between cyl-
–0.030 +0.457 0.400 to
3 inder bottom support Arm 80 1.0
–0.076 +0.370 0.533
shaft and bushing
–0.030 +0.424 0.380 to
Bucket 70 1.0
–0.060 +0.350 0.484

Unit: mm
–0.030 +0.190 0.100 to
Boom 80 1.0
–0.060 +0.070 0.250
–0.030 +0.190 0.100 to
–0.076 +0.070 0.266
and bushing
–0.030 +0.170 0.100 to
Bucket 70 1.0
–0.060 +0.070 0.230 Replace pin or
–0.030 +0.165 0.075 to bushing
Boom 70 1.0
–0.060 +0.045 0.225
–0.030 +0.190 0.100 to
–0.076 +0.070 0.266
shaft and bushing
–0.030 +0.165 0.075 to
Bucket 70 1.0
–0.060 +0.045 0.225
PC200, 200LC, 220, 220LC-8M0 10-403 53

SEN06121-02 Hydraulic cylinder
PC220-8M0 and PC220LC-8M0

Boom cylinder
Arm cylinder
Bucket cylinder
10-403 54 PC200, 200LC, 220, 220LC-8M0

Hydraulic cylinder SEN06121-02
Unit: mm
Standard Tolerance Standard Clearance

Cylinder
size Shaft Hole clearance limit
–0.036 +0.222 0.083 to
Boom 90 0.437
Clearance between pis- –0.090 +0.047 0.312
1 Replace bushing
ton rod and bushing –0.036 +0.222 0.083 to
Arm 100 0.447
–0.090 +0.047 0.312
–0.030 +0.258 0.078 to
Bucket 90 0.447
–0.076 +0.048 0.334

Unit: mm
–0.030 +0.457 0.400 to
Boom 80 1.0
–0.060 +0.370 0.517
–0.030 +0.457 0.400 to
–0.076 +0.370 0.533
and bushing
–0.030 +0.457 0.400 to
Bucket 80 1.0
–0.060 +0.370 0.517 Replace pin or
–0.030 +0.457 0.400 to bushing
Boom 80 1.0
–0.060 +0.370 0.517
–0.030 +0.457 0.400 to
–0.076 +0.370 0.533
shaft and bushing
–0.030 +0.457 0.400 to
Bucket 80 1.0
–0.060 +0.370 0.517

Unit: mm
–0.030 +0.190 0.100 to
Boom 80 1.0
–0.060 +0.070 0.250
–0.030 +0.190 0.100 to
–0.076 +0.070 0.266
and bushing
–0.030 +0.175 0.100 to
Bucket 80 1.0
–0.060 +0.075 0.246 Replace pin or
–0.030 +0.190 0.075 to bushing
Boom 80 1.0
–0.060 +0.070 0.225
–0.030 +0.190 0.100 to
–0.076 +0.070 0.266
shaft and bushing
–0.030 +0.190 0.075 to
Bucket 80 1.0
–0.060 +0.070 0.225
PC200, 200LC, 220, 220LC-8M0 10-403 55

SEN06121-02

© 2018 KOMATSU
All Rights Reserved
10-403 56
SEN06122-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

500 Work equipment
Work equipment .............................................................................................................................................. 2
Dimensions of arm ........................................................................................................................................ 10
Dimensions of bucket.................................................................................................................................... 12
PC200, 200LC, 220, 220LC-8M0 10-500 1

500 Work equipment
SEN06122-00 Work equipment
Work equipment 1
a The portion B in the figure shows L.H. boom cylinder.
10-500 2 PC200, 200LC, 220, 220LC-8M0

500 Work equipment
Work equipment SEN06122-00
PC200-8M0, PC200LC-8M0
Unit: mm
No. Item Criteria Remedy
Clearance between mounting pin dimension clearance clearance
Shaft Hole
1 and bushing of revolving frame and
boom –0.036 +0.135 0.110 to
90 1.0
–0.071 +0.074 0.206
Clearance between mounting pin –0.036 +0.137 0.113 to
2 90 1.0
and bushing of boom and arm –0.071 +0.077 0.208
Clearance between mounting pin –0.030 +0.158 0.108 to Replace pin and
3 70 1.0 bushing
and bushing of arm and link –0.076 +0.078 0.234
4 80 1.0
and bushing of arm and bucket –0.076 +0.074 0.213
5 80 1.0
and bushing of link and bucket –0.076 +0.086 0.242
6 70 1.0
and bushing of link and link –0.076 +0.074 0.230
Width of boss Width of hinge
Standard
Standard Standard clearance
Tolerance Tolerance
dimension dimension
0 +1 Adjust with shims
Connected part of 625.5 632 4.5 to 8.0
-0.5 -2 so that the clear-
7 revolving frame and
L7: Adjust with combination of shims 2.0 mm (2), 2.5 mm (1), 3.0 mm ance is 1.0 mm or
boom
(*2) (1) and 3.5 mm (1) below
R7: Insert the shim 2.0 mm (1)
L7: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (3)
(*3)
+1.5
96 ±1.2 99.3 2.1 to 6.0 Adjust with shims
(*1) 0
so that the clear-
Connected part of L8: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2)
8 (*2) ance is 1.0 mm
revolving frame and R8: Insert the shim 1.0 mm (1)
(*3), 1.5 mm (*2)
boom cylinder L8: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (2)
(*3) or below
PC200, 200LC, 220, 220LC-8M0 10-500 3

500 Work equipment
Unit: mm
Standard
Tolerance Tolerance
dimension dimension
+3
695 ±2.4 701 2.6 to 11.4
-1 Adjust with shims
L9-1: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2) so that the clear-
Connected part of boom
9 L9-2: Insert the shim 1.0 mm (1) ance is 1.0 mm
and boom cylinder (*2)
R9-1: Insert the shim 1.0 mm (1) (*3), 1.5 mm (*2)
R9-2: Insert the shim 1.0 mm (1) or below
L9-1: Insert the shims 0.8 mm (1) and 1.5 mm (2)

L9-2: Insert the shim 1.5 mm (1)
(*3)
R9-1: Insert the shim 1.5 mm (1)
+1.5
0
so that the clear-
Connected part of boom L10: Insert the shim 1.0 mm (1)
10 (*2) ance is 1.0 mm
and arm cylinder R10: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2)
(*3), 1.5 mm (*2)
L10: Insert the shim 1.5 mm (1) or below
(*3)
R10: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (3)
0 +0.5
305.5 310 4.5 to 5.5
-0.5 0 Adjust with shims
Connected part of boom L11: Insert the shim 2.0 mm (1) so that the clear-
11 (*2)
and arm R11: Adjust with either shim 2.0 mm (1) or 2.5 mm (1) or 3.0 mm (1) ance is 1.0 mm or
L11: Insert the shim 1.5 mm (1) below
(*3)
+1.5
106 ±1.2 109.3 2.1 to 6.0
0
Connected part of arm L12: Insert the shim 1.0 mm (1)
12 (*2) Replace shim
cylinder and arm R12: Insert the shim 1.0 mm (1)
L12: Insert the shim 1.5 mm (1)
(*3)
R12: –
+1.5
0
so that the clear-
13 (*2) ance is 1.0 mm
and bucket cylinder R13: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2)
(*3), 1.5 mm (*2)
(*3)
325 ±0.5 326.5 ±1 0 to 3.0
Connected part of link
14 L14: – –
and bucket –
R14: –
96 ±1.2 100.2 +0.5 2.5 to 5.9
Connected part of
15a L15a: – –
bucket cylinder and link –
R15a: –
0 Adjust with shims
280 – – –
Connected part of link -0.5 so that the clear-
15b
and link R15b: – ance is 1.0 mm or
(*3) below
L15b: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (4)
0 Adjust with shims
280 – – –
Connected part of arm -0.5 so that the clear-
16
and link L16: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (3) ance is 1.0 mm or
(*3) below
R16: –
0 +2.2 Adjust with shims
325 327.5 2.3 to 5.2
-0.5 -0.2 so that the clear-
Connected part of arm
17 ance is between
and bucket L17: –
(*4) 0.5 mm and 1.0
R17: Adjust with combination of shims 0.5 mm (4) and 1.0 mm (12) mm
10-500 4 PC200, 200LC, 220, 220LC-8M0

500 Work equipment
*1: The criterion indicates the L.H. boom cylinder. The shim adjustment place for the R.H. boom cylinder is opposite to L.H.
*2: Use plastic shim (with flange).
*3: Use iron shim (without flange).
*4: Use the separated iron shim.
a A number written in ( ) after the shim thickness means the number of shims to prepare.
PC200, 200LC, 220, 220LC-8M0 10-500 5

500 Work equipment
PC220-8M0, PC220LC-8M0
Unit: mm
Clearance between mounting pin dimension clearance clearance
Shaft Hole
1 and bushing of revolving frame and
boom –0.036 +0.138 0.114 to
100 1.0
–0.071 +0.078 0.209
2 90 1.0
and bushing of boom and arm –0.071 +0.077 0.208
Clearance between mounting pin –0.030 +0.166 0.116 to Replace pin and
3 80 1.0 bushing
and bushing of arm and link –0.076 +0.086 0.242
4 80 1.0
and bushing of arm and bucket –0.076 +0.074 0.213
5 80 1.0
and bushing of link and bucket –0.076 +0.086 0.242
6 80 1.0
and bushing of link and link –0.076 +0.066 0.242
Standard
Tolerance Tolerance
dimension dimension
0 +1 Adjust with shims
Connected part of 625.5 632 4.5 to 8.0
-0.5 -2 so that the clear-
7 revolving frame and
L7: Adjust with combination of shims 2.0 mm (2), 2.5 mm (1), 3.0 mm ance is 1.0 mm or
boom
(*2) (1) and 3.5 mm (1) below
L7: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (3)
(*3)
+1.5
(*1) 0
so that the clear-
Connected part of L8: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2)
8 (*2) ance is 1.0 mm
revolving frame and R8: Insert the shim 1.0 mm (1)
(*3), 1.5 mm (*2)
boom cylinder L8: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (2)
(*3) or below
+3
695 ±2.9 701 2.1 to 11.9
-1
L9-1: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2)
Adjust with shims
(*2) so that the clear-
Connected part of boom R9-1: Insert the shim 1.0 mm (1)
9 ance is 1.0 mm
and boom cylinder R9-2: Insert the shim 1.0 mm (1)
(*3), 1.5 mm (*2)
L9-1: Insert the shims 0.8 mm (1) and 1.5 mm (2) or below
(*3)
+1.5
0
so that the clear-
Connected part of boom L10: Insert the shim 1.0 mm (1)
10 (*2) ance is 1.0 mm
and arm cylinder R10: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2)
(*3), 1.5 mm (*2)
(*3)
0 +0.5
305.5 310 4.5 to 5.5
-0.5 0 Adjust with shims
Connected part of boom L11: Insert the shim 2.0 mm (1) so that the clear-
11 (*2)
and arm R11: Adjust with either shim 2.0 mm (1) or 2.5 mm (1) or 3.0 mm (1) ance is 1.0 mm or
L11: Insert the shim 1.5 mm (1) below
(*3)
10-500 6 PC200, 200LC, 220, 220LC-8M0

500 Work equipment
Unit: mm
Standard
Tolerance Tolerance
dimension dimension
+1.5
Connected part of arm 106 ±1.2 109.3 2.1 to 6.0
12 0 Replace shim
cylinder and arm
(*2)
(*3)
R12: –
+1.5
0
so that the clear-
13 (*2) ance is 1.0 mm
and bucket cylinder R13: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2)
(*3), 1.5 mm (*2)
(*3)
325 ±0.5 326.5 ±1 0 to 3.0
Connected part of link
14 L14: – –
and bucket –
R14: –
96 ±1.2 100.2 +0.5 2.5 to 5.9
Connected part of
15a L15a: – –
bucket cylinder and link –
R15a: –
0 Adjust with shims
280 – – –
Connected part of link -0.5 so that the clear-
15b
and link R15b: – ance is 1.5 mm or
(*3) below
L15b: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (4)
0 Adjust with shims
280 – – –
Connected part of arm -0.5 so that the clear-
16
and link L16: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (3) ance is 1.5 mm or
(*3) below
R16: –
0 +2.2 Adjust with shims
325 327.5 2.3 to 5.2
-0.5 -0.2 so that the clear-
Connected part of arm
17 ance is between
and bucket L17: –
(*4) 0.5 mm and 1.0
R17: Adjust with combination of shims 0.5 mm (4) and 1.0 mm (12) mm
*1: The criterion indicates the L.H. boom cylinder. The shim adjustment place for the R.H. boom cylinder is opposite to L.H.
*2: Use plastic shim (with flange).
*3: Use iron shim (without flange).
*4: Use the separated iron shim.
a A number written in ( ) after the shim thickness means the number of shims to prepare.
PC200, 200LC, 220, 220LC-8M0 10-500 7

500 Work equipment
Shims for work equipment Plastic shim

q The plastic shim is mainly used for the
Outline machine which has the 500 hours greasing
q There are two types of shims for work equip- maintenance specification.
ment, iron shim and plastic shim. q The purpose of using plastic shim is to reduce
q The shims for work equipment are inserted to the lateral play of work equipment and to pre-
adjust the clearance of each connected part of vent the squeal or galling caused when iron
the work equipment so that it will be in the connected parts are rubbed each other.
range of standard value.
q When the plastic shim is used with the bushing
which extends the greasing interval, it prevents
Function
the squeal caused by grease shortage and
then it can extend the greasing interval.
Iron shim
q The iron shim is mainly used for the machine q The plastic shim is always inserted to every
which has the 100 hours greasing mainte- contact face of iron connected part to prevent
nance specification. the iron parts from rubbing each other.
q The purpose of using iron shim is to reduce the
lateral play of work equipment. a Combined use of the plastic shim with the long
a There are two types of iron shims, integrated greasing interval bushing and dust seal
shim and separated shim. enables to extend the greasing interval to 500
hours.
a There are two types of plastic shim which has
different flange shape, type A and type B.
a Whichever type can be used, however, always
use only one type of plastic shim on one con-
nected part and not mix different types.
a When replacing the plastic shim on one con-

nected part, always use only one type and
new plastic shim.
Type A
10-500 8 PC200, 200LC, 220, 220LC-8M0

500 Work equipment
Type B Shims to adjust play of bucket

Outline
q The separated iron shims are used for the con-
nection of arm and bucket.
q By adjusting the number of shims, play at con-
necting part can be adjusted .
a Play can be reduced by deleting some shims
when the play becomes large.
PC200, 200LC, 220, 220LC-8M0 10-500 9

500 Work equipment
SEN06122-00 Dimensions of arm
Dimensions of arm 1
10-500 10 PC200, 200LC, 220, 220LC-8M0

500 Work equipment
Dimensions of arm SEN06122-00
Unit: mm
PC200, 200LC-8M0 PC220, 220LC-8M0
No.
Standard size Tolerance Standard size Tolerance
+0.1 +0.1
1 80 80
+0.0 +0.0
+1.5 +1.5
2 109.3 109.3
+0.0 +0.0
–0.5 –0.5
3 305.5 305.5
–0.5 –0.5
+0.054 +0.054
4 90 90
+0.000 +0.000
5 402.1 ±1 423.9 ±1
6 187.2 ±0.5 206.1 ±0.5
7 829.1 ±1 918.6 ±1
8 2,919 — 3,037 —
9 2,630.5 ±1 2,562.6 ±1
10 410 ±1 465 ±1
11 640 ±0.2 585 ±0.2
12 600 ±0.5 600 ±0.5
13 458.1 — 446.3 —
14 1,486 — 1,575.5 —
+0.1 +0.1
15 80 80
+0.0 +0.0
16 325 ±0.5 325 ±0.5
+0.1 +0.1
17 80 80
+0.0 +0.0
–0.5 –0.5
Arm itself 311 311
–0.5 –0.5
18
When press fitting
325 — 325 —
bushing
Min. 1,680 — 1,605 —
19
Max. 2,800 — 2,625 —
PC200, 200LC, 220, 220LC-8M0 10-500 11

500 Work equipment
SEN06122-00 Dimensions of bucket
Dimensions of bucket 1
10-500 12 PC200, 200LC, 220, 220LC-8M0

500 Work equipment
Dimensions of bucket SEN06122-00
Unit: mm
PC200, 200LC-8M0 PC220, 220LC-8M0
No.
Standard size Tolerance Standard size Tolerance
1 457.6 ±0.5 442.4 ±0.5
2 22 ±0.5 59.2 ±0.5
3 92° 45’ — 97° 37’ —
4 458.1 — 446.3 —
5 1,477.3 — 1,540.3 —
6 158.6 — 185.6 —
7 — — — —
8 15° 54’ — 7° 48’ —
+0.1 +0.1
9 80 80
+0.1 +0.1
10 326.5 ±1 326.5 ±1
11 56 — 59 —
12 106 — 104 —
13 470 — 470 —
14 23.5 — 23.5 —
15 140 — 140 —
16 190 — 190 —
17 133.2 — 156.3 —
18 131.6 — 133.1 —
19 107 — 107 —
20 85 — 82 —
+2 +2
21 348.5 348.5
+0 +0
22 38 — 37 —
PC200, 200LC, 220, 220LC-8M0 10-500 13

SEN06122-00

© 2012 KOMATSU
All Rights Reserved
10-500 14
SEN06123-01
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

600 Electrical system
Engine control ...................................................................................................................................... 2
Electrical control system .................................................................................................................... 12
Machine monitor system .................................................................................................................... 35
Sensor................................................................................................................................................ 56
KOMTRAX system ............................................................................................................................. 60
Clogging detection system of additional filter for breaker .................................................................. 63
PC200, 200LC, 220, 220LC-8M0 10-600 1

SEN06123-01 Engine control
Engine control 1
Operation of system 1
Starting engine
q When the starting switch is turned to the
START position, the starting signal flows to the
starting motor. Then, the starting motor turns to
start the engine.
When it happens, the engine controller checks

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

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

the supply pump depending on the signal volt-
age to control the fuel injection pump, and
eventually controls the engine speed.
Stopping engine
q When detecting that the starting switch is set to
the “STOP” position, the engine controller cuts
the signal of the supply pump drive solenoid to
stop the engine.
10-600 2 PC200, 200LC, 220, 220LC-8M0

Engine control SEN06123-01
Component 1
Fuel control dial
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
PC200, 200LC, 220, 220LC-8M0 10-600 3

Function
q The fuel control dial is installed under the
machine monitor.
q Turning knob (1) rotates the shaft of potentiom-
eter (5).
q The rotation of the shaft changes the resis-
tance of the variable resistor in potentiometer
(5), sending any throttle signal to the engine
controller.
q The hatched area in the graph is the abnormal-
ity detection area. When the throttle voltage is
within this area, the engine is running at low
idle.
10-600 4 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 10-600 5

Engine controller
10-600 6 PC200, 200LC, 220, 220LC-8M0

Input and output signals CN-CE01

q The following is the list of the symbols used for Input/
Pin No. Signal name
signal classification in the input/output signal output
table. 42 NC (*) –
A: Power supply 43 NC (*) –
B: Input 44 Boost pressure sensor B
C: Ground/Shield/Return 45 Injector #1 (+) D
D: Output 46 Injector #5 (+) D
E: Communication 47 G sensor (–) C
48 Ne sensor (–) C
CN-CE01 49 NC (*) –
Input/ 50 NC (*) –
Pin No. Signal name
output
51 Injector #2 (–) C
1 NC (*) –
2 Electric power supply for IMA D
3 Ambient pressure sensor B
54 Injector #2 (+) D
4 NC (*) –
5 NC (*) –
6 CAN (–) E
7 NC (*) –
8 CAN (+) E
9 NC (*) –
10 NC (*) –
*: Never connect to NC or malfunctions or failures will
11 NC (*) – occur.
12 NC (*) –
13 NC (*) –
CN-CE02
14 Water-in-fuel B
Input/
15 Coolant temperature sensor B Pin No. Signal name
output
16 5V electric power supply for sensor A 1 NC (*) –
17 Oil pressure switch B 2 NC (*) –
18 NC (*) – 3 NC (*) –
19 NC (*) – 4 NC (*) –
20 NC (*) – 5 NC (*) –
21 NC (*) – 6 NC (*) –
22 NC (*) – 7 NC (*) –
23 Boost temperature sensor B 8 NC (*) –
24 NC (*) – 9 Fuel control dial (+) B
25 Common rail pressure sensor B 10 NC (*) –
26 Bkup sensor (+) B 11 NC (*) –
27 NE sensor (+) B 12 NC (*) –
28 NC (*) – 13 NC (*) –
29 NC (*) – 14 NC (*) –
30 NC (*) – 15 NC (*) –
31 NC (*) – 16 NC (*) –
32 IMA return C 17 NC (*) –
33 5V electric power supply for sensor A 18 NC (*) –
34 NC (*) – 19 NC (*) –
35 NC (*) – 20 NC (*) –
36 NC (*) – 21 NC (*) –
37 5V electric power supply for sensor A 22 Fuel control dial (+5V) A
38 GND C 23 Fuel control dial (–) C
39 NC (*) – 24 NC (*) –
40 NC (*) – 25 NC (*) –
41 NC (*) – 26 NC (*) –
*: Never connect to NC or malfunctions or failures will *: Never connect to NC or malfunctions or failures will
occur. occur.
PC200, 200LC, 220, 220LC-8M0 10-600 7

CN-CE02
Input/
Pin No. Signal name
output
27 NC (*) –
28 NC (*) –
29 NC (*) –
30 NC (*) –
31 NC (*) –
32 NC (*) –
33 GND C
34 NC (*) –
35 NC (*) –
36 NC (*) –
37 NC (*) –
38 NC (*) –
39 Key switch (ACC) B
Electrical intake air heater relay
40 D
drive
41 NC (*) –
Electrical intake air heater relay
42 C
return
43 NC (*) –
44 NC (*) –
45 NC (*) –
46 CAN(+) E
47 CAN(–) E
48 NC (*) –
49 PWM OUTPUT D
50 NC (*) –
occur.
CN-CE03
Input/
Pin No. Signal name
output
1 GND C
2 NC (*) –
Electric power supply (+24V con-
3 A
stantly)
4 NC (*) –
occur.
10-600 8 PC200, 200LC, 220, 220LC-8M0

Coolant temperature sensor
1. Sensor
2. O-ring
3. Connector
Oil pressure switch
1. Connector
2. Sensor
3. O-ring
PC200, 200LC, 220, 220LC-8M0 10-600 9

Rotation sensor
1. Connector
2. Sensor
3. O-ring
Boost pressure and temperature sensor
1. Connector
2. Sensor
3. O-ring
10-600 10 PC200, 200LC, 220, 220LC-8M0

WIF (water-in-fuel detection) sensor
1. Connector
2. Tube
3. Sensor
4. O-ring
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
PC200, 200LC, 220, 220LC-8M0 10-600 11

SEN06123-01 Electrical control system
Electrical control system 1

Machine control system diagram
10-600 12 PC200, 200LC, 220, 220LC-8M0

Electrical control system SEN06123-01
PC200, 200LC, 220, 220LC-8M0 10-600 13

1. Engine and pump composite control function
10-600 14 PC200, 200LC, 220, 220LC-8M0

Function 1) Control method in each mode

q This function allows the operator to select P mode, E mode, and ATT mode
engine torque (T) and pump absorption torque q Matching point:
d ep en d in g o n t he wo r k c o nt en ts o f th e
Mode Matching point
machine.
Five modes of P, E, L, ATT, and B (three 99.2 kW/1,800 rpm
P and ATT (Work)
modes of P, E, and L for machines with “No {135 HP/1,800 rpm}
ATT” specified) are specified as working E
86.8 kW/1,800 rpm
modes. {118 HP/1,800 rpm}
To select a working mode, use the working
mode selector switch of the machine monitor.
q The pump controller controls the pump so that q In P, E, or ATT mode, engine speed is always
it can absorb all the torque at the output points controlled so that it is kept around the match-
of the engine depending on the pump absorp- ing point specified for each mode.
tion torque specified for each mode, rotation q If the pump load increases and the pressure
set by the fuel control dial, and actual engine rises, engine speed (N) lowers. If it happens,
speed. the engine speed is increased to around the
matching point, allowing the pump controller to
decrease pump discharge (Q). On the con-
trary, the pump load decreases and the pres-
sure lowers, the pump controller continues to
increase pump discharge until the engine
speed reaches around the matching point.
PC200, 200LC, 220, 220LC-8M0 10-600 15

B mode and L mode

Mode B L
Partial output point 75% 70%
Mode Matching point

80.9 kW/1,780 rpm
B
{108 HP/1,780 rpm}
73.6 kW/1,800 rpm
L
{99 HP/1,800 rpm}
q In B or L mode, engine output is controlled to a

constant level. 2) Function to control pump during travel
q The controller controls the pump absorption q Traveling the machine in P or ATT mode
torque to decrease the engine speed while increases engine speed (N).
keeping the engine torque at a constant level q Traveling the machine in E or B mode leaves
along the equal engine horsepower curve. the working mode unchanged, but raises the
q The controller controls pump discharge (Q) so pump absorption torque and engine speed (N)
that the engine torque can be kept at a con- to values same as those in P mode.
stant level along the equal engine horsepower q If the machine travels in L mode, the working
curve. mode and engine speed (N) do not change,
but the pump absorption torque is increased.
10-600 16 PC200, 200LC, 220, 220LC-8M0

3) Function to control when emergency pump

drive switch is turned on
q Even if any abnormality occurs in the controller
or sensor, setting emergency pump drive
switch (1) to the “ON” position activates the
machine with an absorption torque approxi-
mately equivalent to that in E mode.
In this case, a constant current flows from the
battery to the EPC valve for PC and therefore,
the oil pressure is sensed by only the EPC
valve for PC.
PC200, 200LC, 220, 220LC-8M0 10-600 17

2. Pump and valve control function
Function
q The machine is matched to various types of
work properly with the 2-stage relief function to
increase the digging force, etc.
10-600 18 PC200, 200LC, 220, 220LC-8M0

1) LS control function 3) 2-stage relief function

q Depending on the operation condition of the q The relief pressure in the normal work is 34.8
actuator, this function changes the pressure MPa {355 kg/cm2}. If the 2-stage relief function
output from the LS-EPC valve to LS valve to is turned on, however, the relief pressure rises
change the change point (LS set differential to about 37.2 MPa {380 kg/cm2}. By this opera-
pressure (DLS)) of the pump discharge in the tion, the hydraulic force is increased further.
LS valve.
q By this operation, the start-up time of the pump Operating condition for turning on 2-
discharge is optimized and the composite Relief pressure
stage relief function
operation and fine control performance is
• During travel
improved. • When swing lock switch is turned to 34.8 MPa
the ON position {355 kg/cm2}
• When boom is lowered O
• When power maximizing function is 37.2 MPa
turned on {380 kg/cm2}
• When L mode is operated
2) Cut-off function
q This function increases PC-EPC current (J) to
reduce the flow rate in the relief state, improv-
ing fuel consumption.
Operating condition for turning on cut-off function

When the average value of the front and rear pressure
sensors is above 27.9 MPa {285 kg/cm2} with the power
maximizing function off.
The cut-off function does not work, however, while the
machine is travelling in A mode, swing lock switch is in
the “ON” position.
PC200, 200LC, 220, 220LC-8M0 10-600 19

3. Power maximizing function
Function q These settings are automatically reset after 8.5

q The power maximizing function allows the seconds when the switch is pressed.
operator to increases power for a certain time
by operating the left knob switch.
q This function is used to increase digging force
for a certain period of time (e.g., when digging
up a large rock).
q Pressing the L.H. knob switch in P, E, or ATT
mode increases a hydraulic force by approxi-
mately 7% and horsepower by approximately
3%, increasing a digging force.
At this time, each function is automatically set
as shown below.
Function Setting
Matching at rated output
Engine and pump control
point
34.8 MPa {355 kg/cm2}
2-stage relief function O
37.2 MPa {380 kg/cm2}
Software cut-off function Cancel
10-600 20 PC200, 200LC, 220, 220LC-8M0

4. Auto-deceleration function
Function
q The auto-deceleration function automatically
reduces the engine speed to its medium speed
range when the all control levers are set in
NEUTRAL while waiting for a dump truck or
work to reduce the fuel consumption and
noise.
q If any lever is operated, the engine speed
instantly returns to the speed set with the fuel
control dial.
Operation
When control levers are set in neutral
q If all the control levers are kept to NEUTRAL
for 4 sec. during operation at a engine speed
above a decelerator operation level (approxi-
mately 1,050 rpm), this function lowers the
engine speed to the deceleration operation
level (approximately 1,050 rpm) and keeps it
until you operate any lever.
When any control lever is operated
q If you operate any control lever while the
engine speed is kept at the deceleration opera-
tion level, the engine speed instantly rises to
the level set with the fuel control dial.
PC200, 200LC, 220, 220LC-8M0 10-600 21

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

pump load when coolant or hydraulic oil tem-
perature is too high during operation to protect
the engine from overheating.
10-600 22 PC200, 200LC, 220, 220LC-8M0

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

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

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

q This function reduces the pump load and
engine speed when coolant or hydraulic oil
temperature is too high to protect the engine
and hydraulic components from overheating.
q This function starts when coolant temperature reaches 100°C or hydraulic oil temperature reaches
95°C.
Operating condition Operation/Remedy Resetting condition
Coolant temperature: Coolant temperature, hydraulic oil temperature:

Working mode: Any mode Below 105°C
Min. 105°C
Engine speed: Low idle Fuel control dial: Return to low idle position once.
or
Monitor alarm lamp: Lights up
Hydraulic oil temperature: Under above condition, controller is set to condi-
Alarm buzzer: Sounds
Min. 105°C tion before operation of function. (Manual reset)

Coolant temperature: Working mode: Coolant temperature, hydraulic oil temperature:
Min. 102°C P, E, B, or L mode Below 102°C
or Engine speed: Kept as is. Under above condition, controller is set to condi-
Hydraulic oil temperature: Monitor alarm lamp: Lights up tion before operation of function. (Automatic
Min. 102°C Reduce pump discharge. reset)

Coolant temperature: Coolant temperature, hydraulic oil temperature:
Min. 100°C Working mode: P or E mode Below 100°C
or Engine speed: Kept as is. Under above condition, controller is set to condi-
Hydraulic oil temperature: Reduce pump discharge. tion before operation of function. (Automatic
Min. 100°C reset)

Hydraulic oil temperature: Below 95°C
Working mode: Travel
Hydraulic oil temperature: Under above condition, controller is set to condi-
Engine speed: Kept as is.
Min. 95°C tion before operation of function. (Automatic
Lower travel speed.
reset)
PC200, 200LC, 220, 220LC-8M0 10-600 23

6. Swing control function
Function
The swing lock and swing holding brake function
are provided as a swing control function.
10-600 24 PC200, 200LC, 220, 220LC-8M0

1) Swing lock and swing holding brake func- 2) Quick hydraulic oil warm-up function when
tion swing lock switch is turned on
q The swing lock function (manual) is used to q If swing lock switch (2) is turned on, the pump
lock machine from swinging at any position. cut-off function is cancelled and the relief pres-
The swing holding brake function (automatic) sure rises from 34.8 MPa {355 kg/cm2} to 37.2
is used to prevent hydraulic drift after the MPa {380 kg/cm2}.
machine stops swinging. If the work equipment is relieved under this
q Operation of swing lock switch and swing lock/ condition, the hydraulic oil temperature rises
holding brake quickly and the warm-up time can be short-
ened.
Lock Lock
Function Operation
switch lamp
If swing lever is set in neu-
tral, swing brake operates
Swing
in about 5 sec. If swing
OFF OFF holding
lever is operated, brake is
brake
released and machine can
swing freely.
Swing lock operates and
machine is locked from
Swing swinging. Even if swing
ON ON
lock lever is operated, swing
lock is not reset and
machine does not swing.
Swing holding brake cancel switch

q If the controller, etc. has a problem, the swing
holding brake does not work normally, and the
machine cannot swing, the swing lock can be
reset with the swing holding brake cancel
switch.
Swing
ON OFF
holding
(when controller has (when controller is
brake cancel
trouble) normaly)
switch
Swing lock
ON OFF ON OFF
switch
Swing
Swing Swing Swing
holding
Swing brake lock is lock is lock is
brake is
turned on. canceled. turned on.
turned on.
q Even if the swing holding brake cancel switch

is turned on, if the swing lock switch is placed
in the ON position, the swing brake is not
released.
q If the swing lock is reset, only the hydraulic
brake is applied by the safety valve. Note that
if swinging is stopped on a slope, the upper
structure may swing by its gravity.
PC200, 200LC, 220, 220LC-8M0 10-600 25

7. Travel control function
Function
q The machine is provided with a function that
ensures travel performance best fit to the type
of work and jobsite by controlling pumps during
travel or allowing operator to change travel
speed automatically or manually.
10-600 26 PC200, 200LC, 220, 220LC-8M0

1) Pump control function during travel PC200-8M0, PC200LC-8M0

q For details, see "Engine and pump composite
control function".
2) Travel speed change function
1] Manual change with travel speed
selector switch
Switching the travel speed selector
switch from Lo to Mi and Hi causes
the pump controller to control the
pump capacity and motor capacity at
each gear speed as shown below,
switching the travel speed.
a PC200-8M0, PC200LC-8M0
Lo Mi Hi
Travel speed switch (Low (Medium (High PC220-8M0, PC220LC-8M0
speed) speed) speed)
Pump capacity (%) 66 89 100
Motor capacity Max. Max. Min.
Travel speed (km/h) 3.0 4.1 5.5
a PC220-8M0, PC220LC-8M0
Lo Mi Hi
Travel speed switch (Low (Medium (High
speed) speed) speed)
Pump capacity (%) 77 71 100
Motor capacity Max. Min. Min.
Travel speed (km/h) 3.0 4.1 5.5
2] Automatic change by engine speed 3) Travel junction function

If you adjust the engine speed to q The controller detects the pilot pressure
1,500 rpm or less with the fuel control when travel cotrol lever is operated, and
dial, j udges the operator ’s intention, the
q The travel speed does not switch straight travel or turning operation.
to Hi when the machine is travel- q For straight-travel, a signal is sent to the
ing in Mi. travel junction solenoid valve, controlling
q The travel speed automatically the pump flow rate between the right and
changes to Mi when the machine left to be equal, to prevent travel deve-
is travelling in Hi. ation and improve straight-travel ability.
3] Automatic change by pump discharge q For turning operation, the signal to the
pressure travel junction solenoid valve is shut off.
If the travel pressure is kept to 24.5 This separates the pump flow rate to the
MPa {250 kg/cm 2 } at least 0.5 sec. right and left travel motors from each other
due to increased load during traveling and improves the traction while turning.
in Hi on an uphill, the travel motor
capacity automatically switches to the
medium speed (Mi) (the travel speed
switch stays at Hi).
If the machine starts traveling on level
ground or downhill during operation of
the above mentioned function and the
travel pressure goes below 14.7 MPa
{150 kg/cm2} and continues such the
condition at least 0.5 sec., the travel
motor capacity will automatically
change, switching the travel speed
switch to Hi again.
PC200, 200LC, 220, 220LC-8M0 10-600 27

8. Attachment flow control circuit selector function (if equipped)
Function
q This function is available only with attachment
specification.
q The function acts as follows according to the
flow command and working mode from the
monitor.
1) It throttles the attachment PPC pressure
and controls the flow when the pedal is
depressed fully.
2) Attachment operation switches depend-
ing on the working mode as shown below.
Working mode Attachment operation
ATT Double-acting
B Single-acting
10-600 28 PC200, 200LC, 220, 220LC-8M0

9. System component parts

1) PPC oil pressure switch
1. Plug
2. Switch
3. Connector
Specifications
Type of contacts: Normally open contacts
Operating (ON) pressure:
0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure:
0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm2}
Function
q The attachment PPC valve has a PPC oil pres-
sure switch.
q This sensor detects the operating condition of
each actuator by the PPC pressure and trans-
mit it to the pump controller.
PC200, 200LC, 220, 220LC-8M0 10-600 29

2) Oil pressure sensor
1. Sensor
2. Connector
Function q The relationship between the pressure applied

q The junction block has 8 PPC oil pressure sen- to sensors (P) and output voltage (E) is shown
sors. in the figure below.
The travel PPC valve has 4 PPC oil pressure
sensors.
q This sensor detects the operating condition of
each actuator by the PPC pressure and trans-
mit it to the pump controller.
Operation
q The oil pressure is applied to the diaphragm of
the oil pressure sensor from the pressure
intake part, the diaphragm is deformed.
q The deformation in the diaphragm causes the
resistance of the gauge to change. This
causes a change in the output voltage, which
is transmitted to the amplifier (voltage ampli- q The amplifier magnifies output voltage (E) and
fier). transmits it to the pump controller.
10-600 30 PC200, 200LC, 220, 220LC-8M0

3) Pump pressure sensor
1. Sensor
2. Connector
Operation
q The relationship between the pressure applied
to sensors (P) and output voltage (E) is shown
in the figure below.
PC200, 200LC, 220, 220LC-8M0 10-600 31

4) Pump controller
10-600 32 PC200, 200LC, 220, 220LC-8M0

Input and output signals

CN-C01 CN-C01
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
1 Power Input 51 NC (*) —
2 Power GND Input 52 NC (*) —
3 Washer motor power Output 53 Boom up pressure sensor Input
4 Power Input Front of L.H. travel oil pressure
54 Input
5 Power GND Input sensor
6 NC (*) — Front of R.H. travel oil pressure
55 Input
7 NC (*) — sensor
8 Power (+5 V) Output 56 Wiper (W) Input
9 Power (+5 V) Output 57 Window limit SW Input
10 NC (*) — 58 Machine select 4 Input
11 NC (*) — 59 NC (*) —
12 NC (*) — 60 Key SW (C) Input
13 NC (*) — 61 NC (*) —
14 Boom down pressure sensor Input 62 External drive signal Input
15 Arm dump pressure sensor Input 63 NC (*) —
16 Swing (L) pressure sensor Input 64 CAN_L Input/Output
17 Arm digging pressure sensor Input 65 NC (*) —
18 Analog GND Input 66 NC (*) —
19 Swing lock Input 67 NC (*) —
20 NC (*) — 68 R pump pressure sensor Input
21 Machine select 2 Input 69 NC (*) —
22 NC (*) — 70 NC (*) Input
23 NC (*) — 71 NC (*) —
24 Key SW (ACC) Input 72 Swing (R) pressure sensor Input
25 NC (*) — 73 Bucket digging pressure sensor Input
26 NC (*) — 74 NC (*) —
27 NC (*) — 75 Wiper (P) Input
28 NC (*) — 76 Service pressure SW Input
29 Hydraulic oil temperature Input 77 Machine select 3 Input
30 NC (*) — 78 NC (*) —
31 NC (*) — 79 Key SW (ACC) Input
32 NC (*) — 80 NC (*) —
33 NC (*) — 81 NC (*) —
34 Bucket dump pressure sensor Input *: Never connect to NC or malfunctions or failures will
Back of L.H. travel oil pressure occur.
35 Input
sensor
Back of R.H. travel oil pressure
36 Input
sensor
37 NC (*) —
38 Swing brake cancel switch Input
39 Machine select 5 Input
40 Machine select 1 Input
41 Knob SW Input
42 NC (*) —
43 Key SW (ACC) Input
44 NC (*) —
45 CAN_H Input/Output
46 Analog GND Input
47 NC (*) —
48 NC (*) —
49 F pump pressure sensor Input
50 NC (*) —
occur.
PC200, 200LC, 220, 220LC-8M0 10-600 33

CN-C02
Pin No. Signal name Input/Output
82 NC (*) —
83 NC (*) —
84 NC (*) —
85 Variable back pressure SOL Output
86 Attachment selector SOL Output
87 Travel speed SOL Output
88 LS-EPC Output
89 Merge-divider LS EPC Output
90 NC (*) —
91 NC (*) —
92 NC (*) —
93 NC (*) —
94 NC (*) —
95 NC (*) —
96 PC-EPC (F) Output
97 Service current EPC Output
98 NC (*) —
99 NC (*) —
100 NC (*) —
101 Swing parking brake SOL Output
102 NC (*) —
103 NC (*) —
104 PC-EPC (R) Output
105 NC (*) —
106 NC (*) —
107 Travel alarm Output
108 Battery relay Output
109 2-stage relief SOL Output
110 Travel junction SOL Output
111 NC (*) —
112 Merge-divider main EPC Output
113 NC (*) —
114 Wiper motor (–) Output
115 Solenoid GND Input
116 Solenoid power Input
119 Wiper motor (+) Output
occur.
10-600 34 PC200, 200LC, 220, 220LC-8M0

Machine monitor system SEN06123-01
Machine monitor system 1
1. Machine monitor Function

2. Battery q The monitor system keeps the operator
3. Pump controller informed of all machine functions, by monitor-
4. Engine controller ing the machine conditions by using the sen-
5. Air conditioner controller sors and switches installed in various parts of
6. KOMTRAX terminal the machine and processing them instantly to
7. Sensors and switches display on the machine monitor.
8. Wiper motor and window washer motor The information displayed on the machine
9. Camera monitor falls into the following types:
1. Alarm when the machine has trouble
Input and output signals 2. Machine status display (coolant tempera-
a. Power supply ture, hydraulic oil temperature, fuel level,
b. CAN signal etc.)
c. Sensor and switch signals 3. Display of camera image
d. Drive signal q The switches on the machine monitor have an
e. Camera signal operating function to control the machine.
PC200, 200LC, 220, 220LC-8M0 10-600 35

SEN06123-01 Machine monitor system
Machine monitor 1
Function q When the engine is started, the battery voltage

q The machine monitor has monitor display func- may drop suddenly, depending on the ambient
tion, mode selection function and switch func- temperature and the condition of the battery. In
tion for electrical parts etc. Also it has an alarm this case, the machine monitor display may go
buzzer. off for a moment. However, this phenomenon
q The machine monitor has a CPU (Central Pro- is not a failure.
cessing Unit) in it to process, display, and out- q Continuous operation of the machine monitor
put the information. may display blue bright spots on the screen
q The machine monitor consists of a display and having a black background; it is quite normal.
switches: the display is of LCD type, and the Blue bright spots can never be a problem as
switches are of flat sheet switch. the screen has usually blue or white back-
q If a failure occurs in the machine monitor itself, ground. (White in the LCD is made up of red,
controller or wiring circuit between monitor and green and blue.)
controller, the monitor does not display prop-
erly.
Precautions on the machine monitor display

q One of the features of liquid crystal display
panels is that there may be black spots (spots
that do not light up) or white spots (spots that
stay lit up) on the screen. If there are fewer
than 10 black or white spots, this is not a fail-
ure or a defect. Products having 10 or less
black or bright spots conform the product spec-
ification; such the condition is quite normal.
10-600 36 PC200, 200LC, 220, 220LC-8M0


070-18P [CN-CM01]
Pin No. Signal name Input/Output signal
1 Continuous power supply (24 V) Input
2 Continuous power supply (24 V) Input
3 GND (continuous power supply) —
4 GND (continuous power supply) —
5 External start signal Input
6 Starting motor cut-off relay (for personal code) Output
7 NC (*) —
8 System operating lamp Input/Output
9 Lamp switch Input
10 Starting switch (ACC) Input
11 Starting switch (C) Input
12 Preheating Input
13 Engine shutdown secondary switch Input
14 GND (body signal) —
15 Fuel level sensor Input
16 Charge level (Alternator R terminal) Input
17 NC (*) —
18 NC (*) —
*: Never connect these pins. Malfunctions or failures may occur.
070-12P [CN-CM02]
1 NC (*) —
2 Engine oil level sensor Input
3 Radiator coolant level sensor Input
4 Air cleaner clogging sensor Input
5 Swing lock switch Input
6 NC (*) —
7 CAN (C) terminating resistor terminal —
8 CAN (C)_H Input/Output
9 CAN (C)_L Input/Output
10 NC (*) —
11 NC (*) —
12 NC (*) —
070-20P [CN-CM03]
1 NC (*) —
2 NC (*) —
3 NC (*) —
4 NC (*) —
5 NC (*) —
6 NC (*) —
7 NC (*) —
8 NC (*) —
PC200, 200LC, 220, 220LC-8M0 10-600 37

070-20P [CN-CM03]
9 NC (*) —
10 NC (*) —
11 NC (*) —
12 NC (*) —
13 NC (*) —
14 NC (*) —
15 NC (*) —
16 NC (*) —
17 NC (*) —
18 NC (*) —
19 NC (*) —
20 NC (*) —
070-8P [CN-CM04]
1 Camera power supply (8 V) Output
2 Camera NTSC signal 1 Input
5 GND (Camera power supply) —
6 Switching camera 2 to original/mirror image Output
7 Switching camera 3 to original/mirror image Output
8 Shield GND —
10-600 38 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 10-600 39

Display 1
A: Standard screen 7. Auto-deceleration monitor

B: Check before starting screen 8. Working mode monitor
C: Maintenance interval warning screen 9. Travel speed monitor
D: Warning screen 10. Fuel level gauge
E: Guidance screen 11. Fuel level monitor
F: Camera image screen 12. Eco gauge
a Camera image screen (F) shown in the figure 13. Fuel consumption gauge
is when two or more cameras are installed 14. Hydraulic oil temperature monitor
15. Hydraulic oil temperature gauge
1. Message monitor 16. Engine coolant temperature monitor
2. Air conditioner monitor 17. Engine coolant temperature gauge
3. Wiper monitor 18. Radiator coolant level monitor
4. Swing lock monitor 19. Charge level monitor
5. Engine preheating monitor 20. Engine oil pressure monitor
6. Service meter 21. Engine oil level monitor
10-600 40 PC200, 200LC, 220, 220LC-8M0

22. Air cleaner clogging monitor

23. Water separator monitor
24. Clock
25. Maintenance interval warning monitor
26. System status monitor
27. Action level monitor
28. ECO guidance
PC200, 200LC, 220, 220LC-8M0 10-600 41

Gauge
Gauge Display item Description Remarks

Temperature Background
Range
(°C) color
• Indicates corresponding
W1 105 Red temperature range.
(*1)
W2 102 Red • Alarm buzzer sounds when the
Engine coolant
temperature is 105°C or higher.
temperature W3 100 Blue
• If the monitor background
gauge W4 85 Blue appears white, warm-up the
W5 60 Blue engine.
W6 30 White
Temperature Background
Range
(°C) color
• Indicates corresponding
H1 105 Red temperature range.
(*1)
H2 102 Red • Alarm buzzer sounds when the
Hydraulic oil
temperature is 105°C or higher.
temperature H3 100 Blue
• If the monitor background
gauge H4 85 Blue appears white, warm up the
H5 40 Blue hydraulic components.
H6 20 White
Background
Range Quantity (l)
color
F1 289 Blue
(*1) F2 244.5 Blue • Indicates corresponding
Fuel level
F3 200 Blue remaining fuel level.
gauge
F4 100 Blue
F5 60 Blue
F6 41 Red
Segment Load level • Indicates instantaneous fuel
Light to consumption (average of fuel
Green 1 to 8 consumption per 3 minutes) in 10
medium
(*2) steps.
Eco gauge (It is displayed when the user
Orange 9, 10 Heavy menu’s “ECO guidance” o
Display setting o “Eco gauge
display” is set.)
• Indicates accumulated engine
operating hours (the alternator is
Service meter 00000.0 h - 99999.9 h running).
(F4 switch changes it to clock
display.)
• Displays time.
• 12-hour display (AM/PM)
Clock (F4 switch changes it to service
• 24-hour display
meter display.)
• Indicates average fuel

(*2) consumption.
• 1 day
Fuel (Display is switched when the
• Split
consumption user menu’s “ECO guidance” o
• Not installed
gauge “Display setting” o “Fuel gauge
display” are specified.)
*1: If the gauge signal is not available due to open circuit in CAN communication line, the gauge pointer dis-
appears.
*2: Display item is switched when the user menu’s “ECO guidance” o “Display setting” are specified.
10-600 42 PC200, 200LC, 220, 220LC-8M0

Caution monitor
Description
Symbol Display item Monitor display Remarks

Action level
Range (Background
monitor
color)
Min. 102°C Lights up (Red) L02 • Background color changes
Min. 30°C or Lights up depending on the
— temperature detected.
below 102°C (Blue)
(*1) • Alarm buzzer sounds when
Engine coolant the temperature is 105°C or
temperature Lights up higher.
Below 30°C — • If the monitor background
(White)
appears white, warm-up the
engine.
Min. 102°C Lights up (Red) L02 • Background color changes
Min. 20°C or Lights up depending on the
— temperature detected.
below 102°C (Blue)
(*1) • Alarm buzzer sounds when
Hydraulic oil the temperature is 105°C or
temperature Lights up higher.
Below 20°C — • If the monitor background
(White)
appears white, warm up the
hydraulic components.
Below 41 l Lights up (Red) —
• Background color changes
(*1)
Lights up depending on the remaining
Fuel level Min. 41 l — fuel level.
(Blue)
When
abnormal Lights up (*3) • When failure is detected with
(*1)
(When below (Yellow) L01 the engine stopped, the
Radiator coolant
specified level) monitor lights up on the
level
screen.
When normal Lights out —
When charge
is defective • The monitor lights up on the
(*1) (Charge screen and alarm buzzer
Lights up (Red) L03
Battery charge voltage < sounds when failure is
condition battery detected while the engine
voltage) running.
When • The monitor lights up on the
(*1) abnormal screen and alarm buzzer
Lights up (Red) L03
Engine oil (When below sounds when failure is
pressure specified level) detected while the engine
When normal Lights out — running.
When
(*1) (When below (Yellow) L01 the engine stopped, the
Eng. oil level specified level) monitor lights up on the
screen.
When
(*1)
(When above (Yellow) L01 the engine running, the
Clogging of air
specified level) monitor lights up on the
cleaner
screen.
PC200, 200LC, 220, 220LC-8M0 10-600 43

Description

Action level
Range (Background
monitor
color)
When
abnormal
(There is water • When failure is detected with
(*1) collected Lights up (Red) — the engine running, the
Water separator above the monitor lights up on the
specified screen.
amount.)
When • The display changes
exceeding depending on the time to/
Lights up (Red) —
maintenance after the maintenance.
interval • After the starting switch is
Maintenance
(*2) turned to ON position , the
interval warning
When monitor turns on if the
Lights up monitor light-up conditions
exceeding —
(Yellow) are met, and then goes out in
maintenance
notifying time 30 seconds.
When action
level “L04” or • When failure is detected in
Lights up (Red) L04 and L03 the machine system, the
“L03” is
detected monitor lights up.
System status
• When the background color
When action is red, the alarm buzzer
Lights up (*3)
level “L01” is sounds.
(Yellow) L01
detected
When action
Lights up (Red) L04 and L03 the engine system, the
“L03” is
State of engine detected monitor lights up.
system • When the background color
Lights up (*3)
(Yellow) L01
detected
When action
Lights up (Red) L04 and L03 the hydraulic system, the
“L03” is
State of hydraulic detected monitor lights up.
system • When the background color
Lights up (*3)
(Yellow) L01
detected
• The monitor lights up and

Engine
Engine alarm buzzer sounds when
overspeed is Lights up (Red) L02
overspeed engine overspeed is
detected
detected.
Sate of air When air • When failure is detected in

Lights up
conditioner conditioner is (*3) L01 the air conditioner system,
(Yellow)
system abnormal the monitor lights up.
10-600 44 PC200, 200LC, 220, 220LC-8M0

Description

Action level
Range (Background
monitor
color)
When action
level “L04” is Lights up (Red) L04
detected
When action • When failure is detected on
level “L03” is Lights up (Red) L03 the machine, the monitor
detected lights up.
Action level
When action When the background color
level “L02” is Lights up (Red) L02 is red, the alarm buzzer
detected sounds.
When action
Lights up (*3)
level “L01” is
(Yellow) L01
detected
*1: It is included in the check before starting items. After the staring switch is turned to “ON” position, the
monitor turns on for two seconds, and changes to the standard screen if no failure is found.
*2: The notifying time is changeable from the items in “Maintenance mode display setting” of the service
mode.
*3: Monitor goes out after lighting up for 2 seconds.
PC200, 200LC, 220, 220LC-8M0 10-600 45

Pilot monitor
Symbol Display item Description Remarks

• It operates automatically at a
low temperature.
Automatic (Symbol lights up as long as
preheating for approx. 30 seconds)
• It goes off after the engine is
started.
Elapsed time
after turning • Indicates preheat operating
Preheating the starting
Monitor display status.
switch to
“HEAT
Manual
(Preheating)”
preheating
0 to 30 sec. Lights up
30 to 40 sec. Flashes
After 40 sec.
Lights out
or longer
One-touch
power max. Monitor display
switch • Indicates the operating status
One-touch power
Lights up of one-touch power
max.
ON (Goes out if pressed for 8.5 maximizing function.
seconds)
OFF Lights out
Swing lock Swing brake
Monitor display
switch cancel switch
OFF OFF Lights out • Indicates swing lock
Swing lock
ON OFF Lights up operating status.
OFF ON Flashes
ON ON Flashes
INT: Intermittent operation

• Indicates front glass wiper
Wiper ON: Continuous operation
operating condition.
Lights out: Holds in position
Lights up: ON • Indicates air conditioner and

Air conditioner
Lights out: OFF air blower operating status.
Message Lights up: There is unread message. • State of the message is

(Unread) Lights out: No message displayed.
Message
(No return Lights up: There is an already-read message
• State of the message is
message, but return message for it is not sent yet.
displayed.
already-read Lights out: No message
message)
Lights up: ON • Indicates auto-decelerator

Auto-deceleration
Lights out: OFF operating status.
10-600 46 PC200, 200LC, 220, 220LC-8M0

Symbol Display item Description Remarks

P: Heavy-duty operation
E: Low-fuel consumption operation
L: Fine operation
Working mode B: Breaker operation • Displays working mode.
ATT-P: Double-acting attachment operation
ATT-E: Double-acting attachment and low-fuel
consumption operation
Lo: Low speed

Travel speed Mi: Middle speed • Displays travel speed setting.
Hi: High speed
Idle stop guidance

Guidance on deterrence of hydraulic relief • Guidance for supporting the
ECO guidance E-mode recommendation guidance machine operation and
Travel partial recommendation guidance control are displayed.
Low oil level guidance
PC200, 200LC, 220, 220LC-8M0 10-600 47

Switches 1
No. Name Function Operation

Switches the auto-deceleration
Auto-deceleration • When working mode is “L”, this switch is always
function ON/OFF.
1 switch “OFF” after engine started.
Lights up: ON
[Numeric keypad: 1] OFF io ON
Lights out: OFF
P: Heavy-duty operation
E: Low-fuel operation
(*1)
L: Fine operation
Working mode Displays the working mode
2 B: Breaker operation
selector switch selector screen.
ATT-P: Double-acting attachment operation
[Numeric keypad: 2]
ATT-E: Double-acting attachment and low-fuel
operation
Changes the travel speed.
Travel speed selector • Speed is sequentially changed as shown below.
Lo lights up: Low speed
3 switch • Lo (Low speed) o Mi (Medium speed) o Hi (High
Mi lights up: Medium speed
[Numeric keypad: 3] speed) o Lo (Low speed)
Hi lights up: High speed
Stops the alarm buzzer.
• The alarm buzzer stops sounding.
Buzzer cancel switch (Some alarm buzzer does not
4 • The alarm buzzer sounds again if another error
[Numeric keypad: 4] stop sounding even if the switch is
worth alarming is detected.
pressed.)
Operates the front glass wiper. • Pressing the switch sequentially changes the
(*2)
INT: Intermittent operation wiper operation.
5 Wiper switch
ON: Continuous operation OFF (Stop) o INT (Intermittent) o ON
[Numeric keypad: 5]
Lights out: Holds in position (Continuous) o OFF (Stop)
10-600 48 PC200, 200LC, 220, 220LC-8M0

No. Name Function Operation

ON: Washer fluid is sprayed and windshield wiper
works continuously.
[When wiper stops]
(*2)
OFF: Windshield wiper works twice continuously
Window washer Sprays washer fluid onto the front
6 and stops after the switch is released.
switch [Numeric window glass.
[When wiper operates intermittently]
keypad: 6]
OFF: Windshield wiper works twice continuously
and returns to intermittent operation after the switch
is released.
Fan switch (increase) Controls the air flow of the air • The air flow increases immediately after the air
7a
[Numeric keypad: 7] conditioner in 6 levels. conditioner adjustment screen appears.
(Low, Medium 1, Medium 2, • The air flow decreases immediately after the air
7b Fan switch (decrease) Medium 3, Medium 4 and High)
conditioner adjustment screen appears.
Temperature control • The preset temperature increases immediately
8a switch (raise) Controls the temperature inside after the air conditioner adjustment screen
[Numeric keypad: 8] the cab. appears.
Temperature control (18.0°C to 32.0°C: Setting is • The preset temperature decreases immediately
8b switch (lower) available in 0.5°C steps) after the air conditioner adjustment screen
[Numeric keypad: 0] appears.
• The air flow, combination of vents, and selection
Operates the air conditioner and
(*3) of FRESH/RECIRC air are automatically selected
air flow with automatic operation.
9 Auto switch according to the set temperature immediately
AUTO lights up: Automatic
[Numeric keypad: 9] after the air conditioner adjustment screen
operation
appears.
Selects the air conditioner ON/
• Switches to the air conditioner adjustment
(*4) OFF.
10 screen, and pressing it again switches ON/OFF.
Air conditioner switch A/C ON lighted: Manual operation
OFF io ON
Not lighting: Stop
• Switches to the air conditioner adjustment
FRESH/RECIRC air screen, and pressing it again switches FRESH/
11 Changes the FRESH/RECIRC.
changeover switch RECIRC.
RECIRC io FRESH
Selects the air vent mode from 6
modes.
1. Front vent • Switches to the air conditioner adjustment
2. Front and rear vents screen, and pressing it again switches air vent
12 Vent selector switch
3. Front, rear and foot vents mode.
4. Foot vent 1o2o3o4o5o6o1
5. Foot and defroster vents
6. Defroster vent
Stops the fan and air conditioner.
13 OFF switch • The fan and air conditioner stop.
Lights OFF: OFF
14a Guidance icon
a See Guidance icon and function switch
14b Function switch
*1: When the working mode is changed, the auto-deceleration function is turned ON. But, when L mode is
selected, it is turned OFF.
*2: When the front window is open, the wiper and washer do not operate even if the switch is pressed.
*3: If temperature is set to 18.0°C or 32.0°C, the air flow from the fan is always set to “High” and does not
change even if the set temperature is reached.
*4: Air conditioner cannot be operated while the fan stops.“
PC200, 200LC, 220, 220LC-8M0 10-600 49

Guidance icon and function switch

q Functions available with the function switch vary depending on the guidance icon displayed above the
switch.
q No function is available if no guidance icon appears above the function switch.
q The following is the list of guidance icons and the functions displayed above the function switches.
Guidance icon Item Function

Selects user menu screen.
Background colors allow confirming the type of information transmitted.
Selection of user mode • Gray: When the condition is normal
screen • Red: When exceeding maintenance interval warning
• Yellow: When exceeding maintenance interval warning
• Green: When there is unread KOMTRAX message
Switching clock/service
Switches clock/service meter display.
meter
Switching to camera screen Switches to camera image display screen.
Enters selected/setting item.

Background colors allow confirming the type of information transmitted.
Enter
• Gray: When the condition is normal
• Green: When energy saving guidance is displayed
Return Returns to the previous screen or status.
Selects the item right above the current item

Switching the select item
(To the bottom item from the top item.)
Selects the item right below the current item

(To the top item from the bottom item.)
Green arrow: Selects the item on the right side of the tab.
Switching the select item White arrow: Selects the item on the right side of the current item.
(To the leftmost item from the rightmost item.)
Green arrow: Selects the item on the left side of the tab.
Switching the select item White arrow: Selects the item on the left side of the current item.
(To the rightmost item from the leftmost item.)
Selects the page right above the current page.

(To the bottom page from the top page.)
10-600 50 PC200, 200LC, 220, 220LC-8M0

Selects the page right below the current page.

(To the top page from the bottom page.)
Clear Clears selected/displayed item.
Sets selected item back to default.

Restores default value
(Used for screen adjustment.)
Set Performs setting.
Starts function.
Start (Used for starting measurement of split fuel consumption on the fuel
consumption display screen.)
Stops operation.
Stop (Used for stopping measurement of split fuel consumption on fuel
consumption display screen.)
Saving Saves setting
Switching to the name

Switches the current screen to the name setting screen
setting screen
Switching to ATT1 oil flow Switching the current screen to attachment 1 oil flow setting screen.
setting screen (Enabled only when attachments 1 and 2 are equipped)
Switching to ATT2 oil flow Switching the current screen to attachment 2 oil flow setting screen.
setting screen (Enabled only when attachments 1 and 2 are equipped)
Holds the value of the target item of monitoring.

HOLD
(Used when monitoring is turned on)
Resets the currently held value of the target item of monitoring.

Resetting the hold
(Used when monitoring is turned on)
PC200, 200LC, 220, 220LC-8M0 10-600 51

Switching the fuel

Switches the graphs on the fuel consumption record screen.
consumption record screen
Switching to oil flow setting

Switches to the attachment and breaker oil flow setting screen.
screen
Switches to the currently occurring failures list screen.

Switching to the currently Background colors allow confirming the type of information transmitted.
occurring failures list screen • Red: When an action level of L2, L3 or L4 is displayed
• Yellow: When the action level of L1 is displayed
Display No. 1 camera

Selects No. 1 camera image display screen.
screen
Display No. 2 camera

Selects No. 2 camera image display screen.
screen
Display No. 1 and No. 2

Display both images of No. 1 and No. 2 cameras simultaneously.
camera screens
10-600 52 PC200, 200LC, 220, 220LC-8M0

Operator mode function

q The operator can select the information to be displayed usually on the screen and the function to be
used by operating the switches.
Display and setting of some functions require special operation of the switch.
q Items available in the operator mode are as follows:
Category Display order (*2)

Item
(*1) V W X Y Z
KOMATSU logo screen 1 1 1 1 1
Password input screen 2 — — — —
Breaker mode check screen — — 2 — —
Checks before starting screen 3 2 3 2 2
A Warning screen after check before starting — — — 3 —
Overdue maintenance time item screen — — — — 3
Working mode and travel speed check screen 4 3 4 4 4
Standard screen 5 4 5 5 5
End screen
Selecting auto-deceleration function
Selecting working mode
Selecting travel speed
Stopping alarm buzzer
Operating windshield wiper
Operating window washer
Operating air conditioner
B Operating camera mode display
Switching between clock display and service meter display
Checking maintenance information
Setting and displaying user menu
• ECO Guidance
• Machine Setting
• Maintenance
• Monitor Setting
• Message display (including KOMTRAX messages for user)
Displaying ECO guidance
C Displaying caution monitor
Displaying action level and failure code
LCD (Liquid Crystal Display) display condition checking function
D Service meter reading checking function
Access restriction setting/password changing function
*1: The items available in the operator mode are categorized as shown below.
A: Displays that appear since starting switch is turned to “ON” position until the standard screen appears,
and the displays that appear after starting switch is turned to “OFF” position .
B: Displays that appear when the switch on the machine monitor is operated.
C: Displays when a certain condition is satisfied
D: Displays that require special switch operations.
*2: Display sequence from “ON” of starting switch to the standard screen varies depending on the settings
and conditions of the machine as follows:
V: When engine start lock is set effective
W: When engine start lock is disabled
X: When working mode at start is set to “Breaker Mode (B)”.
PC200, 200LC, 220, 220LC-8M0 10-600 53

Y: When a failure is detected during check before starting.

Z: When a maintenance time overdue is detected for an item.
a For how to operate the operator mode functions, see the Operation and Maintenance Manual or “Oper-
ator mode (Outline)” section in Testing and adjusting.
a For how to set the engine start lock on/off, see “Password setting/cancel manual”.
10-600 54 PC200, 200LC, 220, 220LC-8M0

Service mode function

q The functions in this mode are not displayed usually on the screen. Information display and various set-
tings can be made only by the technician through the special operation of the switches.
This mode is used for special setting, testing, adjusting, or troubleshooting.
q Items available in the service mode are as follows:
Monitoring / Pre-defined
Monitoring / Custom
Mechanical Systems
Abnormality Record
Electrical Systems
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Key-on Mode
Unit
Default
With/Without Attachment
Camera
Diagnostic Tests Cylinder Cut-out
Pump Absorption Torque (F)
Pump Absorption Torque (R)
Adjustment
Low Speed
Attachment Flow Adjustment
No Injection
Terminal Status
KOMTRAX Settings GPS & Communication Status
Modem Status
Service Message
a For how to operate the service mode functions, see “section in Testing and adjusting”.
PC200, 200LC, 220, 220LC-8M0 10-600 55

SEN06123-01 Sensor
Sensor 1
q The signals from the sensors are input to the
monitor panel directly.
q Either side of a sensor of contact type is
always connected to the chassis ground.
Type of When When
Sensor name
sensor normal abnormal
ON OFF
Hydraulic oil level Contact
(Closed) (Open)
Resis-
Fuel level — —
tance
OFF ON
Air cleaner clogging Contact
(Closed) (Open)
ON OFF
Coolant level Contact
(Closed) (Open)
Hydraulic oil level sensor 1
1. Connector
2. Bracket
3. Float
4. Switch
10-600 56 PC200, 200LC, 220, 220LC-8M0

Sensor SEN06123-01
Fuel level sensor 1
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor 1
1. Adapter 3. Indicator
2. Hood 4. Connector
PC200, 200LC, 220, 220LC-8M0 10-600 57

SEN06123-01 Sensor
Coolant level sensor 1
1. Reserve tank
2. Float
3. Sensor
4. Connector
10-600 58 PC200, 200LC, 220, 220LC-8M0

Sensor SEN06123-01
PC200, 200LC, 220, 220LC-8M0 10-600 59

SEN06123-01 KOMTRAX system
KOMTRAX system 1
q The KOMTRAX system consists of the KOMTRAX terminal, communication antenna and GPS antenna.
q This system transmits various machine information by use of the radio communication. This system
allows the KOMTRAX operator to refer the information and provide various services to the customers.
q Information transmittable from the KOMTRAX system are as follows.
1. Operation map
2. Service meter reading
3. Location information
4. Abnormality record
a To provide the services, you need to make an arrangement for starting the KOMTRAX service sepa-
rately.
KOMTRAX terminal
Type: TC330
1. GPS antenna connection 3. Machine harness connection (070-12P)

2. Machine harness connection (070-18P) 4. Communication antenna connection
10-600 60 PC200, 200LC, 220, 220LC-8M0

KOMTRAX system SEN06123-01

070-18P[CN-CK01]

1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 CAN (C)_H Input/Output
11 CAN (C)_L Input/Output
12 (*1) —
13 (*1) —
14 External start signal Input/Output
15 (*1) —
16 (*1) —
17 (*1) —
18 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
070-12P [CN-CK02]

1 GND —
2 GND —
3 Starting switch (ACC) Input
4 Alternator (R) Input
5 (*1) —
6 Power supply Input
7 Power supply Input
8 (*1) —
9 (*1) —
10 (*1) —
11 Starting switch (C) Input
12 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
PC200, 200LC, 220, 220LC-8M0 10-600 61

SEN06123-01 KOMTRAX system
Function
q This terminal uses the satellite communications technology.
q The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the com-
munication antenna.
q The status of the terminal can be checked by using the menu of “KOMTRAX setting” in the service
mode of the machine monitor .
q Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
q This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When changing the country where the system is used, you must give notice to Komatsu Ltd. the infor-
mation which country the system is used in advance.
10-600 62 PC200, 200LC, 220, 220LC-8M0

Clogging detection system of additional filter for breaker SEN06123-01
Clogging detection system of additional filter for breaker 1
1. Filter clogging caution device 3. Filter clogging detection sensor

2. Caution lamp 4. Magnet
q The clogging detection system of additional filter for breaker consists of the clogging caution lamp for
breaker and additional filter with clogging sensor for breaker.
q The clogging caution lamp for breaker lights up when the additional filter for breaker is clogged during
breaker operation.

1 Power supply (24V) Input
2 GND (0V) -
3 Sensor signal Input
4 Alarm output Output
PC200, 200LC, 220, 220LC-8M0 10-600 63

SEN06123-01

© 2017 KOMATSU
All Rights Reserved
10-600 64
SEN06125-01
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
20 Standard value table 1

100 Standard service value table
Standard value table for engine related parts ................................................................................................. 2
Standard value table for chassis related parts ................................................................................................ 4
PC200, 200LC, 220, 220LC-8M0 20-100 1

SEN06125-01 Standard value table for engine related parts
Standard value table for engine related parts 1

PC200, 200LC-8M0
Applicable model PC200, 200LC-8M0
Engine SAA6D107E-1
Cate- Standard value for new

gory
Item Measurement condition Unit Judgement criteria
machine
High idle rpm 2,060 ± 70 2,060 ± 70

• Coolant
temperature:
Engine speed Low idle rpm 1,050 ± 50 1,050 ± 50
operating range
(60 to 100°C)
Rated speed rpm 2,000 2,000
• Coolant temperature: operating

Intake pressure kPa Min. 133 103
range (60 to 100°C)
(boost pressure) {mmHg} {Min. 1,000} {775}
• Arm IN relief + Power Max.
• Coolant At sudden
% Max. 25 35
temperature: acceleration
Exhaust gas color
operating range
(60 to 100°C) At high idle % — —
Intake valve mm 0.25 0.152 to 0.381

Valve clearance • Normal temperature
Exhaust valve mm 0.51 0.381 to 0.762
Compression MPa Min. 2.41 1.69

Compression • Oil temperature: pressure {kg/cm2} {Min. 24.6} {17.2}
pressure 40 to 60°C
Engine
Engine speed rpm 250 to 280 250 to 280

kPa Max. 0.98 1.96
Blowby pressure range (60 to 100°C)
{mmH2O} {Max. 100} {200}
• Arm IN relief + power max.
• SAE0W30EOS,
SAE5W40EOS, MPa Min. 0.29 0.25
SAE10W30DH, High idle
{kg/cm2} {Min. 3.0} {2.5}
SAE15W40DH,
Oil pressure SAE30DH engine oil
• Coolant
temperature: MPa Min. 0.10 0.07
Low idle
operating range {kg/cm2} {Min. 1.0} {0.7}
(60 to 100°C)
Oil temperature • Whole speed range (inside oil pan) °C 80 to 110 120
• Between fan pulley and alternator

pulley
Fan belt tension mm 8 6 to 10
• Deflection when pressed with finger
force of approx. 98 N{10 kg}
• Between fan pulley and compressor
Air conditioner
pulley
compressor belt mm 6.3 to 8.7 6.3 to 8.7
tension
force of approx. 60 N{6.2 kg}
20-100 2 PC200, 200LC, 220, 220LC-8M0

Standard value table for engine related parts SEN06125-01
PC220, 220LC-8M0
Engine SAA6D107E-1

gory
machine
High idle rpm 2,100 ± 70 2,100 ± 70

• Coolant
temperature:
Engine speed Low idle rpm 1,050 ± 50 1,050 ± 50
operating range
(60 to 100°C)
Rated speed rpm 2,000 2,000

Intake pressure kPa Min. 133 103
range (60 to 100°C)
(boost pressure) {mmHg} {Min. 1,000} {775}
• Arm IN relief + Power Max.
• Coolant At sudden
% Max. 25 35
temperature: acceleration
Exhaust gas color
operating range
(60 to 100°C) At high idle % — —
Intake valve mm 0.25 0.152 to 0.381

Valve clearance • Normal temperature
Exhaust valve mm 0.51 0.381 to 0.762
Compression MPa Min. 2.41 1.69

Compression • Oil temperature: pressure {kg/cm2} {Min. 24.6} {17.2}
pressure 40 to 60°C
Engine
Engine speed rpm 250 to 280 250 to 280

kPa Max. 0.98 1.96
Blowby pressure range (60 to 100°C)
{mmH2O} {Max. 100} {200}
• Arm IN relief + power max.
• SAE0W30EOS,
SAE5W40EOS, MPa Min. 0.29 0.25
SAE10W30DH, High idle
{kg/cm2} {Min. 3.0} {2.5}
SAE15W40DH,
Oil pressure SAE30DH engine oil
• Coolant
temperature: MPa Min. 0.10 0.07
Low idle
operating range {kg/cm2} {Min. 1.0} {0.7}
(60 to 100°C)
Oil temperature • Whole speed range (inside oil pan) °C 80 to 110 120
• Between fan pulley and alternator

pulley
Fan belt tension mm 8 6 to 10
force of approx. 98 N{10 kg}
• Between fan pulley and compressor
Air conditioner
pulley
compressor belt mm 6.3 to 8.7 6.3 to 8.7
tension
force of approx. 60 N{6.2 kg}
PC200, 200LC, 220, 220LC-8M0 20-100 3

SEN06125-01 Standard value table for chassis related parts
Standard value table for chassis related parts 1

PC200, 200LC-8M0

gory
machine
• Engine coolant temperature: Within
operating range (60 to 100°C)
• Hydraulic oil temperature: Within
2 pumps at relief operating range (45 to 55°C) rpm 1,800 ± 100 1,800 ± 100
• Engine at high idle
• Power mode (P)
• Arm IN relief condition
Engine speed

At 2-pump relief +
operating range (45 to 55°C) rpm 1,950 ± 100 1,950 ± 100
power max.
• Working mode: P mode
• Arm IN relief + Left knob switch ON
Speed when auto- • Auto-deceleration switch in ON
deceleration is condition rpm 1,050 ± 100 1,050 ± 100
operated • All control levers in NEUTRAL
condition
Raise mm 11.5 ± 0.5 11.5 ± 0.5

Boom control valve
Lower mm 9.5 ± 0.5 9.5 ± 0.5
IN mm 11.5 ± 0.5 11.5 ± 0.5

Spool stroke
Arm control valve • Engine stopped

• For measuring
OUT mm 9.5 ± 0.5 9.5 ± 0.5
point, see Control
valve.
Bucket control valve CURL, DUMP mm 9.5 ± 0.5 9.5 ± 0.5
Swing control valve LH, RH travel mm 9.5 ± 0.5 9.5 ± 0.5
Forward,
Travel control valve mm 9.5 ± 0.5 9.5 ± 0.5
Reverse
Boom control lever mm 85 ± 10 85 ± 10
Arm control lever • Engine stopped mm 85 ± 10 85 ± 10

Travel of control levers
• Control lever grip at center

Bucket control lever • Max. reading up to stroke end mm 85 ± 10 85 ± 10
(except lever play in NEUTRAL
Swing control lever position) mm 85 ± 10 85 ± 10
Travel control lever mm 115 ± 12 115 ± 12
Work
mm Max. 15 Max. 20
equipment
Play of control lever
Travel mm Max. 20 Max. 25
20-100 4 PC200, 200LC, 220, 220LC-8M0

Standard value table for chassis related parts SEN06125-01

gory
machine
N 15.7 ± 3.9 Max. 24.5
Boom control lever
Operating force of control levers
{kg} {1.6 ± 0.4} {Max. 2.5}

N 15.7 ± 3.9 Max. 24.5
Arm control lever
• Hydraulic oil temperature: Within {kg} {1.6 ± 0.4} {Max. 2.5}
operating range (45 to 55°C) N 12.7 ± 2.9 Max. 21.6
and pedal
Bucket control lever

• Engine at high idle {kg} {1.3 ± 0.3} {Max. 2.2}
• Control lever grip at center N 12.7 ± 2.9 Max. 21.6
Swing control lever • Pedal at tip {kg} {1.3 ± 0.3} {Max. 2.2}
• Max. reading up to stroke end N 24.5 ± 5.9 Max. 39.2
Travel control lever
{kg} {2.5 ± 0.6} {Max. 4.0}
N 74.5 ± 18.6 Max. 107.6
Travel control pedal
{kg} {7.6 ± 1.9} {Max. 11}
MPa 3.5 ± 1.0 3.5 ± 1.0
Unload pressure • Working mode: P mode
{kg/cm2} {36 ± 10} {36 ± 10}
• Hydraulic pump output pressure
with all control levers in NEUTRAL
position
MPa 34.8 (+1.5/-1.2) 33.1 to 37.2
Normal relief
• Hydraulic oil {kg/cm2} {355 (+15/-12)} {338 to 380}
Boom relief
temperature: Within MPa 37.3 (+1.5/-1.2) 36.1 to 39.7
operating range Power max.
{kg/cm2} {380 (+15/-12)} {368 to 405}
(45 to 55°C) MPa 34.8 (+1.5/-1.2) 33.1 to 37.2
• Engine at high idle Normal relief
{kg/cm2} {355 (+15/-12)} {338 to 380}
Arm relief • Working mode: P
mode MPa 37.3 (+1.5/-1.2) 36.1 to 39.7
Power max.
• Hydraulic pump {kg/cm2} {380 (+15/-12)} {368 to 405}
output pressure with MPa 34.8 (+1.5/-1.2) 33.1 to 37.2
Normal relief
all measurement {kg/cm2} {355 (+15/-12)} {338 to 380}
Bucket relief
circuits relieved MPa 37.3 (+1.5/-1.2) 36.1 to 39.7
Power max.
{kg/cm2} {380 (+15/-12)} {368 to 405}
Hydraulic pressure

operating range (45 to 55°C) MPa 30.3 ± 1.5 28.4 to 32.3
Swing relief
• Engine at high idle {kg/cm2} {310 ± 15} {290 to 330}
• Hydraulic pump output pressure MPa 38.7(+1.0/–2.0) 36.8 to 40.2
Travel relief with all measurement circuits {kg/cm2} {395(+10/–20)} {375 to 410}
relieved
Control circuit source • Engine running at high idle MPa 3.23(+0.2/–0.3) 2.75 to 3.43
pressure • Self pressure reducing valve output {kg/cm2} {33(+2/–3)} {28 to 35}
pressure with all control levers in
NEUTRAL position
• Hydraulic oil
temperature: Within When all
operating range control levers MPa 3.5 ± 1.0 3.5 ± 1.0
(45 to 55°C) in NEUTRAL {kg/cm2} {36 ± 10} {36 ± 10}
• Engine at high idle position
• Working mode: P
LS differential
mode
pressure
• Traveling speed: Hi
• Run either track with When
no load MPa 1.8 ± 0.1 1.8 ± 0.1
traveling at
• Hydraulic oil pump {kg/cm2} {18 ± 1} {18 ± 1}
half stroke
pressure – LS
pressure
PC200, 200LC, 220, 220LC-8M0 20-100 5


gory
machine
• Engine running at high idle
• Working mode: P mode deg. Max. 100 Max. 130
Swing brake angle
• Swing circle misalignment amount (mm) (—) (—)
when stopping after one turn
• For measuring posture, see Swing
1
• Hydraulic oil
temperature: Within
operating range
(45 to 55°C) 90° sec. 3.1 ± 0.3 Max. 3.7
• Engine running at
high idle
• Working mode: P
Time taken to start
mode
swing
• Time required for
passing points 90°
and 180° from
starting point 180° sec. 4.4 ± 0.4 Max. 5.5
• For measuring
posture, see Swing
1
Swing

Time taken to swing sec. 24.2 ± 2.5 Max. 30
• Time required for 5 more turns after
making initial one turn
1
• Engine stopped
• Keeping upper structure transverse
on slope of 15°
Hydraulic drift of
• Notching a mating mark on inner mm 0 0
swing
and outer races of swing circle
• Mating mark misalignment amount
during 5 minutes
2
Leakage from swing • Engine running at high idle
l/min Max. 5 Max. 10
motor • Swing lock switch: ON
• Leakage amount for one minute
during swing relief
• Hydraulic oil [PC200-8M0] [PC200-8M0]
temperature: Within 51.3 (+3.6/-6.7) 44.6 to 58.8
operating range Lo sec.
[PC200LC-8M0] [PC200LC-8M0]
(45 to 55°C)
55.9 (+3.9/-7.3) 48.6 to 63.8
high idle [PC200-8M0] [PC200-8M0]
• Working mode: P 37.5 ± 3.8 33.7 to 45.3
Travel
Travel speed Mi sec.

mode [PC200LC-8M0] [PC200LC-8M0]
(without load)
• Time required for 40.8 ± 4.1 36.7 to 48.9
track shoes to make
[PC200-8M0] [PC200-8M0]
5 turns after making
26.5 ± 1.3 25.2 to 29.8
one initial idle turn
• For measuring Hi sec.
[PC200LC-8M0] [PC200LC-8M0]
posture, see Travel
28.8 ± 1.5 27.3 to 32.3
1
20-100 6 PC200, 200LC, 220, 220LC-8M0


gory
machine
• Hydraulic oil
temperature: Within
operating range Lo sec. 24 (+1.7/-3.1) 20.9 to 26.9
(45 to 55°C)
high idle
• Working mode: P
Travel speed Mi sec. 17 ± 2.5 14.5 to 20.5
mode
(actual run)
• Flat ground
traveling 20 m after
10 m trial run
• For measuring Hi sec. 13 ± 1.0 12.0 to 15.0
posture, see Travel
2
Travel
• Travel speed: Lo
Travel deviation mm Max. 150 Max. 250
• Solid and flat ground
• Swerving amount while traveling 20
m (X) after initial 10 m trial run
• For measuring posture, see Travel
2 and 3
• Engine stopped
Hydraulic drift of • Parking machine on slope of 12°
mm 0 0
travel with sprocket facing upslope
• Sliding distance for 5 minutes
4
Leakage of travel • Engine at high idle
l/min 13.6 27.2
motor • Traveling with sprocket locked
• Oil leakage amount for one minute
with traveling in relief condition
Whole work operating range (45 to 55°C) mm Max. 644 Max. 966
Hydraulic drift of work equipment
equipment • Flat and level ground

• Fill bucket with dirt or rated load
(1260 kg)
Work equipment
Boom cylinder • Boom horizontal, arm fully retracted, mm Max. 19 Max. 29

bucket cylinder fully extended
• Engine stopped
• Work equipment control lever in
Arm cylinder NEUTRAL position mm Max. 184 Max. 276
• Fall amount for 15 minutes as
measured every 5 minutes starting
immediately after initial setting
Bucket cylinder • For measuring posture, see Work mm Max. 42 Max. 63
equipment 1
PC200, 200LC, 220, 220LC-8M0 20-100 7


gory
machine
• Hydraulic oil
temperature: Within
operating range
(45 to 55°C) RAISE sec. 3.3 ± 0.4 Max. 4.8
high idle
• Working mode: P
Boom mode
• Time required from
raise stroke end till
bucket touches
ground LOWER sec. 2.4 ± 0.3 Max. 3.7
• For measuring
posture, see Work
equipment 2
• Hydraulic oil
temperature: Within
operating range
(45 to 55°C)
Work equipment speed
IN sec. 3.5 ± 0.4 Max. 4.5

Work equipment
high idle
• Working mode: P
Arm mode
dumping stroke end
to digging stroke
end OUT sec. 2.7 ± 0.3 Max. 3.5
• For measuring
posture, see Work
equipment 3
• Hydraulic oil
temperature: Within
operating range
(45 to 55°C) CURL sec. 2.4 ± 0.3 Max. 3.3
high idle
• Working mode: P
Bucket mode
dumping stroke end
to digging stroke
end DUMP sec. 1.8 ± 0.2 Max. 2.7
• For measuring
posture, see Work
equipment 4
20-100 8 PC200, 200LC, 220, 220LC-8M0


gory
machine
• Engine running at low idle
Boom • Time required from raise stroke end sec. Max. 1.0 Max. 1.2
till bucket touches ground and
pushes up machine front
• For measuring posture, see Work
equipment 5
Time lag
• Time required from dumping stroke

Arm sec. Max. 2.0 Max. 2.8
end till bucket stops momentarily
Work equipment
after control lever is tilted to digging

and starts to move again
equipment 6
Bucket sec. Max. 1.0 Max. 3.6
equipment 7
Cylinders operating range (45 to 55°C) cc/min 4.5 20
leakage
Internal

Center swivel with cylinder or travel to be cc/min 10 50
joint measured in relief condition
compound operation

Performance in
Swerving amount in • Working mode: P mode

simultaneous • Traveling speed: Lo
mm Max.200 Max.220
operation of work • On hard and flat ground, make
equipment and travel approach run of 10 m and then mea-
sure deviation in the travel of 20 m
2 and 3
PC flow control valve
Characteristics of
• Rated load applied to bucket

(1260 kg)
Time required for
• On hard and flat ground, set arm 4.2 ± 0.4
turning from 0 to 90° sec.
vertically and lower back of bucket (Reference value)
with boom raised
to ground
• Time required till passing spot of
90° starting from illustrated posture
and with boom raised
equipment 8
Discharge amount of
— See performance of hydraulic pump (next page)
hydraulic pump
PC200, 200LC, 220, 220LC-8M0 20-100 9

Cate- Standard lower limit of

gory
Item Measurement condition Unit Standard value
discharge
• Pump speed (rpm): 2,000rpm
• PC-EPC current value (mA): 440mA
Hydraulic pump
• Discharge pressure of test pump

Performance of (MPa {kg/cm2}): P1 Q Q
l/min
hydraulic pump • Discharge pressure of another (See graph) (See graph)
pump (MPa {kg/cm2}): P2
• Average discharge pressure
(MPa {kg/cm2}): Pp=(P1+P2)÷2
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pres-
sure when measuring.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to
the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at
the point of measurement, and use them as a base for calculating the pump discharge amount at the
specified speed.
20-100 10 PC200, 200LC, 220, 220LC-8M0

PC220, 220LC-8M0

gory
machine
2 pumps at relief operating range (45 to 55°C) rpm 1,900 ± 100 1,940 ± 100
• Power mode (P)
• Arm IN relief condition
Engine speed

At 2-pump relief +
operating range (45 to 55°C) rpm 1,950 ± 100 1,950 ± 100
power max.
• Arm IN relief + Left knob switch ON
Speed when auto- • Auto-deceleration switch in ON
deceleration is condition rpm 1,050 ± 100 1,050 ± 100
operated • All control levers in NEUTRAL
condition
Raise mm 11.5 ± 0.5 11.5 ± 0.5

Boom control valve
Lower mm 9.5 ± 0.5 9.5 ± 0.5
IN mm 11.5 ± 0.5 11.5 ± 0.5

Spool stroke
Arm control valve • Engine stopped

• For measuring
OUT mm 9.5 ± 0.5 9.5 ± 0.5
point, see Control
valve.
Bucket control valve CURL, DUMP mm 9.5 ± 0.5 9.5 ± 0.5
Swing control valve LH, RH travel mm 9.5 ± 0.5 9.5 ± 0.5
Forward,
Travel control valve mm 9.5 ± 0.5 9.5 ± 0.5
Reverse
Boom control lever mm 85 ± 10 85 ± 10
Arm control lever • Engine stopped mm 85 ± 10 85 ± 10

Travel of control levers
• Control lever grip at center

Bucket control lever • Max. reading up to stroke end mm 85 ± 10 85 ± 10
(except lever play in NEUTRAL
Swing control lever position) mm 85 ± 10 85 ± 10
Travel control lever mm 115 ± 12 115 ± 12
Work
mm Max. 15 Max. 20
equipment
Play of control lever
Travel mm Max. 20 Max. 25
PC200, 200LC, 220, 220LC-8M0 20-100 11


gory
machine
N 15.7 ± 3.9 Max. 24.5
Boom control lever
Operating force of control levers
{kg} {1.6 ± 0.4} {Max. 2.5}

N 15.7 ± 3.9 Max. 24.5
Arm control lever
• Hydraulic oil temperature: Within {kg} {1.6 ± 0.4} {Max. 2.5}
operating range (45 to 55°C) N 12.7 ± 2.9 Max. 21.6
and pedal
Bucket control lever

• Engine at high idle {kg} {1.3 ± 0.3} {Max. 2.2}
• Control lever grip at center N 12.7 ± 2.9 Max. 21.6
Swing control lever • Pedal at tip {kg} {1.3 ± 0.3} {Max. 2.2}
• Max. reading up to stroke end N 24.5 ± 5.9 Max. 39.2
Travel control lever
{kg} {2.5 ± 0.6} {Max. 4.0}
N 74.5 ± 18.6 Max. 107.6
Travel control pedal
{kg} {7.6 ± 1.9} {Max. 11}
MPa 3.5 ± 1.0 3.5 ± 1.0
Unload pressure • Working mode: P mode
{kg/cm2} {36 ± 10} {36 ± 10}
• Hydraulic pump output pressure
with all control levers in NEUTRAL
position
MPa 34.8 (+1.5/-1.2) 33.1 to 37.2
Normal relief
• Hydraulic oil {kg/cm2} {355 (+15/-12)} {338 to 380}
Boom relief
temperature: Within MPa 37.3 (+1.5/-1.2) 36.1 to 39.7
operating range Power max.
{kg/cm2} {380 (+15/-12)} {368 to 405}
(45 to 55°C) MPa 34.8 (+1.5/-1.2) 33.1 to 37.2
• Engine at high idle Normal relief
{kg/cm2} {355 (+15/-12)} {338 to 380}
Arm relief • Working mode: P
mode MPa 37.3 (+1.5/-1.2) 36.1 to 39.7
Power max.
• Hydraulic pump {kg/cm2} {380 (+15/-12)} {368 to 405}
output pressure with MPa 34.8 (+1.5/-1.2) 33.1 to 37.2
Normal relief
all measurement {kg/cm2} {355 (+15/-12)} {338 to 380}
Bucket relief
circuits relieved MPa 37.3 (+1.5/-1.2) 36.1 to 39.7
Power max.
{kg/cm2} {380 (+15/-12)} {368 to 405}
Hydraulic pressure

operating range (45 to 55°C) MPa 30.3 ± 1.5 28.4 to 32.3
Swing relief
• Engine at high idle {kg/cm2} {310 ± 15} {290 to 330}
• Hydraulic pump output pressure MPa 38.7(+1.0/–2.0) 36.8 to 40.2
Travel relief with all measurement circuits {kg/cm2} {395(+10/–20)} {375 to 410}
relieved
Control circuit source • Engine running at high idle MPa 3.23(+0.2/–0.3) 2.75 to 3.43
pressure • Self pressure reducing valve output {kg/cm2} {33(+2/–3)} {28 to 35}
pressure with all control levers in
NEUTRAL position
• Hydraulic oil
temperature: Within When all
operating range control levers MPa 3.5 ± 1.0 3.5 ± 1.0
(45 to 55°C) in NEUTRAL {kg/cm2} {36 ± 10} {36 ± 10}
• Engine at high idle position
• Working mode: P
LS differential
mode
pressure
• Traveling speed: Hi
• Run either track with When
no load MPa 1.8 ± 0.1 1.8 ± 0.1
traveling at
• Hydraulic oil pump {kg/cm2} {18 ± 1} {18 ± 1}
half stroke
pressure – LS
pressure
20-100 12 PC200, 200LC, 220, 220LC-8M0


gory
machine
• Working mode: P mode deg. Max. 165 Max. 200
Swing brake angle
• Swing circle misalignment amount (mm) (—) (—)
when stopping after one turn
1
• Hydraulic oil
temperature: Within
operating range
(45 to 55°C) 90° sec. 3.0 ± 0.3 Max. 3.5
high idle
• Working mode: P
Time taken to start
mode
swing
passing points 90°
and 180° from
starting point 180° sec. 4.5 ± 0.4 Max. 5.4
• For measuring
posture, see Swing
1
Swing

Time taken to swing sec. 25.7 ± 2.8 Max. 31
• Time required for 5 more turns after
making initial one turn
1
• Engine stopped
• Keeping upper structure transverse
on slope of 15°
Hydraulic drift of
• Notching a mating mark on inner mm 0 0
swing
and outer races of swing circle
• Mating mark misalignment amount
during 5 minutes
2
Leakage from swing • Engine running at high idle
l/min Max. 5 Max. 10
motor • Swing lock switch: ON
during swing relief
• Hydraulic oil [PC220-8M0] [PC220-8M0]
temperature: Within 53.6 (+3.8/-7.0) 46.6 to 61.5
operating range Lo sec.
[PC220LC-8M0] [PC220LC-8M0]
(45 to 55°C)
• Engine running at 58.1 (+4.1/-7.6) 50.5 to 66.3
high idle [PC220-8M0] [PC220-8M0]
• Working mode: P 39.2 (+4.4/-3.6) 35.6 to 47.6
Travel
Travel speed Mi sec.

mode
(without load) [PC220LC-8M0] [PC220LC-8M0]
track shoes to make 42.5 (+4.7/-3.9) 38.6 to 51.2
5 turns after making [PC220-8M0] [PC220-8M0]
one initial idle turn 28.0 (+1.5/-1.3) 26.7 to 31.5
• For measuring Hi sec.
posture, see Travel [PC220LC-8M0] [PC220LC-8M0]
1 30.3 (+1.6/-1.4) 28.9 to 33.9
PC200, 200LC, 220, 220LC-8M0 20-100 13


gory
machine
• Hydraulic oil
temperature: Within
operating range Lo sec. 24 (+1.7/-3.1) 20.9 to 26.9
(45 to 55°C)
high idle
• Working mode: P
Travel speed Mi sec. 17 ± 2.5 14.5 to 20.5
mode
(actual run)
• Flat ground
traveling 20 m after
10 m trial run
• For measuring Hi sec. 13 ± 1.0 12.0 to 15.0
posture, see Travel
2
Travel
• Travel speed: Lo
Travel deviation mm Max. 150 Max. 250
• Solid and flat ground
• Swerving amount while traveling 20
m (X) after initial 10 m trial run
2 and 3
• Engine stopped
Hydraulic drift of • Parking machine on slope of 12°
mm 0 0
travel with sprocket facing upslope
• Sliding distance for 5 minutes
4
Leakage of travel • Engine at high idle
l/min 13.6 27.2
motor • Traveling with sprocket locked
• Oil leakage amount for one minute
with traveling in relief condition
Whole work operating range (45 to 55°C) mm Max. 600 Max. 900
Hydraulic drift of work equipment
equipment • Flat and level ground

• Fill bucket with dirt or rated load
(1620 kg)
Work equipment
Boom cylinder • Boom horizontal, arm fully retracted, mm Max. 18 Max. 27

bucket cylinder fully extended
• Engine stopped
• Work equipment control lever in
Arm cylinder NEUTRAL position mm Max. 160 Max. 240
• Fall amount for 15 minutes as
measured every 5 minutes starting
immediately after initial setting
Bucket cylinder • For measuring posture, see Work mm Max. 40 Max. 58
equipment 1
20-100 14 PC200, 200LC, 220, 220LC-8M0


gory
machine
• Hydraulic oil
temperature: Within
operating range
(45 to 55°C) RAISE sec. 3.4 (+0.5/-0.3) Max. 4.7
high idle
• Working mode: P
Boom mode
raise stroke end till
bucket touches
ground LOWER sec. 2.7 ± 0.3 Max. 4.4
• For measuring
posture, see Work
equipment 2
• Hydraulic oil
temperature: Within
operating range
(45 to 55°C)
Work equipment speed
IN sec. 4.1 ± 0.4 Max. 4.6

Work equipment
high idle
• Working mode: P
Arm mode
dumping stroke end
to digging stroke
end OUT sec. 3.0 (+0.4/-0.2) Max. 3.5
• For measuring
posture, see Work
equipment 3
• Hydraulic oil
temperature: Within
operating range
(45 to 55°C) CURL sec. 2.7 ± 0.3 Max. 3.3
high idle
• Working mode: P
Bucket mode
dumping stroke end
to digging stroke
end DUMP sec. 2.1 ± 0.2 Max. 2.7
• For measuring
posture, see Work
equipment 4
PC200, 200LC, 220, 220LC-8M0 20-100 15


gory
machine
Boom • Time required from raise stroke end sec. Max. 1.0 Max. 1.2
till bucket touches ground and
pushes up machine front
equipment 5
Time lag

Arm sec. Max. 2.0 Max. 2.8
Work equipment

equipment 6
Bucket sec. Max. 1.0 Max. 3.6
equipment 7
Cylinders operating range (45 to 55°C) cc/min 4.5 20
leakage
Internal

Center swivel with cylinder or travel to be cc/min 10 50
joint measured in relief condition
compound operation

Performance in
Swerving amount in • Working mode: P mode

simultaneous • Traveling speed: Lo
mm Max.200 Max.220
operation of work • On hard and flat ground, make
equipment and travel approach run of 10 m and then mea-
sure deviation in the travel of 20 m
2 and 3
PC flow control valve
Characteristics of
• Rated load applied to bucket

(1620 kg)
Time required for
• On hard and flat ground, set arm 4.3 ± 0.4
turning from 0 to 90° sec.
vertically and lower back of bucket (Reference value)
with boom raised
to ground
• Time required till passing spot of
90° starting from illustrated posture
and with boom raised
equipment 8
Discharge amount of
— See performance of hydraulic pump (next page)
hydraulic pump
20-100 16 PC200, 200LC, 220, 220LC-8M0

Cate- Standard lower limit of

gory
Item Measurement condition Unit Standard value
discharge
• Pump speed (rpm): 2,000rpm
• PC-EPC current value (mA): 440mA
Hydraulic pump
• Discharge pressure of test pump

Performance of (MPa {kg/cm2}): P1 Q Q
l/min
hydraulic pump • Discharge pressure of another (See graph) (See graph)
pump (MPa {kg/cm2}): P2
• Average discharge pressure
(MPa {kg/cm2}): Pp=(P1+P2)÷2
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pres-
sure when measuring.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to
the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at
the point of measurement, and use them as a base for calculating the pump discharge amount at the
specified speed.
PC200, 200LC, 220, 220LC-8M0 20-100 17

For all models (Posture of machine for measur- Travel 1: Travel speed (without load)
ing performance and measurement procedure)
Control valve: spool stroke
Travel 2: Travel speed (actual run), travel deviation
Swing 1: Swing brake angle, time taken to start

swing, time taken to swing
Travel 3: Travel deviation
Swing 2: Hydraulic drift of swing
20-100 18 PC200, 200LC, 220, 220LC-8M0

Travel 4: Hydraulic drift of travel Work equipment 3: Arm speed
Work equipment 1: Hydraulic drift of work Work equipment 4: Bucket speed

equipment
Work equipment 5: Boom time lag

Work equipment 2: Boom speed
PC200, 200LC, 220, 220LC-8M0 20-100 19

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

control valve
20-100 20 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 20-100 21

SEN06125-01

© 2016 KOMATSU
All Rights Reserved
20-100 22
SEN06127-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
30 Testing and adjusting 1

101 Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Sketch of special tool ...................................................................................................................................... 7
Testing engine speed ...................................................................................................................................... 8
Testing intake air pressure (boost pressure) ................................................................................................... 9
Testing exhaust gas color ............................................................................................................................. 10
Adjusting valve clearance ..............................................................................................................................11
Testing compression pressure ...................................................................................................................... 13
Testing blowby pressure ............................................................................................................................... 16
Testing engine oil pressure ........................................................................................................................... 17
Handling fuel system parts............................................................................................................................ 18
Releasing residual pressure from fuel system .............................................................................................. 18
Testing fuel pressure..................................................................................................................................... 19
Handling reduced cylinder mode operation .................................................................................................. 22
Handling no-injection cranking operation...................................................................................................... 22
Testing fuel discharge, return and leak amount ............................................................................................ 23
Bleeding air from fuel circuit.......................................................................................................................... 26
PC200, 200LC, 220, 220LC-8M0 30-101 1

SEN06127-00
Testing fuel circuit for leakage....................................................................................................................... 27

Handling controller high voltage circuit ......................................................................................................... 28
Testing and adjusting air conditioner compressor belt tension...................................................................... 29
Replacing alternator belt ............................................................................................................................... 30
Testing swing circle bearing clearance.......................................................................................................... 31
Testing and adjusting track tension ............................................................................................................... 32
Testing and adjusting oil pressure in work equipment, swing, and travel circuits ......................................... 34
Testing control circuit source pressure.......................................................................................................... 37
Testing and adjusting oil pressure in pump PC control circuit....................................................................... 38
Testing and adjusting oil pressure in pump LS control circuit ....................................................................... 41
Testing solenoid valve output pressure ......................................................................................................... 46
Testing PPC valve output pressure ............................................................................................................... 49
Adjusting play of work equipment and swing PPC valves............................................................................. 51
Testing parts which cause hydraulic drift of work equipment ........................................................................ 52
Releasing remaining pressure from hydraulic circuit .................................................................................... 54
Testing oil leakage......................................................................................................................................... 55
Bleeding air from each part ........................................................................................................................... 58
Testing cab tipping stopper ........................................................................................................................... 60
Adjusting mirrors ........................................................................................................................................... 61
Installation and adjustment of mirrors ........................................................................................................... 62
Angle adjustment of rear view camera.......................................................................................................... 65
30-101 2 PC200, 200LC, 220, 220LC-8M0

Tools for testing, adjusting, and troubleshooting SEN06127-00
Tools for testing, adjusting, and troubleshooting 1

Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
Testing intake air pressure –101 to 200 kPa
R 799-201-2202 Boost gauge kit 1
(boost pressure) {–760 to 1,500 mmHg}
1 799-201-9001 Handy smoke checker 1
Testing exhaust gas color A Commercially Bosch index: 0 to 9
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting valve clearance B Commercially
2 Thickness gauge 1 Intake: 0.25 mm, Exhaust: 0.51 mm
available
1 795-799-6700 Puller 1
2 795-502-1590 Compression gauge 1 0 to 7.0 MPa {0 to 70 kg/cm2}
Testing compression 3 795-790-4410 Adapter 1 For 107E-1 engine
C
pressure 4 6754-11-3130 Gasket 1 For 107E-1 engine
Commercially
5 Hose 1 Inside diameter: Approx. 15 mm
available
1 799-201-1504 Blowby checker 1 0 to 5 kPa {0 to 500 mmH2O}
Testing blow-by pressure D
2 795-790-3300 Blowby tool 1 For 107E-1 engine
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
Testing engine oil pres- 1 {25, 60, 400, 600 kg/cm2}
E
sure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
795-790-4430 Adapter 1
2 10 × 1.0 mm o R1/8
Testing fuel pressure F 6215-81-9710 O-ring 1
3 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
4 795-790-5110 Screw 1
5 799-201-2202 Boost gauge kit 1
6 07005-01212 Gasket 1
1 795-790-4700 Tester kit 1
6164-81-5790 Joint 1
2
07005-01212 Washer 2
6754-71-5340 Connector 1
3
6754-71-5350 Washer 1
Commercially
4 Measuring cylinder 1
Testing fuel return rate available
G
and leakage Commercially
5 Stopwatch 1
available
Commercially
6 Hose 1 Inside diameter: f14 mm
available
Commercially
available
Commercially
available
Testing swing circle bear- Commercially
H Dial gauge 1
ing clearance available
Testing and adjusting 1 {25, 60, 400, 600 kg/cm2}
oil pressure in work 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
J
equipment, swing, and
travel circuits 799-101-5220 Nipple 2
2 Size: 10 × 1.25 mm
07002-11023 O-ring 2
PC200, 200LC, 220, 220LC-8M0 30-101 3

SEN06127-00 Tools for testing, adjusting, and troubleshooting
Sym-
Q'ty
bol
1 {25, 60, 400, 600 kg/cm2}
Testing basic 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
K
pressure of control circuit
799-101-5220 Nipple 1
2 Size: 10 × 1.25 mm
07002-11023 O-ring 1
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting oil
pressure in pump PC con- L 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
trol circuit 799-101-5220 Nipple 4
2 Size: 10 × 1.25 mm
07002-11023 O-ring 4
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting oil 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
pressure in pump LS con- M Differential pressure
2 799-401-2701 1 49 MPa {500 kg/cm2}
trol circuit gauge
799-101-5220 Nipple 4
3 Size: 10 × 1.25 mm
07002-11023 O-ring 4
Testing solenoid valve 1 {25, 60, 400, 600 kg/cm2}
N
output pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
1 {25, 60, 400, 600 kg/cm2}
Testing PPC valve output 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
P
pressure
2 799-401-3100 Adapter 1 Size: 02
3 799-401-3200 Adapter 1 Size: 03
Commercially
Testing oil leakage Q Measuring cylinder 1
available
799-601-4101
or T-adapter assembly 1
799-601-4201
Troubleshooting for For DRC60, ECONO
799-601-4350 • Measurement box 1
engine (Does not include 799-601-4201)
S
Controller/sensors/actua- 799-601-4211 • T-adapter 1 Engine controller
tors
799-601-4220 • T-adapter 1 Engine controller
799-601-4260 • T-adapter 1 Engine controller
799-601-9020 • T-adapter 1 For injector
30-101 4 PC200, 200LC, 220, 220LC-8M0

Tools for testing, adjusting, and troubleshooting SEN06127-00
Sym-
Q'ty
bol
799-601-4101
or
799-601-4201
or T-adapter assembly 1
799-601-9000
or
799-601-9200
For ECONO
(Does not include 799-601-4201/
799-601-4350 799-601-9000 and 799-601-9200)
or • Measurement box 1
799-601-9320 For ECONO
(Does not include 799-601-4101/
799-601-4201 and 799-601-9200)
799-601-9020 • Adapter for DT 1 For DT2P
For DT3P
799-601-9030 • Adapter for DT 1 (Does not include 799-601-4101 and
799-601-4201)
For DT4P
799-601-4260 • Adapter for DT 1 (Does not include 799-601-9000 and
799-601-9200)
799-601-7000
or
Troubleshooting for 799-601-7100
chassis T or T-adapter assembly 1
Sensors/wiring harnesses 799-601-7400
or
799-601-8000
For ECONO
799-601-2600 • Measurement box 1
(Does not include 799-601-7000)
799-601-7090 • Adapter for M 1 For M2P
799-601-7140 • Adapter for S 1 For S8P
For SW6P
799-601-7050 • Adapter for SWP 1
For SW8P
799-601-7060 • Adapter for SWP 1
For X1P
799-601-7010 • Adapter for X 1 (Does not include 799-601-7000 and
799-601-7100)
799-601-7020 • Adapter for X 1 For X2P
799-601-7360 Adapter for relay 1 For REL-5P
799-601-7310 Adapter for SWP 1 For SW12P
799-601-9890 Adapter for multiple 1 For DT-2, 3, 4/DTM-2
799-601-4280 Measurement box 1 For pump controller
Testing coolant tempera-
— 799-101-1502 Digital thermometer 1 –99.9 to 1,299°C
ture and oil temperature
Testing operating effort 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}
—
and depressing force 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
Testing stroke and Commercially
— Ruler 1
hydraulic drift available
Testing work equipment Commercially
— Stopwatch 1
speed available
Testing voltage and Commercially
— Circuit tester 1
resistance available
Removal and installation
Commercially 3.26 mm torque wrench
of boost pressure and — Hexlobe (TORX) wrench 1
available (KTC Q4T15 or equivalent)
temperature sensors
PC200, 200LC, 220, 220LC-8M0 30-101 5

SEN06127-00 Tools for testing, adjusting, and troubleshooting
Sym-
Q'ty
bol
of engine oil pressure — 795-799-6210 Deep socket 1 27 mm deep socket
sensor
of engine coolant
temperature sensor Commercially 21 mm deep socket
— Deep socket 1
(6261-81-6900) available (MITOLOY 4ML-21 or equivalent)
Engine serial No.:
26500006 – 26530192
of engine coolant
temperature sensor
— 795T-981-1010 Deep socket 1 19 mm deep socket
(6261-81-6901)
Engine serial No.:
26530193 and up
a For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the
machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see “Trou-
bleshooting (General information on troubleshooting), List of T-boxes and T-adapters”.
30-101 6 PC200, 200LC, 220, 220LC-8M0

Sketch of special tool SEN06127-00
Sketch of special tool 1

—: Socket
PC200, 200LC, 220, 220LC-8M0 30-101 7

SEN06127-00 Testing engine speed
Testing engine speed 1 3. Measuring high idle speed

1) Start the engine and set the fuel control
a Measure the engine speed with the monitoring dial in the high idle (MAX) position.
function of the machine monitor. 2) Set the working mode in the power mode
a Measure the engine speed under the following (P) and turn the auto-decelerator OFF.
condition. 3) Set all the levers and pedals for work
q Engine coolant temperature: Within oper- equipment control, swing control, and
ating range travel in neutral and measure the engine
q Hydraulic oil temperature: Within operat- speed.
ing range
4. Measuring 2-pump relief speed
1. Preparation work 1) Start the engine and operate the arm cyl-
Operate the machine monitor so that the inder to the IN stroke end.
engine speed can be monitored. 2) Set the fuel control dial in the high idle
a For the operating method of the machine (MAX) position and set the working mode
monitor, see Special functions of machine in the power mode (P).
monitor. 3) Operate the left work equipment control
a Monitoring code: 01002 Engine speed lever to relieve the arm circuit at the IN
stroke end and measure the engine
speed.
5. Measuring 2-pump relief and power maxi-

mizing speed (near rated speed)
1) Start the engine and operate the arm cyl-
inder to the IN stroke end.
2) Set the fuel control dial in the high idle
(MAX) position and set the working mode
in the power mode (P).
3) While operating the left work equipment
control lever to relieve the arm circuit at
the IN stroke end and depressing the
power maximizing switch, measure the
engine speed.
a The power maximizing function is reset
2. Measuring low idle speed automatically in approximately 8.5 sec-
1) Start the engine and set the fuel control onds even if the switch is kept depressed.
dial in the low idle (MIN) position. Accordingly, measure the engine speed in
2) Set all the levers and pedals for work that period.
equipment control, swing control, and a You may check with the swing lock switch
travel in neutral and measure the engine ON (In this case, you do not need to oper-
speed. ate the power maximizing switch.)
6. Measuring auto-deceleration speed

1) Start the engine, set the fuel control dial in
the high idle position (MAX), and turn the
auto-decelerator ON.
2) Set all the levers and pedals for work
equipment control, swing control, and
travel in neutral and measure the engine
speed when the auto-decelerator oper-
ates.
a The engine speed lowers to a certain level
approximately 5 seconds after all the
levers and pedals are set in neutral. This
level is the auto-deceleration speed.
30-101 8 PC200, 200LC, 220, 220LC-8M0

Testing intake air pressure (boost pressure) SEN06127-00
Testing intake air pressure (boost 3. Run the engine at middle or higher speed and
pressure) 1 bleed oil from the hose.
a Install the connecting parts of the gauge
a Measuring tools for intake air pressure (boost and hose approximately a half and open
pressure) the self-seal on the hose side repeatedly,
Symbol Part No. Part name and the oil will be drained.
a If Pm kit (A) is available, you use the air-
R 799-201-2202 Boost gauge kit
bleeding coupling (790-261-1130) in that
k
kit.
Stop the machine on a level ground and
a If oil is left in the hose, the gauge does not
lower the work equipment to the ground.
work. Accordingly, be sure to drain the oil.
a Measure the intake air pressure under the fol-
lowing condition.
4. Set the working mode in the power mode (P)
q Engine coolant temperature: Within oper-
and turn the swing lock switch ON.
ating range
a If the swing lock switch is turned ON, the
q Hydraulic oil temperature: Within operat-
main relief valve is set for high-pressure
ing range
relief.
1. Open the engine hood and remove intake air
5. While running the engine with full throttle,
pressure pickup plug (1) from the intake air
relieve the arm circuit and measure the intake
connector.
air pressure.
2. Install nipple [1] of boost gauge kit R and con-

6. After finishing measurement, remove the mea-
nect it to gauge [2].
suring tools and return the removed parts.
PC200, 200LC, 220, 220LC-8M0 30-101 9

SEN06127-00 Testing exhaust gas color
Testing exhaust gas color 1

a Checking tools for exhaust gas color
Symbol Part No. Part name
1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available
k Stop the machine on a level ground and

k Be careful not to touch any hot part when
removing or installing the checking tools.
a Check the exhaust gas color under the follow-
ing condition. 2) Connect the probe hose, receptacle of the
q Engine coolant temperature: Within oper- accelerator switch, and air hose to smoke
ating range meter A2.
a If an air source and an electric power source a Limit the supplied air pressure to 1.5
are not available in the field, use handy smoke MPa {15 kg/cm2}.
checker A1. When recording official data, use 3) Connect the power cable to an AC recep-
smoke meter A2. tacle.
a Before connecting the cable, check
1. Testing with handy smoke checker A1 that the power switch of the smoke
1) Stick a sheet of filter paper to smoke meter is turned OFF.
checker A1. 4) Loosen the cap nut of the suction pump
2) Insert the exhaust gas intake pipe in and fit the filter paper.
exhaust pipe (1). a Fit the filter paper securely so that the
3) Start the engine and accelerate it sud- exhaust gas will not leak.
denly or run it at high idle and operate the 5) Turn on the power switch of smoke meter
handle of smoke checker A1 so that the A2.
filter paper will absorb the exhaust gas.
a Absorbing time: 1.4 ± 0.2 sec
6) Start the engine and accelerate it sud-

denly or run it at high idle and depress the
4) Remove the filter paper and compare it accelerator pedal of smoke meter A2 and
with the attached scale. collect the exhaust gas into the filter
5) After finishing measurement, remove the paper.
measuring tools and return the removed 7) Place the contaminated filter paper on the
parts. clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
2. Checking with smoke meter A2 value.
1) Insert probe [1] of smoke meter A2 in the 8) After finishing measurement, remove the
outlet of the exhaust pipe and fix it to the measuring tools and return the removed
exhaust pipe with a clip. parts.
30-101 10 PC200, 200LC, 220, 220LC-8M0

Adjusting valve clearance SEN06127-00
Adjusting valve clearance 1 5. Loosen injector terminal nut (6), and remove
12 terminals from the injectors.
a Measuring tools for valve clearance
1 795-799-1131 Gear
B Commercially
2 Thickness gauge
available

a Measure the valve clearance under the follow-
ing condition.
q Engine coolant temperature: Normal tem-
perature
1. Open the engine hood and remove the belt 6. Remove gasket (7).
guard at the top of the air conditioner compres- a Take care not to allow any foreign matter
sor. to get into the engine.
a If defects, such as crack, deterioration
2. Disconnect three connectors (2) and two and/or wear, are found on gasket (7),
bands (3) from wiring harness (1), and sepa- replace the gasket with a new one.
rate wiring harness (1) from the head cover.
a Since the connector has a lock stopper,
press down the stopper with your finger
and pull the connectors apart. At that time,
support the gasket with your hand not to
move.
3. Remove five head cover mounting bolts (6).

a After loosening the bolts, hold the head
cover and blow off the sludge and foreign
matters attached around with air so that
they do not get into the head cover mount-
ing section.
4. Remove head cover (5). 7. Remove plate (8) and cap (10) from the fly-
a Take care not to hit the cover against wheel housing, and install gear B1.
nearby parts.
a Since the breather connector on the rear
side of the cylinder head cover is con-
nected to the flywheel housing through the
O-ring, pull it together with the cylinder
head cover.
PC200, 200LC, 220, 220LC-8M0 30-101 11

SEN06127-00 Adjusting valve clearance
8. Rotate the crankshaft forward with gear B1, 10. Adjust the valve clearance according to the fol-
and align wide slit (b) of the rotation sensor lowing procedure:
ring with the top surface of projection (a) of the 1) Insert clearance gauge B2 into the clear-
front cover. ance between rocker arm (12) and cross-
a When seen from the air conditioner com- head (13).
pressor side, the top surface of projection 2) Loosen locknut (14), and adjust the valve
(a) must be in the range of wide slit (b). clearance by using adjustment screw (15).
a If you can find the yellow marks of projec- a With the clearance gauge inserted,
tion top (a) and wide slit (b), you may turn the adjustment screw to the
match them each other. degree that you can move the clear-
k No. 1 or No. 6 piston is not set to the ance gauge lightly.
compression top dead center (TDC) if 3) With adjustment screw (15) fixed, tighten
the crankshaft is set as described locknut (14).
above. 3 Locknut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
a After tightening the locknut, check the
valve clearance again.
9. Check the movement of the rocker arm of the

No. 1 cylinder to determine which valve should
be adjusted.
a If you can manually move the rocker arms 11. Turn the crankshaft one rotation forward
of intake air valves (IN) the same distance according to step 10 and align wide slit (b) with
as the valve clearance, adjust the valves the top surface of projection (a).
marked with Q in the valve arrangement
figure. 12. Adjust the remaining valve clearances accord-
a If you can manually move the rocker arms ing to steps 11 and 12.
of exhaust valves (EX) the same distance a If you adjust the valves marked with Q of
as the valve clearance, adjust the valves the valve arrangement figure in steps 11
marked with q in the valve arrangement and 12, adjust the remaining valves
figure. marked with q.
a Valve arrangement figure a If you adjust the valves marked with q of
the valve arrangement figure in steps 11
and 12, adjust the remaining valves
marked with Q.
13. After finishing the adjustment, remove the tools

and restore the machine .
k Make sure not to forget removal of gear
B1.
3 Cylinder head cover mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 Injector terminal nut (8):
1.5 ± 0.25 Nm {0.15 ± 0.025 kgm}
a Check that the injector wiring harness
does not interfere with the rocker arm.
30-101 12 PC200, 200LC, 220, 220LC-8M0

Testing compression pressure SEN06127-00
Testing compression pressure 1

a Measuring tools for compression pressure
Symbol Part No. Part Name
1 795-799-6700 Puller
2 795-502-1590 Gauge assembly
3 795-790-4410 Adapter
C
4 6754-11-3130 Gasket
Commercially Hose inside diameter:
5
available approx. 15 mm
k Be careful not to touch the exhaust mani-

fold or muffler, which may get you burnt, or
5. Disconnect fuel high-pressure tube (6).
get caught in a rotating part when checking
a When measuring compression pressure,
compression pressure.
k
fuel spurts from the disconnected portion
Keep the cable disconnected from the nega- on the common rail side. Therefore, con-
tive (-) battery terminal.
a Measure the compression pressure after the nect hose C5 and drain the fuel into a con-
tainer.
k Do not make bending modification of
engine is warmed up.
(Engine oil temperature: 40 to 60°C)
the high-pressure pipes to be used.
1. Open the engine hood and remove the belt
guard at the top of the air conditioner compres-
sor.
2. Disconnect three connectors (2) and two

bands (3) from wiring harness (1), and sepa-
rate wiring harness (1) from the head cover.
a Since the connector has a lock stopper,
press down the stopper with your finger
and pull the connectors apart. At that time,
support the gasket with your hand not to
move.
3. Remove five head cover mounting bolts (4).

a After loosening the bolts, hold the head 6. Loosen injector terminal nut (7), and remove
cover and blow off the sludge and foreign the terminal from the injector.
matters attached around with air so that
they do not get into the head cover mount- 7. Set the piston in the cylinder to be checked to
ing section. the compression top dead center.
a See "Adjusting valve clearance".
4. Remove head cover (5).
a Take care not to hit the cover against 8. Remove rocker arm assembly (8).
nearby parts.
a Since the breather connector on the rear
side of the cylinder head cover is con-
nected to the flywheel housing through the
O-ring, pull it together with the cylinder
head cover.
PC200, 200LC, 220, 220LC-8M0 30-101 13

SEN06127-00 Testing compression pressure
9. Remove retainer (12) and fuel inlet connector 14. Connect gauge assembly C2 to adapter C3.
(10). a Engine oil if applied thinly to the portion
a In advance, remove the mud and dirt connecting the adapter and gauge offers
attached around so that they do not get resistance to air leak.
into the mounting section of the inlet con-
nector. 15. Install rocker arm assembly (8).
3 Rocker arm assembly mounting bolt:
10. Remove holder (11). 36 ± 5 Nm {3.67 ± 0.51 kgm}
11. Remove injector (12). 16. Adjust the valve clearance.

a Use tool C1 to remove the injector. a See "Adjusting valve clearance".
Remove the injector with impacts of a
slide hammer.
a Do not remove the injector by prying its
top up.
a Take care not to allow any dirt or foreign
matter to get into the mounting section of
the injector.
17. By referring to "Special functions of Equipment

Management Monitoring System (EMMS)", set
the engine in the no-injection cranking mode.
k Engine may start during a check and
incur a great danger to human body
unless it is set in the no-injection
cranking mode. Make sure not to for-
get setting the engine in the no-injec-
tion cranking mode.
18. Check the compression pressure when crank-

ing the engine with the starting motor.
a Read the gauge when its pointer stops
movement.
12. Fit gasket C4 to the top end of adapter C3, and

insert them in the injector (12) mounting por-
tion.
13. Fix adapter C3 by using the injector holder

(11).
a Tighten the holder mounting bolts alter-
nately.
3 Holder mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
30-101 14 PC200, 200LC, 220, 220LC-8M0

Testing compression pressure SEN06127-00
19. After finishing the measurement, remove the

tools. Be sure to restore the machine .
For details, see Disassembly and assembly,
"Removal and installation of cylinder head
assembly".
a Install the injector and fuel high-pressure
tube according to the following procedure:
1) Match injector’s projection (a) to holder’s
notch (b), and set the injector in the cylin-
der head.
a When setting the injector, face the
above matching point toward the fuel
inlet connector insertion side.
7) Tighten the sleeve nuts of fuel high pres-

sure tube (6) on the head side and then on
the common rail side.
3 Sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
2) Tighten injector holder mounting bolts (13)

by approximately three to four turns.
3) Set fuel inlet connector (10).
a Push the fuel inlet connector until the
O-ring fits in firmly and produces a
click.
4) Lightly tighten retainer (9) of fuel inlet con- 8) Connect injector harness connectors (12).
nector (10). a After installing the rocker arm assembly
3 Retainer: (8), adjust the valve clearance by referring
15 ± 5 Nm {1.5 ± 0.5 kgm} to " Adjusting valve clearance ".
a Tighten above retainer (11) to the 3 Rocker arm assembly mounting
specified torque in step 6). bolt:
5) Tighten injector holder mounting bolts (13) 36 ± 5 Nm {3.67 ± 0.51 kgm}
alternately.
3 Holder mounting bolt: a Tighten the injector terminal nut (7) with
8 ± 0.8 Nm {0.8 ± 0.08 kgm} the following torque
6) ighten retainer (9) of the fuel inlet connec- 3 Terminal nut:
tor. 1.5 ± 0.25 Nm {0.15 ± 0.025 kgm}
3 Retainer:
50 ± 5 Nm {5.1 ± 0.5 kgm} a Check that the injector harness (1) does
not interfere with the rocker arm.
a Tighten the head cover with the following

torque.
3 Head cover mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
PC200, 200LC, 220, 220LC-8M0 30-101 15

SEN06127-00 Testing blowby pressure
Testing blowby pressure 1

a Measuring tools for blowby pressure
1 799-201-1504 Blowby checker
D
2 799-790-3300 Blowby tool

a Measure the blowby pressure under the follow-
ing condition.
ating range
q Hydraulic oil temperature: Within operat-
ing range 5. After finishing measurement, remove the mea-
1. Remove the undercover of the hydraulic pump.
2. Install tool and adapter [1] of blowby checker

D1 or blowby tool D2 to breather hose (1) and
connect gauge [2].
3. Start the engine, set the working mode in the

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

the arm circuit and measure the blowby pres-
sure.
a Read the gauge when the pointer is stabi-
lized.
30-101 16 PC200, 200LC, 220, 220LC-8M0

Testing engine oil pressure SEN06127-00
Testing engine oil pressure 1

a Measuring tools for engine oil pressure
799-101-5002 Hydraulic tester
1
E 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

a Measure the engine oil pressure under the fol-
lowing condition.
ating range
1. Open the side cover of the pump room and suring tools and return the removed parts.
remove oil pressure pickup plug (1) from the
engine oil filter.
2. Install nipple [1] of hydraulic tester E1 and con-

nect hydraulic tester E2.
3. Start the engine and turn the auto-decelerator

OFF.
4. Run the engine and measure the engine oil

pressure at high idle and low idle.
PC200, 200LC, 220, 220LC-8M0 30-101 17

SEN06127-00 Handling fuel system parts
Handling fuel system parts 1 Releasing residual pressure from

a Precautions for checking and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel main filter – Supply pump
trouble. High-pressure circuit:
When checking and maintaining the fuel sys- Supply pump – Common rail – Injector
tem, take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is checked and its parts
cartridge. are removed, the remaining pressure in the
Since the common rail fuel injection system fuel circuit must be released completely.
(CRI) consists of more precise parts than the Accordingly, observe the following.
k
conventional fuel injection pump and nozzle, it Before checking the fuel system or remov-
employs a high-efficiency special filter to pre- ing its parts, wait at least 30 seconds after
vent foreign matter from entering it. If a filter stopping the engine until the residual pres-
other than the genuine one is used, the fuel sure in the fuel circuit is released. (Do not
system may have a trouble. Accordingly, never start the work just after stopping the engine
use such a filter. since there is residual pressure.)
30-101 18 PC200, 200LC, 220, 220LC-8M0

Testing fuel pressure SEN06127-00
Testing fuel pressure 1

a Measuring tools for fuel pressure
1
790-261-1204 Digital hydraulic tester
Adapter
795-790-4430
2 (10 × 1.0 mm o R1/8)
F 6215-81-9710 O-ring
3 799-401-2320 Gauge
4 795-790-5110 Screw
5 799-201-2202 Boost gauge kit
6 07005-01212 Gasket
3) Run the engine at low idle and measure
k Stop the machine on a level ground and the pressure in the fuel low-pressure cir-
lower the work equipment to the ground. cuit.
a Measure only the fuel pressure in the low-pres- a If the pressure in the fuel low-pres-
sure circuit from the feed pump through the sure circuit is in the following range, it
fuel main filter to the supply pump and the is normal.
return circuit from the supply pump/common 0.5 to 1.3 MPa
At low idle
rail/injector to fuel tank. {5.1 to 13.3 kg/cm2}
k Since the pressure in the high-pressure cir- 0.3 to 1.1 MPa
cuit from the supply pump through the During cranking
{3.1 to 11.3 kg/cm2}
common rail to the injector is very high, it
cannot be measured. k If the engine cannot be started, you
may measure the fuel return rate
1. Measuring pressure in fuel low-pressure while rotating the engine with the
circuit starting motor. Do not rotate for
1) Open the engine hood and remove fuel more than 30 seconds continu-
pressure pickup plug (1) from the fuel ously, however, for protection of
main filter. the starting motor.
2) Install adapter F2 and nipple [1] of hydrau- 4) After finishing measurement, remove the
lic tester F1 and connect them to oil pres- measuring tools and return the removed
sure gauge [2] parts.
a Use the oil pressure gauge of 2.5 MPa 3 Fuel pressure pickup plug:
{25 kg/cm2}. 10 ± 2 Nm {1 ± 0.2 kgm}
PC200, 200LC, 220, 220LC-8M0 30-101 19

SEN06127-00 Testing fuel pressure
2. Measuring pressure in fuel return circuit

1) Remove joint bolt (2) from the fuel return
circuit.
5) After finishing measurement, remove the

measuring tools and return the removed
parts.
3 Joint bolt (2):
2) Connect fuel return hose (3) again by
using tool F4.
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
a When installing tool F4, fit gaskets F6
to both sides of the fuel return hose
3. Measuring fuel negative-pressure circuit
eye-joint.
3 Tool F4:
pressure
1) Remove joint bolt (2) of fuel hose (1)
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
between the prefilter and supply pump.
3) Install nipple [1] of hydraulic tester F1, and
connect them to hydraulic tester F3.
a Nipple [1]: 799-101-5160
4) Run the engine at low idle and measure

the pressure in the fuel return circuit.
a If the pressure in the fuel return circuit
is in the following range, it is normal.
At low idle Max. 0.02 MPa
During cranking {Max. 0.19 kg/cm2}
k If the engine cannot be started, you

may measure the fuel return rate
while rotating the engine with the
starting motor. Do not rotate for
more than 30 seconds continu-
ously, however, for protection of
the starting motor.
30-101 20 PC200, 200LC, 220, 220LC-8M0

Testing fuel pressure SEN06127-00
2) Connect fuel hose (1) to supply pump (3)

by tool F4 instead of joint bolt (2).
a When installing tool F4, fit the gaskets to
both sides of the fuel hose joint.
3 Tool F4:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
3) Connect tool F4 to tool F5.
4) Run the engine and measure the circuit

negative pressure at high idle.
Circuit standard negative pressure:
Max. –50.7 kPa {–380 mmHg}
5) If the negative pressure is higher than the
standard pressure, the fuel prefilter may
be clogged. In this case, replace the fuel
prefilter and measure again.
measuring instruments and return the
removed parts.
3 Joint bolt (2):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
PC200, 200LC, 220, 220LC-8M0 30-101 21

SEN06127-00 Handling reduced cylinder mode operation
Handling reduced cylinder mode Handling no-injection cranking

operation 1 operation 1
a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The purpose
the number of effective cylinders. The pur- and effect of this operation are as follows.
poses and effects of this operation are as fol- q When a machine or engine has been stored for
lows. a long time, implementing the no-injection
cranking before starting the engine lubricates
1. This operation is used to find out a cylinder the engine parts and thus prevents its seizure.
which does not output power normally (or, a The no-injection cranking operation is set from
combustion in it is abnormal). the service mode of the machine monitor. For
details, see "Special functions of machine
2. When a cylinder is selected for the reduced monitor (EMMS)", “6. No-injection cranking
cylinder mode operation, if the engine speed function”.
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
are as follows.
q Leakage through cylinder head gasket
q Defective injection
q Defective piston, piston ring
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system

controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a The reduced cylinder mode operation is
set from the service mode of the machine
monitor.
For details, see "Special functions of
machine monitor (EMMS)", "5. Reduced
cylinder mode operation function".
30-101 22 PC200, 200LC, 220, 220LC-8M0

Testing fuel discharge, return and leak amount SEN06127-00
Testing fuel discharge, return and

leak amount 1
a Testing tools for fuel discharge, return and leak
amount.
1 795-790-4700 Tester kit
6164-81-5790 Joint
2
07005-01212 Washer
6754-71-5340 Connector
3
6754-71-5350 Washer
Commercially
4 Measuring cylinder
available 3) Crank the engine for 30 seconds and
G
Commercially measure the discharge with measuring
5 Stopwatch
available cylinder G4.
Commercially Hose a Adjust the route of the test hose so
6 that it will not slacken and put its end
available (Inside diameter: 14 mm)
Commercially Hose
in an oil receiving pan.
7
available (Inside diameter: 7 mm) a Do not crank the engine for more than
30 seconds to protect the starting
Commercially Hose
8 motor in any case other than this
available (Inside diameter: 12 mm)
measurement.
a If the supply pump discharge is in the
a Since some fuel flows out during check, pre-
following standard range, it is normal.
pare an oil (receiving) pan of approximately 20
l. At cranking speed
Min. 75 cc
k
(125 rpm)
lower the work equipment to the ground. At cranking speed
Min. 90 cc
(150 rpm)
1. Measuring supply pump discharge
1) Loosen clamp (2) of discharge tube (1) of
the supply pump and disconnect tube (1).

parts.
2) Install test hose G6 to the nipple on the 3 Tube sleeve nut:
discharge side of the supply pump. 35 ± 4 Nm {3.6 ± 0.4 kgm}

a Fix the hose with a wire etc. 3 Clamp mounting bolt:
a Adjust the route of the test hose so 24 ± 4 Nm {2.5 ± 0.4 kgm}

that it will not slacken and put its end
in an oil receiving pan.
PC200, 200LC, 220, 220LC-8M0 30-101 23

SEN06127-00 Testing fuel discharge, return and leak amount
2. Measuring return rate from supply pump

At low idle Max. 1,000 cc/min.
1) Open the right side cover of the engine,
and remove joint bolt (1) of the supply During cranking Max. 140 cc/min.
pump (4). Then, disconnect return hoses
(2) and (3).
6) Remove the tools after finishing measur-

ing. Be sure to restore the machine.
2) To prevent the fuel from flowing out, install
a If you are going to measure the leak-
joint bolt [1], cap nut [2] and seal washer
age from the pressure limiter or finish
[3] of tester kit G1 to the return hose (2).
the measurement: Restore the
3) Install joint G2 to supply pump (4) by using
machine.
joint bolt (1).
a If you are going to measure the leak-
a Fit seal washer G2 to both sides.
3 Joint bolt:
age from the injector: Leave the
machine as it is, and keep the top end
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
of the test hose put in the container.
4) Connect test hose [4] of tester kit G1 to
joint G2. 3. Measuring leakage from pressure limiter
a Arrange the hose run so that slack be 1) Open the right side cover of the engine,
eliminated from the test hose. Put the and disconnect return hose (1) of the
hose’s top end in the oil receiving pressure limiter.
container. a Disconnect hose clamp (2), and dis-
connect the hose at quick coupler (a).
5) Start the engine. By using measuring cyl-

inder G4, measure the return rate for 1
minute with the engine speed at low idle.
a You may make the measurement for
20 seconds and multiply the mea-
sured result by 3.
a If the return rate from the supply
pump is within the following standard
range, it is normal.
30-101 24 PC200, 200LC, 220, 220LC-8M0

Testing fuel discharge, return and leak amount SEN06127-00
2) Insert connector G6 on the drain side of 4. Measuring return rate from injector
the hose, and install cap nut [2] of tester 1) Open the right engine side cover. Remove
kit G1 to prevent fuel from flowing out. joint bolt (1) from the supply pump (4).
3) Connect test hose G7 on the pressure lim- Disconnect return hoses (2) and (3).
iter side. 2) Disconnect the return hose (2) at quick
a Arrange the hose run so that slack be coupler (a).
eliminated from the test hose. Put the
hose’s top end in the oil receiving
container.
3) To prevent the fuel from flowing out, install

joint bolt [1], cap nut [2] and seal washer
[3] of tester kit G1 on the drain side of
4) Start the engine. By using measuring cyl- return hose (2).
inder G4, measure the leakage for 1 min- 4) Connect return hose (3) to supply pump
ute with the engine speed at low idling. (4).
a If the leakage from the pressure lim- 3 Joint bolt:
iter is within the following standard 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
value, it is normal. 5) Connect hose G7 to return hose (2-1).
6) Install connector G6 to return hose (2),
0 cc
At low idle
(No leakage)
and connect test hose G8.
a Arrange the hose run so that slack be
eliminated from the test hose. Put the
hose’s top end in the oil receiving
container.
5) Remove the tool used after measurement.

Be sure to restore the machine.
3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
PC200, 200LC, 220, 220LC-8M0 30-101 25

SEN06127-00 Bleeding air from fuel circuit
7) Start the engine. By using measuring cyl- Bleeding air from fuel circuit 1
inder G4, measure the return rate from the
injector for 1 minute with the engine speed a If fuel is used up or if a fuel circuit part is
at low idle. removed and installed, bleed air from the fuel
a You may make the measurement for circuit according to the following procedure.
20 seconds and multiply the mea-
sured result by 3. lower the work equipment to the ground.
a If the return rate from the supply
pump is within the following standard 1. Fill up fuel tank with fuel.
range, it is normal. a Add fuel until the float of the sight gauge
reaches the maximum position.
Low idle Max. 180 cc
Cranking Max. 90 cc 2. Open the side cover of the pump room.
3. Loosen knob (1) of the feed pump and pull it

k If you cannot start the engine, you out, and then operate it forward and backward.
may measure the return rate with a Move the knob until it becomes heavy.
the engine cranked with the start- a The plug at the top of the fuel main filter
ing motor. However, for protection does not need to be removed.
of the starting motor, do not keep a After bleeding air, some air may be left in
cranking continuously for 20 sec- the water separator. If the feed pump is
onds or longer. operated until it becomes heavy, however,
the engine can be started. The remaining
air is bled naturally while the engine is run-
ning for a while. This phenomenon occurs
when the fuel in the fuel prefilter is drained
too much and does not indicate an abnor-
mality or a trouble.
8) Remove the tools after finishing measur-

ing. Be sure to restore the machine.
3 Joint bolt:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
4. After bleeding air, push in and tighten knob (1).
30-101 26 PC200, 200LC, 220, 220LC-8M0

Testing fuel circuit for leakage SEN06127-00
Testing fuel circuit for leakage 1 9. Check the fuel piping and devices for fuel leak-
k
age.
Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After checking the fuel system or removing and check again from step 2.
its parts, check it for fuel leakage according a If no fuel leakage is detected, check is
to the following procedure.
k
completed.
a Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

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

age.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and check again from step 2.
4. Run the engine at low idle.

age.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
6. Run the engine at high idle.

age.
a Check around the high-pressure circuit
parts coated with the color checker for fuel
leakage.
8. Run the engine at high idle and load it.

a Relieve the arm circuit at the IN stroke
end.
PC200, 200LC, 220, 220LC-8M0 30-101 27

SEN06127-00 Handling controller high voltage circuit
Handling controller high voltage

circuit 1
1. Disconnection or connection of the connector
between the engine controller and engine must
be done after turning off the starting switch.
2. It is prohibited to start the engine when T-

adapter is inserted or connected, for trouble-
shooting purpose, to the connector between
the engine controller and engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
30-101 28 PC200, 200LC, 220, 220LC-8M0

Testing and adjusting air conditioner compressor belt ten- SEN06127-00
Testing and adjusting air Adjusting

conditioner compressor belt a If the belt deflection is abnormal, adjust it
tension 1 according to the following procedure.
k Stop the machine on a level ground and 1. Loosen bolts (1) and (2).
2. Move compressor (3) and bracket (4) together
Testing to adjust the belt tension.
1. Open the engine hood and remove the belt
guard from the top of the air conditioner com- 3. After positioning compressor (3), tighten bolts
pressor. (1) and (2).
a Check each pulley for breakage, wear of
2. Press the intermediate point of the belt the V-groove, and contact of the V-belt
between fan pulley and compressor pulley with and V-groove.
a finger and measure deflection (a) of the belt. a If the V-belt is so lengthened that the
q Belt pressing force: 60 N {6.2 kg} adjustment allowance is eliminated or it
has a cut or a crack, replace it.
a If the belt is replaced, adjust their tension
again after operating the machine for 1
hour.
a After tightening the bolts, check the belt
tension again according the above proce-
dure.
4. After finishing measurement, return the removed

parts.
PC200, 200LC, 220, 220LC-8M0 30-101 29

SEN06127-00 Replacing alternator belt
Replacing alternator belt 1 3. Replace the fan belt (3).

q Check each pulley for breakage and
a The auto-tensioner is provided for the fan belt. crack.
Thus, testing and adjustment of the belt is usu-
ally not necessary.
a Disconnect air conditioner compressor belt
before replacing the fan belt.
1. Open engine hood and remove fan belt cover

(1).
2. Insert a wrench to the portion (A) (width across

flats T 12.7 mm) of the tensioner assembly (2),
and rotate it to the opposite to the winding-up
direction to decrease the fan belt (3) tension.
k Make sure that the wrench is secured
at the portion (A) of the tensioner
assembly (2) before rotating it. (The
spring of the tensioner assembly (2) is
strong. If the wrench is loosely
inserted, the wrench may accidentally
come off while being rotated and it is
extremely dangerous.)
k After removing the fan belt (3), return
the tensioner assembly (2) slowly with
care.
k Be careful not to get your fingers
caught between the pulley and fan belt
(3) during work.
30-101 30 PC200, 200LC, 220, 220LC-8M0

Testing swing circle bearing clearance SEN06127-00
Testing swing circle bearing 4. Set the arm almost perpendicular to the
clearance 1 ground and lower the boom until the front track
shoe floats.
a Measuring tools for swing circle bearing clear- a At this time the front of the upper structure
ance rises and the rear lowers.
5. Under this condition, read dial gauge H.
Commercially
H Dial gauge a The value indicated by dial gauge H is the
available
clearance of the bearing.
a For the standard value, see Structure,
a When testing the swing circle bearing clear-
function and maintenance standard,
ance installed to the machine, perform the fol-
“Swing circle”.
lowing procedure.
k Do not put your hands or feet under the
undercarriage during test.
1. Fix dial gauge H to the track frame and apply

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

and check that dial gauge H indicates 0.
a If the dial gauge does not indicate 0,
repeat steps 2 through 5.
2. Set the work equipment to the maximum reach

position and set the bucket tip to the height of
the under side of the revolving frame.
a At this time the front of the upper structure
lowers and the rear rises.
3. Set dial gauge H to the 0 point.
PC200, 200LC, 220, 220LC-8M0 30-101 31

SEN06127-00 Testing and adjusting track tension
Testing and adjusting track Adjusting

tension 1 a If the track tension is abnormal, adjust it
according to the following procedure.
Testing
1. Run the engine at low idle and drive the 1. Increasing tension
machine forward by the length of track on 1) Add grease through grease fitting (1) with
ground, and then stop slowly. a grease gun.
2) To check that the tension is normal, run
2. Place straight bar [1] on the track shoe the engine at low idle and move the
between the idler and the 1st carrier roller. machine forward by the length of track on
a As the straight bar, use an angle steel, etc. ground, then stop slowly.
which will be deflected less. 3) After adjusting, check the track tension
again according to the above procedure.
3. Measure maximum clearance (a) between
steel bar [1] and track shoe.
q Standard maximum clearance (a):
10 to 30 mm
a You may add grease until dimension (b)

between the idler guide and track frame
end becomes 0 mm. If the tension is still
low, the pins and bushings are worn
much. In this case, reverse or replace the
pins and bushings.
30-101 32 PC200, 200LC, 220, 220LC-8M0

Testing and adjusting track tension SEN06127-00
2. Decreasing tension
1) Loosen valve (2) to discharge grease, and
then tighten it.
k Do not loosen the valve more than
1 turn. If it is loosened more, it
may jump out because of the high-
pressure grease in it.
2) To check that the tension is normal, run
the engine at low idle and move the
machine forward by the length of track on
ground, then stop slowly.
3) After adjusting, check the track tension
again according to the above procedure.
PC200, 200LC, 220, 220LC-8M0 30-101 33

SEN06127-00 Testing and adjusting oil pressure in work equipment,
Testing and adjusting oil pressure 2) Install nipples J2 and connect oil pressure
in work equipment, swing, and gauges [1] of hydraulic tester J1.
a Use the oil pressure gauge with
travel circuits capacity 60 MPa {600 kg/cm2}.
a Measuring and adjusting tools for oil pressure
in work equipment, swing, and travel circuits
1
J
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring

Then, release the residual pressure from the
hydraulic circuit. For details, see “Releasing
residual pressure from hydraulic circuit”.
2. Combination of pump, actuator, and valve
Measuring
a When the oil from the pumps is divided,
a The oil pressure in the work equipment, swing, the front pump and rear pump act inde-
and travel circuits (pump discharge pressure) pendently on each actuator. Note that dif-
can be checked with monitoring function of the ferent actuators relieve different valves.
machine monitor, too (For details, see “Special a When the work equipment circuit or swing
functions of machine monitor”). circuit is relieved singly, the oils of the
q Monitoring code: 01100 F pump pressure pumps are merged. When the travel circuit
q Monitoring code: 01101 R pump pressure is relieved singly, the oils of the pumps are
a Measure the oil pressure in the work equip- divided.
ment, swing, and travel circuits under the fol- a The actuators in the table are arranged in
lowing condition. the order when the control valve is seen
q Hydraulic oil temperature: Within operat- from the front of the machine (and an
ing range attachment is installed to the service
valve).
1. Preparation work
1) Open the side cover of the pump room Actuator Valve relieved
and remove oil pressure pickup plugs (1) (R unload valve) (R main relief valve)
and (2). Service Safety-suction valve
Rear pump
q (1): Front pump discharge pressure

Bucket R main relief valve
pickup plug
q (2): Rear pump discharge pressure Left travel R main relief valve
pickup plug Raise: R main relief valve
Boom
Lower: Safety-suction valve
(Pump merge-divider valve) (Travel junction valve)
(Self pressure reducing valve)
Swing Swing motor safety valve
Front pump
Right
F main relief valve
travel
Arm F main relief valve
(F unload valve) (F main relief valve)
(Centralized safety valve) (Back pressure valve)
30-101 34 PC200, 200LC, 220, 220LC-8M0

Testing and adjusting oil pressure in work equipment, SEN06127-00
3. Measuring unload pressure 2) Run the engine at high idle, operate the
1) Start the engine, set the working mode in left work equipment control lever to relieve
the power mode (P), and turn the auto- the swing motor, and measure the oil
decelerator OFF. pressure.
2) Run the engine at high idle, set all the a The pressure measured when the
levers and pedals for work equipment con- swing motor relief valve is relieved is
trol and travel in neutral, and test the oil indicated.
pressure. a The swing relief pressure is lower
a The pressure measured when the than the main relief pressure.
unload valve is unloaded is indicated.
6. Measuring travel relief pressure
1) Run the engine and lock the travel mecha-
nism.
k Put pin [2] between the sprocket
and track frame to lock the travel
mechanism securely.
4. Measuring work equipment relief pressure

1) Start the engine and move the cylinder to
be measured to the stroke end.
2) Set the working mode in the power mode
(P).
3) Run the engine at full speed, operate the 2) Set the working mode in the power mode
right and left work equipment control (P).
levers to relieve the cylinder, and measure 3) Run the engine at high idle, operate the
the oil pressure. travel lever and pedal to relieve the travel
a The pressure measured when the motor, and measure the oil pressure.
main relief valve is relieved is indi- k Before operating the travel lever
cated (If the boom is lowered singly, and pedal, check the position and
the safety-suction valve of the control locking direction of the locked
valve for lowering the boom is sprocket again.
relieved). a The pressure measured when the main
a If the power maximizing switch is relief valve of the control valve is
released, the main relief valve is relieved is indicated. The travel circuit
relieved at low pressure. If the former is always relieved at high pressure.
is pressed, the latter is relieved at
high pressure. 7. Work after finishing measurement
a If the swing lock switch is set in After finishing measurement, remove the mea-
turned ON, the 2-stage relief solenoid suring tools and return the removed parts.
valve is kept turned ON and the relief 3 Oil pressure pickup plug:
valve is relieved at high pressure. 20 to 27 Nm {2.0 to 2.8 kgm}
Accordingly, keep the swing lock
switch turned OFF.
Adjusting
5. Measuring swing relief pressure a The unload valve and suction safety valve for
1) Start the engine, set the working mode in lowering the boom cannot be adjusted.
the power mode (P), and turn the swing
lock switch ON.
PC200, 200LC, 220, 220LC-8M0 30-101 35

SEN06127-00 Testing and adjusting oil pressure in work equipment,
1. Adjusting work equipment and travel relief 5) Connect pilot hose (5).
pressure 6) After finishing adjustment, check again
a If the relief pressure of the work equip- that the oil pressure is normal according to
ment circuit and travel circuit is abnormal, the above described measurement proce-
adjust main relief valves (3) and (4) dure.
q (3): Front (F) main relief valve 2. Adjusting swing relief pressure
q (4): Rear (R) main relief valve a If the swing relief pressure is abnormal,
a When adjusting the main relief valves, adjust safety valve (8) of the swing motor
remove the top cover of the control valve. according to the following procedure.
a Adjust only the low relief pressure of the
main relief valve. If the low repair proce-
dure is adjusted, the high repair procedure
is set automatically.
a The low relief pressure is the pressure
applied when the 2-stage relief solenoid
valve is turned OFF and the pilot pressure
is not applied to the selector port.
1) While fixing adjustment screw (9), loosen

locknut (10).
2) Turn adjustment screw (9) to adjust the
pressure.
a If the adjustment screw is
q Turned to the right, the set pres-
sure is increased.
q Turned to the left, the set pres-
1) Disconnect pilot hose (5). sure is decreased.
2) While fixing holder (6), loosen locknut (7). a Quantity of adjustment per turn of
3) Turn holder (6) to adjust the set pressure. adjustment screw: Approx. 6.7 MPa
a If the holder is {Approx. 68.4 kg/cm2}
q Turned to the right, the set pres- 3) While fixing adjustment screw (9), tighten
sure is increased. locknut (10).
q Turned to the left, the set pres- 3 Locknut:
sure is decreased. 78 to 103 Nm {8 to 10.5 kgm}
a Quantity of adjustment per turn of
holder: Approx. 20.5 MPa
{Approx. 209 kg/cm2}
4) While fixing holder (6), tighten locknut (7).
3 Locknut: 49 to 58.8 Nm {5 to 6 kgm}
4) After finishing adjustment, check again

that the oil pressure is normal according to
the above described measurement proce-
dure.
30-101 36 PC200, 200LC, 220, 220LC-8M0

Testing control circuit source pressure SEN06127-00
Testing control circuit source 3. Start the engine, set the working mode in the
pressure 1 power mode (P), and turn the auto-decelerator
OFF.
a Measuring tools for control circuit basic pres-
sure 4. Run the engine at high idle, set all the levers
Symbol Part No. Part name and pedals for work equipment control, swing
control, and travel to the neutral, and measure
1 the oil pressure.
K
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring

Then, release the remaining pressure from
the hydraulic circuit. For details, see
“Releasing remaining pressure from
hydraulic circuit”.
a Measure the control circuit source pressure
under the following condition.
q Hydraulic oil temperature: Within operating
range
1. Remove the control valve top cover and oil 5. After finishing measurement, remove the mea-
pressure pickup plug (1). suring tools and return the removed parts.
a The control circuit basic pressure may be mea-

sured with oil pressure pickup plug (2) on the
hydraulic pump side.
2. Install nipple K2 and connect oil pressure

gauge [1] of hydraulic tester K1.
a Use the oil pressure gauge with capacity a Do not adjust the relief valve for control circuit
6 MPa {60 kg/cm2}. source pressure.
PC200, 200LC, 220, 220LC-8M0 30-101 37

SEN06127-00 Testing and adjusting oil pressure in pump PC control cir-
Testing and adjusting oil pressure

in pump PC control circuit 1
in pump PC control circuit
1
L
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring

lower the work equipment to the ground. 2) Install nipples L2 and nipples [1] of
Then, release the remaining pressure from hydraulic tester L1 and connect them to oil
the hydraulic circuit. For details, see pressure gauges [2].
“Releasing remaining pressure from a Connect the measuring part of plug
hydraulic circuit”. (3) by using joint (790-301-1271) and
elbow (790-301-1530) of hydraulic
Measuring tester L1 and nipple [1] so that it will
a Before measuring the oil pressure in the PC not interfere with the drain piping.
control circuit, check that the oil pressure in the a Use the oil pressure gauge of 60 MPa
work equipment, swing, and travel circuits and {600 kg/cm2}.
the control circuit source pressure are normal.
a Measure the oil pressure in the pump PC con-
trol circuit under the following condition.
range
1. Measuring of PC valve output pressure

(servo piston inlet pressure)
a Measure the PC valve output pressure
(servo piston inlet pressure) and pump
discharge pressure simultaneously to
compare them.
1) Open the side cover of the pump room
and remove oil pressure pickup plugs (1),
(2), (3), and (4). 3) Start the engine and operate the arm cyl-
q (1): Front pump discharge pressure inder to the IN stroke end.
pickup plug 4) Set the working mode in the power mode
q (2): Rear pump discharge pressure (P) and turn the swing lock switch ON.
pickup plug a If the swing lock switch is turned ON,
q (3): Front PC valve output pressure the main relief valve is set for high-
pickup plug pressure relief.
q (4): Rear PC valve output pressure
pickup plug
30-101 38 PC200, 200LC, 220, 220LC-8M0

Testing and adjusting oil pressure in pump PC control cir- SEN06127-00
5) Run the engine at high idle, operate the

left work equipment control lever to relieve
the arm circuit at the IN stroke end, and
measure the oil pressure.
2) Install nipples L2 and connect them to oil

pressure gauges [2].
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.
a Measuring condition and method of
judgment: If the pressures are in the
following ratio, the PC valve is nor-
mal.
Tested oil Operation of Ratio of oil
pressure lever pressures
Pump discharge
1
pressure
Arm IN relief
PC valve output Approx. 0.6
pressure (Approx. 3/5)
a If the PC valve or the servo piston is

abnormal, the PC valve output pres-
sure (servo piston inlet pressure) is
3) Start the engine and set the working mode
"the same as the pump discharge
in the power mode (P).
pressure" or "almost 0".
4) Run the engine at high idle and low idle,
set all the levers and pedals for work
equipment control, swing control, and
parts.
travel in neutral, and measure the oil pres-
sure at each speed.
2. Measuring PC-EPC valve output pressure
and remove oil pressure pickup plugs (5)
and (6).
(5): Front PC-EPC valve output pressure
pickup plug
(6): Rear PC-EPC valve output pressure
pickup plug
PC200, 200LC, 220, 220LC-8M0 30-101 39

SEN06127-00 Testing and adjusting oil pressure in pump PC control cir-
a Measuring condition and method of 1. Loosen locknut (9).

judgment: If the output pressures are a Before loosening the locknut, make coun-
the following values, the PC-EPC ter mark at the adjustment screw end so
valve is normal. that you can see the position of the lock-
nut before the adjustment (and you can
Operation of
Engine Output pressure return the locknut to its original position
lever
after turning it in reverse).
All control Approx. 2.9 MPa
Low idle
levers and {Approx. 30 kg/cm2}
2. Turn adjustment screw (10) clockwise or coun-
pedals in 0 MPa
High idle neutral terclockwise to adjust.
{0 kg/cm2}
a Turn the adjustment screw
q Clockwise when the work equipment
speed is low (to in crease pu mp
absorption torque) and
parts.
q Counterclockwise when the engine
speed lowers (to decrease pump
Adjusting
absorption torque).
Adjusting pump PC valve
a If either of the following phenomena occurs 3. Tighten locknut (9).
and the PC valve seems to be defective, adjust 3 Locknut: 27 to 34 Nm {2.8 to 3.5 kgm}
PC valves (7) and (8) according to the proce-
dure shown below.
q As the working load increases, the engine
speed lowers remarkably.
q The engine speed is normal but the work
equipment speed is low.
q (7): Front pump PC valve
q (8): Rear pump PC valve
a The width across flats of the PC valve locknut
is 13 mm and that of the adjustment screw
(inside width) is 4 mm.
Do not turn any other locknuts or adjustment
screws since they affects the hydraulic pump
performance.
4. After finishing adjustment, check again that the

PC valve output pressure (servo piston inlet
pressure) is normal according to the above
described measurement procedure.
30-101 40 PC200, 200LC, 220, 220LC-8M0

Testing and adjusting oil pressure in pump LS control cir- SEN06127-00
Testing and adjusting oil pressure

in pump LS control circuit 1
in pump LS control circuit
1
M 2 799-401-2701 Differential pressure gauge
799-101-5220 Nipple (10 × 1.25 mm)
3
07002-11023 O-ring

lower the work equipment to the ground. 2) Install nipples M3 and nipples [1] of
Then, release the residual pressure from hydraulic tester M1 and connect them to
the hydraulic circuit. For details, see oil pressure gauges [2].
“Releasing residual pressure from hydrau- a Connect the measuring part of plug
lic circuit”. (3) by using joint (790-301-1271) and
elbow (790-301-1530) of hydraulic
Measuring tester M1 and nipple [1] so that it will
a Before measuring the oil pressure in the pump not interfere with the drain piping.
LS control circuit, check that the oil pressure in a Use the oil pressure gauge of 60 MPa
the work equipment, swing, and travel circuits {600 kg/cm2}.
and the control circuit source pressure are nor-
mal.
a Measure the oil pressure in the pump LS con-
trol circuit under the following condition.
range
1. Measurement of LS valve output pressure

(servo piston inlet pressure)
a Measure the LS valve output pressure
(servo piston inlet pressure) and pump
discharge pressure simultaneously to
compare them.
and remove oil pressure pickup plugs (1), 3) Start the engine and push up the track
(2), (3), and (4). shoe on the side to be measured with the
q (1): Front pump discharge pressure work equipment and prepare for running
pickup plug the track shoe idle.
q (2): Rear pump discharge pressure q When measuring front circuit: Right
pickup plug track shoe
q (3): Front LS valve output pressure q When measuring rear circuit: Left
pickup plug track shoe
q (4): Rear LS valve output pressure k Since the raised track will be run in
pickup plug the air during measurement, secure
a sufficient working area.
4) Set the working mode in the power mode
(P) and set the travel speed in the High
position.
PC200, 200LC, 220, 220LC-8M0 30-101 41

SEN06127-00 Testing and adjusting oil pressure in pump LS control cir-
5) Run the engine at high idle, set all the 2. Measurement of LS differential pressure
levers and pedals for work equipment con- a Measure the pump discharge pressure
trol, swing control, and travel control in and LS pressure (actuator load pressure)
neutral, and measure the oil pressure. simultaneously and calculate the differ-
Then, operate the travel lever to run the ence between them, to obtain the LS dif-
track in the air and measure the oil pres- ferential pressure.
sure. 1) Open the side cover of the pump room
k While taking extreme care for and remove oil pressure pickup plugs (1),
safety, run the raised track shoe. (2), (5), and (6).
a Do not operate the travel lever to its q (1): Front pump discharge pressure
stroke end (but stop it halfway). pickup plug
q (2): Rear pump discharge pressure
pickup plug
a Testing condition and judgment

method: When the hydraulic pres-
q (5): Front LS pressure pickup plug
sures are within ratio in the table, LS
q (6): Rear LS pressure pickup plug
valve is normal.
Position of levers and pedals
Travel lever
All levers and
move half-
pedals are at
way (Travel
neutral
without load)
Hydraulic pressure
1
to be measured
Pump discharge
(Actual value
pressure
is set as 1)
Almost same
pressure
Approx. 3/5 of
LS valve output
pressure
pressure
above

parts.
30-101 42 PC200, 200LC, 220, 220LC-8M0

2) Install nipples M3 and connect it to differ- 3) Run the engine, push up the track shoe on
ential pressure gauge M2 or the oil pres- the side to be measured with the work
sure gauge of hydraulic tester M1. equipment, and prepare for running track
a When using differential pressure gauge shoe idle.
M2: q When measuring front circuit: Right
Connect the pump discharge pres- track shoe
sure to the high pressure side (back q When measuring rear circuit: Left
side) and connect the LS pressure to track shoe
the low pressure side (lower side). k Since the raised track shoe will be
Since the differential pressure gauge run idle during measurement,
needs a 12V power source, connect it secure a sufficient working area.
to a battery. 4) Set the working mode in the power mode
a When using oil pressure gauge (in M1): (P) and set the travel speed in the High
Use the oil pressure gauge of 60 MPa position.
{600 kg/cm 2 } having the unit of 1.0 5) Run the engine at high idle, set all the
MPa {10 kg/cm2}. Since the differen- levers and pedals for work equipment con-
tial pressure is approximately 4.0 trol, swing control, and travel in neutral,
MPa {40 kg/cm2} at maximum, mea- and measure the oil pressure at each
sure it by installing the same gauge to speed. Then, operate the travel lever to
the pickup plugs alternately. run the track shoe idle and measure the oil
q The figure shows the pump discharge pressure.
pressure side. k While taking extreme care for
safety, run the raised track shoe.
a Do not operate the travel lever to its
stroke end (but stop it halfway).
q The figure shows the LS pressure side.

judgment: If the pressures are in the
following value, the LS valve is nor-
mal.
LS differential
Operation of levers
pressure
All control levers and pedals Specified LS dif-
in neutral ferential pressure
Travel lever moved halfway (See standard
(Track running in the air) values table)

parts.
PC200, 200LC, 220, 220LC-8M0 30-101 43

SEN06127-00 Testing and adjusting oil pressure in pump LS control cir-
3. Measurement of LS-EPC valve output pres-

sure
and remove oil pressure pickup plug (7).

parts.
2) Install nipple M3 and connect them to oil
pressure gauge [2].
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.
3) Start the engine.

4) Run the engine at high idle, operate the
travel speed selector switch and travel
lever, and measure the output pressure in
each case.
judgment: If the output pressures are
the following value, the LS-EPC valve
is normal.
Travel Operation of
Output pressure
speed lever
Travel lever Approx. 2.9 MPa
Lo
in neutral {Approx. 30 kg/cm2}
Travel lever
0 MPa
Hi operated a
{0 kg/cm2}
little (Note)
Note: Move the travel lever to a degree

that the PPC oil pressure switch is
turned ON (before the track starts
moving).
30-101 44 PC200, 200LC, 220, 220LC-8M0

Adjusting
Adjusting LS valve
a If the LS differential pressure is abnormal,
adjust the LS valve according to the following
procedure.
q (8): Front pump LS valve
q (9): Rear pump LS valve
1. While fixing adjustment screw (10), loosen

locknut (11).
2. Turn adjustment screw (10) to adjust the differ-

ential pressure.
a If the adjustment screw is
q Turned to the right, the differential
pressure is increased.
q Turned to the left, the differential
pressure is decreased.
a Quantity of adjustment (LS differential
pressure) per turn of adjustment screw:
Approx. 1.1 MPa {Approx. 10.8 kg/cm2}
3. While fixing adjustment screw (10), tighten

locknut (11).
3 Locknut: 49 to 68.6 Nm {5 to 7 kgm}
4. After finishing adjustment, check again that the

LS differential pressure is normal according to
the above described measurement procedure.
PC200, 200LC, 220, 220LC-8M0 30-101 45

SEN06127-00 Testing solenoid valve output pressure
Testing solenoid valve output a When measuring with hoses (2) – (6),
pressure 1 remove the undercover of the control
valve.
a Measuring tools for solenoid valve output pres-
sure
1
N 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (Size 02)

a Before measuring the solenoid valve output
pressure, check that the control circuit source 2. Install adapter N2 and connect the discon-
pressure is normal. nected hose again.
a Measure the solenoid valve output pressure
under the following condition. 3. Fit nipple [1] of hydraulic tester N1 and then
q Hydraulic oil temperature: Within operating connect it to oil pressure gauge [2].
range a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.
1. Disconnect outlet hoses (1) – (6) of the sole- a The figure shows the measuring tools con-
noid valves to be measured. nected to outlet hose (1) of the PPC lock
solenoid valve.
No. Solenoid valve to be measured
1 PPC lock solenoid valve
2 2-stage relief solenoid valve
3 Swing holding brake solenoid valve
4 Travel speed selector solenoid valve
5 Travel junction solenoid valve
ATT return selector solenoid valve
6
(Attachment installation specification)
a When measuring with hose (1), remove

the undercover (rear side) of the opera-
tor's cab.
4. Start the engine.
5. Run the engine at high idle, operate the control

levers and switches to turn the solenoid valve
ON or OFF, and measure the oil pressure.
a For the conditions for turning the solenoid
valve ON and OFF, see the operation
table of each solenoid valve.
a The operating condition of the solenoid
valve can be checked with the monitoring
function of the machine monitor (For
details, see “Special functions of machine
monitor”).
q Monitoring code: 02300 Solenoid 1
q Monitoring code: 02301 Solenoid 2
30-101 46 PC200, 200LC, 220, 220LC-8M0

Testing solenoid valve output pressure SEN06127-00
a If the output pressure is as follows, the

solenoid valve is normal.
Solenoid valve Output pressure
OFF
0 MPa {0 kg/cm2}
(Demagnetization)
ON (Excitation) 2.9 MPa {30 kg/cm2}

PC200, 200LC, 220, 220LC-8M0 30-101 47

SEN06127-00 Testing solenoid valve output pressure
Operation table of PPC lock solenoid valve

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

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

Work equipment, swing, and All are OFF OFF
travel signals Any one is ON ON
Operation table of travel speed selector solenoid valve

Overheat 2nd setting signal is ON
Fuel control dial is at 1,500 rpm or below
Travel speed switch is at Lo/Mi (PC200-8M0)
OFF
Travel speed switch is at Lo (PC220-8M0)
Travel speed switch is at Hi (PC200- Travel signal is OFF
8M0)
F or R pump pressure is 24.5 MPa {250 kg/cm2}
Travel speed switch is at Mi/Hi (PC220- Travel signal is
8M0) ON F or R pump pressure is 15.3 MPa {150 kg/cm2}
ON
Other than above condition
Operation table of travel junction solenoid valve

Travel steering signal is ON
ON
Travel steering Travel lever is operated independently F or R pump pressure is 24.5 MPa {250 kg/cm2}
signal is OFF Other than above condition OFF
Operation table of ATT return selector solenoid valve (Machine with provision for attachment)
Working mode: Other than B OFF
Working mode: B ON
30-101 48 PC200, 200LC, 220, 220LC-8M0

Testing PPC valve output pressure SEN06127-00
Testing PPC valve output pressure 1

Connecting points of PPC piping
a The above figure shows the connecting points

of the PPC piping on the control valve of 1
attachment installation specification. The col-
ors in ( ) are the colors of the bands installed
for distinction of the pipes.
PC200, 200LC, 220, 220LC-8M0 30-101 49

SEN06127-00 Testing PPC valve output pressure
a Measuring tools for PPC valve output pressure

1
P
2 799-401-3100 Adapter (Size 02)
3 799-401-3200 Adapter (Size 03)

a If the output pressure is as follows, the
a Before measuring the PPC valve output pres-
PPC valve is normal.
sure, check that the control circuit source pres-
sure is normal. Operation of lever Output pressure
a Measure the solenoid valve output pressure Neutral 0 MPa {0 kg/cm2}
under the following condition.
Almost same as control
q Hydraulic oil temperature: Within operating Stroke end circuit basic pressure (See
range standard values table)
1. Disconnect the hose of the PPC circuit to be

measured. 6. After finishing measurement, remove the mea-
a For the hose to be disconnected, see suring tools and return the removed parts.
“Connecting points of PPC piping”.
2. Install adapter P2 and connect the discon-

nected hoses again.
3. Install nipple [1] of hydraulic tester P1 and con-

nect it to oil pressure gauge [2].
a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.
a The figure shows the measuring tools con-
nected to the hose of the bucket dump
PPC circuit.
4. Start the engine and set the working mode in

the power mode (P).
5. Run the engine at high idle and measure the

oil pressure with the control lever in neutral
and moved to its stroke end.
30-101 50 PC200, 200LC, 220, 220LC-8M0

Adjusting play of work equipment and swing PPC valves SEN06127-00
Adjusting play of work equipment

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

valve assembly.
2. Remove bellows (1).
3. Loosen locknut (2) and tighten disc (3) until it

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

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

valve assembly.
PC200, 200LC, 220, 220LC-8M0 30-101 51

SEN06127-00 Testing parts which cause hydraulic drift of work equipment
Testing parts which cause 2. Inspection of arm cylinder

hydraulic drift of work equipment 1) Stop the arm cylinder approximately 100
mm before the IN stroke end and stop the
a If the work equipment (cylinder) drifts hydrauli- engine.
cally, check to see if the causal part is the cyl-
inder packing or control valve side according to
the following procedure.
1. Measurement of boom and bucket cylin-

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

position.
q If the lowering speed is increased at
this time, the cylinder packing is
defective.
q If the lowering speed does not
change at this time, the control valve
is defective.
a Operate the control lever while the
starting switch is in the ON position.
2) When checking the boom cylinder, set the a If the pressure in the accumulator is
boom control lever to the RAISE position. lost, run the engine for approximately
When checking the bucket cylinder, set 5 seconds to increase the pressure in
the bucket control lever to the CURL posi- the accumulator.
tion. [Reference]
q If the lowering speed is increased at Reason why the lowering speed is increased
this time, the cylinder packing is by the above operation when the cylinder
defective. packing is the cause of the hydraulic drift:
q If the lowering speed does not 1) If the machine is set in the above posture
change at this time, the control valve (where the holding pressure is applied to
is defective. the bottom side), the oil leaks from the
a Operate the control lever while the bottom side to the head side. Since the
starting switch is in the ON position. volume on the head side is less than that
a If the pressure in the accumulator is on the bottom side by the volume of the
lost, run the engine for approximately rod, the pressure in the head side is
5 seconds to increase the pressure in increased by the oil flowing in from the
the accumulator. bottom side.
2) As the pressure in the head side is
increased, it is balanced at a certain level
(which depends on the leakage), and then
the lowering speed is lowered.
3) If the circuit on the head side is opened to
the drain circuit by the above operation of
the lever (the bottom side is closed by the
check valve at this time), the oil on the
head side flows in the drain circuit. As a
result, the pressure is unbalanced and the
lowering speed is increased.
30-101 52 PC200, 200LC, 220, 220LC-8M0

Testing parts which cause hydraulic drift of work equipment SEN06127-00
3. Checking PPC valve

While the pressure in the accumulator is high,
set the lock lever to the LOCK/FREE position
and measure the lowering distance.
a Operate the control lever while the starting
switch is in the ON position.
a If the pressure in the accumulator is lost,
run the engine for approximately 5 sec-
onds to increase the pressure in the accu-
mulator.
a If there is a difference in the lowering dis-
tance between the LOCK position and
FREE position, the PPC valve is defective
(it has an internal defect).
PC200, 200LC, 220, 220LC-8M0 30-101 53

SEN06127-00 Releasing remaining pressure from hydraulic circuit
Releasing remaining pressure 4) Repeat steps 2) and 3) above 2 – 3 times,

from hydraulic circuit 1 and the residual pressure in the piping is
released completely.
1. Releasing remaining pressure from hydrau-
lic tank 3. Release of remaining pressure from swing
k Since the hydraulic tank is enclosed motor circuit
and pressurized, release the residual The remaining pressure in the swing motor cir-
pressure from it when removing a hose cuit can be released by performing the opera-
or a plug connected to it. tion for “Releasing remaining pressure from
1) Lower the work equipment to the ground hydraulic cylinder circuit” (Operate the lever to
in a stable posture and stop the engine. SWING only, however).
2) Loosen oil filler cap (1) of the hydraulic
tank gradually to release the air in the 4. Release of remaining pressure from travel
tank. motor circuit
Since the control valve spool of the travel
motor circuit is connected to the drain circuit,
the pressure in this circuit can be released by
performing “Releasing remaining pressure
from hydraulic tank”.
2. Release of remaining pressure from

hydraulic cylinder circuit
k When disconnecting a pipe between a
hydraulic cylinder and the control
valve, release the remaining pressure
from the piping according to the follow-
ing procedure.
1) Lower the work equipment to the ground
and release the residual pressure from the
hydraulic tank. For details, see “Releasing
remaining pressure from hydraulic tank”.
a Keep the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch to ON position
and set the lock lever to the FREE posi-
tion, and then operate the right and left
work equipment control levers forward,
backward, to the right, and to the left.
a The control valve is operated by the
pressure in the accumulator. The
pressure in the accumulator is used
up, however, after the control valve is
operated 2 – 3 times.
3) Run the engine at low idle for 5 seconds to
increase the pressure in the accumulator.
a The engine does not start until the
lock lever is set to the LOCK position
once.
30-101 54 PC200, 200LC, 220, 220LC-8M0

Testing oil leakage SEN06127-00
Testing oil leakage 1 2. Measuring oil leakage from arm cylinder

1) Move the arm cylinder to the IN stroke end
a Measuring tools for oil leakage and stop the engine.
Symbol Part No. Part name k Release the residual pressure from
the piping on the arm cylinder
Commercially
Q Measuring cylinder head side. For details, see Releas-
available
ing residual pressure from hydrau-
a Measure the oil leakage under the following lic circuit (Operate the lever to arm
condition. IN only, however).
q Hydraulic oil temperature: Within operat- 2) Disconnect hose (2) on the cylinder head
side and block the hose side with a flange.
k Take care not to disconnect the
ing range
1. Measuring oil leakage from boom cylinder hose on the cylinder bottom side.
1) Move the boom cylinder to the RAISE a Use the following part to block the
stroke end and stop the engine. hose side.
k Release the residual pressure from
07379-00640 (Flange #06)
the piping on the boom cylinder
head side. For details, see “Releas-
lic circuit” (Operate the lever in the
boom RAISE direction only, how-
ever).
2) Disconnect hose (1) on the cylinder head
hose on the cylinder bottom side.
a Use the following part to block the
hose side.
07379-00640 (Flange #06)
3) Run the engine at high idle and relieve the
arm circuit by moving the arm IN.
k Take care not to "move the arm
OUT".
4) Start measuring the oil leakage 30 sec-
onds after relieving is started and mea-
sure for 1 minute.
5) After finishing measurement, return the
removed parts.

boom circuit by raising the boom.
k Take care not to "lower the boom".
sure for 1 minute.
removed parts.
PC200, 200LC, 220, 220LC-8M0 30-101 55

SEN06127-00 Testing oil leakage
3. Measuring oil leakage from bucket cylinder 4. Measuring oil leakage from swing motor
1) Move the bucket cylinder to the CURL 1) Disconnect 2 drain hoses (4) and block
stroke end and stop the engine. the hose side with plugs.
k Release the residual pressure from a Use the following part to block the
the piping on the bucket cylinder hose side.
head side. For details, see Releas- 07376-70522 (Plug #05)
lic circuit (Operate the lever in the
bucket CURL direction only, how-
ever).
2) Disconnect hose (3) on the cylinder head
hose on the cylinder bottom side.
hose side.
07379-00640 (Flange #06)
2) Turn the swing lock switch ON.

swing circuit by swinging.
a Start measuring the oil leakage 30
seconds after relieving is started and
measure for 1 minute.
a After measuring 1 time, swing 180°,
and then measure again.
removed parts.

bucket circuit by curling the bucket.
k Take care not to “dump the bucket”.
sure for 1 minute.
removed parts.
30-101 56 PC200, 200LC, 220, 220LC-8M0

Testing oil leakage SEN06127-00
5. Measuring oil leakage from travel motor 5) After finishing measurement, return the
1) Remove the travel motor cover. removed parts.
2) Run the engine, lock the sprocket, and
stop the engine.
k Put pin [1] between the sprocket
and track frame to lock the travel
mechanism securely.
3) Disconnect drain hose (5) of the travel

motor and block the hose side with a plug.
hose side.
07376-70422 (Plug #04)
4) Run the engine at high idle, relieve the

travel circuit, and measure the oil leakage.
k Before operating the travel lever,
check the position and locking
direction of the locked sprocket
again.
k Wrong operation of the lever can
cause an accident. Accordingly,
make signals and checks securely.
a Start measuring the oil leakage 30
seconds after relieving is started and
measure for 1 minute.
a Measure several times, moving the
motor a little (changing the position of
the valve plate and cylinder and that
of the cylinder and piston) each time.
PC200, 200LC, 220, 220LC-8M0 30-101 57

SEN06127-00 Bleeding air from each part
Bleeding air from each part 1

q: Execution of work
o: Go to next procedure
Air bleeding item Air bleeding procedure
1 2 3 4 5 6
Bleeding air Checking oil
Bleeding air Bleeding air
from Starting Bleeding air level and
from swing from travel
hydraulic engine from cylinder starting
Contents of work motor motor
pump operation
• Replacing hydraulic oil q q
q q q q
• Cleaning strainer (See note) (See note)
• Replacing return filter element q o o o q
• Replacing and repairing hydraulic pump

q q q o o q
• Removing suction piping
• Replacing and repairing control valve
q q o o q
• Removing control valve piping
• Replacing and repairing cylinder
q q o o q
• Removing cylinder piping
• Replacing and repairing swing motor
q o q o q
• Removing swing motor piping
• Replacing and repairing travel motor
q o o q q
• Removing travel motor piping
• Replacing and repairing swivel joint
q o o o q
• Removing swivel joint piping
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
1. Bleeding air from hydraulic pump 2. Starting engine

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

a If a cylinder is replaced, bleed air from it
before installing it to the work equipment.
In particular, the boom cylinder does not
move to the lowering stroke end, if it is
installed to the work equipment.
1) Run the engine at low idle for approxi-
mately 5 minutes.
2) While running the engine at low idle, raise
and lower the boom 4 to 5 times.
a Stop the piston rod approximately 100
mm before each stroke end. Do not
relieve the oil.
30-101 58 PC200, 200LC, 220, 220LC-8M0

Bleeding air from each part SEN06127-00
3) While running the engine at high idle, per- 2) Check the oil level by sight gauge (3) on
form step 2). the rear side of the hydraulic tank.
4) While running the engine at low idle, move a If the oil level is below line L, it is
the piston rod to the stroke end and insufficient. Add oil.
relieve the oil. a The oil level changes according to the
5) Bleed air from the arm cylinder and bucket oil temperature. Add oil when the oil
cylinder according to steps 2) to 4). level is out of the following standard
ranges.
4. Bleeding air from swing motor q When oil temperature is 10 to 30°C:
1) Run the engine at low idle. Between line H and line L
2) Swing slowly to bleed air. q When oil temperature is 50 to 80°C:
Near line H
5. Bleeding air from travel motor
1) Run the engine at low idle.
2) Loosen air bleeder (2) and check that oil
oozes out through the air bleeder.
3) After the oil oozes out, tighten air bleeder
(2).
3 Air bleeder:
27.5 to 35.3 Nm {2.8 to 3.6 kgm}
6. Checking oil level and starting work

1) Run the engine, retract the arm cylinder
and bucket cylinder fully, lower the work
equipment to the ground, and stop the
engine.
PC200, 200LC, 220, 220LC-8M0 30-101 59

SEN06127-00 Testing cab tipping stopper
Testing cab tipping stopper 1
a Check the cab tipping stopper according to the

following procedure.
1. Remove the additional under cover at the rear

of the operator's cab. (Only for the machine
equipped with the reinforced type under cover)
2. Check the tightening torque of the mounting

bolt (2) of the lock plate (1).
3 Bolt (2):
98 to 123 Nm {10 to 12.5 kgm}
[Reference]
q The tightening torque of mounting bolt (4) of
cab tipping stopper (3) is different from that of
a common bolt 30 mm in diameter. Take care.
3 Bolt (4): 245 to 309 Nm {25 to 31.5 kgm}
30-101 60 PC200, 200LC, 220, 220LC-8M0

Adjusting mirrors SEN06127-00
Adjusting mirrors 1
PC200, 200LC, 220, 220LC-8M0 30-101 61

SEN06127-00 Installation and adjustment of mirrors
Installation and adjustment of 4) Retract the mirror into position (C) when
mirrors 1 transporting the machine.
1. Installation of retractable mirrors 5) Retractable mirror (b1): Install at 15 mm

Install retractable mirrors (a1) and (b1) as (from the top of the stay). Install mirror
shown in the figure. stay (4) so that the mirror will be fixed at
1) Retractable mirror (a1): Install at 20 mm (A) of the 3 stopping positions where the
(from the bottom of the intermediate stay). mirror is extracted most and fixed angle (f)
Install mirror stay (1) so that the mirror will to be at an angle of approximately 26 deg.
be fixed at (A) of the 3 stopping positions to the side of the machine body.
where the mirror is extracted most and a If the mirrors are not installed to the cor-
fixed angle (e) to be at an angle of approx- rect positions, they may interfere with the
imately 94 deg. to the intermediate stay. exterior parts.
a If the mirrors are not installed to the cor-
rect positions, they may interfere with the
exterior parts.
6) Tighten bolts (5) of mirror.

3 Bolt: 6.0 to 7.0 Nm {0.61 to 0.71 kgm}
7) Tightening torque of mirror stay bolt (6).
3 Bolt: 15 to 19.6 Nm {1.5 to 2 kgm}
2) Tighten bolts (2) of mirror.
3 Bolt: 6.0 to 7.0 Nm {0.61 to 0.71 kgm} a If the tightening torque is low, the bolts
3) Tightening torque of mirror stay bolt (3).
3 Bolt: 15 to 19.6 Nm {1.5 to 2 kgm}
may be dragged. If the former is too high,
the body may be broken.
a If the tightening torque is low, the bolts
may be dragged. If the former is too high,
the body may be broken.
8) Retract the mirror into position (C) when

transporting the machine.
30-101 62 PC200, 200LC, 220, 220LC-8M0

Installation and adjustment of mirrors SEN06127-00
2. Adjustment of retractable mirrors

1) Adjust the retractable mirrors at position
(A).
2) With retractable mirrors (a1) and (b1)
open, loosen mirror bolts (1) and (2) and
stay mounting bolts (3) and (4) and adjust
the mirrors so that the operator can see
the right and left rear views best which are
blind corners from the operator’s seat.
a Adjust the mirror so that the operator can
see persons (or things 1 m high and
approximately 30 cm in diameter) at the
right and left rear ends of the machine.
a Take care not to tighten stay mounting
bolts (3) and (4) (If they are tightened too
strongly, the stay may be broken since it is
made by die-casting).
PC200, 200LC, 220, 220LC-8M0 30-101 63

SEN06127-00 Installation and adjustment of mirrors
3) Tighten the stay mounting bolts so that the

clearance to the stay mating face will be
even.
3. Adjustment of unretractableble mirrors

1) See the "Adjusting mirrors" page, adjust
mirrors (c1) and (d1) so that the operator
can see persons at 1 m arou nd the
machine (hatched area) from the opera-
tors seat.
a If the mirror is hard to adjust, loosen mirror
screw (1).
2) Tighten screw (1) of mirror.
3 Screw:
3.0 to 3.5 Nm {0.31 to 0.35 kgm}
a When adjusting mirror, secure clearance
(g) so that mirror stay does not interfere
with mirror.
30-101 64 PC200, 200LC, 220, 220LC-8M0

Angle adjustment of rear view camera SEN06127-00
Angle adjustment of rear view 1. Remove cover (2) by inserting flat-head screw-
camera 1 driver [1] in the hole in cover (3) and pressing
the internal pawl.
Adjust the camera so that persons in area (w) at 1
meter around the machine is displayed on the
machine monitor in the operator cab.
a Claw of cover (2) is made of plastic, it is

easily damaged while removing, therefore
take special care at work.
If the image displayed on the monitor is out of posi-
tion, remove cover (2) of camera (1) and adjust the
installation angle (A) of the rear view camera.
2. Remove two bolts (4).
3. Remove cover (2).
PC200, 200LC, 220, 220LC-8M0 30-101 65

SEN06127-00 Angle adjustment of rear view camera
4. Loosen mounting bolts (5) of camera (1) and

adjust installation (A) of camera so that the
side line of camera is matched with the corner
(B) of the bracket.
Angle (A): 48°(+2°/0)
a A part of the machine is displayed on the

monitor screen.
Adjust the camera so that the image of the
counterweight occupy approximately 10 to
15% of the monitor screen.
5. After adjusting, tighten bolts (5).

3 Camera mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6. Install covers (2) and (3).
30-101 66 PC200, 200LC, 220, 220LC-8M0

Angle adjustment of rear view camera SEN06127-00
PC200, 200LC, 220, 220LC-8M0 30-101 67

SEN06127-00

© 2012 KOMATSU
All Rights Reserved
30-101 68
SEN06128-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

Special functions of machine monitor ............................................................................................................. 2
PC200, 200LC, 220, 220LC-8M0 30-102 1

SEN06128-00 Special functions of machine monitor
Special functions of machine monitor 1
30-102 2 PC200, 200LC, 220, 220LC-8M0

Special functions of machine monitor SEN06128-00
Upper part of machine monitor (display portion)

(a): Multi-information display
a When the engine is started, the battery voltage may drop suddenly, depending on the ambient tempera-
ture and the condition of the battery.
In this case, the screen display of the machine monitor may go off for a moment. This phenomenon is
not a failure, however.
Upper part of machine monitor (switch portion)

[F1]: F1 Function switch
a The function of each function switch is indicated by the icon which is displayed just above the function
switch on the screen of the multi-information display panel (a).
a If the icon for a function switch is not displayed, that function switch is not working.
Lower part of machine monitor (switch portion)

[1]: Numeral 1 input switch/Auto-deceleration switch
[2]: Numeral 2 input switch/Working mode selector switch
[3]: Numeral 3 input switch/Travel speed selector switch
[4]: Numeral 4 input switch/Alarm buzzer stop switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Window washer switch
[7]: Numeral 7 input switch/Air conditioner switch
Switch having no numerals : Air conditioner switch
a Each switch has the function indicated by the icon on it and the function of inputting a numeral.
a The machine monitor automatically judges which function of each switch is currently enabled according
to the screen display of the multi-information display panel (a).
PC200, 200LC, 220, 220LC-8M0 30-102 3

Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary functions and special functions and displays information of various
types on the multi-information display panel.
Some information are displayed automatically according to the configuration of the machine monitor and the
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The information items in this mode are displayed ordinarily. The operator can display and set them by
operating the switches (Display and setting of some items need special operations of the switches).
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting.
30-102 4 PC200, 200LC, 220, 220LC-8M0

Operator mode (outline) Service mode

A Display of KOMATSU logo Monitoring / Pre-defined
A Display of inputting password Monitoring / Custom
A Display of check of breaker mode Abnormality Record (Mechanical Systems)
A Display of check before starting Abnormality Record (Electrical Systems)
A Display of warning after check before starting Maintenance record
A Display of ending of maintenance interval Maintenance Mode Setting
A Display of check of working mode and travel speed Phone Number Entry
A Display of standard screen Default (Key-On Mode)
A Display of end screen Default (Unit)
O (Special operation)
B Selection of auto-deceleration Default (With/Without Attachment)
B Selection of working mode Default (Camera)
B Selection of travel speed Diagnostic Tests (Cylinder Cut-out)
B Operation to stop alarm buzzer Adjustment (Pump Absorption Torque (F))
B Operation of windshield wiper Adjustment (Pump Absorption Torque (R))
B Operation of window washer Adjustment (Low Speed)
B Operation of air conditioner/heater Adjustment (Attachment Flow Adjustment)
Operation to display camera mode No Injection
B
(if camera is installed)
KOMTRAX Settings (Terminal Status)
B Operation to display clock and service meter
KOMTRAX Settings (GPS and Communication Status)
B Check of maintenance information
KOMTRAX Settings (Modem Information)
Setting and display of user mode (including
B Service Message
KOMTRAX messages for user)
C Display of ECO guidance
C Display of caution monitor
C Display of action level and failure code
Function of checking display of LCD
D
(Liquid Crystal Display)
D Function of checking service meter
Function of usage limitation setting/maintenance
D
password
a Group of screens or functions in operator mode

A: Display or function from turning ON of starting switch to switching to the standard screen is over, and
display after starting switch is turned OFF
B: Display or function when the machine monitor switches are operated
C: Display or function when certain conditions are met
D: Display or function when operation of special switches is required
PC200, 200LC, 220, 220LC-8M0 30-102 5

Operator mode (Outline) a Display sequence in operator mode

a Only outline of the operator mode is described The contents of display from the time when
in this section. starting switch is turned ON to time when
For details of contents and operations of each screen changes to standard screen depends
function and display, see “Structure and func- on the setting and condition of the machine.
tion”, or the “Operation and Maintenance Man- A : When the engine start lock is set effective
ual”. B : When the engine start lock is set ineffective
a The following are the screens or functions of C : When working mode at start is set to
the operator mode explained in this section breaker mode (B)
(including some items which need special D : When there is abnormal item in check-
operations). before-starting items
E : When an overdue maintenance item is dis-
Display pattern covered
A B C D E
Display of KOMATSU logo 1 1 1 1 1
Display of inputting password 2 — — — —
Display of check of breaker mode — — 2 — —
Display of check before starting 3 2 3 2 2
Display of warning after check
— — — 3 —
before starting
Display of ending of maintenance
— — — — 3
interval
Display of check of working mode
4 3 4 4 4
and travel speed
Display of standard screen 5 4 5 5 5
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of window washer
Operation of air conditioner/heater
Operation to display camera mode (if camera is
installed)
Operation to display clock and service meter
Check of maintenance information
Setting and display of user mode (including
KOMTRAX messages for user)
Display of ECO guidance
Display of caution monitor
Display of action level and failure code
Function of checking display of LCD (Liquid Crystal
Display)
Function of checking service meter
Function of usage limitation setting/maintenance
password
30-102 6 PC200, 200LC, 220, 220LC-8M0

Display of KOMATSU logo

When starting switch is turned to ON position,
KOMATSU logo is displayed for 2 seconds.
a After the KOMATSU logo screen is displayed
for 2 seconds, the screen changes to “Pass-
word input” screen, or “Check before starting”
screen.
Display of check of breaker mode

When the starting switch is turned ON, if the work-
ing mode is set to the breaker mode [B], a message
to inform the operator of starting in the breaker
mode is displayed on the screen.
k If an attachment other than the breaker is
used while the working mode is set to the
Display of inputting password breaker mode [B], the machine may move
After the KOMATSU logo screen is displayed, the unexpectedly or may not operate normally
screen to input the engine start lock password is or the hydraulic components may be dam-
displayed. aged.
a This screen is displayed only when the engine a After operation to check of the breaker mode is
start lock function is enabled. finished, the screen changes to “Display of
a If correct password is input, the screen check before starting”.
changes to “Check before starting” screen. If [No] is selected: Working mode is set to
a The machine monitor has some password pro- economy mode [E]
tect functions other than the engine start lock. If [Yes] is selected: Working mode is set to
Those functions are independent from one breaker mode [B]
another.
a The following screen may be displayed instead

of the above “Password input” screen.
a If this screen is displayed, call the person
responsible for the operation of KOMTRAX in
your Komatsu distributor and ask for remedy.
PC200, 200LC, 220, 220LC-8M0 30-102 7

Display of check before starting Display of maintenance due time over

When the screen changes to the check before If the check before starting detected a maintenance
starting screen, the check before starting is per- item that is near or overdue the set interval, the
formed for 2 seconds. maintenance monitor is displayed for 30 seconds to
a If any abnormalities are detected in the check urge the operator to perform maintenance.
before starting, the screen changes to “Warning a This screen is displayed only when the mainte-
after the check before starting” screen or “Over- nance reminder function is enabled. If the
due Maintenance” screen. remaining time of any item is set time hours or
a If no abnormalities were detected in the check less, the yellow icon is displayed. If the remain-
before starting, display changes to “Working ing time of any item is 0 hour or less, the red
Mode and Travel Speed Check” screen. icon is displayed.
a The monitors (6 monitors) on the screen shows a The maintenance reminder function is enabled
the items currently subjected to the check before or disabled by using the machine monitor in
starting. the service mode.
Display of check of working mode and travel

Display of warning after check before starting speed
If any abnormalities are detected in the check If the check before starting is finished normally, the
before starting, the alarm monitor is displayed on screen for checking the working mode and travel
the screen. speed is displayed for 2 seconds.
a The figure shows how air cleaner clogging a After the “Working mode and travel speed
monitor (a) warns of clogging on air cleaner. check” screen is finished, the screen changes
to the “Standard” screen.
30-102 8 PC200, 200LC, 220, 220LC-8M0

Display of standard screen a If the auto-deceleration is set to OFF, auto-

If the machine monitor starts normally, the standard deceleration monitor (b) goes off.
screen is displayed.
a Service meter (a) or clock is displayed in the
top center area of the screen (use [F4] to
switch the display of the service meter and
clock).
a Right end of the screen displays ECO gauge
(b) (turn on or off the display in the operator
mode).
Selection of working mode

Select desired working mode according to the fol-
lowing procedure.
1. While the standard screen is displayed, press
the working mode selector switch, and the
working mode selection screen is displayed.
a Following figure shows the working mode
selection screen when “with attachment” is
Display of end screen set. (If “with attachment” is not set in ser-
When starting switch is turned to OFF position, the vice mode, attachment mode “ATT/P”,
end screen is displayed for 5 seconds. “ATT/E” are not displayed.)
a Another message may be displayed on the
end screen due to the message display func-
tion of KOMTRAX.
2. Operate the function switches or working mode

selector switch to select the desired working
mode and enter the selection.
Selection of auto-deceleration Function switch
While the ordinary screen is displayed, if the auto- q [F3]: Moves to lower item
deceleration switch is pressed, large auto-deceler- q [F4]: Moves to upper item
ation monitor (a) is displayed for 2 seconds and the q [F5]: Cancels selection and returns to
setting of the auto-deceleration is changed. standard screen
a Each time the auto-deceleration switch is q [F6]: Enters selection and returns to stan-
pressed, the auto-deceleration is changed in dard screen
the order of [ON] o [OFF] o [ON]. Working mode selector switch
a If the auto-deceleration is set to ON, large q Pressed : Moves to lower item
monitor (a) and auto-deceleration monitor (b) q Kept pressed : Enters selection and
are displayed simultaneously. returns to standard screen
PC200, 200LC, 220, 220LC-8M0 30-102 9

a If you do not touch any of the function If “No” is selected: Screen returns to work-
switches and working mode selector ing mode selecting screen
switch for 5 seconds, the selection is If [Yes] is selected: Working mode is set to
determined and the screen changes to the breaker mode [B]
standard screen.
Selection of travel speed

3. When the ordinary screen is displayed again, While the standard screen is displayed, if the travel
large working mode monitor (a) is displayed for speed selector switch is pressed, large travel
2 seconds, and then the setting of the working speed monitor (a) is displayed for two seconds and
mode is changed to the selected mode. the setting of the travel speed is changed.
a When large monitor (a) is displayed, the a Travel speed setting sequentially changes
display of working mode monitor (b) is between [Lo] o [Mi] o [Hi] o [Lo] in this order
changed, too. every time the switch is pressed.
a When large monitor (a) is displayed, the dis-
play of travel speed monitor (b) is changed,
too.
<Precautions for selecting breaker mode [B]>

q If breaker mode [B] is selected, both of the
control of the hydraulic pump and the set-
ting of the hydraulic circuit are changed. Operation to stop alarm buzzer
q If an attachment other than the breaker is While the alarm buzzer is sounding, if the alarm
used, the machine may move unexpect- buzzer cancel switch is pressed, the alarm buzzer
edly or may not operate normally or the stops.
hydraulic components may be damaged. a Even if the alarm buzzer cancel switch is
q After the breaker mode is selected, the pressed, the screen display does not change.
screen to confirm the selection of the
breaker mode is displayed (The buzzer
sounds intermittently while this screen is
displayed).
q If the setting is confirmed on this screen,
the screen changes to the standard
screen.
30-102 10 PC200, 200LC, 220, 220LC-8M0

Operation of windshield wiper Operation to display camera mode (if camera is

While the ordinary screen is displayed, if the wiper installed)
switch is pressed, large wiper monitor (a) is dis- If [F3] is pressed, the multi-display changes to the
played for 2 seconds and the wiper starts or stops. camera image (Set the connection of the camera in
a The window washer does not operate if the the service mode).
window limit switch is “ON”.
a The wiper setting changes sequentially
between [INT] o [ON] o [OFF] o [INT] every
time you press the switch.
a When the wiper is set to INT or ON, large mon-
itor (a) is displayed and the display of wiper
monitor (b) is changed at the same time.
a If the wiper is set to OFF, large monitor (a) is
not displayed and the wiper monitor disap-
pears.
a Up to two cameras can be connected. When

the camera mode is selected, however, only
the image of camera 1 is always displayed at
first.
Operation of window washer

While the ordinary screen is displayed, if the win-
dow washer switch is pressed, the washer fluid is
splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen display does not change.
Operation of air conditioner/heater

While the standard screen is displayed, if the air a If any caution is issued with the display panel
conditioner switch is pressed, “Air-conditioner Set- in the camera mode, the corresponding cau-
ting” screen is displayed. tion monitor is displayed at the left top of the
a While “Air-conditioner Setting” screen is dis- screen (excluding the low hydraulic oil temper-
played, if you do not touch any switch for 5 ature caution monitor).
seconds, the screen changes to the standard
screen.
PC200, 200LC, 220, 220LC-8M0 30-102 11

a If no control lever is operated for 10 seconds Check of maintenance information

while a failure enough to display an action level You can check the maintenance information on the
is occurring with the display panel in the cam- maintenance screen by pressing [F6] while the
era mode, the screen returns to the standard maintenance monitor is displayed.
screen and displays information about that fail- When the maintenance monitor does not appear,
ure. press [F6] and then press [F1] or [F2]. Then make
a When two or more cameras are connected, the sure the display is switched to the maintenance
image of one of them or the images of two of screen.
them can be displayed.
a When 2-camera image display [F4] is selected,
images of cameras 1 and 2 are displayed on
the right and left side of the screen.
You can specify which of image of cameras 1
and 2 to appear on the right side and which on
the left side from “Camera” in the service
mode.
Operation to display clock and service meter

While the standard screen is displayed, if [F4] is
pressed, the service meter and the clock are dis-
played alternately in section (a).
a When selecting the clock display, perform the
time adjustment, 12-hour or 24-hour display
a To reset the remaining time after finishing
setting, and summer time setting by using the
maintenance, more operations are necessary.
user mode functions.
30-102 12 PC200, 200LC, 220, 220LC-8M0

Setting and display of user mode (including Display of ECO guidance

KOMTRAX messages for user) When the machine is set in a certain operating con-
To enter the user mode, press [F6] to display the dition, the ECO Guidance screen is displayed auto-
“User Menu” screen while the standard screen is matically to urge the operator to perform the
displayed. energy-saving operation.
a “ECO Guidance” screen is displayed when the
following conditions are met while this display
function is set to enabled in operator mode.
a Conditions for display:
q Idle stop guidance
If no lever is operated for a period of at least 5
minutes and the engine keeps running at idle
speed during this period, the guidance on idle
stop is displayed on the monitor. This function
helps reduce unnecessary fuel consumption
by alerting the operator to stop the engine
while waiting for the next operation, or during a
break.
a The lamp for the idle stop guidance goes
out automatically when the lever operation
a The User Menu has following menus. is resumed, or if the function switch [F5] is
pressed.
ECO Guidance
Machine setting
Maintenance
Monitor setting
Check mail
[KOMTRAX message]
q There are two types of KOMTRAX message;
one is for the user and the other is for the tech-
nician.
q For user: It denotes the messages transmitted
from the KOMTRAX base station to users.
Upon receiving a message, the message mon-
itor is displayed on the standard screen. Oper- Guidance on deterrence of hydraulic relief
ate this “Check mail” when viewing contents of If relieving lasts for 3 or more seconds during oper-
a message. ation, guidance on deterrence of hydraulic relief is
q For technician: It refers to the messages trans- displayed on the monitor.
mitted to the technicians from the KOMTRAX a The lamp for the guidance on deterrence of
base station. When a message is received, the hydraulic relief goes out automatically after 10
standard screen does not display any informa- seconds has passed since it appeared, or if the
tion relevant to the message received. To view function switch [F5] is pressed.
contents of a message, operate “Display ser-
vice message” of the service menu in the ser-
vice mode.
PC200, 200LC, 220, 220LC-8M0 30-102 13

q E-mode recommendation guidance q Low fuel level guidance

If light-load work continues for 10 or more min- If the amount of time the machine can be oper-
utes in P- or ATT/P-mode, E-mode recommen- ated that is projected from the remaining fuel
dation guidance is displayed. This function level and the latest average fuel consumption
helps reduce unnecessary fuel consumption drops to less than 8 hours, the low oil level
by alerting the operator to turn on E-mode. guidance is displayed.
a The lamp for the E-mode recommendation a The lamp for the low oil level guidance
guidance goes out automatically after 10 goes out automatically after 10 seconds
seconds has passed since it appeared, or has passed since it appeared, or if the
if the function switch [F5] is pressed. function switch [F5] is pressed.
q Travel partial recommendation guidance Display of caution monitor

If machine travel in the travel mode Hi and the If an error that is serious enough to display Action
fuel control dial at MAX continues for 2 or more Level “L01” alarm monitor on the standard screen
minutes, the travel partial recommendation or camera mode screen occurs, a large alarm mon-
guidance is displayed. When traveling the itor is displayed on the screen once and is continu-
machine for a long period of time, moving the ously shown in window (a).
fuel control dial from MAX to a lower position a On the camera mode screen, the alarm moni-
helps reduce fuel consumption. tor flashes at the left upper of the screen when
a The lamp for the travel partial recommen- a caution is issued.
dation guidance goes out automatically
after 10 seconds has passed since it
appeared, or if the function switch [F5] is
pressed.
30-102 14 PC200, 200LC, 220, 220LC-8M0

If an error serious enough to display a alarm moni- a The telephone No. is displayed only when the
tor of Action Level [L02], [L03] or [L04] occurs, the telephone number is registered in the service
alarm monitor is displayed at the center of the mon- mode.
itor screen until the error is eliminated. a If multiple problems occur simultaneously, all
the codes are displayed repeatedly in order.
a Because the information of the displayed fail-
ure code is logged in the abnormality record in
the service mode, check the details in the ser-
vice mode.
a The “Error list” automatically returns to the
standard screen after 30 seconds.
a Since “Error list” cannot be displayed from the
screen on which the camera mode is dis-
played, move to “Error list” from the standard
screen side.
Display of action level and failure code

If an abnormality that displays an action level and a
failure code occurs on the standard screen or cam-
era mode screen, the alarm monitor lights up.
If the alarm monitor lights up, press function switch

[F5] to display the “Error list”.
q [F1]: Moves to next page (screen) (if dis-
played)
q [F2]: Moves to previous page (screen) (if dis-
played)
q [F5]: To return to standard screen
On the “Error list” screen, the following information
is displayed.
(a): Alarm monitor
(b): Action level (3 digits)
(c): Failure code (5 or 6 digits)
(d): Failure code name
(e): Message
(f): Telephone No. (if registered)
a This screen display appears only when a prob-
lem (failure code) for which an action level is
set occurs.
PC200, 200LC, 220, 220LC-8M0 30-102 15

a Actions to take given by action levels to opera- a To return to the former screen, press any one
tor (Excerpt from the Operation and Mainte- of the function switches.
nance Manual) Reference: An LCD panel, as one of its characteris-
tics, sometimes shows black spots (spots that
Degree remain unlit) and bright spots (spots that do not go
Action Alarm off).
of emer- Buzzer Remedy
level monitor If the number of the bright points and black points
gency
Stop immediately does not exceed 10, the LCD panel is not faulty or
and perform defective.
Q checking and
(Con- maintenance.
High L04 Q
tinu- Ask your Komatsu
ous) distributor for test-
ing and repair ser-
vices.
Stop work, move
machine to safe
place, stop it, and
Q perform checking
L03 (Inter- Q and maintenance.
mittent) Ask your Komatsu
distributor for test-
ing and repair ser-
vices.
I Stop work, and Function of checking service meter

then run the When checking the service meter with the starting
engine at medium switch in the OFF position, operate the numeral
speed with no input switches as follows to display only the service
Q load, or stop it. If
meter section.
L02 (Inter- Q the condition does
q Switch operations (simultaneous): [4] + [1]
mittent) not improve, ask
your Komatsu dis- a There is some time lag in start of the LCD, so
tributor for testing hold down the switches until the service meter
and repair ser- is displayed.
vices. a If you release one of the switches, the monitor
Some functions goes off.
are restricted, but Reference: After the machine monitor is used con-
the machine can tinuously over a long period of time, blue points
work. After finish- (points that remain lit) may appear on this screen. It
L01 ing work, perform does not indicate that the LCD panel is faulty or
(For 2 checking and defective.
Low — Q
seconds maintenance.
only) Ask your Komatsu
distributor to per-
form testing or
repairs as neces-
sary.
Function of checking display of LCD (Liquid

Crystal Display)
While the standard screen is displayed, if the
numeral input switches or function switches are
operated in the following manner, the entire LCD
screen turns white.
q Switch operations (simultaneous): [4] + [F2]
a When finishing the operation of the switches,
release [F2] first.
a If there is a display error in the LCD, only that
part is indicated in black.
30-102 16 PC200, 200LC, 220, 220LC-8M0

Function of usage limitation setting/mainte- 3. After the “Usage Limitation Setting” screen is
nance password displayed, select a setting using the function
Selecting the Usage Limitation Setting displays the switch.
password input screen when you proceed to setting q [F3]: Moves to lower item
of the breaker or attachment, or maintenance reset- q [F4]: Moves to upper item
ting Observe the following procedure when using q [F5]: Cancels the selection and return the
the Usage Limitation Setting. display to the preceding screen
1. While the standard screen is displayed, per- q [F6]: Validates the selection
form the following operation with the numeral
input switches.
q Operation of switches (While pressing [4],
press the switches in order):
[4]+[5]o[5]o[5]
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned to ON position.
Selection of “Usage limitation ON/OFF”

After the “Usage Limitation ON/OFF” screen is
displayed, select a desired one using the func-
tion switch.
q Disable Password input screen is not dis-
played
q Enable: The password input screen for
setting of the breaker or attachment, or
2. After the “Usage Limitation password screen is maintenance resetting appears.
displayed, input the current password using q [F3]: Moves to lower item
the numeral input switches and validate it q [F4]: Moves to upper item
using the function switch. q [F5]: Cancels the selection and return the
display to the preceding screen
q [F5]: Deletes the entered numbers/ q [F6]: Validates the selection
Restores the standard screen
q [F6]: Validates the entered password
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to request inputting the password
again is displayed.
a The password for the Usage Limitation and the

engine start lock password are not identical.
PC200, 200LC, 220, 220LC-8M0 30-102 17

4. Changing a password If the screen to notify completion of setting is

After the “Usage Limitation New Password displayed and then the standard screen is dis-
Input” screen is displayed, input a new pass- played, the password has been changed suc-
word with the numeral input switches and vali- cessfully
date it with the function switch.
q [F5]: Deletes the entered numbers/
Returns the display to the preceding
screen
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to request inputting the password
again is displayed.
a Set a new password in 4 to 6 digits (a
password of 3 or less digits or 7 or more
digits is not accepted).
After the “Usage Limitation New Password

Input” screen is displayed again, input the new
pa ssword again with the numeral inpu t
switches and validate it with the function
switch.
q [F5]: Deletes the entered numbers/
Restores the standard screen
a If the input password is different from the
entered in the first time, the message to
request reentry is displayed.
30-102 18 PC200, 200LC, 220, 220LC-8M0

Service mode
To change the mode of the machine monitor to the
service mode from the operator mode, perform the
following operation.
This operation is always required when you use the
service mode.
1. Check of screen display and operation of

switches
While the standard screen is displayed, per-
form the following operation by using the
numeral input switches.
q Operation of switches (While pressing [4],
press the switches in order):
[4] + [1] o [ 2 ] o [ 3 ] a The menu items which can be selected in
a This operation of the switches is accepted the service menu are as follows (including
only while the standard screen is dis- some items which need special opera-
played. tions).
01 Monitoring / Pre-defined
02 Monitoring / Custom
Abnormality Record (Mechanical Systems)
03
Abnormality Record (Electrical Systems)
04 Maintenance record
05 Maintenance Mode Setting
06 Phone Number Entry
Default (Key-On Mode)
Default (Unit)
07
Default (With/Without Attachment)
Default (Camera)
2. Selection of service menu 08 Diagnostic Tests (Cylinder Cut-out)
When the “Service Menu” screen is displayed, Adjustment (Pump Absorption Torque (F))
the service mode is selected. Select the
Adjustment (Pump Absorption Torque (R))
desired service menu by using the function 09
switches or numeral input switches. Adjustment (Low Speed)
q [F3]: Moves to lower item Adjustment (Attachment Flow Adjustment)
q [F4]: Moves to upper item 10 No Injection
q [F5]: Returns the display to the standard
KOMTRAX Settings (Terminal Status)
screen (operator mode)
q [F6]: Validates the selection KOMTRAX Settings (GPS and Communication
11
a If you input a 2-digit code by using the Status)
numeral input switches, the corresponding KOMTRAX Settings (Modem Information)
menu is directly selected. This will allow 12 Service Message
you to validate the selection using [F6].
PC200, 200LC, 220, 220LC-8M0 30-102 19

Monitoring / Pre-defined a If the working mode is changed to breaker

The machine monitor can monitor the condition of mode [B], the screen to confirm the change of
the machine in real time by receiving signals from the setting is displayed as in changing the
various switches, sensors, and actuators installed working mode on the standard screen.
to many parts of the machine and the information
from the controllers which control them.
In the monitoring / pre-defined, monitoring items
that are used frequently in daily work are selected
beforehand.
1. Selecting the menu

Select “Monitoring / Pre-defined” on the “Ser-
vice Menu” screen.
2. Check of monitoring / pre-defined information

After the “Monitoring / Pre-defined” screen is
displayed, you can check the items displayed
in the troubleshooting support by using the
function switches.
q [F1]: Moves to the next page (screen)
q [F2]: Moves to the previous page (screen)
q [F4]: Selects hold or its releasing
(If hold is selected, a diagonal line is dis-
played on the HOLD portion)
q [F5]: Returns to service menu screen
a You can select and check any items not
displayed in “Monitoring / Pre-defined”
from the “Monitoring items”.
30-102 20 PC200, 200LC, 220, 220LC-8M0

List of monitoring / pre-defined items (SI unit indicates the default values)
Support screen (1/7) Fuel injection

Applicable equip-
No. ID Item name Unit (SI)
ment
1 01002 Engine speed r/min ENG
2 04107 Coolant temperature °C ENG
3 04501 Engine oil level — MON
4 04401 Hydr. oil temperature °C PUMP
5 03203 Battery power supply V ENG
Support screen (2/7) Fuel injection

Applicable equip-
ment
2 04107 Coolant temperature °C ENG
3 36400 Rail pressure MPa ENG
4 36200 Rail pressure command MPa ENG
5 18500 Boost temperature °C ENG
6 37400 Ambient pressure kPa ENG
Support screen (3/7) F & R pumps basic items

Applicable equip-
ment
2 01100 F pump pressure MPa PUMP
3 01101 R pump pressure MPa PUMP
4 01300 PC-EPC sol current (F) mA PUMP
5 01302 PC-EPC sol current (R) mA PUMP
Support screen (4/7) F & R pumps application items

Applicable equip-
ment
2 01100 F pump pressure MPa PUMP
3 01101 R pump pressure MPa PUMP
4 01300 PC-EPC sol current (F) mA PUMP
5 01302 PC-EPC sol current (R) mA PUMP
6 01500 LS-EPC sol current mA PUMP
PC200, 200LC, 220, 220LC-8M0 30-102 21

Support screen (5/7) PPC pressure

Applicable equip-
ment
2 07400 Boom Raise PPC pressure MPa PUMP
3 07500 Boom Lower PPC pressure MPa PUMP
4 07200 Arm In PPC pressure MPa PUMP
5 07600 Arm Out PPC pressure MPa PUMP

Applicable equip-
ment
2 09002 Swing Right PPC pressure MPa PUMP
3 09001 Swing Left PPC pressure MPa PUMP
4 07300 Bucket Curl PPC pressure MPa PUMP
5 07301 Bucket Dump PPC pressure MPa PUMP

Applicable equip-
ment
2 07102 Travel Fwd LH PPC pressure MPa PUMP
3 07103 Travel Fwd RH PPC pressure MPa PUMP
4 07104 Travel Rev LH PPC pressure MPa PUMP
5 07105 Travel Rev RH PPC pressure MPa PUMP
6 04401 Hydr. oil temperature AaC PUMP
30-102 22 PC200, 200LC, 220, 220LC-8M0

Monitoring / Custom a You can select up to six monitoring codes

The machine monitor can monitor the condition of at the same time. Note, however, that six
the machine in real time by receiving signals from items may not be available depending on
various switches, sensors, and actuators installed how they are displayed on the screen.
to many parts of the machine and the information
from the controllers which control them.
The monitoring function allows you to select a
desired monitoring item.
Select “Monitoring” on the “Service Menu”
screen.
3. Getting machine monitor ready for monitoring

After selecting monitoring items, set the
machine monitor ready for monitoring by using
the function switch or numeral input switch.
a Execution by use of function switches:
Double-click [F6] or hold it down (for
approximately 2 seconds).
2. Selecting monitoring item a Execution using numeral input switch:
After the “Monitoring selection menu” screen [99999] and press [F6].
for monitoring item selection is displayed, a When monitoring only two items, for
select the item to be monitored by using the example, select them and enter them by
function switches or numeral input switches. using [F6]. If [F6] is pressed once more at
q [F1]: Moves to left item this time, the machine monitor is set ready
q [F2]: Moves to right item for monitoring.
q [F3]: Moves to lower item a If monitoring items are selected up to the
q [F4]: Moves to upper item limit number, the machine monitor is auto-
q [F5]: Deletes the entered numbers/ matically set ready for monitoring.
Returns the display to the service menu
q [F6]: Validates the selection
a In setting of the monitoring, each time
function switch [F2] is pressed, sequential
switching among [ENG] o [PUMP] o
[MON] o [ENG] takes place in this order.
(Pressing [F1] induces the sequential
switching in the reverse order.)
a Selection with function switches: Select an
applicable equipment using [F1] or [F2],
and select an item using [F3] or [F4] and
determine it using [F6].
a Selection with numeral input switch:
Select a desired item by entering the cor-
responding 5-digit code and then validate
it using [F6].
a If the color of the selection cursor changes
from yellow to red, selection of the item is
entered.
PC200, 200LC, 220, 220LC-8M0 30-102 23

4. Performing monitoring 6. Changing machine setting mode during moni-

After the “Monitoring” screen for execution is toring
displayed, perform the necessary operation of To change the setting of the working mode,
the machine and check the monitoring informa- travel speed, or auto-deceleration during moni-
tion. toring, operate the corresponding switch under
a Monitoring information is indicated by the current condition to turn on the applicable
value, ON/OFF, or special display. mode.
a The unit of display can be selected in SI a If the setting is changed during monitoring,
unit, metric unit, or inch unit with the the new setting is held even after the
Default function in the service mode. screen returns to the standard screen
after monitoring is finished.
5. Holding monitoring information

The monitoring information can be held and a If the working mode is changed to breaker
released with the function switches. mode [B], the screen to confirm the change of
q [F4]: Selects hold or its releasing the setting is displayed as in changing the
(If hold is selected, a diagonal line is dis- working mode on the standard screen.
played on the HOLD portion)
q [F5]: Returns the display to monitoring
selection menu screen
30-102 24 PC200, 200LC, 220, 220LC-8M0

7. Saving monitoring item

A function switch lets you save and delete the
selected item.
q [F1]: MEMORY
q [F2]: CLEAR
a When you saved a monitoring item,

selecting “Monitoring” again displays the
screen that confirms whether you want to
display the once saved item.
a When you saved an item, you can display
it as may times as you want until it is
deleted.
a If you save an item when another item is
saved already, the currently saved item is
overwritten by the last one.
a In addition to [F2], using [F6] in the follow-
ing screen allows deleting a saved moni-
toring item.
q KOMTRAX terminal screen
q With/Without Attachment screen
q Functional specification screen
q Air conditioner setting screen
PC200, 200LC, 220, 220LC-8M0 30-102 25

Monitoring items table
Unit (Default: SI) Equipment

Code No. Monitoring item (Displayed on screen) Remarks
SI Metric Imperial in charge
01002 Engine speed r/min rpm rpm ENG
04107 Coolant temperature °C °C °F ENG
03203 Battery power supply V V V ENG
2
36400 Rail pressure MPa kg/cm psi ENG
2
37400 Ambient pressure kPa kg/cm psi ENG
18500 Charge temperature °C °C °F ENG
Display in
absolute
value
36500 Charge pressure-A kPa kg/cm2 psi ENG
(including
ambient
pressure)
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Throttle position sensor volt V V V ENG
04105 Coolant temp sensor volt V V V ENG
37401 Ambient pressure sensor volt V V V ENG
18501 Charge temp sensor volt V V V ENG
36501 Charge pressure sensor volt V V V ENG
17500 Engine power mode - ENG
31701 Throttle Position % % % ENG
31706 Final throttle position % % % ENG
18600 Inject fueling command mg/st mg/st mg/st ENG
2
36200 Rail pressure command MPa kg/cm psi ENG
36300 Injection Timing command CA CA CA ENG
37300 Fuel rate (Note 1) l/h l/h gal/h ENG
WIF: Water
18800 Water in fuel ON•OFF ENG
In Fuel
20216 ECM build version — ENG
20217 Calibration data version — ENG
18900 ECM internal temp °C °C °F ENG
20400 ECM S/N — ENG
2
47000 KDPF outlet pressure kPa kg/cm psi KDPF
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
2
01100 F pump pressure MPa kg/cm psi PUMP
2
01101 R pump pressure MPa kg/cm psi PUMP
2
07400 Boom Raise PPC pressure MPa kg/cm psi PUMP
2
07500 Boom Lower PPC pressure MPa kg/cm psi PUMP
2
07200 Arm In PPC pressure MPa kg/cm psi PUMP
2
07600 Arm Out PPC pressure MPa kg/cm psi PUMP
07300 Bucket Curl PPC pressure MPa kg/cm2 psi PUMP
07301 Bucket Dump PPC pressure MPa kg/cm2 psi PUMP
09001 Swing Left PPC pressure MPa kg/cm2 psi PUMP
30-102 26 PC200, 200LC, 220, 220LC-8M0


09002 Swing Right PPC pressure MPa kg/cm2 psi PUMP
07102 Travel Fwd LH PPC pressure MPa kg/cm2 psi PUMP
2
07103 Travel Fwd RH PPC pressure MPa kg/cm psi PUMP
2
07104 Travel Rev LH PPC pressure MPa kg/cm psi PUMP
2
07105 Travel Rev RH PPC pressure MPa kg/cm psi PUMP
04401 Hydr. oil temperature °C °C °F PUMP
01300 PC-EPC sol current (F) mA mA mA PUMP
01302 PC-EPC sol current (R) mA mA mA PUMP
01500 LS-EPC sol current mA mA mA PUMP
08000 Merge-divide sol current main mA mA mA PUMP
08001 Merge-divide sol current LS mA mA mA PUMP
01700 Attachment sol current mA mA mA PUMP
03200 Battery voltage V V V PUMP
03701 Controller Output 2 — PUMP
04402 Hydr. temp. sensor volt V V V PUMP
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
2
15900 Boom Bottom Pressure MPa kg/cm psi PUMP
Swing ON•OFF PUMP
Travel ON•OFF PUMP
Boom Lower ON•OFF PUMP
01900 Pressure Switch 1 Boom Raise ON•OFF PUMP
Arm In (Curl) ON•OFF PUMP
Arm Out
ON•OFF PUMP
(Dump)
Bucket Curl ON•OFF PUMP
Bucket Dump ON•OFF PUMP
01901 Pressure Switch 2
Service ON•OFF PUMP
Travel steering ON•OFF PUMP
Travel Junc-
ON•OFF PUMP
tion
Swing holding
ON•OFF PUMP
02300 Solenoid valve 1 brake
Merge-divider ON•OFF PUMP
2-stage Relief ON•OFF PUMP
Travel Speed ON•OFF PUMP
Service Return ON•OFF PUMP
02301 Solenoid valve 2 Variable back
ON•OFF PUMP
press
Lever Sw. ON•OFF PUMP
Swing
ON•OFF PUMP
02200 Switch Input 1 Release SW.
Swing holding
ON•OFF PUMP
brake SW.
PC200, 200LC, 220, 220LC-8M0 30-102 27


Model select 1 ON•OFF PUMP
02201 Switch Input 2 Model select 4 ON•OFF PUMP
Overload
ON•OFF PUMP
Alarm
Key
02202 Switch Input 3 ON•OFF PUMP
switch(ACC)
02203 Switch Input 4 — PUMP
Window Limit
ON•OFF PUMP
SW.
02204 Switch Input 5
P Limit SW. ON•OFF PUMP
W Limit SW. ON•OFF PUMP
Pump controller Ass'y
20229 — PUMP
P/N
20403 Pump controller Serial No. — PUMP
20230 Pump controller prog. P/N — PUMP
20212 — — PUMP
04300 Battery charge volt V V V MON
04200 Fuel level sensor volt V V V MON
Key switch ON•OFF MON
Start ON•OFF MON
Preheating ON•OFF MON
04500 Monitor Input 1
Light ON•OFF MON
Radiator cool-
ON•OFF MON
ant level
Aircleaner ON•OFF MON
Eng. oil level ON•OFF MON
04501 Monitor Input 2
Battery charge
ON•OFF MON
volt
Swing brake
04502 Monitor Input 3 ON•OFF MON
Sw.
F1 ON•OFF MON
F2 ON•OFF MON
F3 ON•OFF MON
04503 Monitor Function Switches
F4 ON•OFF MON
F5 ON•OFF MON
F6 ON•OFF MON
SW1 ON•OFF MON
SW2 ON•OFF MON
Monitor 1st & 2nd Row SW3 ON•OFF MON
04504
Switches SW4 ON•OFF MON
SW5 ON•OFF MON
SW6 ON•OFF MON
30-102 28 PC200, 200LC, 220, 220LC-8M0


SW7 ON•OFF MON
SW8 ON•OFF MON
Monitor 3rd & 4th Row SW9 ON•OFF MON
04505
Switches SW10 ON•OFF MON
SW11 ON•OFF MON
SW12 ON•OFF MON
SW13 ON•OFF MON
04506 Monitor 5th Row Switches SW14 ON•OFF MON
SW15 ON•OFF MON
20227 Monitor Ass'y P/N — MON
20402 Monitor serial No. — MON
20228 Monitor prog. P/N — MON
20200 Monitor prog. version — MON
55300 Aircon compressor status ON•OFF MON
55000 Aircon outside temp. code — MON
55100 Aircon inside temp. code — MON
55200 Aircon mode data(mon) — MON
Aircon mode data(aircon
55201 — MON
ECU)
Only when
20260 KOMTRAX Ass’y P/N — MON KOMTRAX
is used
Only when
20418 KOMTRAX Serial No — MON KOMTRAX
is used
Only when
20261 KOMTRAX Prog. P/N — MON KOMTRAX
is used
a Listing order of monitoring items in table

The monitoring items are listed in the order of display on the Monitoring selection menu screen for mon-
itoring item selection.
a Unit
The display unit can be set to SI, meter, or inch as required (select a desired unit from “Unit” of
“Default”).
mg/st in the display unit is an abbreviation for milligram/stroke.
a Equipment in charge
ENG: The engine controller detects monitoring information.
PUMP: The pump controller detects monitoring information.
MON: The machine monitor detects monitoring information.
Note 1: Fuel Rate (Code No. : 37300) is theoretical fuel consumption ratio. (Since it is a theoretical value,
there is some differences between the actual fuel consumption ratio).
PC200, 200LC, 220, 220LC-8M0 30-102 29

Abnormality Record (Mechanical Systems) 3. Information displayed on abnormality record

The machine monitor classifies and logs the fail- screen
ures which occurred in the past or which are occur- On the “Mechanical Systems” abnormality
ring at present into the mechanical system record screen, the following information is dis-
abnormality, and electrical system abnormality. played.
To check the mechanical system abnormality (a): Occurrence order of abnormalities from
record, perform the following procedures. latest one/Total number of abnormalities in
a For the failure code list, see “40 Failure codes the log
table”. (b): Failure codes
(c): Detail of failure
1. Selecting the menu (d): Number of occurrences (displayable
Select “Abnormality Record” on the “Service range: 0 to 65,535 times)
Menu” Screen. (e): Service meter reading at first occurrence
(f): Service meter reading at last occurrence
played)
q [F2]: Moves to previous page (screen) (if
displayed)
q [F5]: Returns to the “Abnormality Record”
screen
a If no failure is logged, the message of “No
Error” is displayed.
a In the mechanical systems abnormality
record screen, up to 50 cases currently
stored are displayed.
a If the number of occurrences is one (first
occurrence), the service meter reading at
the first occurrence and that at the last
2. Selecting sub menu occurrence are the same.
After the “Abnormality Record” screen is dis- When the latest service meter reading is
played, select “Mechanical Systems” by using recovered, the value at the recovery time
the function switches or numeral input is displayed, thus the above readings may
switches. not be the same.
q [F3]: Moves to lower item a If [E] is displayed on the left of a failure
q [F4]: Moves to upper item code, the abnormality is still occurring or
q [F5]: Returns the display to the service restoration of it has not been confirmed.
menu screen a For all the failure codes that the machine
q [F6]: Validates the selection monitor can record, see the “Failure codes
a You may enter a 2-digit code by using the table”.
numeral input switches to select the item
of that code and enter it by using [F6].
4. Clearing abnormality record

A contents of the mechanical system abnor-
mality record cannot be cleared.
30-102 30 PC200, 200LC, 220, 220LC-8M0

Abnormality Record (Electrical Systems) 3. Information displayed on abnormality record

The machine monitor classifies and logs the fail- screen
ures which occurred in the past or which are occur- On the “Electrical Systems” abnormality record
ring at present into the mechanical system screen, the following information is displayed.
abnormality, and electrical system abnormality. (a): Occurrence order of abnormalities from
To check the electrical system abnormality record, latest one/Total number of abnormalities in
perform the following procedures. the log
a For the failure code list, see “40 Failure codes (b): Failure codes
table”. (c): Detail of failure
(d): Number of occurrences (displayable
1. Selecting the menu range: 0 to 65,535 times)
Select “Abnormality Record” on the “Service (e): Service meter reading at first occurrence
Menu” Screen. (f): Service meter reading at last occurrence
played)
q [F2]: Moves to previous page (screen) (if
displayed)
q [F3]: Moves to lower item
q [F4]: Moves to upper item
q [F5]: Returns to the “Abnormality Record”
screen
a If no failure is logged, the message of “No
Error” is displayed.
a In the electrical systems abnormality
record screen, up to 20 cases currently
stored are displayed.
If the number of the cases reaches 21, the
code that occurred most recently is dis-
2. Selecting sub menu played and the oldest code is deleted.
After the “Abnormality Record” screen is dis- a If the number of occurrences is one (first
played, select “Electrical Systems” by using occurrence), the service meter reading at
the function switches or numeral input the first occurrence and that at the last
switches. occurrence are the same.
q [F3]: Moves to lower item a If [E] is displayed on the left of a failure
q [F4]: Moves to upper item code, the abnormality is still occurring or
q [F5]: Returns the display to the service restoration of it has not been confirmed.
menu screen a For all the failure codes that the machine
q [F6]: Validates the selection monitor can record, see the “Failure codes
a You may enter a 2-digit code by using the table”.
PC200, 200LC, 220, 220LC-8M0 30-102 31

4. Clearing abnormality record 3) After the “Electrical Sys. Error Reset”

1) While the “Electrical Systems” abnormality screen is displayed, press the function
record screen is displayed, press the switches.
numeral input switches as follows. q [F5]: Returns to “Electrical Systems
q Operation of switches (While pressing Abnormality Record” screen (delete
[4], press the switches in order): mode)
[4] + [1] o [ 2 ] o [ 3 ] q [F6]: Performs deletion
a The following figure shows the screen
displayed when the items are cleared
one by one (which is a little different
from the screen displayed when all
the items are cleared together).
2) Check that the screen is set in the clear

mode, and then clear the items one by
one or together by using the function
switches.
a If the screen is set in the clear mode,
icon [CLEAR] is indicated above [F2]. 4) If the screen to notify completion of clear-
q [F2]: Deletes all items ing is displayed and then the “Electrical
q [F3]: Moves to lower item Systems” (clear mode) screen is dis-
q [F4]: Moves to upper item played, the clearing of the abnormality
q [F5]: Returns to the “Abnormality record is completed.
Record” screen a After a while, the screen returns to
q [F6]: Deletes items one by one the “Electrical Systems” screen of
a To clear items one by one: Select the abnormality record.
item to be cleared by using [F3] or
[F4] and press [F6].
a To clear all items together: Press
[F2], and all the items are cleared,
regardless of selection of the items.
a If [E] is displayed on the left of a fail-
ure code, the clearing operation is
accepted but the information is not
cleared.
30-102 32 PC200, 200LC, 220, 220LC-8M0

Maintenance record a The following items can be selected on

The machine monitor records the maintenance “Maintenance Record” screen.
information of the filters, oils, etc., which are dis-
played and checked by the following operations. 49 Cleaning and replacement of cleaner
When maintenance is performed, if the remaining
01 Engine Oil Change
time is reset in the operator mode, the number of
maintenance times is recorded in this record. 02 Engine Oil Filter Change
1. Selecting the menu 03 Fuel Main Filter Change
Select “Maintenance Record” on the “Service 41 Fuel Pre Filter Change
Menu” screen.
04 Hyd Oil Filter Change
05 H/Tank Breather Change
07 Damper Case Service
08 Final Drive Oil Change Interval
09 S/Machinery Oil Change
10 Hydraulic Oil Change
3. Items displayed on Maintenance Record

screen
The following information is displayed on the
screen.
(a): Maintenance items
(b): Replacement time elapsed up to present
2. Selecting maintenance item (c): Service meter reading (SMR) at previous
After the “Maintenance Record” screen is dis- replacement
played, select a maintenance item to be
checked by using the function switches or
numeral input switches.
q [F5]: Returns the display to the service
menu screen
a You may enter a 2-digit code by using the
of that code.
PC200, 200LC, 220, 220LC-8M0 30-102 33

Maintenance Mode Setting a The following items can be selected on the

The actuating condition of the maintenance “Maintenance Mode Setting” screen.
reminder function in the operation mode can be set
and changed by using this menu. 00 Maintenance Mode Change
q To enable or disable the function
49 Air Cleaner cleaning / Change Interval
q To change set replacement interval (by item)
q To initialize all set replacement intervals 01 Engine Oil Change Interval
02 Eng Oil Filter Change Interval
1. Selecting the menu 03 Fuel Main Filter Change Interval
Select “Maintenance Mode Setting” on the
41 Fuel Pre Filter Change Interval
“Service Menu” screen.
04 Hyd. oil filter change interval
05 H/tank breather change interval
07 Damper Case Service Interval
08 Final Drive Oil Change Interval
09 S/Machinery oil change interval
10 Hydraulic Oil Change Interval
99 All Default Value
3. Contents of “Maintenance Mode Change”

After selecting “Maintenance Mode Change”
and the screen is displayed, select the desired
setting with the function switches.
q ON: Functions of all maintenance items
2. Selecting sub menu
are set effective in operator mode
After the “Maintenance Mode Setting” screen is
q OFF: Maintenance reminder functions of
displayed, select an item to change the setting
all maintenance items are disabled in
with the function switches or the numeral input
operator mode
switches.
q [F5]: Cancels selection and return to the
“Maintenance Mode Change” screen
q [F6]: Enters selection and return to the
menu screen
a Even if ON/OFF of each item has been
q [F6]: Validates the selection
set, if the above setting is changed, it
a You may enter a 2-digit code by using the
overrides the individual setting.
30-102 34 PC200, 200LC, 220, 220LC-8M0

4. Contents of “Maintenance Notice Time Setting” 5. Setting of each maintenance item

After selecting “Maintenance Notice Time Set- After selecting each maintenance item to dis-
ting”, if the screen is displayed, select the play its setting screen, perform the setting by
desired setting with the function switches. using the function switches.
q ON: Function of each maintenance item
selected is enabled in the operator mode
q OFF: Function of each maintenance item
selected is disabled in the operator mode
q [F3]: Moves to lower set value
q [F4]: Moves to upper set value
q [F5]: Cancels selection and returns to the
q [F6]: Enters selection and returns to the
a Even if ON/OFF of each item has been
set, if the above setting is changed, it
overrides the individual setting.
q Default value: “Maintenance Notice Time”

set in machine monitor (Recommended by
the manufacturer and not changeable).
q Set value code: Maintenance interval that
can be freely set. Maintenance reminder
function works according to this set time in
operator mode (which is set in increments
of 10 hours).
q [F3]: Decreases set value
q [F4]: Increases set value
q [F5]: Cancels setting before enter and
return to the “Maintenance Mode Change”
screen.
q [F6]: Enters selection and returns to the 6. Contents of setting of set value of each mainte-
“Maintenance Mode Setting” screen nance item
After selecting the set value of each mainte-
nance item, if the screen is displayed, perform
the setting for the item with the function
switches.
PC200, 200LC, 220, 220LC-8M0 30-102 35

q Default value: “Maintenance Notice Time” 7. Function of All Default Value

set in machine monitor (Recommended by After selecting “99 All Default Value” and the
the manufacturer and not changeable). screen is displayed, set with the function
q Set value code: Maintenance interval that switches.
can be freely set. Maintenance reminder
function works according to this set time in
operator mode (which is set in increments
of 25 hours).
q [F5]: Cancels setting before enter and
returns to the “Maintenance Mode
Change” screen.
q [F6]: Enters setting and returns to “Main-
tenance Mode Change” screen
a After entering the selection with the [F6]
key, return to the “Maintenance Mode Set-
ting” screen by pressing [F5], and the set-
ting will be made.
q If this function is executed, the set values
a If the set value of an item of which mainte-
of all the maintenance items are initialized.
nance reminder function is set to “ON” is
q [F5]: Returns to “Maintenance Mode Set-
changed after one operating hours or
ting” screen
more from the setup, the change is recog-
q [F6]: Enters initialization
nized as a reset of the remaining time.
a A while after [F6] is pressed, the initializa-
tion completion screen is displayed. Then,
if the “Maintenance Mode Setting” screen
is displayed, initialization is completed.
30-102 36 PC200, 200LC, 220, 220LC-8M0

Phone Number Entry q If [F6] is pressed without inputting a digit,

The telephone number, which is displayed together there is not information of phone number.
with the “Occurred error list” in the operator mode, Accordingly, no phone number is dis-
can be input and changed according to the follow- played in the operator mode.
ing procedure.
If a telephone number is not input by using this
function, no telephone number is displayed in the
operator mode.

Select “Phone Number Entry” on the “Service
Menu” screen.
Default (Key-On Mode)

Use the menu of “Default” to check or change vari-
ous settings of the machine monitor and machine.
Use the sub menu of “Key-on Mode” to set the
working mode selected and displayed on the
machine monitor when the starting switch is turned
to ON position.
2. Registering and changing phone number 1. Selecting the menu

After the “Phone Number Entry” screen is dis- Select “Default” on the “Service Menu” screen.
played, register or change the phone number
q [F2]: Deletes all input No.
q [F3]: Moves to left position (if not blank)
q [F4]: Moves to right position (if not blank)
q [F5]: Resets input digit/Returns the dis-
play to the service menu screen
q [F6]: Confirms input
q Up to 14 digits can be input from the left.

Input nothing in the surplus positions.
q If one of the input digits is wrong, move to
that digit (its background changes to
orange) and overwrite it to correct.
PC200, 200LC, 220, 220LC-8M0 30-102 37

2. Selecting sub menu selected, turning on the starting switch

After the “Default” screen is displayed, select displays Power mode [P] when [ATT/P] is
“Key-on Mode” by using the function switches selected and displays economy mode [E]
or numeral input switches. when [ATT/E] is selected.
a Select this sub menu as in the case of a If the engine is stopped with the working
selecting a menu on the “Service Menu” mode set to breaker mode [B] in the oper-
screen. ator mode, Breaker Mode [B] is always
displayed when the starting switch is
turned to ON position, regardless of the
above setting.
3. Selecting mode
After the “Key-on Mode” screen is displayed,
select the mode to be set by using the function
switches. Default (Unit)
q Power mode: [P] is displayed when the Use the menu of “Default” to check or change vari-
starting switch is set to the ON position ous settings of the machine monitor and machine.
q Economy mode: [E] is displayed when the Use the sub menu of “Unit” to select the unit of the
starting switch is set to the ON position. data displayed for monitoring, etc.
q Lifting mode: [L] is displayed when the
starting switch is set to the ON position. 1. Selecting the menu
q Breaker mode: [B] is displayed when the Select “Default” on the “Service Menu” screen.
starting switch is set to the ON position.
q Attachment mode/P-mode: [ATT/P] is dis-
played when the starting switch is set to
the ON position.
q Attachment mode/E-mode: [ATT/E] is dis-
played when the starting switch is set to
the ON position.
q Mode at previous key-off: The mode
selected the last time is displayed when
the starting switch is set to the ON posi-
tion.
q [F5]: Cancels the selection and returns
the display to the default screen
q [F6]: Validates the selection and returns
a Factory default is “Mode at Previous Key-
off”.
a If “With Attachment” is not selected, selec-
tion of the Attachment /P-Mode and
Attachment/E-mode is disabled.
a If you change the setting to “Without
attachment” when Attachment/P-mode
[ATT/P] or Attachment/E-mode [ATT/E] is
30-102 38 PC200, 200LC, 220, 220LC-8M0

2. Selecting sub menu Default (With/Without Attachment)

After the “Default” screen is displayed, select Use the menu of “Default” to check or change vari-
“Unit” by using the function switches or ous settings of the machine monitor and machine.
numeral input switches. Use the sub menu of “With/Without Attachment” to
a Select this sub menu as in the case of configure attachment setting when the attachment
selecting a menu on the “Service Menu” is installed or removed.
screen.
Select “Default” on the “Service Menu” screen.
3. Selecting unit
After the “Unit” screen is displayed, select the
unit to be set by using the function switches. 2. Selecting sub menu
q [F3]: Moves to lower item After the “Default” screen is displayed, select
q [F4]: Moves to upper item “With/Without Attachment” by using the func-
q [F5]: Cancels the selection and returns tion switches or numeral input switches.
the display to the default screen a Select this sub menu as in the case of
q [F6]: Validates the selection and returns selecting a menu on the “Service Menu”
the display to the default screen screen.
a Factory default is “SI Unit”.
3. Selecting With/Without
After the “With/Without Attachment” screen is
displayed, select the setting by using the func-
tion switches.
q Without Attachment: When attachment is
not installed
q With Attachment: For machines with pro-
vision for attachment
q [F5]: Cancels the selection and returns
PC200, 200LC, 220, 220LC-8M0 30-102 39

q [F6]: Validates the selection and returns 2. Selecting sub menu

the display to the default screen After the “Default” screen is displayed, select
a When an attachment is installed, if this “Camera” using the function switch or numeral
setting is not configured correctly, the set- input switches.
ting of attachment in the operator mode a Select this sub menu as in the case of
cannot be performed. As a result, the selecting a menu on the “Service Menu”
attachment may not work normally or the screen.
hydraulic components may be damaged.
3. Selection of camera setting

Default (Camera) After the “Camera” screen for setting is dis-
Use the menu of “Default” to check or change vari- played, select the setting by using the function
ous settings of the machine monitor and machine. switches.
Use the sub menu of “Camera” to configure camera q Without Attachment: Camera is not
setting when the camera is installed or removed. selected.
q With Attachment: Image of connected
1. Selecting the menu camera is displayed in original position (as
Select “Default” on the “Service Menu” screen. in mirror, used for back monitor)
q [ ]: Image of connected camera is dis-
played in reverse position (as seen
directly, when used as front or side moni-
tor)
q [R]: Image of connected camera is dis-
played in original position (as in mirror,
used for back monitor)
q [F5]: Cancels the setting before validation
and returns the display to the Default
screen
q [F6]: Validates the selection made in each
step
a Camera 1 does not provide switching
between [ ] and [R] .
a After entering the setting of each column
by using [F6], return to the “Default”
screen by using [F5], and the setting is
effective.
a If a camera is connected but not config-
ured normally by using this function, the
icon of camera is not displayed above [F3]
in the operator mode. Accordingly, the
image of the camera cannot be seen.
30-102 40 PC200, 200LC, 220, 220LC-8M0

a If the camera is installed, check that the a The simultaneous display function of two
right and left portions of the displayed images becomes effective when camera 1
image are correct. and camera 2 are configured.
a If two or more cameras are connected, be

sure to configure them from camera 1 in
order.
PC200, 200LC, 220, 220LC-8M0 30-102 41

Diagnostic Tests (Cylinder Cut-out) 3. Selecting cylinder to be cut out

The operator can perform “Cylinder Cut-out mode” After the “Cylinder Cut-out” screen is dis-
operation with the machine monitor. played, select a cylinder to be Cut out by using
Cylinder Cut-out mode operation means to run the the function switches.
engine with 1 or more fuel injectors disabled electri- q [F1]: Moves to left item
cally to reduce the number of effective cylinders. q [F2]: Moves to right item
This operation is used to identify a cylinder that q [F4]: Selects hold or release
does not output power normally (combustion in it is (If hold is selected, a diagonal line is dis-
abnormal). played on the HOLD portion)
q [F5]: Returns to the testing screen
1. Selecting the menu q [F6]: Validates the selection
Select “Testing” on the “Service Menu” screen. a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes white,
the cylinder is cut out.
a If the machine monitor cuts out a cylinder
but the engine controller cannot cut out
that cylinder, the background (a) of the
cylinder No. becomes yellow.
a One or more cylinders can be cut-out.
a During the Cylinder Cut-out operation, the
auto-deceleration function can be
enabled. If the auto-deceleration is set to
ON, auto-deceleration monitor (b) is dis-
played.

After the “Testing” screen is displayed, select
“Cylinder Cut-out” by using the function
switches or numeral input switches.
a Select this sub menu as in the case of
selecting a menu on the “Service Menu”
screen.
4. Resetting cutout cylinder

When changing a cylinder to be cut out or
when Cylinder Cut-out operation is finished,
select a cut-out cylinder to be reset with the
function switches.
a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes blue,
the cylinder is reset.
a If the machine monitor resets a Cut-out
cylinder but the engine controller cannot
reset that Cut-out cylinder, the back-
ground (a) of the cylinder No. becomes
red.
30-102 42 PC200, 200LC, 220, 220LC-8M0

a The cut-out cylinder is not automatically reset Adjustment (Pump Absorption Torque (F))
even after returning to the operator mode. The machine monitor allows for adjustment of vari-
Accordingly, be sure to perform the resetting ous items related to the machine with the machine
operation after the Cylinder Cut-out operation monitor.
is finished. The sub menu of Pump Absorption Torque (F) is
used to finely adjust the absorption torque of the
5. Holding displayed data front hydraulic pump.
Each time [F4] is pressed during the Cylinder
Cut-out operation, the displayed data is newly 1. Selecting the menu
held (c) (the real-time data is kept displayed on Select “Adjustment” on the “Service Menu”
the left side). screen.
While the data is held, if [F4] is pressed, the
data holding function is reset.
a The holding function is available for a cyl-
inder, regardless of whether it is cut out or
not.

After the “Adjustment” screen is displayed,
select “Pump Absorption Torque (F)” using the
function switches or numeral input switches.
[Reference] selecting a menu on the “Service Menu”
q If a normally operating cylinder is dis- screen.
abled, the following phenomena occur.
1) The engine speed lowers.
2) The value (quantity) of final injection com-
mand increases.
q If the engine is running near the full speed,
however, the engine speed may not lower
for the reason of engine control.
q In this case, lower the engine speed by
using the fuel control dial and judge by
increase of the injection rate command.
PC200, 200LC, 220, 220LC-8M0 30-102 43

3. Selecting pump absorption torque setting Adjustment (Pump Absorption Torque (R))
After the “Pump Absorption Torque (F)” screen The machine monitor allows for adjustment of vari-
is displayed, select a set value in the right col- ous items related to the machine with the machine
umn by using the function switches. monitor.
q Set value code: For actual torque adjust- The sub menu of Pump Absorption Torque (R) is
ment value, see the table shown below. used to finely adjust the absorption torque of the
q [F3]: Increases set value rear hydraulic pump.
q [F6]: Confirms setting and returns to the 1. Selecting the menu
adjustment menu screen Select “Adjustment” on the “Service Menu”
a The 3-digit number in the left column do screen.
not change since it is the code of this func-
tion.

a Relationship between set value code and select “Pump Absorption Torque (R)” using the
torque offset value function switches or numeral input switches.
Set value selecting a menu on the “Service Menu”
Code Torque offset value screen.
code
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm}
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}
3. Selecting pump absorption torque setting

After the “Pump Absorption Torque (R)” screen
is displayed, select a set value in the right col-
umn by using the function switches.
q Set value code: For actual torque adjust-
ment value, see the table shown below.
q [F6]: Confirms setting and returns to the
adjustment menu screen
30-102 44 PC200, 200LC, 220, 220LC-8M0

a The 3-digit number in the left column do Adjustment (Low Speed)

not change since it is the code of this func- The machine monitor allows for adjustment of vari-
tion. ous items related to the machine with the machine
monitor.
The sub menu of Low Speed is used to finely adjust
the travel speed at Low setting.

Select “Adjustment” on the “Service Menu”
screen.
a Relationship between set value code and

torque offset value
Set value
Code Torque offset value
code
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm} After the “Adjustment” screen is displayed,
003 +9.8 Nm {+1 kgm} select “Low speed” using the function switches
022 004 0 Nm {0 kgm} or numeral input switches.
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm} screen.
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}
PC200, 200LC, 220, 220LC-8M0 30-102 45

3. Selecting low speed Adjustment (Attachment Flow Adjustment)

After the “Low Speed” screen for setting is dis- The machine monitor allows for adjustment of vari-
played, select a set value in the right column ous items related to the machine with the machine
by using the function switches. monitor.
q Set value code: For the actual travel The sub menu of “Attachment Flow Adjustment”
speed at Low setting, see the table shown allows for fine adjustment of the oil flow to the
below. attachment during combined operation.
q [F4]: Decreases set value 1. Selecting the menu
q [F6]: Confirms setting and returns to the Select “Adjustment” on the “Service Menu”
adjustment menu screen screen.
a The 3-digit number in the left column do
not change since it is the code of this func-
tion.

select “Attachment Flow Adjustment” by using
a Relationship between set value and travel the function switches or numeral input
speed at Low setting switches.
Set value selecting a menu on the “Service Menu”
Code Travel speed at Low screen.
code
000 3.0 km/h
001 2.8 km/h
020
002 3.2 km/h
003 3.4 km/h
3. Selecting set value code for oil flow distribution

After the screen of “Attachment Flow Adjust-
ment” is displayed, select a set value in the
right column by using the function switches.
q Set value code: For actual distribution of
oil flow, see the table shown below
q [F6]: Confirms setting and returns to the
adjustment menu screen
30-102 46 PC200, 200LC, 220, 220LC-8M0

a The 3-digit number in the left column do 2. Confirmation screen

not change since it is the code of this func- When "No Injection" screen is displayed, the
tion. monitor system checks whether the communi-
cation with the engine controller is available.
The following screen is displayed during the
communication.
a Relationship between set value and distribu-

tion of oil flow to attachment
After checking the communication, the mes-
Set value Distribution of flow sage to ask if no injection cranking should be
Code performed appears. Select the answer by
code to attachment
using the function switch.
000 50%
001 70% 3. Starting no injection cranking
044
002 100% If no injection cranking (fuel injection in no cyl-
003 40% inders) becomes effective, “No Injection.” is
displayed on the screen. Under this condition,
crank the engine by using the starting motor.
No Injection q While the screen is changing to the follow-
If the engine is operated after long storage of the ing screen, the screen of “Getting Ready.”
machine, it may be worn or damaged because of is displayed.
insufficient lubrication with oil. To prevent this, the q Limit the duration of cranking to 20 sec-
machine monitor allows for cranking the engine onds to protect the starting motor.
without injecting fuel to lubricate the engine before
starting it.
Set the no injection cranking while the engine is
stopped.

Select “No Injection” on the “Service Menu”
screen.
4. Finishing no injection cranking

After cranking is finished, turn the key to the
OFF position.
a Switching from the above screen to
another is not available.
5. Prohibiting no injection cranking

Even if the operator tries to perform the no
injection cranking while the engine is running,
PC200, 200LC, 220, 220LC-8M0 30-102 47

the message "The engine is operating. Please KOMTRAX Settings (Terminal Status)
turn the key off once." is displayed and the no The setting and operating status of KOMTRAX can
injection cranking does not become effective. be checked by using the menu of “KOMTRAX Set-
tings”.
“KOMTRAX Settings” is used to check the setting
condition of the KOMTRAX terminal.

Select “KOMTRAX Settings” on the “Service
Menu” screen.
And the “Confirmation screen” appears to dis-

able the attempted no injection cranking in the
following cases.
q Communication between the monitor and
engine controller is not normal.
q Engine was started before the message
“N o i nj e c t i o n c ra n k i n g i s a v a i l a ble ”
appears on the screen. 2. Selecting submenu
After the “KOMTRAX Settings” screen is dis-
played, select “Terminal Status” with the func-
tion switches or numeral input switches.
a Select this submenu as in the case of
screen.
30-102 48 PC200, 200LC, 220, 220LC-8M0

3. Contents displayed on the terminal status 2. Selecting sub menu

screen After the “KOMTRAX Settings” screen is dis-
On the “Terminal Status” screen, the following played, select “GPS & Communication Status”
information is displayed. with the function switches or numeral input
q Terminal Type: Model name of the switches.
KOMTRAX communication modem a Select this sub menu as in the case of
q KOMTRAX Communication : Status of selecting a menu on the “Service Menu”
sign-up test underway screen.
q GMT time: Greenwich Mean Time (add 9
hours to it for Japan time)
q [F5]: Returns the display to the KOMTRAX
settings screen
3. Contents displayed on GPS & Communication

Status screen
On the “GPS & Communication Status” screen,
the following items are displayed.
KOMTRAX Settings (GPS and Communication q Positioning: GPS positioning status
Status) q Communication: Communication environ-
The setting and operating status of KOMTRAX can ment and connection status of the com-
be checked by using the menu of “KOMTRAX Set- munication modem
tings”. q Number of message not yet sent: Number
“GPS & Communication Status” is used to check of mails that are saved on the machine
the positioning and communication status of the monitor and have not yet been transmitted
KOMTRAX terminal. q [F5]: Returns the display to the
KOMTRAX settings screen
Select “KOMTRAX Settings” on the “Service
Menu” screen.
PC200, 200LC, 220, 220LC-8M0 30-102 49

KOMTRAX Settings (Modem Information) 3. Modem status displayed

The setting and operating status of KOMTRAX can IP addresses (2 addresses) of the modem are
be checked by using the menu of “KOMTRAX Set- displayed.
tings”. q [F5]: Returns the display to the KOMTRAX
Modem status is used to check the IP address of settings screen
the KOMTRAX communication modem. a An IP address is a unique number
assigned to each modem that is used
1. Selecting the menu when communication between the modem
Select “KOMTRAX Settings” on the “Service and server is turned on.
Menu” screen.
Service Message
2. Selecting sub menu Special messages for the technician sent from the
After the “KOMTRAX Settings” screen is dis- KOMTRAX base station (a distributor, etc.) can be
played, select “Modem Status” with the func- checked by using this function.
tion switches or numeral input switches. If a received message has return mail setting, a
a Select this sub menu as in the case of return mail can be sent by using the numeral input
selecting a menu on the “Service Menu” switches.
screen.
1. Selecting menu
Select “Service Message” on the Service Menu
screen.
30-102 50 PC200, 200LC, 220, 220LC-8M0

2. Displaying message (read-only)

If a message is received, the content is dis-
played. If there is no message, “No message”
is displayed.
menu screen
a This message is different from that sent
for the operator with the machine monitor
in the operator mode.
a Since this message is special for the tech-
nician, the message monitor is not dis-
played when it is received with the
machine monitor in the operator mode.
3. Displaying message (message with return mail

function)
If a message provides the Numeric Input line
under the text, input a proper number by using
the numeral input switches and enter it by
using the function switch, and the information
is returned to the KOMTRAX base station.
q [F5]: Returns the display to the KOMTRAX
settings screen
q [F6]: Validates and returns the input value.
a This message is different from that sent
for the operator with the machine monitor
in the operator mode.
a Since this message is special for the tech-
nician, the message monitor is not dis-
played when it is received with the
machine monitor in the operator mode.
PC200, 200LC, 220, 220LC-8M0 30-102 51

SEN06128-00

© 2012 KOMATSU
All Rights Reserved
30-102 52
SEN06129-01
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

Handling voltage circuit of engine controller ................................................................................................... 2
Preparation work for troubleshooting of electrical system .............................................................................. 3
Procedure for testing diodes ........................................................................................................................... 8
Handling battery disconnect switch................................................................................................................. 9
Pm Clinic service .......................................................................................................................................... 10
PC200, 200LC, 220, 220LC-8M0 30-103 1

SEN06129-01 Handling voltage circuit of engine controller
Handling voltage circuit of engine

controller 1
1. Before disconnecting or connecting a connec-
tor between the engine controller and engine,
be sure to turn the starting switch OFF.
2. If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
30-103 2 PC200, 200LC, 220, 220LC-8M0

Preparation work for troubleshooting of electrical system SEN06129-01
Preparation work for

troubleshooting of electrical
system
a When carrying out troubleshooting of an elec-
tric circuit related to the machine monitor,
engine controller, pump contoller, or
KOMTRAX communication MODEM, expose
the related connectors according to the follow-
ing procedure.
a Disconnect and connect the connectors having
special locking mechanisms according to the
procedure shown below.
1. Machine monitor
1) Remove the screws (three pcs.) mounting
cover (1).
a One of the three screws is covered
with cap (2).
a Disconnect connector P31 of the sun-
light sensor and remove cover (1).
4) Insert or connect troubleshooting T-adapt-

ers in or to connectors CM01, CM02, and
CM04 on machine monitor (7).
2) Remove a mounting bolt and duct (6).

3) Insert a flat-head screwdriver in slit (3)
and pull it up around projection (4) to
remove cover (5).
PC200, 200LC, 220, 220LC-8M0 30-103 3

SEN06129-01 Preparation work for troubleshooting of electrical system
2. Engine controller 3. Pump controller

1) Open the engine hood. 1) Slide the operator's seat and seat stand to
a The engine controller is mounted on the forward end.
the engine (on the counterweight 2) Remove the 5 mounting bolts and cool &
side). hot box (6).
2) Insert or connect troubleshooting T-adapt- a While removing the cool & hot box,
ers in or to connectors CE01, CE02, and disconnect the drain hose.
CE03 of engine controller (5). 3) Remove the 2 mounting bolts, 1 fastener,
a Connectors CE01 and CE02 are fixed and magazine box (7).
with screws. When disconnecting 4) Remove the 3 mounting bolts and cover
them, loosen the screws. (8).
a When returning connectors CE01 and 5) Remove fuse box cover (9) and cover
CE02, tighten the screws to the spec- (10).
ified torque. a Since the underside of cover (10) is
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm} clamped, pull it up.
6) Remove the 7 mounting bolts and cover
(11).
7) Connect the troubleshooting adapters to

connectors C01 and C02 of pump control-
ler (12).
a Install the adapters to only the wiring
harness side.
30-103 4 PC200, 200LC, 220, 220LC-8M0

a The connectors of the pump control- 6) Connect troubleshooting T-adapters to

ler have a special locking mecha- connectors CK01 and CK02 of
nism. Disconnect them according to KOMTRAX communication module (15).
steps (a) to (c) and connect them
according to steps (d) to (f) as shown
below.
Disconnection: (a) Unlock – (b)
Slide lever – (c) Disconnect connec-
tor.
Connection: (d) Position connector –
(e) Slide lever – (f) Lock.
5. Atmospheric pressure sensor (AMBAIR

PRESSURE)
Engine Ne speed sensor (CRANK SENSOR)
Engine Bkup speed sensor (CAM SENSOR)
Engine oil pressure switch (OIL PRESSURE
SWITCH)
a Disconnection and connection of con-
nector
4. KOMTRAX communication module
The connectors of the atmospheric pres-
1) Slide the operator's seat and seat
sure sensor, engine Ne speed sensor,
stand to the forward end.
engine Bkup speed sensor, engine oil
2) Remove the five mounting bolts and cool
pressure switch have a special locking
& hot box (9).
mechanism. Disconnect them according
a While removing the cool and hot box,
to steps (a) to (c) and connect them
disconnect the drain hose.
according to steps (d) to (f) as shown
3) Remove the two mounting bolts, one fas-
below.
tener, and magazine box (10).
Disconnection: (a) Slide lever – (b)
4) Remove the three mounting bolts and
Unlock – (c) Disconnect connector.
cover (11).
Connection: (d) Connect connector – (e)
5) Remove the seven mounting bolts and
Lock – (f) Slide lever.
cover (14).
PC200, 200LC, 220, 220LC-8M0 30-103 5

SEN06129-01 Preparation work for troubleshooting of electrical system
a Removal and installation of sensor 7. Supply pump IMV solenoid (FUEL REGU-
A deep socket is necessary for removal LATOR)
and installation of the engine oil pressure a Disconnection and connection of con-
switch. See "Tools for testing, adjusting, nector
and troubleshooting". The connector of the supply pump IMV
solenoid has a special locking mecha-
6. Boost pressure and temperature sensor nism. Disconnect it according to steps (a)
(BOOST PRESS & IMT) to (b) and connect it according to steps (c)
a Disconnection and connection of con- to (d) as shown below.
nector Disconnection: (a) Unlock – (b) Discon-
The connector of the boost pressure and nect connector.
temperature sensor has a special locking Connection: (c) Connect connector – (d)
mechanism. Disconnect it according to Lock.
steps (a) to (b) and connect it according to
steps (c) to (d) as shown below.
Disconnection: (a) Unlock – (b) Discon-
nect connector.
Connection: (c) Connect connector – (d)
Lock.
8. Common rail pressure sensor (FUEL RAIL

PRESS)
a Disconnection and connection of con-
nector
The connector of the common rail pres-
sure sensor has a special locking mecha-
nism. Disconnect it according to steps (a)
a Removal and installation of sensor to (b) and connect it according to steps (c)
A torque wrench is necessary for removal to (d) as shown below.
and installation of the boost pressure and Disconnection: (a) Unlock – (b) Discon-
temperature sensor. See "Tools for test- nect connector.
ing, adjusting, and troubleshooting". Connection: (c) Connect connector – (d)
Lock.
30-103 6 PC200, 200LC, 220, 220LC-8M0

a Precautions for disconnecting connector 9. Engine coolant temperature sensor (COOL-

The direction of the lock of the connector ANT TEMP)
varies with the position of the sensor is a Disconnection and connection of con-
screwed in and the lock may face a direc- nector
tion in which it is difficult to unlock (on the The connector of the engine coolant tem-
underside or engine side). perature sensor has a special locking
In this case, pinch the lock in direction (a) mechanism. Disconnect it according to
with bent-nose nippers [1] (commercially steps (a) to (b) and connect it according to
available), and the lock is reset. steps (c) to (d) as shown below.
Since the lock clicks when it is unlocked, Disconnection: (a) Unlock – (b) Discon-
disconnect the connector after a click is nect connector.
heard. Connection: (c) Connect connector – (d)
Lock.
a Precautions for connecting connector

Take care not to connect the connector
reversely. a Removal and installation of sensor
Engage lock (e) on the wiring harness side A deep socket is necessary for removal
with triangular notch (f) on the sensor side and installation of the engine coolant tem-
(Do not engage lock (e) with square guide perature sensor. See "Tools for testing,
(g) on the opposite side of triangular notch adjusting, and troubleshooting".
(f)).
PC200, 200LC, 220, 220LC-8M0 30-103 7

SEN06129-01 Procedure for testing diodes
Procedure for testing diodes 1

a Test the assembled-type diode (8-pin) and the
single diode (2-pin) according to the following
procedure.
a The conductive directions of the assembled-
type diode are as follows.
2. When using analog circuit tester

1) Set the tester in the resistance range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
i) Apply the red (+) lead of the tester to
the anode (P) side of the diode and
a The conductive direction of the single diode is apply the black (–) lead to the cath-
indicated on the surface of the diode. ode (N) side.
ii) Apply the red (+) lead of the tester to
the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Judge the condition of the diode by the
movement of the pointer.
q The pointer does not move in i) but
moves in ii): The diode is normal (The
moving range (resistance) depends
on the type and selected range of the
tester, however).
q The pointer moves in both i) and ii):
The diode is defective (Internal short
circuit).
1. When using digital circuit tester q The pointer moves in neither of i) and
1) Set the tester in the diode range and read ii): The diode is defective (Internal
the indicated value. disconnection).
a When an ordinary circuit tester is
used, the voltage of the internal bat-
tery is indicated.
2) Apply the red (+) lead of the tester to the
anode (P) side of the diode and apply the
black (–) lead to the cathode (N) side and
check the indicated value.
3) Judge the condition of the diode by the
indicated value.
q The indicated value does not change:
The diode does not have continuity
(Defective).
q The indicated value changes:
The diode has continuity (Normal).
Note: In the case of a silicon diode, a
value in the range from 460 to 600 is indi-
cated.
30-103 8 PC200, 200LC, 220, 220LC-8M0

Handling battery disconnect switch SEN06129-01
Handling battery disconnect

switch 1
1. Pull out switch key (1) whenever you have
turned the battery disconnect switch OFF.
k A serious accident can result if some-
one turns switch key (1) ON inadver-
tently.
PC200, 200LC, 220, 220LC-8M0 30-103 9

SEN06129-01 Pm Clinic service
Pm Clinic service 1
Model name Serial No. Service meter
T PC200-8M0 T PC220-8M0
h
T PC200LC-8M0 T PC220LC-8M0
User's name Date of execution Inspector
/ /
Specifications
Main components Attachments Shoe width
Boom T Standard T ( ) T Breaker T 600 mm
Arm T Standard T ( ) T( ) T 700 mm
Bucket T Standard T ( ) T( ) T( )
Check of oil/coolant level
T Radiator coolant When necessary
T Machinery case oil
T Engine oil T Damper case oil
T( )
T Hydraulic oil T Final drive case oil
Ambient temperature Altitude
°C m
Operator's opinion
Result of visual inspection
Mechanical equipment system fault history Electrical equipment system fault history
989EKX times/1st time h/last h times/1st time h/last h
AA10NX times/1st time h/last h times/1st time h/last h
AB00KE times/1st time h/last h times/1st time h/last h
B@BAZG times/1st time h/last h times/1st time h/last h
B@BAZK times/1st time h/last h times/1st time h/last h
B@BCNS times/1st time h/last h times/1st time h/last h
B@BCZK times/1st time h/last h times/1st time h/last h
B@HANS times/1st time h/last h times/1st time h/last h
CA234 times/1st time h/last h times/1st time h/last h
Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge
30-103 10 PC200, 200LC, 220, 220LC-8M0

Pm Clinic service SEN06129-01
Items related to engine
PC200, 200LC, 220, 220LC-8M0 30-103 11

Items related to oil pressure
30-103 12 PC200, 200LC, 220, 220LC-8M0

Check sheet (PC200/200LC-8M0)

Model Serial No. Service meter User's name Date of execution Inspector
/ /
1. Engine
Condition for check
Standard Mea-
Good
Service limit
Bad
No. Check item Fuel Work- Auto- Operation of Unit value for new sured
Left knob value
control ing decel- work machine value
switch
dial mode eration equipment
1,990 to 1,990 to
1 Engine speed rpm
All levers in 2,130 2,130
MAX
Engine oil neutral MPa Min. 0.29 0.25
2
pressure {kg/cm2} {Min. 3.0} {2.5}
OFF
1,000 to 1,000 to
3 Engine speed rpm
MIN OFF
4 P
1,850 to 1,850 to
5 Engine speed rpm
2,050 2,050
ON Arm IN relief
Blow-by kPa Max. 0.98 1.96
6 MAX
pressure {mmH2O} {Max. 100} {200}
All levers in
7 Engine speed ON OFF rpm 950 to 1,050 950 to 1,050
neutral
2. Work equipment speed

Condition for check
Standard Mea-
Good
Service limit
Bad
No. Check item Fuel Work- Unit value for new sured
control ing Checking posture, etc. value
machine value
dial mode
1 Boom RAISE Work equipment extended fully sec 2.9 to 3.7 Max. 4.7
P
sec 3.1 to 3.9 Max. 4.5
2 Arm IN E sec 3.2 to 4.0 Max. 4.5
Boom top horizontal
L sec 6.0 to 7.4 Max. 7.7
3 Arm OUT sec 2.4 to 3.0 Max. 3.5
Boom top horizontal
4 Bucket CURL sec 2.1 to 2.7 Max. 3.1
Arm cylinder retracted fully
MAX Work equipment extended fully
5 Swing (5 turns) sec 21.7 to 26.7 Max. 30
Swing right and left
P STD 44.6 to 54.9 44.6 to 58.8

LO sec
LC 48.6 to 59.8 48.6 to 63.8
Oneside of track STD 33.7 to 41.3 33.7 to 45.3
Travel
6 pushed up and turned MI sec
(5 idle turns) LC 36.7 to 44.9 36.7 to 48.9
forward and backward
STD 25.2 to 27.8 25.2 to 29.8
HI sec
LC 27.3 to 30.3 27.3 to 32.3
PC200, 200LC, 220, 220LC-8M0 30-103 13

3. Hydraulic drift of work equipment

Condition for check
Standard Mea-
Good
Service limit
Bad
machine value
dial mode
Boom top horizontal
Hydraulic drift of mm/
1 Engine stopped Arm cylinder retracted fully Max. 600 Max. 900
bucket tip 15 min
Bucket loaded
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Condition for check
600K 600K 600K 600K 60K
Good
Bad
No. Checked part
Fuel Work-
Left knob Operation of work F pump R pump F pump R pump
control ing Control
switch equipment main main LS LS
dial mode
Self pressure A
1 All lever in neutral — — — —
reducing valve
OFF
Main relief valve B B B B
2 —
(Low pressure)
Arm out relief
Main relief valve C C C C
3 ON —
(Low pressure)
D1 D1 D2 D2
4 Unload valve All levers in neutral —
Right track driven idle E1 E2

— — —
Lever moved halfway
5 LS valve
Left track driven idle E1 E2
— — —
Lever moved halfway
MAX P
Swing lock F F
— — —
Swing motor Right swing relief
6
safety valve Swing lock F F
OFF — — —
Left swing relief
Right travel lock G
— — — —
Right forward relief
Main relief valve Right travel lock G
Travel motor — — — —
Right reverse relief
7 Safety valve
Travel junction Left travel lock G
— — — —
valve Left forward relief
Left travel lock G
— — — —
Left reverse relief
Testing oil pressure Unit Standard value for new machine Service limit value
A (Control circuit source pressure) 2.93 to 3.43 {30 to 35} 2.74 to 3.43 {28 to 35}
B (Work equipment relief pressure,
33.6 to 36.3 {343 to 370} 33.1 to 37.2 {338 to 380}
Standard value
low)
C (Work equipment relief pressure,
MPa 36.1 to 38.7 {368 to 395} 36.1 to 39.7 {368 to 405}
high)
{kg/cm2}
D (Unload pressure) D1 to D2 = 2.5 to 4.5 {26 to 46} D1 to D2 = 2.5 to 4.5 {26 to 46}
E (LS differential pressure) E1 to E2 = 1.7 to 1.9 {17 to 19} E1 to E2 = 1.7 to 1.9 {17 to 19}
F (Swing relief pressure) 28.8 to 31.8 {295 to 325} 28.4 to 32.3 {290 to 330}
G (Travel relief pressure) 36.7 to 39.7 {375 to 405} 36.8 to 40.2 {375 to 410}
30-103 14 PC200, 200LC, 220, 220LC-8M0

* Gauge changing work: Change hoses of gauges [3] and [4].

[1] [2] [3a] [4a] [5]
Condition for check
600K 600K 600K 600K 60K
Good
Bad
No. Check item
Fuel Work-
control ing Control
switch equipment main main servo servo
dial mode
H1 H1 H2 H2
8 Servo piston MAX P OFF Arm out relief —
Standard value
Checked oil pressure Unit Standard value for new machine Service limit value
H1 : H2 = 1 : 0.6
H (Servo control pressure) —
(Oil pressure ratio)
* Gauge changing work: Change gauges [3] and [4] to 60K and change hose conditions of [3], [4],
and [5].
[1] [2] [3b] [4b] [5a]
Condition for check
600K 600K 60K 60K 60K
Good
Bad
No. Check item
Fuel Work-
control ing LS-EPC
switch equipment main main (F) (R)
dial mode
J1 J1
MIN — — —
P
J2 J2
— — —
PC-EPC (F)
valve J3 J3
9 E All levers in neutral — — —
PC-EPC (R)
valve
J4 J4
L — — —
OFF J5 J5
B — — —
MAX
Travel speed: Lo K1
— — — —
travel lever in neutral
Travel speed: Mi K2
10 LS-EPC valve P Travel lever oper- — — — —
ated
Travel speed: Hi K3
Travel lever oper- — — — —
ated
J1
Approx. 2.9 {Approx. 30}
(PC-EPC valve output pressure 1)
J2
J3
Standard value

J4
Approx. 1.7 {Approx. 17.5}
(PC-EPC valve output pressure 4) MPa
J5 {kg/cm2}
K1
(LS-EPC valve output pressure 1)
K2
K3
0 {0}
PC200, 200LC, 220, 220LC-8M0 30-103 15

Check sheet (PC220/220LC-8M0)

Model Serial No. Service meter User's name Date of execution Inspector
/ /
1. Engine
Condition for check
Standard Mea-
Good
Service limit
Bad
No. Check item Fuel Work- Auto- Operation of Unit value for new sured
Left knob value
control ing decel- work machine value
switch
dial mode eration equipment
2,090 to 2,090 to
1 Engine speed rpm
MAX
2
OFF
1,000 to 1,000 to
3 Engine speed rpm
MIN OFF
4 P
1,850 to 1,850 to
5 Engine speed rpm
2,050 2,050
ON Arm IN relief
Blow-by kPa Max. 0.98 1.96
6 MAX
pressure {mmH2O} {Max. 100} {200}
All levers in
7 Engine speed ON OFF rpm 950 to 1,150 950 to 1,150
neutral
2. Work equipment speed

Condition for check
Standard Mea-
Good
Service limit
Bad
machine value
dial mode
1 Boom RAISE Work equipment extended fully sec 3.1 to 3.9 Max. 4.9
P
sec 3.7 to 4.5 Max. 4.8
2 Arm IN E sec 3.8 to 4.6 Max. 4.9
Boom top horizontal
L sec 7.0 to 8.6 Max. 9.0
3 Arm OUT sec 2.8 to 3.4 Max. 3.5
Boom top horizontal
4 Bucket CURL sec 2.4 to 3.0 Max. 3.3
Arm cylinder retracted fully
MAX Work equipment extended fully
5 Swing (5 turns) sec 22.9 to 28.5 Max. 31
Swing right and left
P STD 46.6 to 57.4 46.6 to 61.5

LO sec
LC 50.5 to 62.3 50.5 to 66.3
Oneside of track STD 35.6 to 43.6 35.6 to 47.6
Travel
6 pushed up and turned MI sec
(5 idle turns) LC 38.6 to 46.2 38.6 to 51.2
forward and backward
STD 26.7 to 29.5 26.7 to 31.5
HI sec
LC 28.9 to 31.9 28.9 to 33.9
30-103 16 PC200, 200LC, 220, 220LC-8M0

3. Hydraulic drift of work equipment

Condition for check
Standard Mea-
Good
Service limit
Bad
machine value
dial mode
Boom top horizontal
Hydraulic drift of mm/
1 Engine stopped Arm cylinder retracted fully Max. 600 Max. 900
bucket tip 15 min
Bucket loaded
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Condition for check
600K 600K 600K 600K 60K
Good
Bad
No. Checked part
Fuel Work-
control ing Control
switch equipment main main LS LS
dial mode
Self pressure A
1 All lever in neutral — — — —
reducing valve
OFF
Main relief valve B B B B
2 —
(Low pressure)
Arm out relief
Main relief valve C C C C
3 ON —
(Low pressure)
D1 D1 D2 D2
4 Unload valve All levers in neutral —
Right track driven idle E1 E2

— — —
Lever moved halfway
5 LS valve
Left track driven idle E1 E2
— — —
Lever moved halfway
MAX P
Swing lock F F
— — —
Swing motor Right swing relief
6
safety valve Swing lock F F
OFF — — —
Left swing relief
Right travel lock G
— — — —
Right forward relief
Main relief valve Right travel lock G
Travel motor — — — —
Right reverse relief
7 Safety valve
Travel junction Left travel lock G
— — — —
valve Left forward relief
Left travel lock G
— — — —
Left reverse relief
A (Control circuit source pressure) 2.93 to 3.43 {30 to 35} 2.75 to 3.43 {28 to 35}
B (Work equipment relief pressure,
33.6 to 36.3 {343 to 370} 33.1 to 37.2 {338 to 380}
Standard value
low)
C (Work equipment relief pressure,
MPa 36.1 to 38.8 {368 to 395} 36.1 to 39.7 {368 to 405}
high)
{kg/cm2}
D (Unload pressure) D1 to D2 = 2.5 to 4.5 {26 to 46} D1 to D2 = 2.5 to 4.5 {26 to 46}
E (LS differential pressure) E1 to E2 = 1.7 to 1.9 {17 to 19} E1 to E2 = 1.7 to 1.9 {17 to 19}
F (Swing relief pressure) 28.8 to 31.8 {295 to 325} 28.4 to 32.3 {290 to 330}
G (Travel relief pressure) 36.7 to 39.7 {375 to 405} 36.8 to 40.2 {375 to 410}
PC200, 200LC, 220, 220LC-8M0 30-103 17

* Gauge changing work: Change hoses of gauges [3] and [4].

[1] [2] [3a] [4a] [5]
Condition for check
600K 600K 600K 600K 60K
Good
Bad
No. Check item
Fuel Work-
control ing Control
switch equipment main main servo servo
dial mode
H1 H1 H2 H2
8 Servo piston MAX P OFF Arm out relief —
Standard value
Checked oil pressure Unit Standard value for new machine Service limit value
H1 : H2 = 1 : 0.6
H (Servo control pressure) —
(Oil pressure ratio)
* Gauge changing work: Change gauges [3] and [4] to 60K and change hose conditions of [3], [4],
and [5].
[1] [2] [3b] [4b] [5a]
Condition for check
600K 600K 60K 60K 60K
Good
Bad
No. Check item
Fuel Work-
control ing LS-EPC
switch equipment main main (F) (R)
dial mode
J1 J1
MIN — — —
P
J2 J2
— — —
PC-EPC (F)
valve J3 J3
9 E All levers in neutral — — —
PC-EPC (R)
valve
J4 J4
L — — —
OFF J5 J5
B — — —
MAX
Travel speed: Lo K1
— — — —
travel lever in neutral
Travel speed: Mi K2
10 LS-EPC valve P Travel lever oper- — — — —
ated
Travel speed: Hi K3
Travel lever oper- — — — —
ated
J1
J2
J3
Standard value

J4
(PC-EPC valve output pressure 4) MPa
J5 {kg/cm2}
K1
K2
K3
0 {0}
30-103 18 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 30-103 19

SEN06129-01

© 2014 KOMATSU
All Rights Reserved
30-103 20
SEN06131-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting 1
100 Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Fuse locations................................................................................................................................................. 9
PC200, 200LC, 220, 220LC-8M0 40-100 1

SEN06131-00 Failure codes table
Failure codes table 1

Failure Component Action Category Reference
Trouble (Displayed on screen)
code in charge level of record documents No.
Electrical
879AKA A/C Inner Sensor Open Circuit MON —
system
Electrical
879AKB A/C Inner Sensor Short Circuit MON —
system
Electrical
879BKA A/C Outer Sensor Open Circuit MON —
system
Electrical
879BKB A/C Outer Sensor Short Circuit MON —
system
Electrical
879CKA Ventilating Sensor Open Circuit MON —
system See section 80,
Electrical Appendix
879CKB Ventilating Sensor Short Circuit MON —
system
Electrical
879DKZ Sunlight Sensor Open Or Short Circuit MON —
system
Electrical
879EMC Ventilating Damper Abnormality MON L01
system
Electrical
879FMC Air Mix Damper Abnormality MON L01
system
Electrical
879GKX Refrigerant Abnormality MON L01
system
Electrical
989L00 Engine Controller Lock Caution1 MON —
system
Electrical
989M00 Engine Controller Lock Caution2 MON —
system Troubleshooting
Electrical by failure code,
989N00 Engine Controller Lock Caution3 MON —
system Part 1
Mechanical SEN06133-**
AA10NX Air Cleaner Clogging MON L01
system
Mechanical
AB00KE Charge Voltage Low MON L03
system
Mechanical
B@BAZG Eng Oil Press Low ENG L03
system
Mechanical
B@BAZK Engine Oil Level Low MON L01
system
Mechanical
B@BCNS Eng Water Overheat ENG L02
system
Mechanical
B@BCZK Radiator Coolant Level Low MON L01
system
Mechanical
B@HANS Hyd Oil Overheat PUMP L02
system
Electrical
CA111 ECM Critical Internal Failure ENG L04
system
Electrical
CA115 Eng Ne and Bkup Speed Sens Error ENG L04
system
Electrical
CA122 Chg Air Press Sensor High Error ENG L03
system
Electrical
CA123 Chg Air Press Sensor Low Error ENG L03
system
Electrical
CA131 Throttle Sensor High Error ENG L03
system
40-100 2 PC200, 200LC, 220, 220LC-8M0

Failure codes table SEN06131-00

Electrical
CA132 Throttle Sensor Low Error ENG L03
system
Electrical
CA144 Coolant Temp Sens High Error ENG L01
system
Electrical
CA145 Coolant Temp Sens Low Error ENG L01
system
Electrical
CA153 Chg Air Temp Sensor High Error ENG L03
system
Electrical
CA154 Chg Air Temp Sensor Low Error ENG L03
system
Electrical
CA155 Chg Air Temp High Speed Derate ENG L03
system
Electrical Troubleshooting
CA187 Sens Supply 2 Volt Low Error ENG L03
system by failure code,
Electrical Part 1
CA221 Ambient Press Sens High Error ENG L03 SEN06133-**
system
Electrical
CA222 Ambient Press Sens Low Error ENG L03
system
Electrical
CA227 Sens 2 Supply Volt High Error ENG L03
system
Electrical
CA234 Eng Overspeed ENG —
system
Electrical
CA238 Ne Speed Sens Supply Volt Error ENG L01
system
Electrical
CA271 IMV/PCV1 Short Error ENG L03
system
Electrical
CA272 IMV/PCV1 Open Error ENG L03
system
Electrical
CA322 Inj #1(L#1) Open/Short Error ENG L03
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system Part 2
Electrical SEN06134-**
CA342 Calibration Code Incompatibility ENG L04
system
Electrical
CA351 Injectors Drive Circuit Error ENG L03
system
Electrical
CA352 Sens Supply 1 Volt Low Error ENG L03
system
Electrical
CA386 Sens Supply 1 Volt High Error ENG L03
system
Electrical
CA428 Water in Fuel Sensor High Error ENG L01
system
PC200, 200LC, 220, 220LC-8M0 40-100 3


Electrical
CA429 Water in Fuel Sensor Low Error ENG L01
system
Electrical
CA435 Eng Oil Press Sw Error ENG L01
system
Electrical
CA441 Battery Voltage Low Error ENG L04
system
Electrical
CA442 Battery Voltage High Error ENG L04
system
Electrical
CA449 Rail Press Very High Error ENG L03
system
Electrical
CA451 Rail Press Sensor High Error ENG L03
system
Electrical
CA452 Rail Press Sensor Low Error ENG L03
system
Electrical
CA488 Chg Air Temp High Torque Derate ENG L03
system
Electrical
CA553 Rail Press High Error ENG L01
system
CA559 Rail Press Low Error ENG L01
Electrical Part 2
CA689 Eng Ne Speed Sensor Error ENG L01 SEN06134-**
system
Electrical
CA731 Eng Bkup Speed Sens Phase Error ENG L01
system
Electrical
CA757 All Continuous Data Lost Error ENG L04
system
Electrical
CA778 Eng Bkup Speed Sensor Error ENG L01
system
Electrical
CA2185 Throt Sens Sup Volt High Error ENG L03
system
Electrical
CA2186 Throt Sens Sup Volt Low Error ENG L03
system
Electrical
CA2249 Rail Press Very Low Error ENG L03
system
Electrical
CA2311 lMV Solenoid Error ENG L03
system
Electrical
CA2555 Grid Htr Relay Open Circuit Error ENG L01
system
Electrical
CA2556 Grid Htr Relay Short Circuit Error ENG L01
system
40-100 4 PC200, 200LC, 220, 220LC-8M0


Electrical
D110KB Battery Relay Drive Short Circuit PUMP L01
system
Electrical
D19JKZ Personal Code Relay Abnormality MON L03
system
Electrical
D811MC KOMTRAX Error KOMTRAX —
system
Electrical
D862KA GPS Antenna Open Circuit KOMTRAX —
system
Electrical
D8AQKR CAN2 Discon (KOMTRAX) MON —
system
Electrical
DA22KK Pump Solenoid Power Low Error PUMP L03
system
Electrical
DA25KP 5V Sensor 1 Power Abnormality PUMP —
system
Electrical
DA26KP 5V Sensor 2 Power Abnormality PUMP —
system
Electrical
DA29KQ Model Selection Abnormality PUMP L01
system
Electrical
DA2QKR CAN2 Discon (Pump Con) MON L03
system
Electrical
DAF0MB Monitor ROM Abnormality MON —
DAF0MC Monitor Error MON —
system Part 3
DAF8KB Camera Power Supply Short Circuit MON L03
system
Electrical
DAF9KQ Model Selection Abnormality MON L03
system
Electrical
DAFGMC GPS Module Error KOMTRAX —
system
Electrical
DAFQKR CAN2 Discon (Monitor) KOMTRAX —
system
Electrical
DAZ9KQ A/C Model Selection Abnormality MON —
system
Electrical
DAZQKR CAN2 Discon (Aircon ECU) MON L01
system
Electrical
DB2QKR CAN2 Discon (Engine Con) MON L03
system
Electrical
DGH2KB Hyd Oil Sensor Short Circuit PUMP L01
system
Electrical
DHA4KA Air Cleaner Clog Sensor Open Circuit MON L01
system
Electrical
DHPAMA F Pump Press Sensor Abnormality PUMP L01
system
Electrical
DHPBMA R Pump Press Sensor Abnormality PUMP L01
system
PC200, 200LC, 220, 220LC-8M0 40-100 5


Electrical
DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP L01
system
Bucket CURL PPC Press Sensor Electrical
DHS4MA PUMP L01
Abnormality system
Electrical
DHS8MA Boom Raise PPC Press Sensor Abnormality PUMP L01
system
Boom Lower PPC Press Sensor Electrical
DHS9MA PUMP L01
Abnormality system
Electrical
DHSAMA Swing RH PPC Press Sensor Abnormality PUMP L01
system
Electrical
DHSBMA Swing LH PPC Press Sensor Abnormality PUMP L01
system
Electrical
DHSCMA Arm Dump PPC Press Sensor Abnormality PUMP L01
system
Bucket Dump PPC Press Sensor Electrical
DHSDMA PUMP L01
Abnormality system
Electrical
DHSFMA Travel FW L PPC Press Sensor Abnormality PUMP L01
system
Electrical
DHSGMA Travel FW R PPC Press Sensor Abnormality PUMP L01
system
DHSHMA Travel BW L PPC Press Sensor Abnormality PUMP L01
Travel BW R PPC Press Sensor Electrical Part 4
DHSJMA PUMP L01 SEN06136-**
Abnormality system
Electrical
DHX1MA Overload Sensor Abnormality PUMP L04
system
Electrical
DR21KX Camera 2 Picture Rev. Drive Abnormality MON L01
system
Electrical
DR31KX Camera 3 Picture Rev. Drive Abnormality MON L01
system
Electrical
DV20KB Travel Alarm Short Circuit PUMP L01
system
Electrical
DW43KA Travel Speed Sol Open Circuit PUMP L01
system
Electrical
DW43KB Travel Speed Sol Short Circuit PUMP L01
system
Electrical
DW45KA Swing brake Sol. Valve Open Circuit PUMP L01
system
Electrical
DW45KB Swing Brake Sol Short Circuit PUMP L01
system
Electrical
DW91KA Travel Neutral Sol Open Circuit PUMP L01
system
Electrical
DW91KB Travel Neutral Sol Short Circuit PUMP L01
system
40-100 6 PC200, 200LC, 220, 220LC-8M0


Electrical
DWA2KA Attachment Sol Open Circuit PUMP L03
system
Electrical
DWA2KB Attachment Sol Short Circuit PUMP L03
system
Electrical
DWK0KA 2-stage Relief Sol Open Circuit PUMP L01
system
Electrical
DWK0KB 2-stage Relief Sol Short Circuit PUMP L01
system
Electrical
DWK2KA Variable Back Press Sol Open Circuit PUMP L01
system
Electrical
DWK2KB Variable Back Press Sol Short Circuit PUMP L01
system
Electrical
DXA8KA PC-EPC (F) Sol Open Circuit PUMP L03
system
Electrical
DXA8KB PC-EPC (F) Sol Short Circuit PUMP L03
system
Electrical
DXA9KA PC-EPC (R) Sol Open Circuit PUMP L03
system
Electrical
DXA9KB PC-EPC (R) Sol Short Circuit PUMP L03
system
Electrical
DXE0KA LS-EPC Sol Open Circuit PUMP L01
DXE0KB LS-EPC Sol Short Circuit PUMP L01
system Part 5
DXE4KA Attachment Flow EPC Open Circuit PUMP —
system
Electrical
DXE4KB Attachment Flow EPC Short Circuit PUMP —
system
Electrical
DXE5KA Merge-divide Main Sol Open Circuit PUMP L01
system
Electrical
DXE5KB Merge-divide Main Sol Short Circuit PUMP L01
system
Electrical
DXE6KA Merge-divide LS Sol Open Circuit PUMP L01
system
Electrical
DXE6KB Merge-divide LS Sol Short Circuit PUMP L01
system
Electrical
DY20KA Wiper Working Abnormality PUMP —
system
Electrical
DY20MA Wiper Parking Abnormality PUMP —
system
Electrical
DY2CKB Washer Drive Short Circuit PUMP —
system
Electrical
DY2DKB Wiper Drive (For) Short PUMP —
system
Electrical
DY2EKB Wiper Drive (Rev) Short PUMP —
system
PC200, 200LC, 220, 220LC-8M0 40-100 7

a In this table, failure codes are arranged in the order of characters from numeric to alphabetic character.
a A component in charge means a controller or the machine monitor that is in charge of the system check.
MON: Machine monitor
ENG: Engine controller
PUMP: Pump controller
KOMTRAX: KOMTRAX terminal
a The failure codes that do not have numbers in the action level columns are not displayed on the stan-
dard screen even when a failure related to them occurs. They are simply recorded in the abnormality
record (electrical system and mechanical system) of the service menu.
a The "Category of record" shows the abnormality record into which the failure is classified, the electrical
system or mechanical system, when it is recorded in the abnormality record of the service menu.
For details, see "Troubleshooting by failure code (Display of code)".
40-100 8 PC200, 200LC, 220, 220LC-8M0

Fuse locations SEN06131-00
Fuse locations 1
Connection table of fuse box
a This connection table shows the devices to which power supply from each fuse of the fuse box supplies
power (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power while the starting switch is in the
OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
Type of
Fuse
power Fusible link Fuse No. Destination of power
capacity
supply
Lamp relay, rear lamp relay, cab lamp relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve
1 10 A [When pump drive switch is operated in emergency]
Swing holding brake solenoid valve
[When swing holding brake release switch is operated]
2 30 A Pump controller (Solenoid power supply)
Switch power F04
supply (60 A) PPC oil pressure lock solenoid valve
3 10 A Starting motor cut-out relay (PPC lock)
Starting motor cut-out relay (Personal code)
Cigarette lighter
4 10 A
Windshield washer motor
5 10 A Horn relay, horn
6 10 A Electrical intake air heater relay
7 10 A Rotary lamp
Switch power F04 8 20 A Right headlamp, working lamp (boom), working lamp (rear)
supply (60 A) Radio
9 10 A
Left knob switch (pump controller input)
10 5A Air conditioner controller supply
Air conditioner unit
11 20 A
Air conditioner compressor electromagnetic clutch
Switch power F04 12 10 A (Spare)
supply (60 A) 13 10 A Headlamp
14 10 A Optional power supply (1)
15 10 A Optional power supply (2)
Radio (backup power supply)
16 10 A
Room lamp
Starting switch
Constant F05
17 20 A Machine monitor
power supply (30 A)
Pump controller
18 5A Air conditioner controller backup
19 30 A Engine controller
Switch power Starting switch
20 5A Engine controller (ACC signal)
supply ACC
PC200, 200LC, 220, 220LC-8M0 40-100 9

SEN06131-00 Fuse locations
Locations of fusible links
Location of fuse box and fuse Nos.
40-100 10 PC200, 200LC, 220, 220LC-8M0

Fuse locations SEN06131-00
PC200, 200LC, 220, 220LC-8M0 40-100 11

SEN06131-00

© 2012 KOMATSU
All Rights Reserved
40-100 12
SEN06132-02
SEN05984-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
200 General Information on troubleshooting
Symptom and troubleshooting numbers ..................................................................................................... 2

Sequence of events in troubleshooting....................................................................................................... 4
Checks before troubleshooting ................................................................................................................... 6
Classification and procedures for troubleshooting ...................................................................................... 8
Symptom and troubleshooting numbers ..................................................................................................... 10
Information in troubleshooting table............................................................................................................ 12
Connector/electrical wiring connection table............................................................................................... 14
Connector arrangement diagram ................................................................................................................ 44
Connection table for connector pin numbers .............................................................................................. 50
T- branch box and T- branch adapter table ................................................................................................. 86
Troubleshooting method for open circuit in wiring harness of pressure sensor system.............................. 89
PC200, 200LC, 220, 220LC-8M0 40-200 1

SEN06132-02 Symptom and troubleshooting numbers
Symptom and troubleshooting numbers

(Rev. 2011/09)
k Park the machine on a level surface, lower the work equipment to the ground so that it is stable,
and stop the engine.
k When performing the operation with two or more service technicians, 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, hot water 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 from the negative (–) terminal of the bat-
tery first.
k When removing the plug or cap from a component which is under pressure of oil, water, or air, al-
ways release the internal pressure first. When installing measuring equipment, be sure to connect
it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to perform repairs swiftly, and to pre-
vent reoccurrence of the failure. When performing 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 possible causes of the failure that would produce the reported symp-
toms.
1. When performing troubleshooting, do not hurry 2) Perform checks on items listed in "Checks
to disassemble the components. before starting".
If components are disassembled immediately af- 3) Perform checks on other checking items.
ter any failure occurs: 4) Check other maintenance matters which can
q Parts that have no connection with the failure be checked appearance and are considered
or other unnecessary parts will be disassem- to be necessary.
bled.
q It will become impossible to find the cause of 4. Checking failure symptom
the failure. Check the extent of the failure by yourself, and
It will also cause a waste of manhours, parts, or judge whether it is a real failure or a problem with
oil or grease, and at the same time, will also lose the method of operation, etc.
the confidence of the user or operator. a When operating the machine to reproduce
For this reason, when performing troubleshoot- the failure symptom, do not perform any in-
ing, it is necessary to perform thorough prior inspection or measurement that may make the
vestigation and to perform troubleshooting in problem worse.
accordance with the fixed procedure.
5. Troubleshooting
2. Points to ask the user or operator Use the results of the investigation and inspec-
1) Have any other problems occurred apart tion in Items 2 to 4 to narrow down the probable
from the problem that has been reported? causes of the failure, then use the trouble-
2) Was there anything strange about the ma- shooting flowchart to locate the failure exactly.
chine before the failure occurred? a The basic procedure for troubleshooting is as
3) Did the failure occur suddenly, or were there follows.
problems with the machine condition before 1] Start from the simple points.
the failure? 2] Start from the most likely points.
4) Under what conditions did the failure occur? 3] Investigate other related parts or informa-
5) Had any repairs been performed before the tion.
failure? When were these repairs per-
formed? 6. Measures to remove root cause of failure
6) Has the same kind of failure occurred be- Even if the immediate failure is removed, the
fore? same failure may occur again, unless the root
cause of the failure is repaired. To prevent this,
3. Check before troubleshooting always investigate why the cause of the failure
1) Check the machine for other symptoms of occurred. Then, remove the root cause.
failure.
40-200 2 PC200, 200LC, 220, 220LC-8M0

Symptom and troubleshooting numbers SEN06132-02
PC200, 200LC, 220, 220LC-8M0 40-200 3

SEN06132-02 Sequence of events in troubleshooting
Sequence of events in troubleshooting

(Rev. 2011. 7)
40-200 4 PC200, 200LC, 220, 220LC-8M0

Sequence of events in troubleshooting SEN06132-02
PC200, 200LC, 220, 220LC-8M0 40-200 5

SEN06132-02 Checks before troubleshooting
Checks before troubleshooting

No. Item Criterion Remedy
1 Check for unusual sounds and smells – Repair
2 Check for dirt around engine – Remove
3 Check for water leakage around engine – Repair
4 Check for oil leakage around engine – Repair

a: Engine, lubricating oil and coolant
5 Check for leakage from fuel line – Repair
6 Check of radiator for clogging – Remove
7 Check of level and type of fuel – Refilling
8 Check for foreign matter in fuel – Clean and drain
9 Check of fuel pre-filter – Replace
10 Check of fuel main filter – Replace
Between H
11 Check of level (in oil pan) and type of engine oil Refilling
–L
Between H
12 Check of coolant level (in sub tank) Refill with coolant
–L
Dust indi-
cator does
13 Check of air cleaner for clogging Clean or replace
not show
red piston.
1 Check for unusual sounds and smells – Repair
2 Check for oil leakage – Repair

b: Hydraulic and mechanical equipment
Between H
3 Check of hydraulic oil level Refilling
–L
4 Check of hydraulic oil strainer – Clean and drain
5 Check of hydraulic oil filter – Replace
Between H
6 Check of swing machinery case oil level Refilling
–L
Between H
7 Check of damper case oil level Refilling
–L
8 Check of final drive case oil level – Refilling
9 Air bleeding – Air bleeding
40-200 6 PC200, 200LC, 220, 220LC-8M0

Checks before troubleshooting SEN06132-02
No. Item Criterion Remedy
1 Check of battery terminal for looseness and corrosion – Retighten or replace
2 Check of alternator terminal for looseness and corrosion – Retighten or replace
3 Check of starting motor terminal for looseness and corrosion – Retighten or replace
4 Check of battery voltage (with engine stopped) 20 to 30 V Charge or replace
Between H
5 Check of battery electrolyte level Add or replace
and L
6 Check of wiring harness for discoloration, burnt areas and cover peeling – Repair or replace
7 Check for removal of wiring harness clamp and sagging of wiring harness – Repair
c: Electrical equipment
8 Check of grounding – Repair
9 Check for loose connector and damaged lock – Repair or replace
10 Check of connector pin for corrosion, bends and deformation – Repair or replace
11 Check for water and foreign matter in connector – Dry, clean or replace
12 Check of wiring harness for open and short circuit – Repair or replace
13 Check of fuse for blowing out and corrosion – Replace

After sev-
eral min-
utes
14 Check of alternator voltage (when engine speed is medium or higher) Replace
operation:
27.5 – 29.5
V
Check of battery relay operation sound (when starting switch is turned to
15 – Replace
ON or OFF position)
16 Check and cleaning of rear view camera – Clean or repair

e: Interior parts d: Exterior parts
1 Check of undercarriage – Repair
2 Check of handrails and steps – Repair
3 Check of mirrors – Clean or repair
1 Check of gauges and monitors – Clean or replace
2 Check of seat belt – Repair
PC200, 200LC, 220, 220LC-8M0 40-200 7

SEN06132-02 Classification and procedures for troubleshooting
Classification and procedures for troubleshooting
Classification of troubleshooting
Mode Content
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon which appears to be connected with machine trouble occurs on 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 standard screen of the machine monitor, perform
the troubleshooting for the corresponding "Display of code" according to the displayed failure code.
a If multiple failures occur simultaneously, all the failure codes are displayed repeatedly in order. Note
down all the codes.
2. Procedure for troubleshooting when a user code and a failure code are not displayed on machine
monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1].)
1) If a code is recorded, carry out troubleshooting for the "Display of code" corresponding to the recorded
code.
a If an electrical system failure code is recorded, delete all the codes once, follow the procedure to
reproduce the failure code, and then see if the failure is still detected. (See [*2].)
a A failure code of the mechanical system cannot be deleted.
2) If no failure code is found in the abnormality record, a trouble 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 phenomenon which appears to be connected with machine trouble again and
select the same phenomenon from the list on the next page, and then perform troubleshooting corre-
sponding to that phenomenon in the "E-mode", "H-mode", or "S-mode" troubleshooting.
3. Action to take after failure is eliminated

Clear all the failure codes in the electrical system abnormality record, referring to the next page.
40-200 8 PC200, 200LC, 220, 220LC-8M0

Classification and procedures for troubleshooting SEN06132-02
[*1], [*2] 5. Press the [F3] switch (R) on the panel switch to
1. While pressing numerical key [4] on the panel see if the next failure code is displayed and note
switch on the standard screen, press [1], [2] and down all of the failure codes.
[3] in order. a A failure code of the mechanical system can-
not be deleted.
6. Press [F5] switch (RETURN) on the panel switch
to return to the "Abnormality Record" screen.
7. Enter the "Electrical System Abnormality
Record" screen similarly to steps 2 and 3.
2. On the service menu screen, press switch [F3]

(R) twice in the panel switch section, and select
"03 Abnormality Record".
3. Press [F6] switch ( ) on the panel switch to
enter the selection and go to "Abnormality 8. Press the [F3] switch (R) on the panel switch to
Record" screen. see if the next failure code is displayed and note
down all of the failure codes.
a "E" on the left of a failure code indicates that
the failure is "active" (the failure remains or
restoration to normal has not been con-
firmed). A failure code having no "E" on its
left is a "non-active" one. Since it disappears
at the following clear step, be sure to note it
down.
9. While pressing numerical key [4] on the panel
switch, press [1], [2] and [3] in this order to enter
the "Clear mode". (Same as 1)
10. Press [F2] switch(CLEAR) on the panel switch.
4. Press [F6] switch ( ) on the panel switch to

enter the selection and go to "Mechanical
System Abnormality Record" screen.
11. Press [F6] switch ( ) on the panel switch to clear

all the failure codes.
to return to "Electrical System Abnormality
Record" screen. See if any failure code is still
displayed and note down the displayed ones.
to return to the "Abnormality Record" screen.
PC200, 200LC, 220, 220LC-8M0 40-200 9

SEN06132-02 Symptom and troubleshooting numbers
Symptom and troubleshooting numbers

Symptom and troubleshooting number
Troubleshooting
No. Symptom of failure Display
E-mode H-mode S-mode
of code
User code and failure code
1 User code and failure code are displayed on machine monitor
The failure code is displayed on the mechanical system abnormality Follow the troubleshooting procedure for
2
record screen the failure code.
The failure code is displayed on the electrical system abnormality
3
record screen
The failure code is displayed on the air conditioner or heater abnor- "Inspection by self-diagnosis function" in
4
mality record screen Chapter 80
Check items related to engine
5 Startability is poor S-1
6 Engine does not start E-1 S-2
7 Engine does not pick up smoothly S-3
8 Engine stops during operation H-2 S-4
9 Engine runs rough or is unstable (hunts) S-5
10 Engine lacks power S-6
11 Exhaust smoke is black (incomplete combustion) S-7
12 Oil consumption is too much (or exhaust smoke is blue) S-8
13 Oil becomes contaminated early S-9
14 Fuel consumption is excessive S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
16 Oil pressure drops S-12
17 Oil level rises (coolant or fuel in oil) S-13
18 Coolant temperature rises too high (overheating) S-14
19 Unusual noise is heard S-15
20 Vibration is excessive S-16
21 Preheater does not operate E-2
22 Automatic warm-up system does not operate (in cold season) E-13
23 Auto-decelerator does not operate normally E-14
Symptom related to work equipment, swing and travel
All of work equipment, swing, and travel does not work or can not
24 E-20 H-3
swing lock
25 All of work equipment, swing and travel work slow or lack power H-1
26 Engine speed lowers significantly or engine stalls H-2 S-6
27 Working mode does not change E-15
28 Unusual sound is heard from around hydraulic pump H-4
29 Fine control performance or response is poor H-5
Symptom related to work equipment
30 Speed or power of boom is low H-6
31 Speed or power of arm is low H-7
32 Speed or power of bucket is low H-8
33 Work equipment does not move in single operation H-9
34 Hydraulic drift of work equipment is large H-10
35 Time lag of work equipment operation is large H-11
36 Other wok equipment moves when one of work equipment is relieved H-12
37 One-touch power maximizing function does not work. E-22 H-13
38 Attachment circuit can not be changed E-35 H-28
40-200 10 PC200, 200LC, 220, 220LC-8M0

Symptom and troubleshooting numbers SEN06132-02
Troubleshooting
No. Symptom of failure Display
E-mode H-mode S-mode
of code
39 Oil flow in attachment circuit cannot be changed H-29
Symptom related to combined operation

In combined operation of work equipment, equipment having heavier
40 H-14
load moves slower
In combined operations of swing and boom RAISE, boom rising speed
41 H-15
is low
42 Travel speed drops largely in combined operation of swing and travel H-16
Symptom related to travel
43 Machine does not travel straight H-17
44 Travel speed is low H-18
45 Machine is hard to steer or travel power is low H-19
46 Travel speed does not change or travel speed is too low or high E-16 H-20
47 One of tracks does not run H-21
48 Travel alarm does not sound or does not stop sounding E-23
Symptom related to swing
49 Upper structure does not swing H-22
50 Swing acceleration is poor or swing speed is low H-23
51 Upper structure overruns excessively when it stops swinging H-24
52 Shock is larger when upper structure stops swinging H-25
53 Large sound is made when upper structure stops swinging H-26
Swing brake does not operate properly
54 E-21 H-27
Swing drift on a slope is large
Symptom is related to machine monitor
When starting switch is turned to ON position, machine monitor dis-
55 E-3
plays nothing.
When starting switch is turned ON (before starting engine), basic
56 E-4
check monitor lights up
57 Precaution monitor lights up while engine is running E-5
58 Emergency stop monitor lights up while engine is running E-6
59 Engine coolant temperature gauge does not indicate correctly E-8
60 Hydraulic oil temperature gauge does not indicate correctly E-9
61 Fuel level gauge does not indicate correctly E-7
Contents of display on machine monitor is different from that of actual
62 E-10
machine
63 Some areas of machine monitor are not displayed E-11
64 Function switch does not work E-12
65 Alarm buzzer cannot be stopped E-17
66 While starting switch is in OFF position, service meter is not displayed E-18
67 Service mode can not be selected E-19
68 Horn does not sound or does not stop E-24
69 Windshield wiper and window washer do not operate E-25
Air conditioner does not operate normally (including air conditioner "Testing and troubleshooting procedure" in
70
fault record) Chapter 80
71 Monitoring function does not display lever control signal normally E-26–34
Others
72 KOMTRAX system does not operate properly. E-36
PC200, 200LC, 220, 220LC-8M0 40-200 11

SEN06132-02 Information in troubleshooting table
Information in troubleshooting table

(Rev. 2011/12)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action level Failure code
Display on Failure name displayed on the Abnormality Record screen of the
Display on Failure
machine machine monitor
machine monitor
monitor
Detail of
Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by the machine
controller monitor or controller
Problem on A problem that appears as a failure on the machine as a result of an action (above) that is performed by
machine the machine monitor or controller.
Related
Information on occurred failure or troubleshooting
information
Cause Procedure, measuring location, criteria and remarks
<Contents of description>
q Procedure
q Measuring location
1 Defective - a "Between A and B" denotes measuring values such as voltage and resistance
between A and B.
a "Between A and ground" means the measurement of voltage, resistance or
others between terminal A and the place which has a continuity with chassis
frame such as unpainted hexagonal head bolt or bolt hole which has no rust,
Open or short circuit in wir- etc.
2 q Criteria to judge probable causes (standard value), remarks
ing harness
<How to use troubleshooting sheet>
q Perform troubleshooting procedures in numerical order.
q If the check result does not meet the criteria, the probable cause described on the
left column is the actual cause of the failure.
Open circuit in wiring har-
q If the check result shows no failure, and unless otherwise specified, proceed to the
ness
3 next step (next cause item).
(wire breakage or defective
q If a defect is found and repaired, check that the defect has been corrected.
contact of connector)
<Failures in wiring harness>
q Open circuit in wiring
Connection of connector is defective or wiring harness is broken.
Ground fault in wiring har- q Ground fault
4 ness A harness not to be connected to the ground (earth) circuit comes into contact with
(contact with ground circuit) the ground (earth) circuit or chassis accidentally.
q Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into contact with
the power (24 V) circuit accidentally.
q Short circuit
Hot short circuit An independent wire in the harness erroneously comes into contact with another
5
(contact with 24 V circuit) independent wire.
(poor insulation at connector and others)
<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapter as follows unless otherwise spec-
Short circuit in wiring har- ified.
6
ness q When "male" or "female" is not indicated with a connector number, disconnect
the connector, and insert T-adapter between the male and female connectors.
q When "male" or "female" is indicated with a connector number, disconnect the
connector, and connect T-adapter only to either male or female connector.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads as shown be-
7 Defective controller low unless otherwise specified.
q Connect the positive (+) lead to pin or wire indicated first.
q Connect the negative (-) lead to a pin or wire indicated second.
40-200 12 PC200, 200LC, 220, 220LC-8M0

Information in troubleshooting table SEN06132-02
Circuit diagram related to troubleshooting
This is the excerpted circuit diagram related to trouble-

shooting
q The circuit diagram contains the connector Nos., pin
Nos., and connector colors related to the failure.
q The “/“ in a connector number is either:
1) An abbreviation (of more than three letters)
Example: T/C (Torque Converter)
2) Different connector number at male and female sides
Example: BREAK OUT/E24
q The circuit diagram contains the destination or source of
the branch line in a wiring harness.
q The arrow (io) indicates a rough installation position
on the given machine.
q NO: Normally Open
q NC: Normally Closed
q Signal names such as GND and 24 V are included in ad-
dition to connector numbers at junctions, etc. in circuit di-
agrams.
q Except for GND and 24 V, a signal name indicated at a
junction, etc. shows that the wire is connected to another
junction or controller at where the same signal name is
indicated.
PC200, 200LC, 220, 220LC-8M0 40-200 13

SEN06132-02 Connector/electrical wiring connection table
Connector/electrical wiring connection table

Connector From Connector To
Connector Address Wire
No. of Pin Connector Pin dia./color
(terminal) Connector Harness Device name Type
pins No. (terminal) No. No.
No. layout drawing
P13 (male) 1 0.85L
Joint (Switch for ser-
A - D377 - - - P14 1 0.85L
vice pressure (1 ATT)
P15 1 0.85L
C - 0.85L
Joint (Switch for ser- P13 (male) 1 0.85L
A - K377 - - -
vice pressure (2 ATT) P14 1 0.85L
P15 1 0.85L
H15 (male) 7 0.5GL
A - E325 Joint (lamp switch) - - - S02 1 0.5GL
S02 6 0.5GL
A40A (female) 3 BRAID
A - E415 Joint (camera 1 (OPT)) - - - A40A (female) 4 0.5B
A45 4 0.5B
A46 4 0.5B
A - I415 Joint (camera 2 (OPT)) - - - B - BRAID
B - 0.5B
Intermediate connector 1 FX - 1.25R
A13 (male) H1 I250 DT 2
(working lamp (boom)) 2 BT - 1.25B
Intermediate connector 1 L01 1 2R
A13 (female) H1 C364 DT 2
(working lamp (boom)) 2 L01 2 2B
Intermediate connector 1 L09 1 2R
A15 (male) K9 N414 DT 2
(working lamp (rear)) 2 L09 2 2B
Intermediate connector 1 R10 5 1.25R
A15 (female) K9 K295 DT 2
(working lamp (rear)) 2 GY - 1.25B
1 HN - 0.5R
Intermediate connector 2 CM04 2 0.5W
A40 (male) S1 H256 DT 4
(camera 1 (OPT)) 3 XD - BRAID
4 JB - 0.5B
1 A40A (male) 1 0.5R
Intermediate connector 2 A40A (male) 2 0.5W
A40 (female) S1 B409 DT 4
(camera 1 (OPT)) 3 A40A (male) 3 BRAID
4 A40A (male) 4 0.5B
1 A40 (female) 1 0.5R
Intermediate connector 2 A40 (female) 2 0.5W
A40A (male) - B416 DT 4
(camera 1 (OPT)) 3 A40 (female) 3 BRAID
4 A40 (female) 4 0.5B
1 A45 1 0.5R
A40A Intermediate connector 2 A45 2 0.5W
- E409 DT 4
(female) (camera 1 (OPT)) 3 A - BRAID
4 A - 0.5B
1 HN - 0.5R
Intermediate connector 2 CM04 3 0.5W
A41 (male) S1 H259 DT 4
(camera 2 (OPT)) 3 CM04 6 0.5G
4 JB - 0.5B
40-200 14 PC200, 200LC, 220, 220LC-8M0

Connector/electrical wiring connection table SEN06132-02

No. layout drawing
1 A46 1 0.5R
Intermediate connector 2 A46 2 0.5W
A41 (female) S1 I409 DT 4
(camera 2 (OPT)) 3 A46 3 0.5G
4 B - 0.5B
1 A40A (female) 1 0.5R
A45 - E416 Camera 1 (OPT) DT 4 2 A40A (female) 2 0.5W
4 A - 0.5B
1 A41 (female) 1 0.5R
2 A41 (female) 2 0.5W
A46 - I417 Camera 2 (OPT) DT 4
3 A41 (female) 3 0.5G
4 A - 0.5B
Alternator terminal B
AB AG9 G367 Terminal 1 B E12 2 1.25G
(STD)
AB AG9 L364 Terminal 1 B SB B 15R
(STD)
AB AG9 N421 Terminal 1 B SB B 15R
(large capacity)
1 ZF - 0.5L
2 ZE - 0.5W
4 R21 2 0.5Lg
6 P17 1 0.5GB
AC01 X5 N231 Air conditioner unit - 10
7 P18 1 0.85BrR
8 P18 2 0.85RW
9 P31 2 0.5YW
10 P31 1 0.5RB
1 KA - 2B
2 GD - 2RY
AC02 W9 G232 Air conditioner unit - 4
3 F01 18 0.5RL
4 GC - 0.5R
Air conditioner com-
AC03 AF4 G313 X 1 1 R21 3 1.25W
pressor solenoid clutch
1 CE01 33 0.85W
AMB AIR Ambient pressure sen- FRAM-
AE2 - 3 2 S26 - 0.85B
PRESSURE sor ATOME
3 CE01 3 0.85G
P13 (male) 2 0.85B
B - D377 - - - P14 2 0.85B
P15 2 0.85B
D - 0.85B
Joint (Switch for ser- P13 (male) 2 0.85B
B - K377 - - -
vice pressure (2 ATT) P14 2 0.85B
P15 2 0.85B
H15 (male) 21 0.5GR
B - E325 Joint (lamp switch) - - - S02 3 0.5GR
S02 4 0.5GR
A - BRAID
B - I410 Joint (camera 2 (OPT)) - - - A - 0.5B
A41 (female) 4 0.5B
PC200, 200LC, 220, 220LC-8M0 40-200 15


No. layout drawing
F01 9 0.85GY
BA - P238 Joint - - - H16 (female) 2 0.85GY
H16 (female) 4 0.85GY
H09 (female) 1 1.25R
BB - P238 Joint - - - H09 (female) 3 1.25RL
R12 5 1.25R
BD - 0.85B
BC - J280 Joint - - - V02 2 0.85B
V04 2 0.85B
BC - 0.85B
BD - J280 Joint - - - BE - 0.85B
V03 2 0.85B
BD - 0.85B
BE - J280 Joint - - - BK - 0.85B
V05 2 0.85B
BK - 0.85B
B227,
BF - Joint - - - V23 2 0.85B
B229
XQ - 0.85B
BT - 2B
BG - K255 Joint - - - BU - 3B
T09 - 5B
BU - 2B
BH - J280 Joint - - - P23 2 0.85B
V01 2 0.85B
F01 16 0.85GR
BJ - M243 Joint - - - H16 (female) 1 0.85GR
L03 2 0.85LW
BE - 0.85B
BK - K279 Joint - - - BF - 0.85B
V25 2 0.85B
1 CE01 44 0.85G
BOOST Boost pressure and 2 S10 - 0.85W
SUMI-
PRESS. & AG5 - intake manifold temper- 4
TOMO 3 CE01 23 0.85G
IMT ature sensor
4 S11 - 0.85B
H09 (female) 2 3B
BP - P239 Joint - - - HH - 0.85B
T01 - 3B
BR - 3B
L05 (female) 2 0.85B
BQ - M350 Joint - - -
M40 2 1.25B
M41 2 1.25B
BQ - 3B
BR - M351 Joint - - - H09 (male) 2 3B
T02 - 3B
40-200 16 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
H15 (female) 20 0.85GW
BS - E231 Joint - - - K04 2 0.85GW
R08 1 0.85GW
A13 (male) 2 1.25B
BG - 2B
BT - K251 Joint - - -
M07 1 1.25B
M08 1 1.25B
BG - 3B
BU - K254 Joint - - - BH - 2B
V06 2 0.85B
F01 17 2RY
BW - K231 Joint - - - H15 (female) 1 0.85RB
J06 9 2RY
K04 1 0.85B
BY - K260 Joint - - - KA - 5B
T07 - 5B
M07 2 1.25GW
BZ - L250 Joint - - - M08 2 1.25GW
R08 5 1.25GW
A - 0.85L
C - K378 - - - P16 1 0.85L
P30 1 0.85L
PC200, 200LC, 220, 220LC-8M0 40-200 17


No. layout drawing
1 J06 1 1.25RY
2 J05 7 1.25B
3 J04 13 0.85GY
4 J06 2 1.25RY
5 J04 10 1.25B
8 XB - 0.85WB
9 J06 19 0.5WB
14 P02 2 0.85BrR
15 P08 2 0.85BrW
16 P03 2 0.85GL
17 P04 2 0.85LgR
18 XN - 0.85B
19 J02 16 0.5RW
21 S30 2 0.5YG
24 FM - 0.5LW
29 P22 2 0.85YR
34 P05 2 0.85LgW
35 P10 2 0.85Lg
36 P. 12 2 0.85WL
38 S25 (female) 16 0.5LB
39 S30 7 0.5RY
C01 V9 E241 Pump controller AMP 81 40 S30 1 0.5R
41 H16 (female) 5 0.85GW
43 FM - 0.5LW
45 XG - 0.5W
46 P22 1 0.5B
49 P25 2 0.85GR
53 P06 2 0.85BrY
54 P09 2 0.85LgY
55 P11 2 0.85WR
56 M05 6 0.5LR
57 H09 (female) 5 0.5YR
58 S30 4 0.5GW
60 XE - 0.5RW
62 J06 11 0.5GW
64 XH - 0.5L
68 P26 2 0.85YB
72 P07 2 0.85YL
73 P01 2 0.85LgB
75 M05 4 0.5LW
76 P13 (female) 1 0.85LgY
77 S30 3 0.5YB
79 FM - 0.5LW
40-200 18 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
85 V25 1 0.85RW
86 V06 1 0.85BrG
87 V04 1 0.85GR
88 V19 1 0.85G
89 V24 1 0.85RL
96 S25 (female) 3 0.85G
97 V30 1 0.85G
101 D01 7 0.85LW
104 S25 (female) 9 0.85G
107 M14 1 0.85RL
108 J01 1 0.85R
C02 W9 B210 Pump controller AMP 40
109 V02 1 0.85GL
110 V05 1 0.85BrR
112 V23 1 0.85LR
114 M05 1 0.85L
115 GR - 1.25B
116 FN - 1.25RY
117 FH - 1.25B
118 FN - 1.25RY
119 M05 3 0.85YL
120 FL - 1.25B
121 FN - 1.25RY
1 S10 - 0.85W
CAM SEN- FRAM-
AF1 - CAM sensor (Bkup) 3 2 S11 - 0.85B
SOR ATOME
3 CE01 26 0.85G
PC200, 200LC, 220, 220LC-8M0 40-200 19


No. layout drawing
CP3 PUMP
2 1 0.85G
REGULATOR
AMB AIR PRES-
3 3 0.85G
SURE
6 TOOL PORT B 0.85B
8 TOOL PORT A 0.85W
14 E06 (female) 1 0.85G
COOLANT
15 B 0.85G
TEMP
CRANK SEN-
16 1 0.85W
SOR
OIL PRES-
17 - 0.85G
SURE SWICH
BOOST PRESS.
23 3 0.85G
& IMT
FUEL RAIL
25 2 0.85G
PRESS
26 CAM SENSOR 3 0.85G
CRANK SEN-
27 3 0.85G
SOR
CP3 PUMP
32 2 0.85B
REGULATOR
AMB AIR PRES-
33 1 0.85W
SURE
37 S10 - 0.85W
38 S26 - 0.85B
CE01 AG1 - Engine controller DRC 60 BOOST PRESS.
44 1 0.85G
& IMT
INJECTOR CYL
45 3 2W
1 & 2 (female)
INJECTOR CYL
46 3 2W
5 & 6 (female)
47 S11 - 0.85B
CRANK SEN-
48 2 0.85B
SOR
INJECTOR CYL
51 1 2B
1 & 2 (female)
INJECTOR CYL
52 4 2B
3 & 4 (female)
INJECTOR CYL
53 4 2B
1 & 2 (female)
INJECTOR CYL
54 2 2W
1 & 2 (female)
INJECTOR CYL
55 3 2W
3 & 4 (female)
INJECTOR CYL
56 2 2W
3 & 4 (female)
INJECTOR CYL
57 2 2W
5 & 6 (female)
INJECTOR CYL
58 1 2B
3 & 4 (female)
INJECTOR CYL
59 1 2B
5 & 6 (female)
INJECTOR CYL
60 4 2B
5 & 6 (female)
40-200 20 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
9 H15 (female) 15 0.85L
22 H15 (female) 14 0.85WB
23 H15 (female) 16 0.85B
33 HF - 0.85B
39 F01 20 0.85LW
CE02 AF1 - Engine controller DRC 50
40 R18 1 0.85Y
42 R18 2 0.85YB
46 ZA - 0.5W
47 ZB - 0.5L
49 D11 2 0.85RY
1 T12 - 3B
CE03 AG1 - Engine controller DTP 4
3 HD - 3RW
M10 (male) 2 0.85BW
CF - G397 Joint - - - Page 71 2 0.85B
Page 72 2 0.85B
10 XG - 0.5W
CK01 X7 N202 KOMTRAX controller 070 18 11 XH - 0.5L
14 J06 13 0.5GW
1 XJ - 1.25B
2 XJ - 1.25B
3 J03 4 0.5LR
CK02 X7 O204 KOMTRAX controller 070 12 4 XF - 0.5L
6 J06 5 1.25R
7 J06 6 1.25R
11 XE - 0.5RW
1 J06 3 1.25R
2 J06 4 1.25R
3 MB - 1.25B
4 MB - 1.25B
5 J06 12 0.5GW
6 R07 2 0.5BR
CM01 O5 B248 Machine monitor 070 18 9 HA - 0.5G
10 J03 10 0.5LW
11 J01 14 0.5RW
12 J02 7 0.5RY
14 J05 2 0.5B
15 P21 1 0.85Y
16 J02 13 0.5L
2 P44 1 0.85Y
3 P24 1 0.85GL
4 P23 1 0.85LR
CM02 O5 E247 Machine monitor 070 12 5 J02 17 0.5RW
7 ZZ - 0.5W
8 ZZ - 0.5W
9 ZH - 0.5L
PC200, 200LC, 220, 220LC-8M0 40-200 21


No. layout drawing
1 HN - 0.85R
2 A40 (male) 2 0.5W
3 A41 (male) 2 0.5W
CM04 O5 G249 Machine monitor 070 8
5 JB - 0.85B
6 A41 (male) 3 0.5G
8 XD - 1.25B
COOLANT Coolant temperature PACK- A S26 - 0.85B
AE3 - 2
TEMP sensor ARD B CE01 15 0.85G
CP3 PUMP 1 CE01 2 0.85G
REGULA- - - Pump regulator valve BOSCH 2
TOR 2 CE01 32 0.85B
1 CE01 16 0.85W
CRANK FRAM-
AF1 - Crankshaft sensor (Ne) 3 2 CE01 48 0.85B
SENSOR ATOME
3 CE01 27 0.85G
B - 0.85B
D - K379 - - - P16 2 0.85B
P30 2 0.85B
1 HG - 0.85RB
2 J01 4 0.85RB
3 J02 3 0.85WR
4 J02 18 0.85LgR
D01 N9 N210 Diode SWP 8
5 H15 (female) 2 0.85RB
6 J02 11 0.85L
7 C02 101 0.85LW
8 J05 15 0.85BW
1 J02 8 0.85RY
3 J03 16 0.85WL
5 J05 14 0.85BW
7 J04 15 0.85GY
1 HB - 0.5G
2 HB - 0.5G
3 GS - 0.85YL
5 HA - 0.5GL
6 H15 (female) 21 0.5GR
7 GR - 0.85B
1 HC - 0.85Br
D10 - M207 Diode M 2
2 HG - 0.85RB
1 HC - 0.85Br
D11 - M208 Diode M 2
2 CE02 49 0.85RY
DB - 5RY
DA - K210 Joint - - - F01 1A 3R
F01 11D 3R
DA - 5RY
DB - K209 Joint - - - F01 6B 3R
F04 2 8RY
40-200 22 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
NA - 0.85WB
NB - 0.85WB
DD - B280 Joint - - -
P25 3 0.85WB
P26 3 0.85WB
NF - 0.85B
NG - 0.85B
DE - B279 Joint - - -
P25 1 0.85B
P26 1 0.85B
E08 (male) 1 1.25L
DG - K250 Joint - - - R17 (female) 2 1.25L
XF - 1.25L
J05 1 1.25B
DK - K231 Joint - - - J05 13 1.25B
KA - 2B
KB - 2B
DL - D259 Joint - - - MC - 2B
T05 - 3B
J04 3 1.25BW
DM - C229 Joint - - - J04 5 1.25B
T04 - 3B
Electrical intake air
E01 AG5 K313 Terminal 1 - R16A - 15R
heater (ribbon heater)
Intermediate connector 1 P47 1 0.85G
E06 (male) AI1 K305 DT 2
(water-in-fuel sensor) 2 P47 2 0.85B
Intermediate connector 1 CE01 14 0.85G
E06 (female) AI1 - DT 2
(water-in-fuel sensor) 2 S11 - 0.85B
Intermediate connector
E08 (male) AG9 M295 (alternator (terminals IG X 1 1 DG - 1.25L
and L))
E08 (female) AG9 H364 (alternator (terminals IG X 1 1 E12 1 1.25L
and L))
E10 (male) AE6 O368 (starting motor (termi- D 1 1 SC C 8R
nal C))
E10 (female) AE6 O293 (starting motor (termi- D 1 1 R28 - 8R
nal C))
Alternator (terminals IG 1 E08 (female) 1 1.25L
E12 AH8 H369 - 2
and L) 2 AB B 1.25G
PC200, 200LC, 220, 220LC-8M0 40-200 23


No. layout drawing
1 FD - 0.85W
2 FN - 3RY
3 LD - 0.85W
4 J03 13 0.85WL
5 GE - 1.25GW
6 R18 3 0.85Br
7 J03 20 0.85GL
8 FW - 2LR
9 BA - 0.85GY
10 GC - 0.85R
11 GD - 2RL
13 R12 3 1.25LR
F01 T9 E219 Fuse Terminal 20 14 M09 1 0.85G
15 J03 11 0.85LR
16 BJ - 0.85GR
17 BW - 2RY
18 AC02 3 0.5RL
19 HE - 3RW
20 CE02 39 0.85LW
1A DA - 3R
6B DB - 3R
10C J03 5 0.85LW
11D DA - 3R
16E F05 2 3RW
20F J03 6 0.85LW
1 R03 - 8R
F04 B9 C270 Fusible link L 2
2 DB - 8RY
1 R04 - 3R
F05 C8 C271 Fusible link M 2
2 F01 16E 3RW
F01 1 0.85W
H15 (female) 6 0.5LR
FD - K218 Joint - - -
K01 1 0.85W
S25 (female) 13 0.85W
FJ - 1.25B
FF - K209 Joint - - - S25 (female) 6 0.85L
S25 (female) 12 0.85L
FJ - 1.25B
B227,
FG - Joint - - - V19 2 0.85L
B228
V30 2 0.85B
C02 117 1.25B
FJ - 3B
FH - J205 Joint - - -
FL - 1.25B
GR - 1.25B
40-200 24 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
FF - 1.25B
FJ - K205 Joint - - - FG - 1.25B
FH - 3B
C02 120 1.25B
FH - 1.25B
FL - B229 Joint - - -
V24 2 0.85B
XQ - 0.85B
C01 24 0.5LW
C01 43 0.5LW
FM - E231 Joint - - -
C01 79 0.5LW
J03 8 0.5LW
C02 116 1.25RY
C02 118 1.25RY
FN - J205 Joint - - -
C02 121 1.25RY
F01 2 3RY
J04 4 0.85B
S25 (female) 4 0.85B
FP - K209 Joint - - -
S25 (female) 10 0.85B
S25 (female) 15 0.5B
K01 2 0.85GR
FS - J211 Joint - - - S25 (female) 1 0.85GR
S25 (female) 7 0.85GR
J04 8 0.85B
FT - L218 Joint - - - N08 9 0.5B
N08 12 0.85B
1 S11 - 0.85B
FUEL RAIL Common rail pressure
AI5 - BOSCH 3 2 CE01 25 0.85G
PRESS sensor
3 S10 - 0.85W
F01 8 2LR
FW - E232 Joint - - - R05 3 1.25LR
R10 3 1.25LR
A13 (male) 1 1.25R
FX - K250 Joint - - - L02 1 1.25R
R05 5 1.25R
GY - 2B
GB - K278 Joint - - - L02 2 1.25B
T10 - 5B
AC02 4 0.5R
GC - F230 Joint - - - F01 10 0.85R
R21 1 0.5R
AC02 2 2RY
GD - F230 Joint - - - F01 11 2RL
R21 5 2RY
PC200, 200LC, 220, 220LC-8M0 40-200 25


No. layout drawing
F01 5 1.25GW
GE - E229 Joint - - - H15 (female) 19 0.85GW
R08 3 1.25GW
J05 9 0.85B
GF - E233 Joint - - - R08 2 0.85B
R12 2 0.85B
C02 115 1.25B
GR - J205 Joint - - - D03 7 0.85B
FH - 1.25B
D03 3 0.85YL
GS - G259 Joint - - - H15 (female) 12 0.85YL
V03 1 0.85YL
A15 (female) 2 1.25B
GY - K278 Joint - - - GB - 2B
P24 2 0.85B
1 M02 1 0.85RB
Intermediate connector 2 M02 2 0.85RL
H08 (male) - L354 M 4
(L.H. console) 3 M03 1 0.85R
4 M03 2 0.85RW
1 M01 1 0.85RB
H08 (female) - E356 M 4
(L.H. console) 3 M01 2 0.85R
4 M01 6 0.85RW
1 M40 1 1.25R
2 BR - 3B
H09 (male) X4 N353 M 8
(floor harness) 4 L05 (female) 1 0.85Y
5 W03 1 0.5YR
6 W03 2 0.5B
1 BB - 1.25R
2 BP - 3B
Intermediate connector 3 BB - 1.25RL
H09 (female) X4 O227 M 8
(floor harness) 4 J05 17 0.85Y
5 C01 57 0.5YR
6 J04 11 0.5B
40-200 26 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
1 S01 B 0.85RB
2 S01 BR 0.85R
3 S01 R1 0.85RY
4 S01 C 0.85RW
5 S01 ACC 0.85LW
6 S02 5 0.5LR
7 A - 0.5GL
9 S04 5 0.5RW
10 S04 6 0.5B
Intermediate connector 11 S04 3 0.5WR
H15 (male) V1 E319 090 22
(R.H. console harness) 12 S04 4 0.5YL
14 P20 1 0.5WB
15 P20 2 0.5L
16 P20 3 0.5B
17 S07 5 0.85GL
18 S07 6 0.85Y
19 S10 1 0.85GY
20 S10 2 0.85GW
21 B - 0.5GR
22 S02 2 0.5B
1 BW - 0.85RB
2 D01 5 0.85RB
3 J02 5 0.85RY
4 J01 11 0.85RW
5 J03 7 0.85LW
6 FD - 0.5LR
7 HA - 0.5GL
9 J02 15 0.5RW
10 J05 4 0.85B
Intermediate connector 11 J02 1 0.85WR
H15 (female) V1 H261 090 22
(R.H. console harness) 12 GS - 0.85YL
14 CE02 22 0.85WB
15 CE02 9 0.85L
16 CE02 23 0.85B
17 J03 19 0.85GL
18 J05 18 0.85Y
19 GE - 0.85GW
20 BS - 0.85GW
21 D03 6 0.5GR
22 HH - 0.5B
PC200, 200LC, 220, 220LC-8M0 40-200 27


No. layout drawing
1 M01 8 0.85GR
2 M01 3 0.85GY
3 M01 7 0.85B
4 S11 1 0.85GY
H16 (male) X3 G356 S 12 5 S11 2 0.85GW
(floor harness)
6 S14 1 0.85W
7 S14 2 0.85LgR
8 S14 3 0.5GL
11 T03 1 1.25B
1 BJ - 0.85GR
2 BA - 0.85GY
3 HH - 0.85B
4 BA - 0.85GY
H16 (female) X3 M227 S 12 5 C01 41 0.85GW
(floor harness)
6 LD - 0.85W
7 J02 20 0.85LgR
8 R06 1 0.5GL
11 T01 - 1.25B
CM01 9 0.5G
HA - D256 Joint - - - D03 5 0.5GL
H15 (female) 7 0.5GL
D03 1 0.5G
HB - K209 Joint - - - D03 2 0.5G
J01 8 0.5GL
D10 1 0.85Br
D11 1 0.85Br
HC - J208 Joint - - -
R23 1 0.85Br
R24 1 0.85Br
CE03 3 3RW
HD - K243 Joint - - - R23 5 2LR
R24 5 2LR
F01 19 3RW
HE - G208 Joint - - - R23 3 2R
R24 3 2R
CE02 33 0.85B
HF - K242 Joint - - - R23 2 0.85B
R24 2 0.85B
D01 1 0.85RB
HG - K238 Joint - - - D10 2 0.85RB
J01 2 0.85RB
BP - 0.85B
HH - M242 Joint - - - H15 (female) 22 0.5B
H16 (female) 3 0.85B
40-200 28 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
A40 (male) 1 0.5R
HN - E250 Joint - - - A41 (male) 1 0.5R
CM04 1 0.85R
INJECTOR CYL
1 3 1.25D
INJECTOR 1 & 2 (Male)
AE4 - Injector #1 DT 2
#1 INJECTOR CYL
2 4 1.25Y
1 & 2 (Male)
INJECTOR CYL
1 2 1.25Br
AF4 - Injector #2 DT 2
#2 INJECTOR CYL
2 1 1.25R
1 & 2 (Male)
INJECTOR CYL
1 3 1.25D
AF5 - Injector #3 DT 2
#3 INJECTOR CYL
2 4 1.25Y
3 & 4 (Male)
INJECTOR CYL
1 2 1.25Br
AG5 - Injector #4 DT 2
#4 INJECTOR CYL
2 1 1.25R
3 & 4 (Male)
INJECTOR CYL
1 3 1.25D
AH5 - Injector #5 DT 2
#5 INJECTOR CYL
2 4 1.25Y
5 & 6 (Male)
INJECTOR CYL
1 2 1.25Br
AH6 - Injector #6 DT 2
#6 INJECTOR CYL
2 1 1.25R
5 & 6 (Male)
1 INJECTOR #2 2 1.25R
INJECTOR 2 INJECTOR #2 1 1.25Br
CYL 1 & 2 AE4 - DT 4
(injectors #1 and #2) 3 INJECTOR #1 1 1.25D
(Male)
4 INJECTOR #1 2 1.25Y
1 CE01 51 2B
INJECTOR 2 CE01 54 2W
CYL 1 & 2 AE4 - DT 4
(injectors #1 and #2) 3 CE01 45 2W
(female)
4 CE01 53 2B
CYL 3 & 4 AG5 - DT 4
(Male)
1 CE01 58 2B
CYL 3 & 4 AG5 - DT 4
(female)
4 CE01 52 2B
CYL 5 & 6 AI6 - DT 4
(Male)
1 CE01 59 2B
CYL 5 & 6 AI6 - DT 4
(female)
4 CE01 60 2B
PC200, 200LC, 220, 220LC-8M0 40-200 29


No. layout drawing
1 C02 108 0.85R
2 HG - 0.85RB
3 R02 - 1.25R
4 D01 2 0.85RB
5 R12 1 0.5GL
Junction connector 6 R10 1 0.5GL
J01 W3 I231 - 20
(Black) 7 R05 1 0.5GL
8 HB - 0.5GL
11 H15 (female) 4 0.85RW
12 XE - 0.5RW
13 R06 5 0.85RW
14 CM01 11 0.5RW
1 H15 (female) 11 0.85WR
2 S25 (female) 14 0.85WR
3 D01 3 0.85WR
5 H15 (female) 3 0.85RY
6 R15 - 0.85RY
7 CM01 12 0.5RY
8 D02 1 0.85RY
9 R18 5 0.85RY
Junction connector
J02 W2 I225 - 20 11 D01 6 0.85L
(Black)
12 XF - 1.25L
13 CM01 16 0.5L
15 H15 (female) 9 0.5RW
16 C01 19 0.5RW
17 CM02 5 0.5RW
18 D01 4 0.85LgR
19 V01 1 0.85LgR
20 H16 (female) 7 0.85LgR
2 M10 (female) 1 0.85LR
4 CK02 3 0.5LR
5 F01 10C 0.85LW
6 F01 20F 0.85LW
7 H15 (female) 5 0.85LW
8 FM - 0.5LW
9 N08 2 0.85YG
Junction connector
J03 V2 G225 - 20 10 CM01 10 0.5LW
(green)
11 F01 15 0.85LR
13 F01 4 0.85WL
14 M04 1 0.85WL
15 M06 2 0.85WL
16 D02 3 0.85WL
19 H15 (female) 17 0.85GL
20 F01 7 0.85GL
40-200 30 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
1 LC - 1.25B
2 KB - 1.25B
3 DM - 1.25BW
4 FP - 0.85B
5 DM - 1.25B
6 M09 2 0.85BW
7 J05 3 1.25B
8 FT - 0.85B
9 R06 2 0.5BW
Junction connector
J04 X3 I235 - 20 10 C01 5 1.25B
(green)
11 H09 (female) 6 0.5B
12 P17 2 0.5B
13 C01 3 0.85GY
14 M06 1 0.85GY
15 D02 7 0.85GY
17 M10 (female) 2 0.85BR
18 KB - 1.25BR
19 MF - 0.85BR
20 XJ - 1.25B
1 DK - 1.25B
2 CM01 14 0.5B
3 J04 7 1.25B
4 H15 (female) 10 0.85B
5 R05 2 0.85B
6 R10 2 0.85B
Junction connector 7 C01 2 1.25B
J05 X6 I239 - 20
(pink) 8 S30 8 0.5B
9 GF - 0.85B
13 DK - 1.25B
14 D02 5 0.85BW
15 D01 8 0.85BW
17 H09 (female) 4 0.85Y
18 H15 (female) 18 0.85Y
PC200, 200LC, 220, 220LC-8M0 40-200 31


No. layout drawing
1 C01 1 1.25RY
2 C01 4 1.25RY
3 CM01 1 1.25R
4 CM01 2 1.25R
5 CK02 6 1.25R
6 CK02 7 1.25R
Junction connector 8 N08 1 0.85RY
J06 X8 I243 - 20
(pink) 9 BW - 2RY
11 C01 62 0.5GW
12 CM01 5 0.5GW
13 CK01 14 0.5GW
14 N08 6 0.5GW
17 XM - 0.85WB
19 C01 9 0.5WB
A40 (male) 4 0.5B
JB - E250 Joint - - - A41 (male) 4 0.5B
CM04 5 0.85B
1 FD - 0.85W
K01 O8 I211 Pump (PC) resistor M 2
2 FS - 0.85GR
CAN terminating resis- A ZA - 0.5W
K02 AH1 M304 DT 3
tor B ZB - 0.5L
Horn relay dummy 1 BY - 0.85B
K04 - I206 DT 2
resistor 2 BS - 0.85GW
AC02 1 2B
Joint
KA - E229 - - - BY - 5B
DK - 2B
DL - 2B
KB - K230 Joint - - - J04 2 1.25B
J04 18 1.25BR
1 A13 (female) 1 2R
L01 E8 C364 Working lamp (boom) DT 2
2 A13 (female) 2 2B
1 FX - 1.25R
L02 F9 F274 Working lamp DT 2
2 GB - 1.25B
1 MF - 0.85B
L03 T9 C231 Room lamp M 2
2 BJ - 0.85LW
Intermediate connector 1 L15 1 0.85R
L05 (male) AC8 C420 SWP 2
(revolving lamp) 2 L15 2 0.85B
Intermediate connector 1 H09 (male) 4 0.85Y
L05 (female) AC8 K348 SWP 2
(revolving lamp) 2 BQ - 0.85B
1 A15 (male) 1 2R
L09 D9 N410 Working lamp (rear) D 2
2 A15 (male) 2 2B
1 L05 (male) 1 0.85R
L15 AB8 C420 Revolving warning lamp DT 2
2 L05 (male) 2 0.85B
40-200 32 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
J04 1 1.25B
LC - N260 Joint - - - P13 (female) 2 0.85B
T06 - 1.25B
F01 3 0.85W
LD - L215 Joint - - - H16 (female) 6 0.85W
R07 1 0.5L
1 H08 (female) 1 0.85RB
2 H08 (female) 3 0.85R
3 H16 (male) 2 0.85GY
M01 U1 B346 Radio PA 9 5 H08 (female) 2 0.85RL
6 H08 (female) 4 0.85RW
7 H16 (male) 3 0.85B
8 H16 (male) 1 0.85GR
1 H08 (male) 1 0.85RB
M02 AC8 K349 Speaker (L.H.) M 2
2 H08 (male) 2 0.85RL
1 H08 (male) 3 0.85R
M03 AB9 K346 Speaker (R.H.) M 2
2 H08 (male) 4 0.85RW
1 J03 14 0.85WL
M04 S9 F257 Cigarette lighter - 2
2 MF - 0.85B
1 C02 114 0.85L
3 C02 119 0.85YL
M05 O4 B254 Wiper motor M 6 4 C01 75 0.5LW
5 MC - 1.25B
6 C01 56 0.5LR
1 J04 14 0.85GY
M06 L2 G285 Washer motor YAZAKI 2
2 J03 15 0.85WL
1 BT - 1.25B
M07 G1 N249 Horn (high tone) 090 2
2 BZ - 1.25GW
1 BT - 1.25B
M08 G1 N250 Horn (low tone) 090 2
2 BZ - 1.25GW
Optional power supply 1 F01 14 0.85G
M09 M1 N237 M 2
(1) 2 J04 6 0.85BW
Intermediate connector 1 M11 1 0.85WB
M10 (male) N1 B392 (optional power supply M 2
(2)) 2 M11 2 0.85B
Intermediate connector 1 Page 72 1 0.85RW
M10 (male) N1 B392 (optional power supply M 2
(2)) 2 CF - 0.85BW
Intermediate connector 1 J03 2 0.85LR
M10 (female) N1 N234 (optional power supply M 2
(2)) 2 J04 17 0.85BR
1 M10 (male) 1 0.85WB
2 M10 (male) 2 0.85B
M11 - D393 DC/DC converter M 4
3 X - 0.85L
4 Y - 0.85BW
12V optional power sup- 1 X - 0.85L
M12 - C397 M 2
ply 2 Y - 0.85BW
PC200, 200LC, 220, 220LC-8M0 40-200 33


No. layout drawing
1 X - 0.85L
M13 - C399 12V socket (optional) M 2
2 Y - 0.85BW
1 C02 107 0.85RL
M14 I1 H282 Travel alarm DT 2
2 XQ - 0.85YB
1 H09 (male) 1 1.25R
M40 AB1 J350 Headlamp (left) X 2
2 BQ - 1.25B
1 H09 (male) 3 1.25RL
M41 Y8 M342 Headlamp (right) X 2
2 BQ - 1.25B
CM01 3 1.25B
MB - D252 Joint - - - CM01 4 1.25B
MC - 2B
DL - 2B
MC - D258 Joint - - - M05 5 1.25B
MB - 2B
J04 19 0.85BR
MF - F259 Joint - - - L03 1 0.85B
M04 2 0.85B
1 J06 8 0.85RY
2 J03 9 0.85YG
3 ZG - 0.5W
N08 T9 N219 Service connector DT 12 6 J06 14 0.5GW
9 FT - 0.5B
10 ZH - 0.5L
12 FT - 0.85B
DD - 0.85WB
NA - B281 Joint - - - P01 3 0.85WB
P07 3 0.85WB
DD - 0.85WB
NB - B280 Joint - - - NC - 0.85WB
P04 3 0.85WB
NB - 0.85WB
NC - C280 Joint - - - ND - 0.85WB
P05 3 0.85WB
NC - 0.85WB
ND - D280 Joint - - - NE - 0.85WB
P06 3 0.85WB
ND - 0.85WB
NE - D280 Joint - - - P03 3 0.85WB
XM - 0.85WB
DE - 0.85B
NF - B280 Joint - - - P01 1 0.85B
P07 1 0.85B
DE - 0.85B
NG - C280 Joint - - - NH - 0.85B
P04 1 0.85B
40-200 34 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
NG - 0.85B
NH - C280 Joint - - - NI - 0.85B
P05 1 0.85B
NH - 0.85B
NI - D280 Joint - - - NJ - 0.85B
P06 1 0.85B
NI - 0.85B
NJ - D280 Joint - - - P03 1 0.85B
XL - 0.85B
OIL PRES-
Engine oil pressure FRAM-
SURE AI1 - 2 - CE01 17 0.85G
switch ATOME
SWICH
1 NF - 0.85B
Bucket CURL pressure
P01 K9 C290 AMP 3 2 C01 73 0.85LgB
sensor
3 NA - 0.85WB
1 XL - 0.85B
Boom LOWER pressure
P02 K9 C289 AMP 3 2 C01 14 0.85BrR
sensor
3 XM - 0.85WB
1 NJ - 0.85B
Swing (LEFT) pressure
P03 L6 C283 AMP 3 2 C01 16 0.85GL
sensor
3 NE - 0.85WB
1 NG - 0.85B
P04 L8 C286 Arm IN pressure sensor AMP 3 2 C01 17 0.85LgR
3 NB - 0.85WB
1 NH - 0.85B
Bucket DUMP pressure
P05 L7 C285 AMP 3 2 C01 34 0.85LgW
sensor
3 NC - 0.85WB
1 NI - 0.85B
Boom RAISE pressure
P06 L7 C284 AMP 3 2 C01 53 0.85BrY
sensor
3 ND - 0.85WB
1 NF - 0.85B
Swing (RIGHT) pres-
P07 L8 C288 AMP 3 2 C01 72 0.85YL
sure sensor
3 NA - 0.85WB
1 XL - 0.85B
Arm OUT pressure sen-
P08 L5 C281 AMP 3 2 C01 15 0.85BrW
sor
3 XM - 0.85WB
1 XA - 0.85B
L.H. travel FORWARD
P09 P1 J268 AMP 3 2 C01 54 0.85LgY
sensor
3 XB - 0.85WB
1 XR - 0.85B
L.H. travel REVERSE
P10 Q1 J266 AMP 3 2 C01 35 0.85Lg
sensor
3 XT - 0.85WB
1 XS - 0.85B
R.H. travel FORWARD
P11 O2 J265 AMP 3 2 C01 55 0.85WR
sensor
3 XU - 0.85WB
PC200, 200LC, 220, 220LC-8M0 40-200 35


No. layout drawing
1 XS - 0.85B
R.H. travel REVERSE
P. 12 P1 J263 AMP 3 2 C01 36 0.85WL
sensor
3 XU - 0.85WB
Intermediate connector 1 A - 0.85L
P13 (male) O3 D376 (switch for service pres- X 2
sure) (1 ATT) 2 B - 0.85B
Intermediate connector 1 A - 0.85L
P13 (male) O3 K376 (switch for service pres- X 2
sure) (2 ATT) 2 B - 0.85B
Intermediate connector 1 C01 76 0.85LgY
P13 (female) O3 O263 (switch for service pres- X 2
sure) 2 LC - 0.85B
Service oil pressure 1 A - 0.85L
P14 O3 D380 X 2
switch (front) (1 ATT) 2 B - 0.85B
P14 O3 M377 X 2
switch (front) (2 ATT) 2 B - 0.85B
P15 O2 E380 X 2
switch (rear) (1 ATT) 2 B - 0.85B
P15 O2 L381 X 2
switch (rear) (2 ATT) 2 B - 0.85B
Service oil pressure 1 C - 0.85L
P16 - K381 X 2
switch (front) 2 D - 0.85B
Air conditioner high/low 1 AC01 6 0.5GB
P17 S9 H264 S090 2
pressure switch 2 J04 12 0.5B
Air conditioner fresh air 1 AC01 7 0.85BrR
P18 L5 E289 090 2
sensor 2 AC01 8 0.85RW
1 H15 (male) 14 0.5WB
P20 P8 C328 Fuel control dial M 3 2 H15 (male) 15 0.5L
3 H15 (male) 16 0.5B
P21 G9 H270 Fuel level sensor X 1 1 CM01 15 0.85Y
Hydraulic oil tempera- 1 C01 46 0.5B
P22 I9 B302 D 2
ture sensor 2 C01 29 0.85YR
Air cleaner clogging 1 CM02 4 0.85LR
P23 L4 G283 DT 2
sensor 2 BH - 0.85B
Radiator coolant level 1 CM02 3 0.85GL
P24 L3 G287 X 2
sensor 2 GY - 0.85B
1 DE - 0.85B
F pump pressure sen-
P25 J9 C279 AMP 3 2 C01 49 0.85GR
sor
3 DD - 0.85WB
1 DE - 0.85B
R pump pressure sen-
P26 J9 E278 AMP 3 2 C01 68 0.85YB
sor
3 DD - 0.85WB
Service oil pressure 1 C - 0.85L
P30 - L381 X 2
switch (rear) 2 D - 0.85B
1 AC01 10 0.5RB
P31 O6 B250 Sunlight sensor - 2
2 AC01 9 0.5YW
P44 AH8 N294 Engine oil level switch DT 2 1 CM02 2 0.85Y
40-200 36 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
1 E06 (male) 1 0.85G
P47 H9 C298 Water-in-fuel sensor DT 2
2 E06 (male) 2 0.85B
1 Page 72 3 0.85Y
Page 71 - O396 Filter clogging sensor DT-T 2
2 CF - 0.85B
1 M10 (male) 1 0.85RW
Air cleaner clogging
Page 72 - G389 DT-T 4 2 CF - 0.85B
indicator
3 Page 71 1 0.85Y
R01 C8 D273 Battery relay terminal E Terminal 1 - T08 - 5B
Battery relay terminal
R02 C8 E274 Terminal 1 - J01 3 1.25R
BR
F04 1 8R
R03 B7 H273 Battery relay terminal M Terminal 1 - R16B - 15R
SB B 60R
R04 C9 H273 Battery relay terminal B Terminal 1 - F05 1 3R
1 J01 7 0.5GL
2 J05 5 0.85B
R05 T9 D237 Lamp relay Relay 5
3 FW - 1.25LR
5 FX - 1.25R
1 H16 (female) 8 0.5GL
Starting motor cut-off 2 J04 9 0.5BW
R06 N9 N216 Relay 5
relay (PPC lock) 3 R07 4 0.5BW
5 J01 13 0.85RW
1 LD - 0.5L
Starting motor cut-off 2 CM01 6 0.5BR
R07 N9 N215 Relay 5
relay (personal code) 3 R17 (female) 1 0.85RW
4 R06 3 0.5BW
1 BS - 0.85GW
2 GF - 0.85B
R08 U9 B233 Horn relay Relay 5
3 GE - 1.25GW
5 BZ - 1.25GW
1 J01 6 0.5GL
2 J05 6 0.85B
R10 T9 B235 Rear lamp relay Relay 5
3 FW - 1.25LR
5 A15 (female) 1 1.25R
1 J01 5 0.5GL
2 GF - 0.85B
R12 T9 B237 Cab lamp relay Relay 5
3 F01 13 1.25LR
5 BB - 1.25R
R15 A8 K273 heater (ribbon heater) Terminal 1 - J02 6 0.85RY
relay
R16A A8 O270 heater (ribbon heater) Terminal 1 - E01 - 15R
relay
Electrical intake air R03 - 15R
R16B A9 - heater (ribbon heater) Terminal 1 -
relay R29 - 15R
PC200, 200LC, 220, 220LC-8M0 40-200 37


No. layout drawing
Intermediate connector 1 R07 3 0.85RW
R17 (female) B7 I274 (starting motor safety X 1
relay) 2 DG - 1.25L
1 CE02 40 0.85Y
2 CE02 42 0.85YB
R18 V9 H209 Auto preheater relay Relay 5
3 F01 6 0.85Br
5 J02 9 0.85RY
1 GC - 0.5R
2 AC01 4 0.5Lg
R21 W9 G230 Compressor relay Relay 5
3 AC03 1 1.25W
5 GD - 2RY
1 HC - 0.85Br
2 HF - 0.85B
R23 U9 E208 Relay for CM850 (1) Relay 6
3 HE - 2R
5 HD - 2LR
1 HC - 0.85Br
2 HF - 0.85B
R24 V9 E211 Relay for CM850 (2) Relay 6
3 HE - 2R
5 HD - 2LR
Starting motor safety
R28 B9 O271 Terminal 1 - E10 (female) 1 8R
relay terminal C
Starting motor safety
R29 - - Terminal 1 - R16B - 15R
relay (terminal B)
D332 B H15 (male) 1 0.85RB
ACC H15 (male) 5 0.85LW
C331 Steering switch (termi-
S01 P7 Terminal 6 BR H15 (male) 2 0.85R
nal B)
D329 C H15 (male) 4 0.85RW
C330 R1 H15 (male) 3 0.85RY
1 A - 0.5GL
2 H15 (male) 22 0.5B
3 B - 0.5GR
S02 P8 D326 Lamp switch SWP 6
4 B - 0.5GR
5 H15 (male) 6 0.5LR
6 A - 0.5GL
3 H15 (male) 11 0.5WR
4 H15 (male) 12 0.5YL
S04 Q8 D324 Swing lock switch SWP 6
5 H15 (male) 9 0.5RW
6 H15 (male) 10 0.5B
Revolving warning lamp 5 H15 (male) 17 0.85GL
S07 Q8 D323 SWP 6
switch 6 H15 (male) 18 0.85Y
1 H15 (male) 19 0.85GY
S10 R1 E333 R.H. knob switch (horn) Y090 2
2 H15 (male) 20 0.85GW
BOOST PRESS.
2 0.85W
& IMT
CAM SENSOR 1 0.85W
S10 - - Joint - - -
CE01 37 0.85W
FUEL RAIL
3 0.85W
PRESS
40-200 38 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
L.H. knob switch 1 H16 (male) 4 0.85GY
S11 U1 B340 (one-touch power maxi- Y090 2
mizing switch) 2 H16 (male) 5 0.85GW
BOOST PRESS.
4 0.85B
& IMT
CAM SENSOR 2 0.85B
S11 - - Joint - - - CE01 47 0.85B
E06 (female) 2 0.85B
FUEL RAIL
1 0.85B
PRESS
1 H16 (male) 6 0.85W
PPC oil pressure lock
S14 U1 G340 M 3 2 H16 (male) 7 0.85LgR
switch
3 H16 (male) 8 0.5GL
1 S25 (male) 1 0.85GR
2 S25 (male) 2 0.85G
3 S25 (male) 3 0.85GB
4 S25 (male) 4 0.85BW
5 S25 (male) 5 0.85B
Emergency pump drive 6 S25 (male) 6 0.85BR
S21 O9 K325 Terminal 12
switch 7 S25 (male) 7 0.85GR
8 S25 (male) 8 0.85Y
9 S25 (male) 9 0.85YB
10 S25 (male) 10 0.85BrW
11 S25 (male) 11 0.85Br
12 S25 (male) 12 0.85BrR
2 S25 (male) 13 0.85WR
Emergency swing park- 3 S25 (male) 14 0.85W
S22 O9 K327 Terminal 6
ing brake release switch 5 S25 (male) 15 0.85LB
6 S25 (male) 16 0.85L
1 S21 1 0.85GR
2 S21 2 0.85G
3 S21 3 0.85GB
4 S21 4 0.85BW
5 S21 5 0.85B
6 S21 6 0.85BR
7 S21 7 0.85GR
Intermediate connector 8 S21 8 0.85Y
S25 (male) O8 M326 (emergency operation 090 16
switch) 9 S21 9 0.85YB
10 S21 10 0.85BrW
11 S21 11 0.85Br
12 S21 12 0.85BrR
13 S22 2 0.85WR
14 S22 3 0.85W
15 S22 5 0.85LB
16 S22 6 0.85L
PC200, 200LC, 220, 220LC-8M0 40-200 39


No. layout drawing
1 FS - 0.85GR
2 V11 1 0.85G
3 C02 96 0.85G
4 FP - 0.85B
5 V11 2 0.85L
6 FF - 0.85L
7 FS - 0.85GR
Intermediate connector 8 V12 1 0.85G
S25 (female) O8 I221 (emergency operation 090 16
switch) 9 C02 104 0.85G
10 FP - 0.85B
11 V12 2 0.85L
12 FF - 0.85L
13 FD - 0.85W
14 J02 2 0.85WR
15 FP - 0.5B
16 C01 38 0.5LB
AMB AIR PRES-
2 0.85B
SURE
S26 - - Joint - - - CE01 38 0.85B
COOLANT
A 0.85B
TEMP
1 C01 40 0.5R
2 C01 21 0.5YG
3 C01 77 0.5YB
S30 U9 G235 Model Selection S 8
4 C01 58 0.5GW
7 C01 39 0.5RY
8 J05 8 0.5B
Starting motor terminal
SB AE7 L369 Terminal 1 B AB B 15R
B (STD)
SB AE7 N426 Terminal 1 B AB B 15R
B (large capacity)
SB AE7 - Terminal 1 B R03 - 60R
B
SC AE7 O365 Terminal 1 C E10 (male) 1 8R
C
BP - 3B
T01 W2 K225 Ground (floor frame) Terminal 2 -
H16 (female) 11 1.25B
T02 AD2 O352 Ground (cab) Terminal 1 - BR - 3B
T03 (male) U1 B354 M 1 1 T03A - 0.5B
(radio body ground)
T03 (female) U1 D344 M 1 1 H16 (male) 11 1.25B
(radio body ground)
T03A - B352 Radio body ground Terminal 1 - T03 (male) 1 0.5B
Ground (revolving
T04 S1 M256 Terminal 1 - DM - 3B
frame)
Ground (revolving
T05 S1 M255 Terminal 1 - DL - 3B
frame)
Ground (revolving
T06 T1 M254 Terminal 1 - LC - 1.25B
frame)
Ground (revolving
T07 T1 M253 Terminal 1 - BY - 5B
frame)
40-200 40 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
T08 B8 J272 Ground Terminal 1 - R01 - 5B
Ground (revolving
T09 T1 M253 Terminal 1 - BG - 5B
frame)
Ground (revolving
T10 T1 M252 Terminal 1 - GB - 5B
frame)
T12 AH1 F305 Ground (engine body) Terminal 1 - CE03 1 3B
A CE01 8 0.85W
TOOL PORT AE2 - CAN_C DT 3
B CE01 6 0.85B
PPC source pressure 1 J02 19 0.85LgR
V01 J1 I282 DT 2
lock solenoid valve 2 BH - 0.85B
2-stage relief solenoid 1 C02 109 0.85GL
V02 I1 J283 DT 2
valve 2 BC - 0.85B
Swing parking brake 1 GS - 0.85YL
V03 J1 I284 DT 2
solenoid valve 2 BD - 0.85B
Travel HI-LO solenoid 1 C02 87 0.85GR
V04 G9 I285 DT 2
valve 2 BC - 0.85B
Travel flow solenoid 1 C02 110 0.85BrR
V05 K1 I287 DT 2
valve 2 BE - 0.85B
ATT return selector 1 C02 86 0.85BrG
V06 H9 M280 DT 2
solenoid valve 2 BU - 0.85B
1 S25 (female) 2 0.85G
V11 I9 F303 F-PC-EPC valve DT 2
2 S25 (female) 5 0.85L
1 S25 (female) 8 0.85G
V12 J9 B303 R-PC-EPC valve D 2
2 S25 (female) 11 0.85L
1 C02 88 0.85G
V19 I9 B301 LS-EPC valve D 2
2 FG - 0.85L
Merge-divider EPC 1 C02 112 0.85LR
V23 I9 A275 D 2
valve (main) 2 BF - 0.85B
Merge-divider EPC 1 C02 89 0.85RL
V24 H9 C275 D 2
valve (LS) 2 FL - 0.85B
Variable back pressure 1 C02 85 0.85RW
V25 K1 M283 DT 2
solenoid valve 2 BK - 0.85B
1 C02 97 0.85G
V30 O3 L263 ATT flow control EPC DT 2
2 FG - 0.85B
1 H09 (male) 5 0.5YR
W03 AB9 L345 Rear limit switch X 2
2 H09 (male) 6 0.5B
M11 3 0.85L
X - B397 Joint - - - M12 1 0.85L
M13 1 0.85L
P09 1 0.85B
XA - L265 Joint - - - XN - 0.85B
XR - 0.85B
C01 8 0.85WB
XB - M265 Joint - - - P09 3 0.85WB
XT - 0.85WB
PC200, 200LC, 220, 220LC-8M0 40-200 41


No. layout drawing
· - BRAID
XD - E250 Joint - - - A40 (male) 3 BRAID
CM04 8 1.25B
C01 60 0.5RW
XE - I229 Joint - - - CK02 11 0.5RW
J01 12 0.5RW
CK02 4 0.5L
XF - G229 Joint - - - DG - 1.25L
J02 12 1.25L
C01 45 0.5W
XG - E229 Joint - - - CK01 10 0.5W
ZG - 0.5W
C01 64 0.5L
XH - E230 Joint - - - CK01 11 0.5L
ZH - 0.5L
CK02 1 1.25B
XJ - K238 Joint - - - CK02 2 1.25B
J04 20 1.25B
NJ - 0.85B
P02 1 0.85B
XL - C280 Joint - - -
P08 1 0.85B
XN - 0.85B
J06 17 0.85WB
NE - 0.85WB
XM - C280 Joint - - -
P02 3 0.85WB
P08 3 0.85WB
C01 18 0.85B
XN - K260 Joint - - - XA - 0.85B
XL - 0.85B
BF - 0.85B
XQ - D258 Joint - - - FL - 0.85B
M14 2 0.85YB
P10 1 0.85B
XR - M265 Joint - - - XA - 0.85B
XS - 0.85B
P11 1 0.85B
XS - L265 Joint - - - P. 12 1 0.85B
XR - 0.85B
P10 3 0.85WB
XT - M265 Joint - - - XB - 0.85WB
XU - 0.85WB
P11 3 0.85WB
XU - L265 Joint - - - P. 12 3 0.85WB
XT - 0.85WB
40-200 42 PC200, 200LC, 220, 220LC-8M0


No. layout drawing
M11 4 0.85BW
Y - B397 Joint - - - M12 2 0.85BW
M13 2 0.85BW
CE02 46 0.5W
ZA - I304 Joint - - - K02 A 0.5W
ZE - 0.5W
CE02 47 0.5L
ZB - I304 Joint - - - K02 B 0.5L
ZF - 0.5L
AC01 2 0.5W
ZE - B226 Joint - - - ZA - 0.5W
ZG - 0.5W
AC01 1 0.5L
ZF - B227 Joint - - - ZB - 0.5L
ZH - 0.5L
N08 3 0.5W
B227, XG - 0.5W
ZG - Joint - - -
B228 ZE - 0.5W
ZZ - 0.5W
CM02 9 0.5L
B227, N08 10 0.5L
ZH - Joint - - -
B228 XH - 0.5L
ZF - 0.5L
CM02 7 0.5W
ZZ - D252 Joint - - - CM02 8 0.5W
ZG - 0.5W
PC200, 200LC, 220, 220LC-8M0 40-200 43

SEN06132-02 Connector arrangement diagram
Connector arrangement diagram

Layout of connector (1/6)
40-200 44 PC200, 200LC, 220, 220LC-8M0

Connector arrangement diagram SEN06132-02
(2/6)
PC200, 200LC, 220, 220LC-8M0 40-200 45

(3/6)
40-200 46 PC200, 200LC, 220, 220LC-8M0

(4/6)
PC200, 200LC, 220, 220LC-8M0 40-200 47

(5/6)
40-200 48 PC200, 200LC, 220, 220LC-8M0

(6/6)
PC200, 200LC, 220, 220LC-8M0 40-200 49

SEN06132-02 Connection table for connector pin numbers
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.
40-200 50 PC200, 200LC, 220, 220LC-8M0

Connection table for connector pin numbers SEN06132-02
PC200, 200LC, 220, 220LC-8M0 40-200 51

40-200 52 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 53

40-200 54 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 55

40-200 56 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 57

40-200 58 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 59

40-200 60 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 61

40-200 62 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 63

40-200 64 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 65

40-200 66 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 67

40-200 68 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 69

40-200 70 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 71

40-200 72 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 73

40-200 74 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 75

40-200 76 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 77

40-200 78 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 79

40-200 80 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 81

40-200 82 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 83

40-200 84 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 85

SEN06132-02 T- branch box and T- branch adapter table
T- branch box and T- branch adapter table

(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal col-
umn indicates a part number of harness checker assembly.
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
Identifi-
Part No. Part name cati-on
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 ECONO 2P q q
ECONO
799-601-2790 Adapter for ECONO 12
12P
q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
ECONO
799-601-2840 Extension cable (ECONO type) 12
12P
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
799-601-7110 Adapter for M 3 M3P q q q q
799-601-7340 Adapter for M 8 M8P q
40-200 86 PC200, 200LC, 220, 220LC-8M0

T- branch box and T- branch adapter table SEN06132-02
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
Identifi-
symbol
799-601-7140 Adapter for M 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
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
PC200, 200LC, 220, 220LC-8M0 40-200 87

SEN06132-02 T- branch box and T- branch adapter 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
Identifi-
symbol
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*
Common rail pressure
3 1, 2, 3 L q q
799-601-4230*
Air intake pressure/temperature
4 1, 2, 3, 4 C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1, 2, 3 A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1, 2, 3 B 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 to 4 and DTM2 3, – q
4
“*” Shows not T-adapter but socket.
40-200 88 PC200, 200LC, 220, 220LC-8M0

Troubleshooting method for open circuit in wiring harness of pressure sensor system SEN06132-02
Troubleshooting method for open circuit in wiring harness of pressure

sensor system
a Since pressure sensors consisting not only of resistor but also electronic circuit components such as am-
plifiers have variation in measured value and its own polarities. So troubleshooting must be performed
carefully.
Failure codes applicable to this diagnosis

q CA123: Charge air pressure sensor low error
q CA451: Common rail pressure sensor high error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector.
2) Measure resistances R1 and R2 between pins.
a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore,
when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor
connector so that their polarities match these of the sensor.
a If measured value is infinite, take measurements by applying the probes of opposite polarities and
record the finite value obtained as a measured value.
a Since measured values may be dispersed, take several measurements.
Cause of this dispersion appears to be a charge in a sensor. Repeat steps 1 and 2 several times.
Consider this dispersion when judging whether the wiring harness is open in step 3.
2. Measure and record resistance with the wiring harness between the pressure sensor and engine controller
connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) With the pressure sensor to measure connected, disconnect connector (3) on engine controller side,
and connect T-adapter (4) to the harness side connector.
3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins.
3. Judging open circuit

If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is open".
a "Apparent difference" means a difference of 10 or more times.
PC200, 200LC, 220, 220LC-8M0 40-200 89

SEN06132-02 Troubleshooting method for open circuit in wiring harness of pressure sensor system
List of pressure sensor measuring locations and reference values

Measuring location at sen-
Sensor Measured internal resis- Remarks
sor pin
tance of sensor (reference)
Charge pressure sen- R2: between (2) and (4) Approx. 100 z Sensor is common to engine models
sor R1: between (1) and (4) Approx. 200 z 107 and 114
Sensor is common to engine models
R2: Between (3) and (1) Approx. 23 kz
Common rail pressure 107 and 114
sensor R1: Between (1) (+) and If polarities are inverted, resistance is
Approx. 10 Mz
(2) (-) infinite
*: In addition to the above, when measuring R2', disconnect the following: (See circuit diagram related to each
failure code)
q When measuring R2' of charge pressure sensor (CA123):
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water sepa-
rator)
q When measuring R2' of common rail pressure sensor (CA451):
Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator)
Measurement record (For measuring locations, see circuit diagram related to each failure code.)
Sensor + Wiring harness
Sensor unit
(Measuring location on wir-
Sensor (Measuring location on sen- Measured value Measured value
ing harness side connector
sor pin side connetor)
of engine controller)
R2': Between (37) and (47)
Charge pressure sen- R2: between (2) and (4)
(*)
sor
R1: between (1) and (4) R1': Between (44) and (47)
R2': Between (37) and (47)
R2: Between (3) and (1)
Common rail pressure (*)
sensor R1: Between (1) (+) and R1': between (47)(+) and
(2) (-) (25)(-)
40-200 90 PC200, 200LC, 220, 220LC-8M0

Troubleshooting method for open circuit in wiring harness of pressure sensor system SEN06132-02
PC200, 200LC, 220, 220LC-8M0 40-200 91

SEN06132-02
© 2018 KOMATSU
All Rights Reserved
40-200 92
SEN06133-01
SEN06133-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
301 Troubleshooting by failure code, Part 1
Failure code [879AKA] .................................................................................................................................... 3

Failure code [879AKB] .................................................................................................................................... 3
Failure code [879BKA] .................................................................................................................................... 3
Failure code [879BKB] .................................................................................................................................... 3
Failure code [879CKA].................................................................................................................................... 3
Failure code [879CKB].................................................................................................................................... 3
Failure code [879DKZ] .................................................................................................................................... 4
Failure code [879EMC] ................................................................................................................................... 4
Failure code [879FMC] ................................................................................................................................... 4
Failure code [879GKX].................................................................................................................................... 4
Failure code [989L00] ..................................................................................................................................... 5
Failure code [989M00] .................................................................................................................................... 6
Failure code [989N00]..................................................................................................................................... 7
Failure code [AA10NX] ................................................................................................................................... 8
Failure code [AB00KE].................................................................................................................................. 10
Failure code [B@BAZG] ............................................................................................................................... 13
Failure code [B@BAZK]................................................................................................................................ 14
Failure code [B@BCNS] ............................................................................................................................... 16
Failure code [B@BCZK]................................................................................................................................ 17
Failure code [B@HANS] ............................................................................................................................... 19
Failure code [CA111]..................................................................................................................................... 20
Failure code [CA115] .................................................................................................................................... 21
Failure code [CA122] .................................................................................................................................... 22
Failure code [CA123] .................................................................................................................................... 25
Failure code [CA131] .................................................................................................................................... 28
PC200, 200LC, 220, 220LC-8M0 40-301 1

SEN06133-01
Failure code [CA132] .................................................................................................................................... 31

Failure code [CA144] .................................................................................................................................... 34
Failure code [CA145] .................................................................................................................................... 37
Failure code [CA153] .................................................................................................................................... 40
Failure code [CA154] .................................................................................................................................... 43
Failure code [CA155] .................................................................................................................................... 46
Failure code [CA187] .................................................................................................................................... 47
Failure code [CA221] .................................................................................................................................... 49
Failure code [CA222] .................................................................................................................................... 52
Failure code [CA227] .................................................................................................................................... 55
Failure code [CA234] .................................................................................................................................... 56
Failure code [CA238] .................................................................................................................................... 57
Failure code [CA271] .................................................................................................................................... 59
Failure code [CA272] .................................................................................................................................... 61
40-301 2 PC200, 200LC, 220, 220LC-8M0

Failure code [879AKA] SEN06133-01
Failure code [879AKA]

See Chapter 80, Appendix "Failure code [879AKA] Air Conditioner Inside Air Sensor Open Circuit".
a It is not possible to disconnect the connector of the inside air temperature sensor, which remains mounted
on the machine. Replace the air conditioner controller or air conditioner unit.
Failure code [879AKB]

See Chapter 80, Appendix "Failure code [879AKB] Air Conditioner Inside Air Sensor Short Circuit".
a It is not possible to disconnect the connector of the inside air temperature sensor, which remains mounted
on the machine. Replace the air conditioner controller or air conditioner unit.
Failure code [879BKA]

See Chapter 80, Appendix "Failure code [879BKA] Air Conditioner Outside Air Sensor Open Circuit".
Failure code [879BKB]

See Chapter 80, Appendix "Failure code [879BKB] Air Conditioner Outside Air Sensor Short Circuit".
Failure code [879CKA]

See Chapter 80, Appendix "Failure code [879CKA] Vent Sensor Open Circuit".
a It is not possible to disconnect the connector of the vent sensor (evaporator temperature sensor), which
remains mounted on the machine. Replace the air conditioner controller or air conditioner unit.
Failure code [879CKB]

See Chapter 80, Appendix "Failure code [879CKB] Vent Sensor Short Circuit".
a It is not possible to disconnect the connector of the vent sensor (evaporator temperature sensor), which
remains mounted on the machine. Replace the air conditioner controller or air conditioner unit.
PC200, 200LC, 220, 220LC-8M0 40-301 3

SEN06133-01 Failure code [879DKZ]
Failure code [879DKZ]

See Chapter 80, Appendix "Failure code [879DKZ] Sunlight Sensor Open Circuit/Short Circuit".
Failure code [879EMC]

See Chapter 80, Appendix "Failure code [879EMC] Outlet Damper Error".
a It is not possible to disconnect the connector of the outlet selector servomotor, which remains mounted on
the machine. Replace the air conditioner controller or air conditioner unit.
Failure code [879FMC]

See Chapter 80, Appendix "Failure code [879FMC] A/M Damper Error".
a It is not possible to disconnect the connector of the air mix servomotor, which remains mounted on the
machine. Replace the air conditioner controller or air conditioner unit.
Failure code [879GKX]

See Chapter 80, Appendix "Failure code [879GKX] Refrigerant Error".
40-301 4 PC200, 200LC, 220, 220LC-8M0

Failure code [989L00] SEN06133-01
Failure code [989L00]

Detail of failure Engine controller lock up is detected (Factor 1).
Action level -
Action of con- • None in particular
troller • If the cause of the failure is eliminated, the state of the machine returns to normal by itself.
Problem on
Engine cannot be started.
machine
Related infor- When this failure code is displayed after the machine monitor is replaced, the user password must be
mation switched with the one that was used before the machine monitor was replaced.
Inspection
No. Troubleshooting procedure Criterion and remedy
item
• The user password of the
User pass- machine monitor is detec-
word of This failure may occur due to the machine monitor being tive.
1 -
machine replaced. • Change the password.
monitor • Proceed to "Repair
check".
Return to the first inspection
1. Turn the starting switch on. YES
2 Repair check item.
2. Is this failure code displayed?
NO Repairs are completed.
PC200, 200LC, 220, 220LC-8M0 40-301 5

SEN06133-01 Failure code [989M00]
Failure code [989M00]

Detail of failure Machine monitor detects engine controller lock (Factor 2).
Action level -
Problem on
Engine does not start.
machine
Related infor- When this failure code is displayed after the machine monitor is replaced, the user password must be
mation switched with the one that was used before the machine monitor was replaced.
Inspection
item
• The machine monitor user
password setting is appro-
YES priate.
• Proceed to the next
Machine inspection item.
monitor user This failure may occur due to the machine monitor being • The machine monitor user
1
password set- replaced. password setting is not
ting appropriate.
NO • Change the user pass-
word.
• Proceed to "Repair
check".
YES Repairs are completed.
• The machine monitor may
Recheck of be defective.
1. Recheck the preceding troubleshooting.
2 inspection • Replace the machine
2. Can you identify the cause after carrying out a recheck? NO
item monitor.
check".
1. Turn the starting switch off. Return to the first inspection
YES
2. Connect all the component parts. item.
3 Repair check
3. Turn the starting switch on.
4. Is this failure code displayed? NO Repairs are completed.
40-301 6 PC200, 200LC, 220, 220LC-8M0

Failure code [989N00] SEN06133-01
Failure code [989N00]

Detail of failure Machine monitor detects engine controller lock (Factor 3).
Action level -
Action of con- • Tries automatic recovery.
Problem on
-
machine
Related infor-
-
mation
Inspection
item
• The engine controller may
be defective.
If this occurs repeatedly, the engine controller may be defec-
Engine con- • Replace the engine con-
1 tive. (Since this is an internal defect, troubleshooting cannot -
troller troller.
be performed.)
check".
YES
2 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 7

SEN06133-01 Failure code [AA10NX]
Failure code [AA10NX]

Air cleaner clogging switch signal voltage is not 1 V or less while the engine is running, and the
Detail of failure
machine monitor detects clogging of the air cleaner (sensor contacts open).
Action level L01
Action of con-
Displays the air cleaner clogging monitor in yellow on the machine monitor.
troller
Problem on
If machine is used as it is, engine may be damaged.
machine
Related infor- Input condition (ON/OFF) from the air cleaner clogging switch can be checked via the monitoring func-
mation tion.(Code: 04501 monitor input 2)
Inspection
item
• Air cleaner is not clogged.
YES • Proceed to the next
inspection item.
Air cleaner The air cleaner may be clogged. Check it for clogging and
1 • Air cleaner is clogged.
clogging then clean or replace if it is clogged.
• Clean or replace the air
NO
cleaner.
• Proceed to "Repair check".
1. Starting switch: OFF • The state of the air cleaner
2. Disconnect connector P23, and connect the T-adapter to clogging switch is normal.
YES
the male side. • Proceed to the next
3. Start the engine. inspection item.
Air cleaner When the
2 clogging state of the Resis- • The air cleaner clogging
Max. 1 z
switch air cleaner is tance switch is defective.
Between P23 (male) normal *1 NO • Replace the air cleaner
(1) and (2)
When air clogging switch.
Resis- • Proceed to "Repair check".
cleaner is Min. 1 Mz
tance
clogged *2
• An open circuit does not
1. Starting switch: OFF occur in the wiring har-
2. Disconnect connectors CM02 and P23, and insert YES ness.
T-adapter into each female side. • Proceed to the next
Open circuit inspection item.
3 in wiring har-
Between CM02 (female) (4) and P23 Resis- • An open circuit occurs in
ness Max. 1 z
(female) (1) tance the wiring harness.
NO • Repair or replace the wir-
Between P23 (female) (2) and Resis-
Max. 1 z ing harness.
ground tance • Proceed to "Repair check".
Recheck of • The machine monitor may

1. Recheck the preceding troubleshooting. be defective.
4 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the machine
item
monitor.
• Proceed to "Repair check".
YES
5 Repair check
q Air cleaner intake resistance value

*1: Max. -3,430 Pa {Max. -350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
40-301 8 PC200, 200LC, 220, 220LC-8M0

Failure code [AA10NX] SEN06133-01
Circuit diagram related to air cleaner clogging sensor
PC200, 200LC, 220, 220LC-8M0 40-301 9

SEN06133-01 Failure code [AB00KE]
Failure code [AB00KE]

While the engine is running, voltage from the alternator drops, and the machine monitor detects that the
Detail of failure
battery charge voltage is low (below 7.8 V).
Action level L03
• Displays charge level monitor red on the machine monitor.
Action of con-
• Even if the cause of a failure is removed, the state of the machine does not return to normal until the
troller
starting switch is turned to OFF position.
Problem on
If machine continues to be operated, battery may not be charged.
machine
Related infor- Signal voltage of alternator can be checked via the monitoring function. (Code: 04300 Battery Charge
mation Voltage)
Inspection
item
• The state of the alternator
terminal is normal.
YES
inspection item.
• The alternator terminal is
Alternator ter- 1. Starting switch: OFF defective.
1 • If the terminal becomes
minal 2. Check terminal.
loose, tighten it.
NO • If an open circuit is
detected, carry out the
appropriate replacement.
check".
• The power generation of
1. Starting switch: OFF
the alternator is normal.
2. Insert the T-adapter into the connector E12. YES
Power gener- inspection item.
2 ation of alter- • The power generation of
nator Engine
the alternator is defective.
Between E12 (1) and speed: 27.5 to 29.5
Voltage NO • Replace the alternator.
ground Medium or V
above
check".
1. Starting switch: OFF • The state of the diode is
2. Disconnect diode D01, and connect the T-adapter to the normal.
YES
male side. • Proceed to the next
a Measure in diode range. inspection item.
3 Diode
Between D01 (male) (2) (+) and (6) (-) No continuity • The diode is defective.
• Replace the diode.
NO
Between D01 (male) (6) (+) and (2) (-) Continuity • Proceed to "Repair
check".
• The state of the wiring har-
1. Starting switch: OFF ness or machine monitor
2. Insert the T-adapter into the connector CM01. YES is normal.
3. Start the engine. • Proceed to the next
Wiring har- inspection item.
ness or • The wiring harness or
4
machine machine monitor is defec-
monitor tive.
Between CM01 (16) and ground Voltage 20 to 30 V NO • Replace the wiring har-
ness or machine monitor.
check".
40-301 10 PC200, 200LC, 220, 220LC-8M0

Failure code [AB00KE] SEN06133-01
Inspection
item
a If no failure is found by Inspection item 2, this check is not • An open circuit does not
required. occur in the wiring har-
1. Starting switch: OFF YES ness.
2. Disconnect connectors CM01 and E12, and connect the • Proceed to the next
Open circuit T-adapter to each female side. inspection item.
5 in wiring har- • An open circuit occurs in
ness the wiring harness.
Between CM01 (female) (16) and Resis- • Repair or replace the wir-
Max. 1 z NO
E12 (female) (1) tance ing harness.
check".
a If no failure is found by Inspection item 2, this check is not
• No ground fault occurs in
required.
the wiring harness.
1. Starting switch: OFF YES
2. Disconnect connectors CM01 and E12, and connect the
inspection item.
Ground fault T-adapter to either female side.
6 in wiring har- • Ground fault occurs in the
ness wiring harness.
Between ground and CM01 (female) Resis- • Repair or replace the wir-
Min. 1 Mz NO
(16) or E12 (female) (1) tance ing harness.
check".
item monitor.
check".
YES
8 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 11

SEN06133-01 Failure code [AB00KE]
Circuit diagram related to charge
40-301 12 PC200, 200LC, 220, 220LC-8M0

Failure code [B@BAZG] SEN06133-01
Failure code [B@BAZG]

While the engine is running, the engine controller detects a decrease of the engine oil pressure (sensor
Detail of failure
contact closed) by the signal voltage of the engine oil pressure switch.
Action level L03
Action of con- • Displays the engine oil pressure monitor in red on the machine monitor.
Problem on
If machine is used as it is, engine may be damaged.
machine
The engine oil switch signal is input to the engine controller. If the engine oil pressure switch is closed
Related infor-
(ON) while the engine is running, this failure code is transmitted from the engine controller to the
mation
machine monitor.
Inspection
item
• The state of the engine oil
pressure is normal.
YES
inspection item.
Engine oil Engine oil pressure may drop. Check it and remove cause of • Engine oil pressure is
1
pressure failure if oil pressure is low. abnormal (drops).
• Rectify the cause of the
NO
failure.
check".
• The engine oil pressure
monitor system may be
Recheck of defective.
1. Recheck the preceding troubleshooting. • Perform troubleshooting
2 inspection
2. Can you identify the cause after carrying out a recheck? NO for "E-6 Sudden stop item
item
lights up during engine
running." in mode E.
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 13

SEN06133-01 Failure code [B@BAZK]
Failure code [B@BAZK]

When the starting switch is turned ON, the signal voltage from the engine oil level switch is not below 1
Detail of failure
V, and the machine monitor detects a decrease of the engine oil level (oil level switch opened).
Action level L01
Action of con-
Displays the engine oil level monitor in yellow on the machine monitor.
troller
Problem on
If machine is used as it is, engine may be seized.
machine
Related infor- The input state (ON/OFF) from the engine oil level switch can be checked via the monitoring function.
mation (Code: 04501 monitor input 2)
Inspection
item
• The engine oil level is nor-
mal.
YES
inspection item.
Engine oil The engine oil level may decrease. Make an inspection. If the
1 • The engine oil level is not
level oil level decreases, remedy the failure cause.
correct.
NO • Replenish engine oil.
check".
level switch is normal.
2. Disconnect connector P44. YES
3. Turn the starting switch ON.
inspection item.
Engine oil • The engine oil level switch
2
level switch is defective.
Resis- • Replace the engine oil
Between P44 (male) (1) and ground Max. 1 z NO
tance level switch.
check".
2. Disconnect connectors CM02 and P44, and connect the YES ness.
T-adapter to each female side. • Proceed to the next
Between CM02 (female) (2) and P44 Resis- • Repair or replace the wir-
Max. 1 z NO
(female) (1) tance ing harness.
check".
item monitor.
check".
YES
5 Repair check
40-301 14 PC200, 200LC, 220, 220LC-8M0

Failure code [B@BAZK] SEN06133-01
Circuit diagram related to engine oil level switch
PC200, 200LC, 220, 220LC-8M0 40-301 15

SEN06133-01 Failure code [B@BCNS]
Failure code [B@BCNS]

While the engine is running, the voltage from the engine coolant temperature sensor decreases, and
Detail of failure
the engine controller detects engine coolant temperature overheat.
Action level L02
Action of con-
Lights up engine coolant temperature monitor in red on machine monitor.
troller
Problem on
If machine is used as it is, engine may be seized.
machine
• The signal voltage of the engine coolant temperature sensor is input by the engine controller, and its
Related infor- information is transmitted to the machine monitor via CAN communication.
mation • Engine coolant temperature can be checked via the monitoring function (Code: 04107 Engine cool-
ant temperature)
Inspection
item
• The engine coolant tem-
perature is normal.
YES
Engine cool- inspection item.
Engine coolant may overheat. Check coolant temperature
1 ant tempera- • The engine coolant tem-
and remove cause of failure if coolant overheats.
ture perature is abnormal.
NO • Repair the defective part.
check".
perature gauge system
Recheck of may be defective.
2 inspection • Perform troubleshooting for
item failure codes [CA144] and
[CA145].
check".
YES
3 Repair check
40-301 16 PC200, 200LC, 220, 220LC-8M0

Failure code [B@BCZK] SEN06133-01
Failure code [B@BCZK]

While the starting switch is turned ON (the engine is stopped) or the engine is running, the signal volt-
Detail of failure age from the radiator coolant level switch is not below 1 V, and the machine monitor detects a drop in
the radiator coolant level (sensor contact open).
Action level L01
Action of con-
Displays the radiator coolant level monitor in yellow on the machine monitor.
troller
Problem on
If machine is used as it is, engine may overheat.
machine
Related infor- Input condition (ON/OFF) from radiator coolant level switch can be checked via the monitoring function.
Inspection
item
• The state of the radiator
coolant level is normal.
YES
inspection item.
Radiator cool- Coolant level in radiator sub-tank may be low. Check coolant
1 • The radiator coolant level
ant level level and add coolant as necessary.
is not correct.
NO • Replenish radiator water.
check".
• The state of the coolant
level sensor is normal.
2. Disconnect connector P24, and connect the T-adapter to YES
the male side.
inspection item.
Coolant level Between • The coolant level sensor is
2 Resis-
sensor FULL and Max. 1 z defective.
tance
Between P24 (male) LOW • Replace the coolant level
NO
(1) and (2) sensor.
Resis- • Proceed to "Repair
Below LOW Min. 1 Mz
tance check".
occur in the wiring har-
2. Disconnect connectors CM02 and P24, and connect the
YES ness.
T-adapter to each female side.
a Add coolant in advance.
Between CM02 (female) (3) and P24 Resis- • Repair or replace the wir-
Max. 1 z NO
check".
item monitor.
check".
YES
5 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 17

SEN06133-01 Failure code [B@BCZK]
Circuit diagram related to radiator coolant level sensor
40-301 18 PC200, 200LC, 220, 220LC-8M0

Failure code [B@HANS] SEN06133-01
Failure code [B@HANS]

The pump controller detects overheating of hydraulic oil temperature (approximately 102 °C or above)
Detail of failure
by the signal voltage of the hydraulic oil temperature sensor while the engine is running.
Action level L02
Action of con- • Displays the hydraulic oil temperature monitor on the machine monitor in red.
Problem on
If machine is used as it is, hydraulic component may be damaged.
machine
• A signal from the hydraulic oil temperature sensor is input to the pump controller and then data is
transmitted to the machine monitor through CAN communication system.
Related infor-
• Hydraulic oil temperature can be checked via the monitoring function. (Code: 04401: Hydraulic oil
mation
temperature)
• Refer to "E-9 Hydraulic oil temperature gauge does not indicate correct temperature." in mode E.
Inspection
item
• The hydraulic oil tempera-
ture is normal.
YES
Overheating inspection item.
Hydraulic oil may overheat. Check the hydraulic oil tempera-
of hydraulic • The hydraulic oil tempera-
1 ture, and remove the cause of the failure if hydraulic oil over-
oil temperature is abnormal (high).
heats.
ture • Rectify the cause of the
NO
failure.
check".
Recheck of ture gauge system may be
1. Recheck the preceding troubleshooting. defective.
2 inspection
2. Can you identify the cause after carrying out a recheck? NO • Perform troubleshooting
item
for failure code [DGH2KB].
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 19

SEN06133-01 Failure code [CA111]
Failure code [CA111]

Detail of failure An error occurred in the internal memory or internal power supply circuit of the engine controller.
Action level L04
Action of con-
None in particular
troller
Problem on
It may not be possible to stop running during operation or to start when stopped.
machine
Related infor- Power supply voltage of engine controller can be checked via the monitoring function. (Code: 03203
mation Battery Voltage)
Inspection
item
• The relevant system is
operating normally.
YES
Check the failure codes that are displayed simultaneously. If inspection item.
Relevant sys-
1 other failure codes are also displayed, perform troubleshoot- • The relevant system is
tem
ing for them. defective.
check".
YES • Repairs are completed.
• The power supply voltage
Recheck of system may be defective.
2 inspection • Perform troubleshooting
item for failure code [CA441].
check".
YES
3 Repair check
40-301 20 PC200, 200LC, 220, 220LC-8M0

Failure code [CA115] SEN06133-01

Detail of failure An error occurred in both signals of the engine Ne speed sensor and engine Bkup speed sensor.
Action level L04
Action of con-
None in particular
troller
Problem on • Engine stops.
machine • Engine does not start.
Related infor-
-
mation
Inspection
item
• The sensor connector is
connected correctly.
YES
inspection item.
Connection of Since connection of connector between NE speed sensor and
1 sensor con- Bkup speed sensor may be defective (incorrect connection), • The sensor connector is
nector check it. not connected correctly.
• Reattach or replace the
NO
sensor connector.
check".
• The state of the NE speed
sensor system is normal.
YES
NE speed inspection item.
Perform troubleshooting for items 1 to 10 of failure code
2 sensor sys- • The NE speed sensor sys-
[CA689].
tem tem is defective.
check".
• The state of the Bkup
speed sensor system is
YES normal.
Bkup speed inspection item.
3 sensor sys- Perform troubleshooting for failure code [CA778].
tem • The Bkup speed sensor
system is defective.
check".
4 inspection • Replace the engine con-
item troller.
check".
YES
5 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 21


High voltage is detected in the pressure signal circuit of the charge (boost) pressure or temperature
Detail of failure
sensor.
Action level L03
Action of con-
Runs engine by setting charge pressure to a fixed value.
troller
Problem on
Engine output falls.
machine
• Input voltage from charge air pressure sensor (boost pressure sensor) can be checked via the moni-
toring function.
(Code: 36501 (V))
Related infor-
• Boost pressure by charge air pressure sensor (boost pressure sensor) can be checked via the mon-
mation
itoring function.
(Code: 36500 (kPa))
• Even in a normal condition, "Low Error" code [CA123] appears if the sensor connector is removed.
Inspection
item
ness and connector are
YES normal.
inspection item.
Wiring har- See descriptions of wiring harness and connectors in "c: Elec-
1 ness connec- trical equipment" in "Checks before troubleshooting" of • The wiring harness and
tor "Related information on troubleshooting", and check it. connector are defective.
• Repair or replace the
NO defective wiring harness
and connector.
check".
• The state of the sensor
power supply 2 system is
YES normal.
Sensor power inspection item.
If failure code [CA227] is also displayed, perform trouble-
2 supply 2 sys-
shooting for it first. • The sensor power supply
tem
2 system is defective.
check".
40-301 22 PC200, 200LC, 220, 220LC-8M0

Inspection
item
2. Disconnect connector BOOST PRESS & IMT.
3. Turn the starting switch to ON position.
If failure code changes from [CA122] to [CA123], the boost

pressure sensor is defective. • The state of the boost
a Failure code [CA153] for temperature sensor is also dis- pressure or temperature
played. YES sensor is normal.
Ignore this failure code because the sensor connector is • Proceed to the next
only disconnected. inspection item.
Boost pres-
sure and tem- • Reference
3
perature 1. Starting switch: OFF
sensor 2. Insert the T-adapter into the connector ECM.
• The boost pressure or
temperature sensor is
defective.
Between ECM (44) Sensor out- • Replace the boost pres-
Voltage 0.3 to 4.7 V NO
and (47) put sure or temperature sen-
sor.
check".
• No short circuit occurs in
the wiring harness.
2. Disconnect connectors ECM and BOOST PRESS & IMT, YES
and connect the T-adapter to the female side of the ECM.
inspection item.
Short circuit in
4 wiring har- • A short circuit occurs in
Resis- • Repair or replace the wir-
Between ECM (37) and (44) Min. 100 kz NO
tance ing harness.
check".
1. Starting switch: OFF • A hot short circuit does not
2. Disconnect connector BOOST PRESS & IMT, and insert occur in the wiring har-
the T-adapter into connector ECM. YES ness.
3. Turn the starting switch ON (with connector BOOST • Proceed to the next
Hot short cir- PRESS & IMT disconnected). inspection item.
5 cuit in wiring • A hot short circuit occurs
harness in the wiring harness.
• Repair or replace the wir-
Between ECM (44) and (47) Voltage Max. 1 V NO
ing harness.
check".
item troller.
check".
YES
7 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 23

Circuit diagram related to charge air pressure sensor
40-301 24 PC200, 200LC, 220, 220LC-8M0


Low voltage is detected in the pressure signal circuit of the charge (boost) pressure or temperature
Detail of failure
sensor.
Action level L03
Action of con-
Runs engine by setting charge pressure to a fixed value.
troller
Problem on
machine
• Input voltage from charge air pressure sensor (boost pressure sensor) can be checked via the moni-
toring function.
(Code: 36501 (V))
• Boost pressure by charge air pressure sensor (boost pressure sensor) can be checked via the mon-
Related infor-
itoring function.
mation
(Code: 36500 (kPa))
• Because female connector alone is provided in "Socket" for troubleshooting for this sensor, check for
open circuit in wiring harness and voltage check cannot be performed (T-adapter is not provided).
• This failure code appears if the sensor connector is removed.
Inspection
item
YES normal.
inspection item.
and connector.
check".
• The state of the charge
pressure sensor (boost
pressure sensor) power
YES
supply system is normal.
Charge pres- • Proceed to the next
sure sensor inspection item.
(boost pres- If failure code [CA187] or [CA227] is displayed, perform trou-
2 • The charge pressure sen-
sure sensor) bleshooting for it first.
power supply sor (boost pressure sen-
system sor) power supply system
NO is defective.
• Repair the defective part.
check".
1. Starting switch: OFF • No short circuit occurs in
2. Disconnect connectors CAM SENSOR, FUEL RAIL the wiring harness.
YES
PRESS, BOOST PRESS & IMT, and ECM. • Proceed to the next
3. Connect the T-adapter to female side of the ECM. inspection item.
Short circuit in
3 wiring har- Resis- • A short circuit occurs in
Between ECM (37) and (47) Min. 100 kz
ness tance the wiring harness.
NO
Resis- ing harness.
Between ECM (44) and (47) Min. 100 kz • Proceed to "Repair
tance
check".
PC200, 200LC, 220, 220LC-8M0 40-301 25

Inspection
item
the wiring harness.
2. Disconnect connectors ECM and BOOST PRESS & IMT, YES
and connect the T-adapter to the female side of the ECM.
inspection item.
Ground fault
Between ECM (female) (44) and Resis- • Repair or replace the wir-
Min. 100 kz NO
ground tance ing harness.
check".
YES ness.
If no failure is identified by the above checks, the wiring har-
ness may have an open circuit (*).
NO
ing harness.
check".
a If no failure is found by Inspection items 1 to 5 and a fail-
• The state of the boost
ure is found by checks on cause 6, the sensor is defec-
pressure or temperature
tive.
YES sensor is normal.
2. Insert the T-adapter into the connector ECM.
inspection item.
Boost pres- 3. Turn the starting switch to ON position.
sure and tem- • The boost pressure or
6
perature temperature sensor is
sensor defective.
Between ECM (44) Sensor out- • Replace the boost pres-
and (47) put sure or temperature sen-
sor.
check".
item troller.
check".
YES
8 Repair check
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related in-
formation on troubleshooting".
40-301 26 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to charge air pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-301 27


Detail of failure High voltage is detected in fuel dial circuit.
Action level L03
• If error occurs while the starting switch is ON, controller sets to fixed value used before the error has
Action of con- been detected and runs engine.
troller • If starting switch is turned to ON position after the error has occurred, controller uses a value of
100%.
Problem on
Engine speed cannot be controlled by using the fuel control dial.
machine
Related infor- Signal voltage of fuel dial can be checked via the monitoring function. (Code: 03000 Fuel control dial
mation voltage)
Inspection
item
YES normal.
inspection item.
and connector.
check".
• The state of the throttle
sensor power supply sys-
YES tem is normal.
Throttle sen- inspection item.
sor power If failure code [CA2185] is displayed, perform troubleshooting
2 • The throttle sensor power
supply sys- for it first.
tem supply system is defec-
tive.
NO
check".
• The state of the fuel con-
trol dial is normal.
the male side.
inspection item.
Fuel dial Resis-
3 (throttle sen- Between P20 (male) (1) and (3) 4.0 to 6.0 kz • The fuel control dial is
tance defective.
sor)
Resis- 0.25 to 5.0 • Replace the fuel control
Between P20 (male) (2) and (3) NO
tance kz dial.
Resis- 0.25 to 5.0 • Proceed to "Repair
Between P20 (male) (1) and (2) check".
tance kz
40-301 28 PC200, 200LC, 220, 220LC-8M0

Inspection
item
• An open circuit or short
1. Starting switch: OFF circuit does not occur in
2. Disconnect connector CE02, and connect the T-adapter to YES the wiring harness.
Open circuit the female side. • Proceed to the next
or short circuit inspection item.
4
in wiring har- Between CE02 (female) (22) and Resis- • An open circuit or short
ness 4.0 to 6.0 kz
(23) tance circuit occurs in the wiring
NO harness.
Resis- 0.25 to 5.0 • Proceed to "Short circuit in
Between CE02 (female) (9) and (23)
tance kz wiring harness".
required.
the wiring harness.
2. Disconnect connectors CE02 and P20, and connect the
inspection item.
Short circuit in T-adapter to either female side.
Between CE02 (female) (9) and
(22), or between P20 (female) (1) Min. 1 Mz NO
tance ing harness.
and (2)
check".
• A hot short circuit does not
2. Disconnect connector P20, and connect the T-adapter to
YES ness.
the female side.
Hot short cir- inspection item.
Between P20 (female) (2) and • Repair or replace the wir-
Voltage Max. 1 V NO
ground ing harness.
check".
item troller.
check".
YES
8 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 29

Circuit diagram related to throttle sensor
40-301 30 PC200, 200LC, 220, 220LC-8M0


Detail of failure Low voltage is detected in the fuel dial circuit.
Action level L03
• If error occurs while the starting switch is ON, controller sets to fixed value used before the error has
Action of con- been detected and runs engine.
troller • If starting switch is turned to ON position after the error has occurred, controller uses a value of
100%.
Problem on
Engine speed cannot be controlled by using the fuel control dial.
machine
Related infor- Signal voltage of fuel dial can be checked via the monitoring function. (Code: 03000 Fuel control dial
mation voltage)
Inspection
item
YES normal.
inspection item.
and connector.
check".
YES tem is normal.
Throttle sen- inspection item.
sor power If failure code [CA2186] is displayed, perform troubleshooting
2 • The throttle sensor power
supply sys- for it first.
tem supply system is defec-
tive.
NO
check".
• The state of the fuel con-
trol dial is normal.
the male side.
inspection item.
Fuel dial Resis-
3 (throttle sen- Between P20 (male) (1) and (3) 4.0 to 6.0 kz • The fuel control dial is
tance defective.
sor)
Resis- 0.25 to 5.0 • Replace the fuel control
Between P20 (male) (2) and (3) NO
tance kz dial.
Resis- 0.25 to 5.0 • Proceed to "Repair
Between P20 (male) (1) and (2) check".
tance kz
PC200, 200LC, 220, 220LC-8M0 40-301 31

Inspection
item
the female side. • Proceed to the next
or short circuit
4
in wiring har- Between CE02 (female) (22) and Resis-
4.0 to 6.0 kz
ness (23) tance circuit occurs in the wiring
harness.
NO
Resis- 0.25 to 5.0 • Proceed to "Open circuit in
Between CE02 (female) (9) and (23) wiring harness" or "Short
tance kz
circuit in wiring harness".
2. Disconnect connectors CE02 and P20, and connect the • Proceed to the next
T-adapter to each female side. inspection item.
Open circuit
5 in wiring har- Between CE02 (female) (22) and Resis-
Max. 1 z • An open circuit occurs in
ness P20 (female) (1) tance the wiring harness.
Between CE02 (female) (9) and P20 Resis- • Repair or replace the wir-
Max. 1 z NO
Between CE02 (female) (23) and Resis- • Proceed to "Repair
Max. 1 z check".
P20 (female) (3) tance
required.
the wiring harness.
2. Disconnect connectors CE02 and P20, and connect the
inspection item.
Short circuit in T-adapter to either female side.
(23), or between P20 (female) (2) Min. 1 Mz NO
tance ing harness.
and (3)
check".
the wiring harness.
2. Disconnect connectors CE02 and P20, and connect the YES
T-adapter to either female side.
inspection item.
Ground fault
Between ground and CE02 (female) Resis- • Repair or replace the wir-
Min. 1 Mz NO
(9) or P20 (female) (2) tance ing harness.
check".
item troller.
check".
YES
9 Repair check
40-301 32 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-301 33


Detail of failure High voltage is detected in signal circuit of engine coolant temperature sensor.
Action level L01
Action of con-
Runs engine by setting coolant temperature to fixed value.
troller
Problem on • Engine startability becomes poor in low temperature.
machine • Overheat prevention function does not operate.
• Input voltage from engine coolant temperature sensor can be checked via the monitoring function.
(Code: 04105 (V))
• Temperature detected by engine coolant temperature sensor can be checked via the monitoring
Related infor- function. (Code: 04107 (°C))
mation • This failure code appears when temperature sensor connector is removed.
• Because a female connector alone is provided in "Socket" for troubleshooting for this sensor, a
socket cannot be connected to the female connector on the wiring harness side of the sensor, and
checks for wire breakage cannot be performed (T-adapter is not provided).
Inspection
item
YES normal.
inspection item.
and connector.
check".
2. Disconnect connector COOLANT TEMP, and connect
temperature sensor is nor-
socket to male side.
YES mal.
a Regard coolant temperature sensor as normal if its resis-
tance is 700 z to 37 kz when coolant temperature is min.
inspection item.
0 °C.
Resis-
0 °C 30 to 37 kz
Coolant tem- tance
2 perature sen- Resis- 9.3 to 10.7
sor 25 °C • The coolant temperature
Between COOLANT tance kz sensor is defective.
TEMP (male) (A) and
Resis- • Replace the coolant tem-
(B) 50 °C 3.2 to 3.8 kz NO
tance perature sensor.
a Coolant tempera-
ture characteristics 1.0 to 1.3 kz
80 °C tance check".
Resis-
95 °C 700 to 800 z
tance
40-301 34 PC200, 200LC, 220, 220LC-8M0

Inspection
item
2. Disconnect connector ECM, and connect the T-adapter to YES the wiring harness.
or short circuit Between ECM (female) (15) and • An open circuit or short
3
in wiring har- (38) (coolant temperature: 0 °C and circuit occurs in the wiring
ness above) harness.
Resis- 700 z
a Use the coolant temperature NO • Repair or replace the wir-
tance to 37 kz
sensor and resistance character- ing harness.
istics table to check Inspection • Proceed to "Repair
item 2 as resistance criteria. check".
item troller.
check".
YES
5 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 35

Circuit diagram related to engine coolant temperature sensor
40-301 36 PC200, 200LC, 220, 220LC-8M0


Detail of failure Low voltage is detected in signal circuit of engine coolant temperature sensor.
Action level L01
Action of con-
Runs engine by setting coolant temperature to fixed value.
troller
Problem on • Engine startability becomes poor in low temperature.
machine • Overheat prevention function does not operate.
• Input voltage from engine coolant temperature sensor can be checked via the monitoring function.
(Code: 04105 (V))
Related infor- • Temperature detected by engine coolant temperature sensor can be checked via the monitoring
mation function. (Code: 04107 (°C))
• When temperature sensor connector is removed, failure code for High Error [CA144] appears
instead of this failure code.
Inspection
item
YES normal.
inspection item.
and connector.
check".
2. Disconnect connector COOLANT TEMP, and connect
temperature sensor is nor-
socket to male side.
YES mal.
a Regard coolant temperature sensor as normal if its resis-
tance is 700 z to 37 kz when coolant temperature is min.
inspection item.
0 °C.
Resis-
0 °C 30 to 37 kz
tance
Coolant tem- Resis- 9.3 to 10.7

Between COOLANT 25 °C tance kz
2 perature sen-
TEMP (male) (A) and • The coolant temperature
sor Resis-
(B) 50 °C 3.2 to 3.8 kz sensor is defective.
tance
a Coolant tempera- • Replace the coolant tem-
ture characteristics Resis- NO
80 °C 1.0 to 1.3 kz perature sensor.
tance • Proceed to "Repair
Resis- check".
95 °C 700 to 800 z
tance
Whole area
Between (B) and Resis-
of coolant Min. 100 kz
ground tance
temperature
PC200, 200LC, 220, 220LC-8M0 40-301 37

Inspection
item
the wiring harness.
2. Disconnect connector ECM, and connect the T-adapter to YES
the female side.
inspection item.
Short circuit in Between ECM (female) (15) and
(38) (coolant temperature: 0 °C and
above)
Resis- 700 z to 37 • Repair or replace the wir-
a Use the coolant temperature NO
tance kz ing harness.
sensor and resistance character-
istics table to check Inspection
check".
item 2 as resistance criteria.
the wiring harness.
2. Disconnect connectors ECM and COOLANT TEMP, and YES
connect the T-adapter to the female side of the ECM.
inspection item.
Ground fault
Min. 100 kz NO
check".
item troller.
check".
YES
6 Repair check
40-301 38 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to engine coolant temperature sensor
PC200, 200LC, 220, 220LC-8M0 40-301 39


High voltage is detected in the temperature signal circuit of the charge (boost) pressure or temperature
Detail of failure
sensor.
Action level L03
Action of con-
Runs engine by setting charge temperature to a fixed value.
troller
Problem on
The engine protection function by boost temperature does not work.
machine
• Input voltage from charge temperature sensor (boost pressure sensor) can be checked via the mon-
itoring function.
(Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked via
Related infor- the monitoring function.
mation (Code: 18500 (°C))
• Because a female connector alone is provided in "Socket" for troubleshooting for this sensor, a
socket cannot be connected to the female connector on the wiring harness side of the sensor, and
checks for wire breakage cannot be performed (T-adapter is not provided).
• This failure code appears when temperature sensor connector is removed.
Inspection
item
YES normal.
inspection item.
and connector.
check".
1. Starting switch: OFF temperature sensor is nor-
2. Disconnect connector BOOST PRESS & IMT, and YES mal.
connect socket to male side. • Proceed to the next
inspection item.
Resis-
-40 °C 41 to 48 kz
tance
Resis-
-20 °C 14 to 16 kz
tance
Charge tem-
2 perature sen- Resis- • The charge temperature
Between BOOST 0 °C 5.4 to 6.1 kz
sor tance sensor is defective.
PRESS & IMT (male)
Resis- • Replace the charge tem-
(3) and (4) 30 °C 1.6 to 1.8 kz NO
a Charge thermal
characteristics 560 to 600 z
Resis-
90 °C 230 to 250 z
tance
Resis-
130 °C 80 to 90 z
tance
40-301 40 PC200, 200LC, 220, 220LC-8M0

Inspection
item
or short circuit • An open circuit or short
3
in wiring har- Between ECM (23) and (47) circuit occurs in the wiring
ness a Use the charge temperature and
harness.
resistance characteristics table Resis- 80 z to 48
for the charge temperature sen- tance kz
ing harness.
sor in Inspection item 2 as resis-
tance criteria.
check".
item troller.
check".
YES
5 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 41

Circuit diagram related to boost pressure and temperature sensor
40-301 42 PC200, 200LC, 220, 220LC-8M0


Low voltage is detected in the temperature signal circuit of the charge (boost) pressure or temperature
Detail of failure
sensor.
Action level L03
Action of con-
Runs engine by setting charge temperature to a fixed value.
troller
Problem on
The engine protection function by boost temperature does not work.
machine
• Input voltage from charge temperature sensor (boost pressure sensor) can be checked via the mon-
itoring function.
(Code: 18501 (V))
Related infor- • Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked via
mation the monitoring function.
(Code: 18500 (°C))
• When temperature sensor connector is removed, failure code for High Error [CA153] appears
instead of this failure code.
Inspection
item
YES normal.
inspection item.
and connector.
check".
1. Starting switch: OFF temperature sensor is nor-
2. Disconnect connector BOOST PRESS & IMT, and YES mal.
connect socket to male side. • Proceed to the next
inspection item.
Resis-
-40 °C 41 to 48 kz
tance
Resis-
-20 °C 14 to 16 kz
tance
Charge tem-
2 perature sen- Resis- • The charge temperature
Between BOOST 0 °C 5.4 to 6.1 kz
sor tance sensor is defective.
PRESS & IMT (male)
Resis- • Replace the charge tem-
(3) and (4) 30 °C 1.6 to 1.8 kz NO
a Charge thermal
characteristics 560 to 600 z
Resis-
90 °C 230 to 250 z
tance
Resis-
130 °C 80 to 90 z
tance
PC200, 200LC, 220, 220LC-8M0 40-301 43

Inspection
item
the wiring harness.
2. Disconnect connector ECM, and connect the T-adapter to YES
the female side.
inspection item.
Short circuit in
3 wiring har- Between ECM (23) and (47) • A short circuit occurs in
ness a Use the charge temperature and the wiring harness.
resistance characteristics table Resis- 80 z to 48 • Repair or replace the wir-
NO
for the charge temperature sen- tance kz ing harness.
sor in Inspection item 2 as resis- • Proceed to "Repair
tance criteria. check".
required.
the wiring harness.
2. Disconnect connectors ECM and BOOST PRESS & IMT,
inspection item.
Ground fault and connect the T-adapter to the female side of the ECM.
Min. 100 kz NO
check".
item troller.
check".
YES
6 Repair check
40-301 44 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to boost pressure and temperature sensor
PC200, 200LC, 220, 220LC-8M0 40-301 45


The temperature detected by the charge (boost) pressure or temperature sensor exceeds the upper
Detail of failure
control limit.
Action level L03
Action of con-
Limits engine output and runs engine.
troller
Problem on • Engine output falls.
machine • Engine stops.
Related infor-
Boost temperature can be checked via the monitoring function. (Code: 18500 Boost temperature)
mation
Inspection
item
• The cooling performance
of the aftercooler is nor-
YES mal.
Cooling performance of the aftercooler may be lowered; • Proceed to the next
Cooling per- check it for the following items. inspection item.
1 formance of • Loose fan belt or damage • The cooling performance
aftercooler • Insufficient cooling air amount of the aftercooler is defec-
• Clogged aftercooler fin tive.
NO
check".
• The turbocharger outlet
temperature is normal.
YES
Turbocharger inspection item.
Turbocharger outlet temperature may rise abnormally. Check
2 outlet temper- • The turbocharger outlet
the related parts.
ature temperature is abnormal.
check".
temperature sensor sys-
YES tem is normal.
Charge tem- If no failure is identified by the above checks, the charge tem- inspection item.
3 perature sen- perature sensor system may be defective. Perform trouble- • The charge temperature
sor system shooting for failure codes [CA153] and [CA154]. sensor system is defec-
tive.
NO
check".
item troller.
check".
YES
5 Repair check
40-301 46 PC200, 200LC, 220, 220LC-8M0


Detail of failure Low voltage is detected in sensor power supply 2 circuit.
Action level L03
Action of con- • Runs by setting the charge (boost) pressure and charge (boost) temperature to the fixed value.
troller • Limits engine output and runs engine.
machine • Startability deteriorates.
Related infor-
-
mation
Inspection
item
YES normal.
inspection item.
and connector.
check".
2. Disconnect following connectors one by one, and turn the
starting switch to ON position each time.
3. Each time troubleshooting is finished, return to step 1. • The state of the sensor or
wiring harness is normal.
If this failure code is not displayed, disconnected sensor or YES
engine wiring harness is defective. inspection item.
a Many other failure codes are also displayed at the same
Sensor or wir- time. This is because the connector is disconnected.
2 Ignore failure codes other than this failure code [CA187].
ing harness
Sensor and wiring harness Connector • The disconnected sensor
Boost pressure and temperature or wiring harness is defec-
BOOST PRESS & IMT tive
sensor
NO • Replace the disconnected
Common rail pressure sensor FUEL RAIL PRESS
sensor or wiring harness.
Bkup sensor CAM SENSOR • Proceed to "Repair
Engine wiring harness ECM check".
item troller.
check".
YES
4 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 47

Circuit diagram related to sensor power supply 2 circuit
40-301 48 PC200, 200LC, 220, 220LC-8M0


Detail of failure High voltage is detected in signal circuit of ambient pressure sensor.
Action level L03
Action of con-
Runs engine by setting atmosphere to a fixed value.
troller
• Input voltage from ambient pressure sensor can be checked via the monitoring function. (Code:
Related infor- 37401 (V))
mation • Ambient pressure detected by ambient pressure sensor can be checked via the monitoring function.
(Code: 37400 (kPa))
Inspection
item
YES normal.
inspection item.
and connector.
check".
YES normal.
If failure code [CA352] or [CA386] is also displayed, perform
2 supply 1 sys-
troubleshooting for it first. • The sensor power supply
tem
check".
2. Disconnect connector AMB. AIRP RESSURE.
3. Turn the starting switch to ON position. • The ambient pressure
If failure code changes from [CA221] to [CA222], the sensor sensor is defective.
is defective. • Replace the ambient pres-
YES
sure sensor.
Ambient pres- • Reference • Proceed to the next
3 inspection item.
sure sensor 1. Starting switch: OFF
• The state of the ambient
Between ECM (3) and Sensor out- pressure sensor is normal.
(38) put • Proceed to "Short circuit in
wiring harness".
PC200, 200LC, 220, 220LC-8M0 40-301 49

Inspection
item
the wiring harness.
2. Disconnect connectors ECM and AMB. AIR PRESSURE, YES
and connect the T-adapter to either female side.
inspection item.
Short circuit in
Between ECM (female) (33) and (3),
or between AMB. AIR PRESSURE Min. 100 kz NO
tance ing harness.
(female) (1) and (3)
check".
2. Disconnect connector AMB. AIR PRESSURE. • A hot short circuit does not
3. Connect the T-adapter to the female side of connector occur in the wiring har-
AMB. AIR PRESSURE, or insert the T-adapter into YES ness.
connector ECM. • Proceed to the next
Hot short cir- 4. Turn the starting switch ON (with connector AMB. AIR inspection item.
5 cuit in wiring PRESSURE disconnected).
harness • A hot short circuit occurs
in the wiring harness.
Between ECM (3) and (38), or
between AMB. AIR PRESSURE Voltage Max. 1 V NO
ing harness.
check".
item troller.
check".
YES
7 Repair check
40-301 50 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to ambient pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-301 51


Detail of failure Low voltage is detected in signal circuit of ambient pressure sensor.
Action level L03
Action of con-
Runs engine by setting atmosphere to a fixed value.
troller
• Input voltage from ambient pressure sensor can be checked via the monitoring function. (Code:
37401 (V))
Related infor-
• Ambient pressure detected by ambient pressure sensor can be checked via the monitoring function.
mation
(Code: 37400 (kPa))
• This failure code appears if the sensor connector is removed.
Inspection
item
YES normal.
inspection item.
and connector.
check".
If failure code [CA352] or [CA386] is displayed, perform trou-
bleshooting for it first. • The state of the ambient
pressure sensor power
1. Starting switch: OFF YES supply system is normal.
2. Disconnect connector AMB. AIR PRESSURE, and • Proceed to the next
Ambient pres- connect the T-adapter to the female side. inspection item.
sure sensor 3. Turn the starting switch to ON position.
2
power supply • The ambient pressure
system sensor power supply sys-
Between AMB. AIR
Power sup- 4.75 to 5.25 tem is defective.
PRESSURE (female) Voltage NO
ply input V • Repair the defective part.
(1) and (2)
check".
the wiring harness.
2. Disconnect connector AMB. AIR PRESSURE and ECM, YES
and connect the T-adapter to each female side.
inspection item.
a If power supply input in Inspec-
tion item 2 is normal, this check
Resis-
is not required. Max. 10 z
tance
Short circuit in Between ECM (female) (33) and
3 wiring har- AMB. AIR PRESSURE (female) (1) • A short circuit occurs in
the wiring harness.
ness a If power supply input in Inspec-
tion item 2 is normal, this check NO
Resis- ing harness.
is not required. Max. 10 z
Between ECM (female) (38) and
check".
AMB. AIR PRESSURE (female) (2)
Between ECM (female) (3) and
Resis-
AMB. AIR PRESSURE (female) (3) Max. 10 z
tance
(Sensor output)
40-301 52 PC200, 200LC, 220, 220LC-8M0

Inspection
item
the wiring harness.
inspection item.
Ground fault
Between ground and ECM (female)
(3) or AMB. AIR PRESSURE Min. 100 kz NO
tance ing harness.
(female) (3)
check".
the wiring harness.
inspection item.
Short circuit in
Between ECM (female) (3) and (38),
or between AMB. AIR PRESSURE Min. 100 kz NO
tance ing harness.
check".
a If no failure is found by Inspection items 1 to 5 and a fail-
• The state of the ambient
ure is found by Inspection item 6, the sensor is defective.
pressure sensor is normal.
inspection item.
Ambient pres-
6 • The ambient pressure
sure sensor
sensor is defective.
Between ECM (3) and Sensor out- • Replace the ambient pres-
(38) put sure sensor.
check".
item troller.
check".
YES
8 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 53

Circuit diagram related to ambient pressure sensor
40-301 54 PC200, 200LC, 220, 220LC-8M0


Detail of failure High voltage is detected in sensor power supply 2 circuit.
Action level L03
Action of con- • Runs by setting the charge pressure and charge temperature to the fixed values.
troller • Limits engine output and runs engine.
Related infor-
-
mation
Inspection
item
Sensor power • Repairs are completed.
1 supply 2 sys- Perform troubleshooting for failure code [CA187]. - • Proceed to "Repair
tem check".
YES
2 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 55


Detail of failure The engine speed exceeds the upper control limit.
Action level -
Action of con-
Stops injection from the injector until the engine speed lowers to the proper value.
troller
Problem on
Engine speed fluctuates.
machine
Related infor-
Engine speed can be checked via the monitoring function. (Code: 01002 Engine speed)
mation
Inspection
item
• Fuel is proper.
inspection item.
• The wrong fuel is being
1 Fuel used Fuel used may be improper. Check it. used.
• Replace fuel with the
NO
appropriate type.
check".
• The installed machine is
used properly.
YES
inspection item.
The mounted machine may be used incorrectly, instruct to • The installed machine is
2 Use method used improperly.
use it correctly.
• Provide direction to prop-
NO erly use the installed
machine.
check".
item troller.
check".
YES
4 Repair check 3. Start the engine.
4. Increase the engine speed to high idle. NO Repairs are completed.
40-301 56 PC200, 200LC, 220, 220LC-8M0


Detail of failure Low voltage is detected in power supply circuit of engine NE speed sensor.
Action level L01
Action of con-
Controls by Bkup speed sensor signal.
troller
• Running engine stops (when Bkup speed sensor is also defective).
Problem on • Stopped engine cannot be started (when Bkup speed sensor is also defective).
machine • Engine startability is poor.
• Engine speed hunts.
Related infor-
-
mation
Inspection
item
YES normal.
inspection item.
and connector.
check".
2. Disconnect following connectors one by one in order and
turn starting switch ON each time.
If this failure code is cleared, disconnected sensor or engine YES
wiring harness is defective. inspection item.
2
ing harness Ignore failure codes other than this failure code [CA238].
Ne speed sensor CRANK SENSOR or wiring harness is defec-
tive
Engine wiring harness ECM sensor or wiring harness.
check".
item troller.
check".
YES
4 Repair check
PC200, 200LC, 220, 220LC-8M0 40-301 57

Circuit diagram related to NE speed sensor
40-301 58 PC200, 200LC, 220, 220LC-8M0


Detail of failure A short circuit is detected in the drive circuit of the supply pump actuator.
Action level L03
Action of con-
None in particular
troller
• Engine speed does not increase from low idle speed.
Problem on
• Engine output falls.
machine
• Common rail fuel pressure is higher than the command value.
Related infor-
-
mation
Inspection
item
YES normal.
inspection item.
and connector.
check".
• The state of the supply
pump actuator is normal.
2. Disconnect connector CP3 PUMP REGULATOR. YES
inspection item.
Supply pump • The supply pump actuator
2
actuator is defective.
If failure code changes from [CA271] to [CA272], the supply • Replace the supply pump
NO
pump actuator is defective. actuator.
check".
• No short circuit or ground
1. Starting switch: OFF fault occurs in the wiring
2. Disconnect connector ECM, and connect the T-adapter to YES harness.
Short circuit inspection item.
or ground Resis- • A short circuit or ground
3
fault in wiring Between ECM (2) and (32) 1 to 5 z
tance fault occurs in the wiring
harness harness.
NO • Proceed to "Short circuit in
Between ECM (female) (2) and Resis- wiring harness" or
Min. 100 kz
ground tance "Ground fault in wiring har-
ness".
PC200, 200LC, 220, 220LC-8M0 40-301 59

Inspection
item
required. • No short circuit occurs in
1. Starting switch: OFF the wiring harness.
YES
2. Disconnect connectors ECM and CP3 PUMP REGU- • Proceed to the next
LATOR, and connect the T-adapter to the female side of inspection item.
Short circuit in the ECM.
4 wiring har-
ness • A short circuit occurs in
the wiring harness.
tance ing harness.
check".
required. • No ground fault occurs in
YES
2. Disconnect connectors ECM and CP3 PUMP REGU- • Proceed to the next
LATOR, and connect the T-adapter to the female side of inspection item.
Ground fault the ECM.
5 in wiring har-
ness • Ground fault occurs in the
wiring harness.
Min. 100 kz NO
check".
item troller.
check".
YES
7 Repair check
Circuit diagram related to IMV/PCV1
40-301 60 PC200, 200LC, 220, 220LC-8M0


Detail of failure An open circuit is detected in the drive circuit of the supply pump actuator.
Action level L03
Action of con-
None in particular
troller
Problem on • Engine does not run stably.
machine • Common rail fuel pressure is higher than the command value.
Because a female connector alone is provided in "Socket" for troubleshooting for this sensor, a socket
Related infor-
cannot be connected to the female connector on the wiring harness side of the sensor, and checks for
mation
wire breakage cannot be performed (T-adapter is not provided).
Inspection
item
YES normal.
inspection item.
and connector.
check".
1. Starting switch: OFF pump actuator is normal.
YES
2. Disconnect connector CP3 PUMP REGULATOR. • Proceed to the next
inspection item.
Supply pump • The supply pump actuator
2
actuator is defective.
Between CP3 PUMP REGULATOR Resis- • Replace the supply pump
Max. 5 z NO
(male) (1) and (2) tance actuator.
check".
3
in wiring har- circuit does not occur in
Resis-
Between ECM (2) and (32) Max. 5 z NO • Repair or replace the wir-
tance
ing harness.
check".
PC200, 200LC, 220, 220LC-8M0 40-301 61

Inspection
item
1.Starting switch: OFF
2.Disconnect connector CP3 PUMP REGULATOR. • A hot short circuit does not
3.Insert the T-adapter into the connector ECM. occur in the wiring har-
4.Turn the starting switch ON (with connector CP3 PUMP YES ness.
REGULATOR disconnected). After 1 minute or more • Proceed to the next
Hot short cir- lapsed, make measurements. inspection item.
4 cuit in wiring a The average voltage is displayed because PWM is set.
Between ECM (2) and (32) Voltage Max. 3 V NO
ing harness.
check".
item troller.
check".
YES
6 Repair check
Circuit diagram related to IMV/PCV1
40-301 62 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-301 63

SEN06133-01
© 2018 KOMATSU
All Rights Reserved
40-301 64
SEN06134-01
SEN06134-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
Failure code [CA322] ...................................................................................................................................... 3

Failure code [CA323] ...................................................................................................................................... 6
Failure code [CA324] ...................................................................................................................................... 9
Failure code [CA325] .................................................................................................................................... 12
Failure code [CA331] .................................................................................................................................... 15
Failure code [CA332] .................................................................................................................................... 18
Failure code [CA342] .................................................................................................................................... 21
Failure code [CA351] .................................................................................................................................... 22
Failure code [CA352] .................................................................................................................................... 23
Failure code [CA386] .................................................................................................................................... 25
Failure code [CA428] .................................................................................................................................... 26
Failure code [CA429] .................................................................................................................................... 28
Failure code [CA435] .................................................................................................................................... 30
Failure code [CA441] .................................................................................................................................... 32
Failure code [CA442] .................................................................................................................................... 35
Failure code [CA449] .................................................................................................................................... 36
Failure code [CA451] .................................................................................................................................... 38
Failure code [CA452] .................................................................................................................................... 41
Failure code [CA488] .................................................................................................................................... 44
Failure code [CA553] .................................................................................................................................... 45
Failure code [CA559] .................................................................................................................................... 46
Failure code [CA689] .................................................................................................................................... 48
Failure code [CA731] .................................................................................................................................... 51
Failure code [CA757] .................................................................................................................................... 54
Failure code [CA778] .................................................................................................................................... 55
PC200, 200LC, 220, 220LC-8M0 40-302 1

SEN06134-01
Failure code [CA2185] .................................................................................................................................. 60

Failure code [CA2186] .................................................................................................................................. 63
Failure code [CA2249] .................................................................................................................................. 65
Failure code [CA2311]................................................................................................................................... 66
Failure code [CA2555] .................................................................................................................................. 67
Failure code [CA2556] .................................................................................................................................. 70
40-302 2 PC200, 200LC, 220, 220LC-8M0


Detail of failure An open circuit or short circuit is detected in the drive circuit of the No. 1 injector.
Action level L03
Action of con-
None in particular
troller
Problem on • Explosion failure or hunting occurs.
machine • Engine output falls.
Related infor- While the engine is running normally, approximately 65 V of pulse voltage is supplied to the injector (+)
mation side. Because it is pulse voltage, it cannot be measured using multimeter.
Inspection
item
YES normal.
inspection item.
and connector.
check".
• The state of the No. 1
injector is normal.
2. Disconnect connector INJECTOR CYL 1&2, and connect YES
the T-adapter to the male side.
inspection item.
2 No. 1 injector
Between INJECTOR CYL 1&2 Resis- • No. 1 injector is defective.
Max. 2 z
(male) (C) and (D) tance • Replace No. 1 injector.
NO
Between INJECTOR CYL 1&2 Resis- • Proceed to "Repair
Min. 100 kz check".
(male) (C) and ground tance
• No open circuit or ground
or ground Between ECM (female) (45) and Resis- • An open circuit or ground
3
fault in wiring (53) Max. 2 z
harness harness.
NO • Proceed to "Open circuit in
Min. 100 kz
ness".
2. Disconnect connectors ECM and INJECTOR CYL 1&2, • Proceed to the next
Open circuit and connect the T-adapter to each female side. inspection item.
4 in wiring har- Between ECM (female) (45) and Resis- • An open circuit occurs in
ness Max. 2 z
INJECTOR CYL 1&2 (female) (C) tance the wiring harness.
NO
Between ECM (female) (53) and Resis- ing harness.
Max. 2 z • Proceed to "Repair
INJECTOR CYL 1&2 (female) (D) tance
check".
PC200, 200LC, 220, 220LC-8M0 40-302 3

Inspection
item
required.
the wiring harness.
2. Disconnect connectors ECM and INJECTOR CYL 1&2,
inspection item.
Ground fault and connect the T-adapter to either female side.
(45) or INJECTOR CYL 1&2 Min. 100 kz NO
tance ing harness.
(female) (C)
check".
2. Disconnect connectors ECM and INJECTOR CYL 1&2, the wiring harness.
YES
and connect the T-adapter to the female side of the ECM. • Proceed to the next
a Check using multimeter in continuity mode. inspection item.
Short circuit in
6 wiring har- Between ECM (female) (45) and No continuity (no sound • A short circuit occurs in
ness each pin other than pin (45) is heard) the wiring harness.
NO
Between ECM (female) (53) and No continuity (no sound ing harness.
each pin other than pin (53) is heard) • Proceed to "Repair
check".
• The state of other cylinder
injectors and wiring har-
YES ness are normal.
Other cylin- inspection item.
If the failure code for abnormalities of more than one injector
der injectors
7 is displayed, perform the troubleshooting for this failure code • Other cylinder injectors or
or wiring har-
as well. wiring harness is defec-
ness
tive.
NO
check".
item troller.
check".
YES
9 Repair check
40-302 4 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to injector #1
PC200, 200LC, 220, 220LC-8M0 40-302 5


Action level L03
Action of con-
None in particular
troller
Inspection
item
YES normal.
inspection item.
and connector.
check".
injector is normal.
inspection item.
2 No. 5 injector
Max. 2 z
NO
Min. 100 kz check".
3
harness harness.
Min. 100 kz
ness".
ness Max. 2 z
NO
check".
40-302 6 PC200, 200LC, 220, 220LC-8M0

Inspection
item
required.
the wiring harness.
inspection item.
tance ing harness.
(female) (C)
check".
YES
Short circuit in
NO
check".
der injectors
or wiring har-
ness
tive.
NO
check".
item troller.
check".
YES
9 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 7

40-302 8 PC200, 200LC, 220, 220LC-8M0


Action level L03
Action of con-
None in particular
troller
Inspection
item
YES normal.
inspection item.
and connector.
check".
injector is normal.
inspection item.
2 No. 3 injector
Max. 2 z
NO
Min. 100 kz check".
3
harness harness.
Min. 100 kz
ness".
ness Max. 2 z
NO
check".
PC200, 200LC, 220, 220LC-8M0 40-302 9

Inspection
item
required.
the wiring harness.
inspection item.
tance ing harness.
(female) (C)
check".
YES
Short circuit in
NO
check".
der injectors
or wiring har-
ness
tive.
NO
check".
item troller.
check".
YES
9 Repair check
40-302 10 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-302 11


Action level L03
Action of con-
None in particular
troller
Inspection
item
YES normal.
inspection item.
and connector.
check".
injector is normal.
inspection item.
2 No. 6 injector
Max. 2 z
(male) (A) and (B) tance • Replace No. 6 injector.
NO
Min. 100 kz check".
(male) (A) and ground tance
3
harness harness.
Min. 100 kz
ness".
ness Max. 2 z
INJECTOR CYL 5&6 (female) (A) tance the wiring harness.
NO
INJECTOR CYL 5&6 (female) (B) tance
check".
40-302 12 PC200, 200LC, 220, 220LC-8M0

Inspection
item
required.
the wiring harness.
inspection item.
tance ing harness.
(female) (A)
check".
YES
Short circuit in
NO
check".
der injectors
or wiring har-
ness
tive.
NO
check".
item troller.
check".
YES
9 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 13

40-302 14 PC200, 200LC, 220, 220LC-8M0


Action level L03
Action of con-
None in particular
troller
Inspection
item
YES normal.
inspection item.
and connector.
check".
injector is normal.
inspection item.
2 No. 2 injector
Max. 2 z
NO
Min. 100 kz check".
(male) (B) and ground tance
3
harness harness.
Min. 100 kz
ness".
ness Max. 2 z
INJECTOR CYL 1&2 (female) (A) tance the wiring harness.
NO
INJECTOR CYL 1&2 (female) (B) tance
check".
PC200, 200LC, 220, 220LC-8M0 40-302 15

Inspection
item
required.
the wiring harness.
inspection item.
tance ing harness.
(female) (B)
check".
YES
Short circuit in
NO
check".
der injectors
or wiring har-
ness
tive.
NO
check".
item troller.
check".
YES
9 Repair check
40-302 16 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-302 17


Action level L03
Action of con-
None in particular
troller
Inspection
item
YES normal.
inspection item.
and connector.
check".
injector is normal.
inspection item.
2 No. 4 injector
Max. 2 z
NO
Min. 100 kz check".
(male) (B) and ground tance
3
harness harness.
Min. 100 kz
ness".
ness Max. 2 z
INJECTOR CYL 3&4 (female) (B) tance the wiring harness.
NO
INJECTOR CYL 3&4 (female) (A) tance
check".
40-302 18 PC200, 200LC, 220, 220LC-8M0

Inspection
item
required.
the wiring harness.
inspection item.
tance ing harness.
(female) (B)
check".
YES
Short circuit in
NO
check".
der injectors
or wiring har-
ness
tive.
NO
check".
item troller.
check".
YES
9 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 19

40-302 20 PC200, 200LC, 220, 220LC-8M0


Detail of failure Calibration code incompatibility occurs in the engine controller.
Action level L04
Action of con-
None in particular
troller
Problem on
Normal operation or engine stop, start impossible
machine
mation (V))
Inspection
item
operating normally.
YES
Relevant sys-
tem
check".
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 21


Detail of failure An error is detected in the drive power supply circuit of the injector.
Action level L03
Action of con-
troller
• The exhaust gas color changes to black.
• Engine cannot be started.
mation (V))
Inspection
item
operating normally.
YES
Relevant sys-
tem
check".
check".
YES
3 Repair check
40-302 22 PC200, 200LC, 220, 220LC-8M0


Detail of failure Low voltage is detected in sensor power supply 1 circuit.
Action level L03
Action of con-
Runs engine by setting the ambient pressure to the fixed value.
troller
Related infor-
-
mation
Inspection
item
YES normal.
inspection item.
and connector.
check".
2. Disconnect following connectors one by one in order and
turn starting switch ON each time.
If this failure code is cleared, disconnected sensor or engine YES
wiring harness is defective. inspection item.
2
ing harness Ignore failure codes other than this failure code [CA352].
Ambient pressure sensor AMB. AIR PRESSURE or wiring harness is defec-
tive
Engine wiring harness ECM sensor or wiring harness.
check".
item troller.
check".
YES
4 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 23

Circuit diagram related to sensor power supply 1 circuit
40-302 24 PC200, 200LC, 220, 220LC-8M0


Detail of failure High voltage is detected in sensor power supply 1 circuit.
Action level L03
Action of con-
Runs engine by setting the ambient pressure to the fixed value.
troller
Related infor-
-
mation
Inspection
item
Sensor power • Repairs are completed.
1 supply 1 cir- Perform troubleshooting for failure code [CA352]. - • Proceed to "Repair
cuit check".
YES
2 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 25


Detail of failure High voltage occurs in the signal circuit of the water-in-fuel sensor of the fuel prefilter.
Action level L01
Action of con-
None in particular
troller
Problem on
The water separator monitor does not work properly.
machine
The signal status (ON/OFF) of the water-in-fuel sensor of the fuel prefilter can be checked via the mon-
Related infor-
itoring function.
mation
(Code: 18800)
Inspection
item
YES normal.
inspection item.
and connector.
check".
• The state of the
water-in-fuel sensor of the
YES fuel prefilter is normal.
the female side.
a If water is in fuel prefilter, drain it.
inspection item.
Water-in-fuel
2 sensor of fuel • The water-in-fuel sensor
prefilter of the fuel prefilter is
defective.
Resis-
Between P47 (female) (1) and (2) Min. 100 kz NO • Replace the water-in-fuel
tance
sensor of the fuel prefilter.
check".
3
in wiring har- • An open circuit or short
ness Between ECM (female) (14) and circuit occurs in the wiring
Resis-
(47) (Water-in-fuel sensor resis- Min. 100 kz NO harness.
tance
tance) • Proceed to "Open circuit in
wiring harness".
40-302 26 PC200, 200LC, 220, 220LC-8M0

Inspection
item
2. Disconnect connectors ECM and P47, and connect the • Proceed to the next
ness Max. 10 z
P47 (female) (1) tance the wiring harness.
NO
P47 (female) (2) tance
check".
2. Disconnect connectors ECM and P47, and connect the the wiring harness.
YES
T-adapter to the female side of the ECM. • Proceed to the next
Short circuit in
Between ECM (female) (14) and No continuity (no sound • Repair or replace the wir-
NO
each pin other than pin (14) is heard) ing harness.
check".
item troller.
check".
YES
7 Repair check
Circuit diagram related to water-in-fuel sensor
PC200, 200LC, 220, 220LC-8M0 40-302 27


Detail of failure Low voltage occurs in the signal circuit of the water-in-fuel sensor of the fuel prefilter.
Action level L01
Action of con-
None in particular
troller
Problem on
The water separator monitor does not work properly.
machine
The signal status (ON/OFF) of the water-in-fuel sensor of the fuel prefilter can be checked via the mon-
Related infor-
itoring function.
mation
(Code: 18800)
Inspection
item
YES normal.
inspection item.
and connector.
check".
water-in-fuel sensor of the
YES fuel prefilter is normal.
the female side.
a If water is in fuel prefilter, drain it.
inspection item.
Water-in-fuel
2 sensor of fuel Between P47 (female) (1) and (2) Resis- • The water-in-fuel sensor
Min. 100 kz
prefilter tance of the fuel prefilter is
defective.
NO • Replace the water-in-fuel
Between P47 (female) (1) and Resis- sensor of the fuel prefilter.
Min. 100 kz
ground tance • Proceed to "Repair
check".
Short circuit the female side. • Proceed to the next
or ground inspection item.
3
fault in wiring Between ECM (female) (14) and • A short circuit or ground
Resis-
harness (47) (Water-in-fuel sensor resis- Min. 100 kz fault occurs in the wiring
tance
tance) NO harness.
Between ECM (female) (14) and Resis- • Proceed to "Ground fault
Min. 100 kz in wiring harness".
ground tance
2. Disconnect connectors ECM and P47, and connect the the wiring harness.
YES
T-adapter to the female side of the ECM. • Proceed to the next
Short circuit in
Between ECM (female) (14) and No continuity (no sound • Repair or replace the wir-
NO
check".
40-302 28 PC200, 200LC, 220, 220LC-8M0

Inspection
item
required.
the wiring harness.
2. Disconnect connectors ECM and P47, and connect the
inspection item.
Between ECM (female) (14) or P47 Resis- • Repair or replace the wir-
Min. 100 kz NO
(female) (1) and ground tance ing harness.
check".
item troller.
check".
YES
7 Repair check
Circuit diagram related to water-in-fuel sensor
PC200, 200LC, 220, 220LC-8M0 40-302 29


Detail of failure Error occurs in signal circuit of engine oil pressure switch.
Action level L01
Action of con-
None in particular
troller
Problem on • The protection function by engine oil pressure does not work.
machine • The engine oil pressure monitor does not indicate the correct value.
• The engine oil pressure switch is closed (ON) when the oil pressure is low (the engine is stopped),
and opened (OFF) when the oil pressure is high (the engine is running).
Related infor- • When this failure code is displayed, the engine controller checks whether or not the oil pressure
mation switch is closed (ON) or set to the "GND level" only while the engine is stopped.
• An engine oil pressure switch error detected during running of the engine is checked by failure code
[B@BAZG].
Inspection
item
YES normal.
inspection item.
and connector.
check".
pressure switch is normal.
2. Disconnect connector OIL PRESSURE SWITCH, and YES
connect the T-adapter to the male side.
inspection item.
Engine oil
2 pressure • The engine oil pressure
switch switch is defective.
Between OIL PRESSURE SWITCH Resis- • Replace the engine oil
Max. 10 z NO
(male) (1) and ground tance pressure switch.
check".
3
in wiring har- circuit occurs in the wiring
ness harness.
Between ECM (female) (17) and Resis-
Max. 10 z NO • Repair or replace the wir-
ground tance
ing harness.
check".
item troller.
inspection item.
40-302 30 PC200, 200LC, 220, 220LC-8M0

Inspection
item
YES
5 Repair check
3. Turn the starting switch on or start the engine.
Circuit diagram related to engine oil pressure switch
PC200, 200LC, 220, 220LC-8M0 40-302 31


Detail of failure Low voltage occurs in engine controller power circuit.
Action level L04
Action of con-
None in particular
troller
Problem on • Engine stops.
machine • Engine startability is poor.
mation (V))
Inspection
item
• The state of the battery
terminal is normal.
YES
inspection item.
• The battery terminal is
Battery termi- defective.
1 Battery terminal may be loose or corroded. Check it.
nal • If loosened, attach the ter-
minal properly.
NO
• If corroded, replace the
battery terminal.
check".
terminal, battery relay ter-
minal, ground terminal
YES
(T12), etc. are normal.
inspection item.
• The alternator terminal,
Alternator, 1. Starting switch: OFF battery relay terminal,
battery relay, ground terminal (T12), etc.
2 are defective.
or ground ter- Check the alternator terminal, battery relay terminal, ground
minals terminal (T12), etc. • If loosened, attach the ter-
minal properly.
NO • If open circuit occurs,
replace the alternator ter-
minal, battery relay termi-
nal, ground terminal (T12),
etc.
check".
YES normal.
inspection item.
and connector.
check".
40-302 32 PC200, 200LC, 220, 220LC-8M0

Inspection
item
voltage is normal.
2. Perform troubleshooting with starting switch at OFF posi- YES
tion and when starting engine.
inspection item.
Battery volt-
4 • The battery voltage is
age
defective.
Between battery terminals (+) and
Voltage 20 to 30 V NO • Replace the battery.
(-).
check".
is normal.
3. Start the engine. (Engine speed: Medium or above)
inspection item.
5 Alternator
• The alternator is defective.
27.5 to 29.5 • Replace the alternator.
Between E12 (1) and ground Voltage NO
V • Proceed to "Repair
check".
item troller.
check".
YES
7 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 33

Circuit diagram related to engine controller power supply
40-302 34 PC200, 200LC, 220, 220LC-8M0


Detail of failure High voltage (36 V or higher) is generated in controller power supply circuit.
Action level L04
Action of con-
None in particular
troller
Problem on
Operates the engine normally but may stop it running during operation or prevent it from starting.
machine
mation (V))
Inspection
item
Power supply • Repairs are completed.
1 voltage sys- Perform troubleshooting for failure code [CA441]. - • Proceed to "Repair
tem check".
YES
2 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 35


Detail of failure High pressure error (2) occurs in common rail circuit.
Action level L03
Action of con-
troller
Problem on • Engine sound increases when no load or a light load is applied.
Related infor- Common rail pressure can be checked via the monitoring function. (Code: 36400 Common rail pres-
mation sure)
Inspection
item
operating normally.
YES
Relevant sys-
tem
check".
• No air may be in the
low-pressure circuit.
YES
Air may be in low-pressure circuit. Check it according to the inspection item.
Air of 1. Remove the pressure pickup plug (outlet side) of fuel main • Air may be in the low-pres-
2 low-pressure filter. sure circuit.
circuit 2. Operate the feed pump of the fuel prefilter. • Bleed air from the
3. Check how the fuel and air leaks from the pressure pickup low-pressure circuit again,
NO
plug. and repair or replace the
low-pressure circuit.
check".
• The state of the fuel return
a For the pressure test of the fuel return circuit, see Testing circuit device is normal.
YES
and adjusting, Testing fuel Pressure. • Proceed to the next
inspection item.
Fuel return • The fuel return circuit
3
circuit device Max. 0.02 device is defective.
Pressure in fuel return At low idle or at crank- MPa • Repair or replace the fuel
NO
circuit ing {Max. 0.19 return circuit device.
kg/cm2} • Proceed to "Repair
check".
• The state of the common
rail pressure sensor sys-
YES tem is normal.
Common rail inspection item.
Perform troubleshooting for failure codes [CA451] and
4 pressure sen- • The common rail pressure
[CA452].
sor system sensor system is defec-
tive.
NO
check".
40-302 36 PC200, 200LC, 220, 220LC-8M0

Inspection
item
• The state of the pressure
a For check of leakage from pressure limiter, see Testing limiter is normal.
YES
and adjusting, "Testing fuel return rate and leakage". • Proceed to the next
inspection item.
Pressure lim- • The pressure limiter is
5
iter defective.
Leakage from pres- 0cc • Replace the pressure lim-
At low idle NO
sure limiter (No leakage) iter.
check".
Recheck of • The supply pump may be

6 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the supply pump.
item
check".
YES
7 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 37


Detail of failure High voltage occurs in signal circuit of common rail pressure sensor.
Action level L03
Action of con-
troller
Problem on • Engine speed or output falls.
• Signal voltage of common rail pressure sensor can be checked via the monitoring function.
(Code: 36401 Common rail pressure sensor voltage)
Related infor-
• This failure code appears if connector of common rail pressure sensor is removed.
mation
• Because female connector alone is provided in "Socket" for troubleshooting for this sensor, check for
open circuit in wiring harness and voltage check cannot be performed (T-adapter is not provided).
Inspection
item
YES normal.
inspection item.
and connector.
check".
rail pressure sensor power
YES supply system is normal.
Common rail • Proceed to the next
pressure sen- inspection item.
If failure code [CA227] or [CA187] is displayed, perform trou-
2 sor power • The common rail pressure
bleshooting for it first.
supply sys- sensor power supply sys-
NO
check".
2. Disconnect connectors CAM SENSOR, FUEL RAIL the wiring harness.
YES
PRESS, BOOST PRESS & IMT, and ECM. • Proceed to the next
3. Connect the T-adapter to female side of the ECM. inspection item.
Short circuit in
Min. 100 kz NO
(37) tance ing harness.
check".
40-302 38 PC200, 200LC, 220, 220LC-8M0

Inspection
item
2. Disconnect connector FUEL RAIL PRESS, and insert the • A hot short circuit does not
T-adapter into connector ECM. occur in the wiring har-
3. Turn the starting switch ON (with connector FUEL RAIL YES ness.
PRESS disconnected). • Proceed to the next
Hot short cir- a The ECM (25) pin is connected to 5 V through the resistor inspection item.
4 cuit in wiring in the engine controller.
Between ECM (25) and (47) Voltage Approx. 5 V NO
ing harness.
check".
YES ness.
If no failure is identified by the above checks, the wiring har-
ness may have an open circuit (*).
NO
ing harness.
check".
a If no failure is found by Inspection items 1 to 5 and a fail- • The state of the common
ure is found by Inspection item 6, the sensor is defective. rail pressure sensor is nor-
1. Starting switch: OFF YES mal.
2. Insert the T-adapter into the connector ECM. • Proceed to the next
Common rail 3. Turn the starting switch to ON position. inspection item.
sor sensor is defective.
Between ECM (25) Sensor out- • Replace the common rail
and (47) put pressure sensor.
check".
item troller.
check".
YES
8 Repair check
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related in-
formation on troubleshooting".
PC200, 200LC, 220, 220LC-8M0 40-302 39

Circuit diagram related to common rail pressure sensor
40-302 40 PC200, 200LC, 220, 220LC-8M0


Detail of failure Low voltage occurs in signal circuit of common rail pressure sensor.
Action level L03
Action of con-
troller
Problem on • Engine speed or output falls.
• Signal voltage of common rail pressure sensor can be checked via the monitoring function.
Related infor- (Code: 36401 Common rail pressure sensor voltage)
mation • If the sensor connector is removed even in normal condition, failure code for High Error [CA451]
appears instead of this failure code.
Inspection
item
YES normal.
inspection item.
and connector.
check".
rail pressure sensor power
YES supply system is normal.
Common rail • Proceed to the next
pressure sen- If failure code [CA187] (ground fault of the sensor power sup- inspection item.
2 sor power ply line) or [CA227] is also displayed, perform troubleshooting • The common rail pressure
supply sys- for it first. sensor power supply sys-
NO
check".
a Make sure that failure code [CA187] (ground fault of the • The state of the common
sensor power supply line) is not displayed in advance. rail pressure sensor is nor-
1. Starting switch: OFF YES mal.
2. Disconnect connector FUEL RAIL PRESS. • Proceed to the next
Common rail 3. Turn the starting switch to ON position. inspection item.
sor sensor is defective.
If failure code changes from [CA452] to [CA451], the sensor • Replace the common rail
NO
is defective. pressure sensor.
check".
PC200, 200LC, 220, 220LC-8M0 40-302 41

Inspection
item
the wiring harness.
2. Disconnect connectors ECM and FUEL RAIL PRESS, and YES
inspection item.
Ground fault
Min. 100 kz NO
check".
the wiring harness.
2. Disconnect connectors ECM and FUEL RAIL PRESS, and YES
inspection item.
Short circuit in
tance ing harness.
check".
item troller.
check".
YES
7 Repair check
40-302 42 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to common rail pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-302 43


Detail of failure The temperature signal of the boost pressure or temperature sensor exceeds the upper control limit.
Action level L03
Action of con-
troller
Problem on
machine
Related infor-
Boost temperature can be checked via the monitoring function. (Code: 18500 Boost temperature)
mation
Inspection
item
• The cooling performance
of the aftercooler is nor-
YES mal.
Cooling performance of the aftercooler may be lowered; • Proceed to the next
Cooling per- check it for the following items. inspection item.
1 formance of • Loose fan belt or damage • The cooling performance
aftercooler • Insufficient cooling air amount of the aftercooler
• Clogged aftercooler fin decreases.
NO
check".
• The turbocharger outlet
temperature is normal.
YES
Turbocharger inspection item.
Turbocharger outlet temperature may rise abnormally. Check
2 outlet temper- • The turbocharger outlet
the related parts.
ature temperature is abnormal.
check".
• The charge temperature
sensor system may be
item for failure codes [CA153]
and [CA154].
check".
YES
4 Repair check
40-302 44 PC200, 200LC, 220, 220LC-8M0


Detail of failure High pressure error (1) occurs in common rail circuit.
Action level L01
Action of con-
None in particular
troller
Problem on • Engine sound increases when no load or a light load is applied.
mation sure)
Inspection
item
operating normally.
YES
Relevant sys-
tem
check".
• The ground terminal is
connected correctly.
YES
A ground terminal connection failure may occur. Check the • Proceed to the next
following terminals. inspection item.
Connection of
• Machine ground terminal ((-) terminal of battery) • The ground terminal is
2 ground termi-
• Engine ground terminal connected improperly.
nal
• Engine controller ground terminal • Repair the ground terminal
• Starter ground terminal NO
connecting portion.
check".
YES • Repairs are completed.
• The common rail pressure
and [CA452].
check".
YES
4 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 45


Detail of failure Low rail pressure error (1) occurs in common rail circuit.
Action level L01
Action of con-
None in particular
troller
• Engine does not start, or startability is poor.
Problem on
machine
mation sure)
Inspection
item
• The correct fuel is be
used.
YES
inspection item.
1 Fuel used Fuel used may be improper. Check it. • The wrong fuel is being
used.
• Replace fuel with the
NO
appropriate type.
check".
• No external fuel leakage
occurs.
YES
inspection item.
External fuel External fuel leakage may be occurred, check it (visual check
2 • Fuel leaks outside.
leakage with engine at low idle).
• Repair the part fuel is leak-
NO ing from.
check".
• The state of the fuel
a For troubleshooting, see "Note 1". low-pressure circuit device
a For the test of pressure of the fuel low pressure circuit, YES is normal.
see Testing and adjusting, "Testing fuel pressure". • Proceed to the next
inspection item.
Inlet negative pressure Max. -50.7
of fuel supply pump At high idle (with start MPa
Low-pres- (fuel prefilter outlet enabled) {Max. -380
3 sure circuit side) mmHg}
device • The fuel low-pressure cir-
0.3 to 1.1
cuit device is defective.
At cranking (when not MPa
able to start) {3.1 to
Fuel main filter inlet 11.3kg/cm2}
check".
pressure 0.5 to 1.3
At low idle (when pos- MPa
sible to start) {5.1 to
13.3kg/cm2}
40-302 46 PC200, 200LC, 220, 220LC-8M0

Inspection
item
a For check of leakage from pressure limiter, see Testing limiter is normal.
YES
and adjusting, "Testing fuel return rate and leakage". • Proceed to the next
inspection item.
Pressure lim- • The pressure limiter is
4
iter defective.
Leakage from pres- 0cc • Replace the pressure lim-
At low idle NO
sure limiter (No leakage) iter.
check".
• The state of the injector is
a For check of return rate from injector, see Testing and normal.
YES
adjusting, "Testing fuel return rate and leakage". • Proceed to the next
inspection item.
5 Injector
At cranking (when not Max. 90 • The injector is defective.
Return rate from injec- able to start) cc/min • Replace the injector.
NO
tor At low idle (when pos- Max. 180 • Proceed to "Repair
sible to start) cc/min. check".
a For details of testing return rate from supply pump, see
pump is normal.
Testing and adjusting, "Testing fuel return rate and leak- YES
age".
inspection item.
6 Supply pump At cranking (when not Max. 140 • The supply pump is defec-
able to start) cc/min. tive.
Return rate from sup-
NO • Replace the supply pump.
ply pump At low idle (when pos- Max. 1,000 • Proceed to "Repair
sible to start) cc/min. check".
• The common rail pressure
and [CA452].
check".
YES
8 Repair check
Note 1: Check for a low-pressure fuel circuit device failure for the following items.
1) Remaining quantity of fuel
2) Clogged fuel tank breather
3) Leakage or clogging of low pressure fuel piping
4) Clogging of fuel prefilter
5) Clogging of fuel main filter
6) Replace fuel filter when problem is not removed even if no clogging is found.
PC200, 200LC, 220, 220LC-8M0 40-302 47


Detail of failure Error occurs in the signal received from engine NE speed sensor.
Action level L01
Action of con-
Continues control with the signal from the engine Bkup speed sensor.
troller
• Engine hunts.
Problem on
• Engine startability is poor.
machine
• Because the internal speed sensor consists of a hole sensor and an electronic circuit instead of a
coil, whether or not the state of the speed sensor is normal cannot be determined even if the resis-
Related infor- tance of the speed sensor is measured using multimeter.
mation • Since speed sensor output is 5 V of pulse voltage, it cannot be measured using multimeter.
• Speed sensor senses the passes of speed sensing wheel oblong hole installed to inside of crank-
shaft vibration damper rotated with crankshaft.
Inspection
item
YES normal.
inspection item.
and connector.
check".
• The state of the NE speed
YES tem is normal.
NE speed inspection item.
sensor power If failure code [CA238] is also displayed, perform trouble-
2 • The NE speed sensor
supply sys- shooting for it first.
tem power supply system is
defective.
NO
check".
• No damage or installation
failure is detected in the
YES engine NE speed sensor.
inspection item.
Perform checks since the engine NE speed sensor may be
Engine NE • A damage or installation
3 damaged or may not have been installed correctly (loose-
speed sensor failure is detected in the
ness).
engine NE speed sensor.
NO • Remount or replace the
engine NE speed sensor.
check".
40-302 48 PC200, 200LC, 220, 220LC-8M0

Inspection
item
• The state of the engine NE
speed sensor power sup-
2. Disconnect connector CRANK SENSOR, and connect the
YES ply input is normal.
T-adapter to the female side.
inspection item.
NE speed • The engine NE speed sen-
4 sensor power sor power supply input is
supply defective.
Between CRANK
Power sup- 4.75 to 5.25 • Replace the engine NE
SENSOR (female) (1) Voltage NO
ply input V speed sensor power sup-
and (2)
ply.
check".
1. Starting switch: OFF ness.
YES
2. Disconnect connectors ECM and CRANK SENSOR. • Proceed to inspection item
"Short circuit in wiring har-
ness".
a If no failure is found by Inspec-
tion item 4, this check is not
Open circuit Resis-
required. Max. 10 z
5 in wiring har- tance
Between ECM (female) (16) and • An open circuit occurs in
ness CRANK SENSOR (female) (1) the wiring harness.
a If no failure is found by Inspec- • Repair or replace the wir-
NO
tion item 4, this check is not ing harness.
Resis-
required. Max. 10 z • Proceed to "Repair
tance
Between ECM (female) (48) and check".
CRANK SENSOR (female) (2)
Between ECM (female) (27) and Resis-
Max. 10 z
CRANK SENSOR (female) (3) tance
YES
2. Disconnect connectors ECM and CRANK SENSOR. • Proceed to the next
inspection item.
Short circuit in
Between ECM (female) (16) and • A short circuit occurs in
6 wiring har- Resis-
(27), or between CRANK SENSOR Min. 100 kz the wiring harness.
ness tance
(female) (1) and (3) • Repair or replace the wir-
NO
Between ECM (female) (27) and ing harness.
(48), or between CRANK SENSOR Min. 100 kz
tance check".
YES
2. Disconnect connectors ECM and CRANK SENSOR. • Proceed to the next
inspection item.
Ground fault
Between ECM (female) (27) or
CRANK SENSOR (female) (3) and Min. 100 kz NO
tance ing harness.
ground
check".
PC200, 200LC, 220, 220LC-8M0 40-302 49

Inspection
item
2. Disconnect connector CRANK SENSOR. YES ness.
3. Turn the starting switch to ON position. • Proceed to the next
Between CRANK SENSOR (female) • Repair or replace the wir-
Voltage Max. 1 V NO
(3) and ground ing harness.
check".
• The state of the speed
sensing wheel is normal.
YES
inspection item.
Speed sens- • The speed sensing wheel
9 Check speed sensing wheel.
ing wheel is defective.
• Remount or replace the
NO
speed sensing wheel.
check".
• The NE speed sensor may
be defective internally.
If no failure is found in above checks, NE speed sensor is
NE speed • Replace the NE speed
10 defective. (Since this is an internal defect, troubleshooting -
sensor sensor.
cannot be performed.)
check".
item troller.
check".
YES
12 Repair check
Circuit diagram related to engine NE speed sensor
40-302 50 PC200, 200LC, 220, 220LC-8M0


Detail of failure A phase error occurs in the signal of the engine NE speed sensor or engine Bkup speed sensor.
Action level L01
Action of con-
Continues control with the signal from the engine NE speed sensor.
troller
• Engine cannot start or engine is hard to start.
Problem on
• Idle rotation is not stable.
machine
Related infor-
-
mation
Inspection
item
• The state of the engine NE
speed sensor is normal.
YES
inspection item.
Engine NE • The engine NE speed sen-
1 Engine NE speed sensor may be damaged. Check it.
speed sensor sor is defective.
• Replace the engine NE
NO
speed sensor.
check".
• The state of the engine
Bkup speed sensor is nor-
YES mal.
inspection item.
Engine Bkup
2 Engine Bkup speed sensor may be damaged. Check it. • The engine Bkup speed
speed sensor
sensor is defective.
• Replace the engine Bkup
NO
speed sensor.
check".
sensing wheel in the
Speed sensing wheel on crankshaft side may be installed YES crankshaft side is normal.
improperly or damaged. Check it according to the following • Proceed to the next
procedure. inspection item.
Speed sens- 1. Align the painted mark (M1) of the damper with the top
ing wheel in surface (M2) of the NE speed sensor. • The speed sensing wheel
3 in the crankshaft side is
crankshaft aNo. 1 cylinder is not at its compression top dead center.
side defective.
(before top dead center (B.T.D.C), approximately 80°)
2. Installation is correct if the center of speed sensing wheel • Remount or replace the
NO
oblong hole (WS) is on the top surface of the NE speed speed sensing wheel in
sensor (M2). the crankshaft side.
check".
PC200, 200LC, 220, 220LC-8M0 40-302 51

Inspection
item
sensing ring in the cam-
YES shaft side is normal.
The peed sensing ring in the camshaft side may have been • Proceed to the next
incorrectly installed or be damaged. Check it according to the inspection item.
Speed sens- • The speed sensing ring in
1. Set No. 1 cylinder to compression top dead center (align
4 ing ring in the the camshaft side is defec-
stamping mark).
camshaft side tive.
2. Remove Bkup speed sensor.
3. Installation is correct if twin groove (single rib) (B) of speed • Remount or replace the
NO
sensing ring is visible through sensor mounting hole (H). speed sensing ring in the
camshaft side.
check".
• The timing between the
crankshaft and camshaft is
YES normal.
inspection item.
Timing match-
ing between Defective matching of timing between crankshaft and cam- • The timing between the
5 crankshaft and camshaft is
crankshaft shaft may occur. Check it.
and camshaft abnormal.
• Match the timing between
NO
the crankshaft and cam-
shaft.
check".
• The ground terminal may
be connected improperly.
• Repair the ground con-
necting portions shown
below.
• Machine ground termi-
Recheck of
1. Recheck the preceding troubleshooting. nal ((-) terminal of bat-
6 inspection
2. Can you identify the cause after carrying out a recheck? NO tery)
item
• Engine ground termi-
nal
• Engine controller
ground terminal
• Starter ground terminal
check".
YES
7 Repair check
40-302 52 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-302 53


Detail of failure All-data loss error occurs in the engine controller.
Action level L04
Action of con-
None in particular
troller
Problem on • Engine stops, and may not be able to start.
machine • The monitoring function (engine controller system) of the machine monitor may not work properly.
Related infor-
-
mation
Inspection
item
operating normally.
YES
Relevant sys-
tem
check".
check".
YES
3 Repair check
40-302 54 PC200, 200LC, 220, 220LC-8M0


Detail of failure An abnormality is detected in the signal of the engine Bkup speed (CAM) sensor.
Action level L01
Action of con-
Continues control with the signal from the engine NE speed sensor.
troller
Problem on • Engine startability is poor.
• Because the internal speed sensor consists of a hole sensor and an electronic circuit instead of a
coil, whether or not the state of the speed sensor is normal cannot be determined even if the resis-
Related infor- tance of the speed sensor is measured using multimeter.
mation • Since speed sensor output is 5 V of pulse voltage, it cannot be measured using multimeter.
• The speed sensor senses the speed by the groove of the speed sensing ring installed on the cam-
shaft.
Inspection
item
YES normal.
inspection item.
and connector.
check".
YES normal.
If failure code [CA187] or [CA227] is also displayed, perform
2 supply 2 sys-
troubleshooting for it first. • The sensor power supply
tem
check".
• No damage or mounting
failure (looseness) is
detected in the engine
YES Bkup speed (CAM) sen-
sor.
inspection item.
Engine Bkup
The engine Bkup speed (CAM) sensor may be damaged or • The engine Bkup speed
3 speed (CAM)
may not have been installed correctly (loosened). Check it. (CAM) sensor is damaged
sensor
or has not been installed
correctly (loosened).
NO • Remount or replace the
engine Bkup speed (CAM)
sensor.
check".
PC200, 200LC, 220, 220LC-8M0 40-302 55

Inspection
item
Bkup speed sensor power
2. Disconnect connector CAM SENSOR , and connect the
YES supply input is normal.
inspection item.
Engine Bkup • The engine Bkup speed
4 speed sensor sensor power supply input
power supply is defective.
Between CAM SEN-
Power sup- 4.75 to 5.25 • Replace the engine Bkup
SOR (female) (1) and Voltage NO
ply V speed sensor power sup-
(2)
ply.
check".
ness.
2. Disconnect connectors ECM and CAM SENSOR, and YES
• Proceed to inspection item
connect the T-adapter to each female side.
"Short circuit in wiring har-
Open circuit ness".
5 in wiring har- Between ECM (female) (37) and Resis-
ness Max. 10 z • An open circuit occurs in
CAM SENSOR (female) (1) tance the wiring harness.
Max. 10 z NO
CAM SENSOR (female) (2) tance ing harness.
Between ECM (female) (26) and Resis- • Proceed to "Repair
Max. 10 z check".
CAM SENSOR (female) (3) tance
the wiring harness.
connect the T-adapter to either female side.
inspection item.
Short circuit in
Between ECM (female) (26) and • A short circuit occurs in
6 wiring har- Resis-
(37), or between CAM SENSOR Min. 100 kz the wiring harness.
ness tance
(female) (1) and (3) • Repair or replace the wir-
NO
Between ECM (female) (26) and ing harness.
(47), or between CAM SENSOR Min. 100 kz
tance check".
the wiring harness.
inspection item.
Ground fault
Between ECM (female) (26) or CAM Resis- • Repair or replace the wir-
Min. 100 kz NO
SENSOR (female) (3) and ground tance ing harness.
check".
2. Disconnect connector CAM SENSOR , and connect the
YES ness.
Between CAM SENSOR (female) (3) • Repair or replace the wir-
Voltage Max. 1 V NO
and ground ing harness.
check".
40-302 56 PC200, 200LC, 220, 220LC-8M0

Inspection
item
• The speed sensing ring is
not loosened.
YES
Remove Bkup speed (CAM) sensor, and check through hole inspection item.
Speed sens- (H). • The speed sensing ring is
9
ing ring a If camshaft speed sensing ring (B) is loose, see "Refer- loosened.
ence". • Remount the speed sens-
NO
ing ring.
check".
• The engine Bkup speed
(CAM) sensor may be
Engine Bkup If no abnormalities are identified by the above checks, the defective.
10 speed (CAM) engine Bkup speed (CAM) sensor is defective. (Since this is - • Replace the engine Bkup
sensor an internal defect, troubleshooting cannot be performed.) speed (CAM) sensor.
check".
item troller.
check".
YES
12 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 57

Circuit diagram related to engine Bkup speed sensor
40-302 58 PC200, 200LC, 220, 220LC-8M0

CA778 (107 series engine) Reference 5. Check the cam shaft ring (5) mounting bolt (4) for
Cam shaft ring looseness check looseness.
Remove the front cover, and check the cam shaft 3 Mounting bolt (4): 10 ± 2Nm
ring for looseness. (DP): Dowel pin
a See Disassembly and Assembly "Removal and
installation of front seal".
a Prepare the front seal, liquid gasket LG-7, and
front seal tool (795-799-6400) in advance.
Removal
1. Remove the fan and fan belt, seeing Disas-
sembly and Assembly "Removal and installation
of front seal".
2. Remove the damper assembly (1).
(DP): Dowel pin
Installation
a For the figure, see Removal.
1. Install the front cover (2).
3 Front cover: Liquid gasket LG-7
2. Seeing Disassembly and Assembly "Removal
and installation of front seal",
1)Install the front seal (3).
2)Install dowel pin (DP), and install damper
assembly.
3)Install fan and fan belt.
3. Remove the front cover (2).
4)Install the cooling assembly.
4. Remove the front seal (3).
(RING): Ring
PC200, 200LC, 220, 220LC-8M0 40-302 59


Detail of failure High voltage (Min. 5.25 V) is detected in throttle sensor power supply circuit.
Action level L03
Action of con-
Runs by setting the throttle position with a signal other than the throttle sensor.
troller
Problem on
Engine speed cannot be controlled by fuel dial.
machine
Related infor-
-
mation
Inspection
item
YES normal.
inspection item.
and connector.
check".
1. Starting switch: OFF sensor is normal.
YES
2. Disconnect connector P20, and turn the starting switch to • Proceed to the next
ON position. inspection item.
Throttle sen- • The throttle sensor is
2
sor (fuel dial) If this failure code disappears, the throttle sensor is defective. defective.
a Many other failure codes are also displayed at the same • Replace the throttle sen-
time. This is because the connector is disconnected. NO
sor.
Ignore failure codes other than this failure code [CA2185]. • Proceed to "Repair
check".
2. Disconnect the connectors CE02, CE03, and P20, and the wiring harness.
YES
connect the T-adapter to each female side of the CE02 • Proceed to the next
and CE03. inspection item.
Short circuit in
3 wiring har- Between CE02 (female) (22) and • A short circuit occurs in
Resis-
ness each pin other than CE02 (female) Min. 1 Mz the wiring harness.
tance
(22) pin. • Repair or replace the wir-
NO
ing harness.
Between CE02 (female) (22) and Resis- • Proceed to "Repair
Min. 1 Mz
CE03 (female) (3) tance check".
YES ness.
the female side.
3. Starting switch: ON
Between P20 (female) (1) and 4.75 to 5.25 • Repair or replace the wir-
Voltage NO
ground V ing harness.
check".
40-302 60 PC200, 200LC, 220, 220LC-8M0

Inspection
item
item troller.
check".
YES
6 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 61

Circuit diagram related to engine controller power supply
40-302 62 PC200, 200LC, 220, 220LC-8M0


Detail of failure Low voltage occurs in the throttle sensor power supply circuit.
Action level L03
Action of con-
Runs by setting the throttle position with a signal other than the throttle sensor.
troller
Problem on
Engine speed cannot be controlled by fuel dial.
machine
Related infor-
-
mation
Inspection
item
YES normal.
inspection item.
and connector.
check".
sensor is normal.
2. Disconnect connector P20, and turn the starting switch to YES
ON position.
inspection item.
Throttle sen- • The throttle sensor is
2
sor (fuel dial) If this failure code disappears, the throttle sensor is defective. defective.
a Many other failure codes are also displayed at the same • Replace the throttle sen-
NO
time. This is because the connector is disconnected. sor.
Ignore failure codes other than this failure code [CA2186]. • Proceed to "Repair
check".
the wiring harness.
2. Disconnect connectors CE02 and P20, and connect the YES
inspection item.
Ground fault
Min. 1 Mz NO
check".
2. Disconnect connectors CE02 and P20, and connect the the wiring harness.
YES
T-adapter to the female side of connector CE02. • Proceed to the next
3. Turn the starting switch to ON position. inspection item.
Short circuit in
each pin other than CE02 (female) Min. 1 Mz NO
tance ing harness.
(22) pin.
check".
PC200, 200LC, 220, 220LC-8M0 40-302 63

Inspection
item
item troller.
check".
YES
6 Repair check
40-302 64 PC200, 200LC, 220, 220LC-8M0


Detail of failure Pressure low error (level 2) is detected in supply pump.
Action level L03
Action of con-
Limits engine output and runs the engine.
troller
Problem on
machine
• Signal voltage from the common rail pressure sensor can be checked via the monitoring function.
(Code: 36401 (V))
Related infor-
• The common rail pressure in the common rail pressure sensor can be checked via the monitoring
mation
function.
(Code: 36400 (MPa))
Inspection
item
Low pressure • Repairs are completed.
1 in supply Perform troubleshooting for failure code [CA559]. - • Proceed to "Repair
pump check".
YES
2 Repair check
PC200, 200LC, 220, 220LC-8M0 40-302 65


Detail of failure Resistance value of supply pump actuator circuit is unusually high or low.
Action level L03
Action of con-
None in particular
troller
Problem on
machine
Related infor-
-
mation
Inspection
item
• Repairs are completed.
Perform troubleshooting for failure codes [CA271] and
1 IMV solenoid - • Proceed to "Repair
[CA272].
check".
YES
2 Repair check
40-302 66 PC200, 200LC, 220, 220LC-8M0


Detail of failure Open circuit is in preheat relay drive circuit (primary circuit).
Action level L01
Action of con-
None in particular
troller
Problem on Intake air heater does not work in auto preheating mode (resulting in degraded startability and emission
machine of white smoke at low temperatures).
the monitoring function.
(Code: 18500)
Related infor-
• Troubleshooting of this failure code covers circuits from engine controller to primary circuit (coil) of
mation
preheat relay R18.
• For troubleshooting of the secondary circuit of the heater relay and preheat relay R18, see "E-2" in
E-mode.
Inspection
item
YES normal.
inspection item.
and connector.
check".
• The state of the preheat
relay R18 is normal.
2. Disconnect the preheat relay R18, and connect the YES
T-adapter to the male side.
inspection item.
Resis-
Preheat relay Between R18 (male) (1) and (2) 200 to 400 z • The preheat relay R18 is
2 tance
R18 defective.
• Replace the preheat relay
2. Replace the preheat relay R18 with another one. NO
R18.
If this failure code disappears, original preheat relay R18 is check".
defective.
3
ness Between CE02 (female) (40) and
circuit occurs in the wiring
(42) Resis-
200 to 400 z NO harness.
a Coil resistance of preheat relay tance
• Proceed to "Open circuit in
R18
wiring harness".
PC200, 200LC, 220, 220LC-8M0 40-302 67

Inspection
item
2. Disconnect connector CE02 and preheat relay R18, and • Proceed to the next
Open circuit connect the T-adapter to the female side. inspection item.
4 in wiring har- Between CE02 (female) (40) and Resis- • An open circuit occurs in
ness Max. 1 z
R18 (female) (1) tance the wiring harness.
NO
Between R18 (female) (2) and CE02 Resis- ing harness.
(42) tance
check".
2. Disconnect connector CE02 and preheat relay R18, and the wiring harness.
YES
connect the T-adapter to the female side of the CE02. • Proceed to the next
Short circuit in
Between CE02 (female) (40) and No continuity (no sound • Repair or replace the wir-
NO
check".
item troller.
check".
YES
7 Repair check 3. Turn the starting switch on while the charge temperature is
below -4°C. NO Repairs are completed.
40-302 68 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to intake air heater relay
PC200, 200LC, 220, 220LC-8M0 40-302 69


Detail of failure Short circuit is in preheat relay drive circuit (primary circuit).
Action level L01
Action of con-
None in particular
troller
Problem on Intake air heater does not work in auto preheating mode (resulting in degraded startability and emission
machine of white smoke at low temperatures).
the monitoring function.
(Code: 18500)
Related infor-
• Troubleshooting of this failure code covers circuits from engine controller to primary circuit (coil) of
mation
preheat relay R18.
• For troubleshooting of the secondary circuit of the heater relay and preheat relay R18, see "E-2" in
E-mode.
Inspection
item
YES normal.
inspection item.
and connector.
check".
• The state of the preheat
relay R18 is normal.
2. Disconnect the preheat relay R18, and connect the YES
inspection item.
Resis-
Preheat relay Between R18 (male) (1) and (2) 200 to 400 z • The preheat relay R18 is
2 tance
R18 defective.
• Replace the preheat relay
2. Replace the preheat relay R18 with another one. NO
R18.
If this failure code disappears, original preheat relay R18 is check".
defective.
the wiring harness.
2. Disconnect connector CE02 and preheat relay R18, and YES
inspection item.
Ground fault
Min. 1 Mz NO
(40) or R18 (female) (1) tance ing harness.
check".
40-302 70 PC200, 200LC, 220, 220LC-8M0

Inspection
item
2. Disconnect connector CE02 and preheat relay R18, and the wiring harness.
YES
connect the T-adapter to the female side of the CE02. • Proceed to the next
Short circuit in
Between CE02 (female) (40) and No continuity (no sound • Repair or replace the wir-
NO
check".
item troller.
check".
YES
6 Repair check 3. Turn the starting switch on while the charge temperature is
below -4°C. NO Repairs are completed.
PC200, 200LC, 220, 220LC-8M0 40-302 71

Circuit diagram related to intake air heater relay
40-302 72 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-302 73

SEN06134-01
© 2018 KOMATSU
All Rights Reserved
40-302 74
SEN06135-01
SEN06135-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
Failure code [D110KB] .................................................................................................................................... 2

Failure code [D19JKZ] .................................................................................................................................... 4
Failure code [D811MC] ................................................................................................................................... 7
Failure code [D862KA].................................................................................................................................... 8
Failure code [D8AQKR] .................................................................................................................................. 9
Failure code [DA22KK] ................................................................................................................................. 12
Failure code [DA25KP] ................................................................................................................................. 15
Failure code [DA26KP] ................................................................................................................................. 18
Failure code [DA29KQ] ................................................................................................................................. 21
Failure code [DA29KQ] ................................................................................................................................. 24
Failure code [DA2QKR] ................................................................................................................................ 26
Failure code [DAF0MB]................................................................................................................................. 29
Failure code [DAF0MC] ................................................................................................................................ 29
Failure code [DAF8KB] ................................................................................................................................. 30
Failure code [DAF9KQ]................................................................................................................................. 32
Failure code [DAFGMC]................................................................................................................................ 33
Failure code [DAFQKR] ................................................................................................................................ 34
Failure code [DAZ9KQ]................................................................................................................................. 35
Failure code [DAZQKR] ................................................................................................................................ 36
Failure code [DB2QKR] ................................................................................................................................ 37
Failure code [DGH2KB] ................................................................................................................................ 43
Failure code [DHA4KA]................................................................................................................................. 45
Failure code [DHPAMA] ................................................................................................................................ 46
Failure code [DHPBMA]................................................................................................................................ 49
PC200, 200LC, 220, 220LC-8M0 40-303 1

SEN06135-01 Failure code [D110KB]
Failure code [D110KB]

Detail of failure Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
Action level L01
• Stops 24 V output to battery relay primary circuit (coil side).
Action of con-
troller
Problem on
Each controller may fail to write data into its ROM (non-volatile memory).
machine
• As the T-adapter for the pump controller connector is the "socket-type box", operating voltage cannot
Related infor- be measured at the pump controller connector.
mation • Output state (ON/OFF) to battery relay can be checked via the monitoring function.
(Code: 03700 Controller Output 1)
Inspection
item
relay is normal.
inspection item.
1 Battery relay • The battery relay is defec-
tive.
Between terminals R01 and BR Continuity NO • Replace the battery relay.
check".
2. Disconnect the battery ground cable (to prevent short
the wiring harness.
circuit during work). YES
3. Disconnect terminals R01 and R02, and disconnect
inspection item.
connectors D01, H15, and C02.
Ground fault Between terminal R02 (BR) and Resis-
2 in wiring har- Min. 1 Mz • Ground fault occurs in the
ground tance
Between ground and terminal R02
(harness side), C02 (female) (108), Min. 1 Mz NO
tance ing harness.
D01 (female) (1) or (2)
Between D01 (female) (5) and Resis- check".
Min. 1 Mz
ground tance
• The pump controller may
3 inspection • Replace the pump control-
item ler.
check".
YES
4 Repair check 3. Turn the starting switch on and off.
4. Is this failure code displayed? (For 0.5 sec. after being NO Repairs are completed.
turned off)
40-303 2 PC200, 200LC, 220, 220LC-8M0

Failure code [D110KB] SEN06135-01
Circuit diagram related to battery relay
PC200, 200LC, 220, 220LC-8M0 40-303 3

SEN06135-01 Failure code [D19JKZ]
Failure code [D19JKZ]

Detail of failure An open circuit or short circuit error is detected in the primary (coil) circuit of the personal code relay.
Action level L03
• None in particular (when open error occurred)
• Stops driving personal code relay (when short circuit occurred).
Action of
• If the cause of the failure is eliminated, the state of the machine returns to normal by itself (when
machine moni-
open circuit occurred).
tor
starting switch is turned to OFF position (when short circuit occurred).
Problem on • When an open circuit occurs, the engine can be started even if start mode is locked.
machine • Engine cannot be started when ground fault occurs.
• This failure code is only displayed when engine lock function is enabled.
Related infor-
• Troubleshooting for this failure code covers the range of fuse No. 3 in fuse F01 - the primary (coil)
mation
circuit of the personal code relay R07 - the machine monitor.
Inspection
item
• The state of the fuse is
normal.
YES
inspection item.
• If the fuse has burnt out,
If fuse No.3 of fuse F01 has blown, the circuit may have a proceed to "Ground fault
1 Fuse
ground fault. in wiring harness".
• If the fuse has not burnt
NO
out but it has no continuity,
replace the fuse.
check".
• The state of the personal
code relay R07 is normal.
2. Disconnect relay R07, and connect the T-adapter to the YES
male side.
inspection item.
Personal Resis-
Between R07 (male) (1) and (2) 100 to 500 z • The personal code relay
2 code relay tance
R07 R07 is defective.
• Replace the personal
2. Replace relay R07 with another one. NO
code relay R07.
If this failure code disappears, original personal code relay check".
R07 is defective.
• No open circuit, short cir-
cuit, or ground fault occurs
2. Remove No.3 of fuse F01. YES
3. Disconnect connector CM01 and connect the T-adapter to
Open circuit, the female side.
inspection item.
short circuit,
Between F01-3 and CM01 (female) Resis- • An open circuit, short cir-
3 or ground 100 to 500 z
fault in wiring (6) tance cuit, or ground fault occurs
NO
Between F01-3 or CM01 (female) (6) Resis- wiring harness" or
Min. 1 Mz
and ground tance "Ground fault in wiring har-
ness".
40-303 4 PC200, 200LC, 220, 220LC-8M0

Failure code [D19JKZ] SEN06135-01
Inspection
item
required.
YES ness.
2. Remove No.3 of fuse F01.
3. Disconnect connector CM01 and relay R07, and connect
inspection item.
the T-adapter to each female side.
Open circuit
Resis- • An open circuit occurs in
4 in wiring har- Between F01-3 and R07 (female) (1) Max. 1 z
ing harness.
NO
Between R07 (female) (2) and CM01 Resis- • Replace fuse if it has
Max. 1 z blown out.
(female) (6) tance
check".
YES
2. Remove No.3 of fuse F01. • Proceed to the next
3. Disconnect connector CM01 and relay R07, and connect inspection item.
the T-adapter to either female side.
Ground fault
5 in wiring har- Between F01-3 or R07 (female) (1) Resis- • Ground fault occurs in the
Min. 1 Mz
ness and ground tance wiring harness.
ing harness.
NO
Between ground and R07 (female) Resis- • Replace fuse if it has
Min. 1 Mz blown out.
(2) or CM01 (female) (6) tance
check".
2. Remove No.3 of fuse F01.
the wiring harness.
3. Disconnect connector CM01 and relay R07, and connect YES
the T-adapter to the female side of the CM01.
inspection item.
a Check using multimeter in continuity mode.
Short circuit in • A short circuit occurs in
6 wiring har- the wiring harness.
ness • Repair or replace the wir-
Between CM01 (female) (6) pin and No continuity ing harness.
NO
each pin other than (6) (No sound is heard.) • Replace fuse if it has
blown out.
check".
item monitor.
check".
YES
3. Turn the starting switch on (when an open circuit error
occurs).
8 Repair check 4. Is this failure code displayed?
NO Repairs are completed.
Remarks
When a short circuit error occurs, the failure code cannot be
reproduced on the machine.
PC200, 200LC, 220, 220LC-8M0 40-303 5

SEN06135-01 Failure code [D19JKZ]
Circuit diagram related to personal code relay
40-303 6 PC200, 200LC, 220, 220LC-8M0

Failure code [D811MC] SEN06135-01
Failure code [D811MC]

Detail of failure KOMTRAX malfunction
Action level -
Action of con-
-
troller
Problem on
KOMTRAX system does not operate normally.
machine
Related infor-
-
mation
Inspection
item
• The KOMTRAX may be
KOMTRAX malfunction defective.
1 KOMTRAX (Since this is an internal defect, troubleshooting cannot be - • Replace the KOMTRAX.
performed.) • Proceed to "Repair
check".
YES
2 Repair check
PC200, 200LC, 220, 220LC-8M0 40-303 7

SEN06135-01 Failure code [D862KA]
Failure code [D862KA]

Detail of failure Open circuit occurs in GPS antenna circuit.
Action level -
Action of
• None in particular
machine moni-
• If the cause of the failure is eliminated, the state of the machine returns to normal by itself.
tor
Problem on
GPS positioning system does not work.
machine
Related infor-
-
mation
Inspection
item
• The GPS antenna or
antenna cable may be
GPS antenna The GPS antenna may be defective, the antenna cable may
defective.
1 or antenna be disconnected, short circuit, or poor contact of GPS -
cable antenna cable connecting part (A).
check".
YES
2 Repair check
Configuration diagram
40-303 8 PC200, 200LC, 220, 220LC-8M0

Failure code [D8AQKR] SEN06135-01
Failure code [D8AQKR]

Detail of failure Machine monitor does not recognize KOMTRAX via the CAN communication-2 line (KOMNET/c).
Action level -
Action of
machine moni- None
tor
Problem on
None
machine
• Start of CAN communication is recognized by each controller when the ACC signal of the starting
switch is received.
• 4 different failure codes, [DA2QKR], [DB2QKR], [D8AQKR] and [DAZQKR] are used for defective
CAN communication by CAN 2 when it is detected by machine monitor. When all of these 4 failure
codes are displayed simultaneously on screen, ground fault, short circuit, or hot short circuit may
occur in the wiring harness (CAN communication line). In such a case, check whether the air condi-
tioner can be operated (ON/OFF and air flow of air conditioner) via the air conditioner screen since
Related infor-
the air conditioner is also operated through CAN communication.
mation
• The air conditioner can be controlled even when the failure code is displayed on the monitor screen.
If the air conditioner is controlled, there is no possibility of a ground fault, short circuit, or hot short cir-
cuit will occur in the wiring harness (CAN communication line).
• Since each controller and machine monitor are connected directly to battery, they are supplied with
power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by using mul-
timeter.
Inspection
item
• The state of the fusible link
is normal.
2. Disconnect fusible link F05 and connect the T-adapter to YES
the female side.
inspection item.
1 Fusible link Resis- • A ground fault may occur
Between F05 (female) (1) and (2) Max. 1 z
tance in the fusible link.
NO • Replace the fusible link.
a If fusible link has blown, the circuit may have a ground • Proceed to "Repair
fault. check".
1. Starting switch: OFF normal.
YES
2. Remove fuse No. 17 in fuse box F01. • Proceed to the next
inspection item.
2 Fuse • The fuse is defective.

• The fuse may have a
ground fault.
If fuse has blown, the circuit may have a ground fault. NO
• Replace the fuse.
check".
• The power supply to the
KOMTRAX terminal is nor-
YES mal.
Power supply inspection item.
3 to KOMTRAX Perform troubleshooting for "E-36" of E mode. • The power supply to the
terminal KOMTRAX terminal is
insufficient.
NO
check".
PC200, 200LC, 220, 220LC-8M0 40-303 9

SEN06135-01 Failure code [D8AQKR]
Inspection
item
• The state of the CAN
Communication 2 system
YES is normal.
CAN commu- inspection item.
Perform checks on inspection items 4 to 9 in troubleshooting
4 nication 2
for failure code [DB2QKR]. • The CAN communication
system
check".
• The KOMTRAX terminal
may be defective.
If no failure is identified by the above checks, the KOMTRAX
KOMTRAX • Replace the KOMTRAX
5 terminal is defective. (Since this is an internal defect, trouble- -
terminal terminal.
shooting cannot be performed.)
check".
item monitor.
check".
YES
7 Repair check
40-303 10 PC200, 200LC, 220, 220LC-8M0

Failure code [D8AQKR] SEN06135-01
Circuit diagram related to power supply
PC200, 200LC, 220, 220LC-8M0 40-303 11

SEN06135-01 Failure code [DA22KK]
Failure code [DA22KK]

Detail of failure Power supply voltage of controller for driving solenoids is below 20 V.
Action level L03
• Stops detecting the failure codes (open and short circuit) for all solenoid systems while this failure
Action of con-
code is displayed.
troller
Problem on
No solenoid valve is energized correctly, so the machine does not work properly.
machine
• If failure code [D110KB] is displayed, perform troubleshooting for it first.
Related infor-
mation
be measured at the pump controller connector.
Inspection
item
or fuse is normal.
YES
inspection item.
• If the fusible link or fuse
has burnt out, proceed to
Fusible link or If fusible link F04 or fuse No.2 in fuse box F01 has blown, the "Ground fault in wiring har-
1
fuse circuit may have a ground fault. (See Inspection item 5.) ness".
NO
replace the fusible link and
fuse.
check".
• The state of the battery is
normal.
2. After measuring voltage, measure it again when starting YES
the engine.
inspection item.
2 Battery
• The battery is defective.
• Replace the battery.
Between battery (+) and ground Voltage 20 to 30 V NO
check".
1. Turn the starting switch OFF, and disconnect the battery
ground cable. • The state of the wiring har-
2. Disconnect connector C02, and connect the T-adapter to ness is normal.
YES
3. Connect the battery ground cable, and turn the starting inspection item.
Wiring har- switch ON.
3
ness • The wiring harness is
defective.
Between ground and each of C02 • Repair or replace the wir-
Voltage 20 to 30 V NO
(116), (118), and (121) ing harness.
check".
40-303 12 PC200, 200LC, 220, 220LC-8M0

Failure code [DA22KK] SEN06135-01
Inspection
item
required. • An open circuit does not
1. Turn the starting switch OFF, and disconnect the battery occur in the wiring har-
ground cable. YES ness.
2. Remove fusible link F04 and fuse (2) in fuse box F01. • Proceed to the next
3. Disconnect connector C02, and connect the T-adapter to inspection item.
Open circuit
the female side.
4 in wiring har-
ness Between F01-2 and each of C02 Resis-
(female) (116), (118) and (121) tance the wiring harness.
Between F01-1A and F04 (male) (2) Max. 1 z NO
tance ing harness.
Between F04 (male) (1) and terminal Resis- • Proceed to "Repair
Max. 1 z check".
R03 tance
required.
the wiring harness.
ground cable. YES
2. Remove fusible link F04 and fuse No.2 in fuse box F01.
inspection item.
3. Disconnect connector C02, and connect the T-adapter to
the female side.
Ground fault Between ground and C02 (female) Resis- • Ground fault occurs in the
5 in wiring har- Min. 1 Mz
(116), (118), (121), or F01-2 tance wiring harness.
ness • Repair or replace the wir-
Between F01-1A or F04 (male) (2) Resis-
Min. 1 Mz ing harness.
and ground tance
• Replace the fusible link if it
NO
has blown out.
Between ground and F04 (male) (1) Resis- • Replace fuse if it has
or terminal R03 tance
check".
item ler.
check".
YES
7 Repair check
PC200, 200LC, 220, 220LC-8M0 40-303 13

SEN06135-01 Failure code [DA22KK]
Circuit diagram related to pump controller power supply
40-303 14 PC200, 200LC, 220, 220LC-8M0

Failure code [DA25KP] SEN06135-01
Failure code [DA25KP]

Detail of failure Voltage of 5 V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
Action level -
• Stops output of power from 5 V sensor power supply output 1.
Action of con-
troller
• Automatic travel speed selector function does not work (pump pressure sensor system).
Problem on
• Auto-decelerator function remains activated or fine control performance of work equipment is poor.
machine
(PPC (Proportional Pressure Control) pressure sensor system)
Related infor- As the T-adapter for the pump controller connector is the "socket-type box", operating voltage cannot
mation be measured at the pump controller connector.
Inspection
item
2. Disconnect the following connectors one by one, and turn • The state of the pressure
the starting switch to ON position each time. sensor is normal.
YES
a If this failure code is cleared, the disconnected sensor is • Proceed to the next
defective. inspection item.
3. Each time troubleshooting is finished, return to step 1.
Sensor Connector
Bucket CURL PPC pressure sensor P01
Pressure sen- Boom LOWER PPC pressure sensor P02

1
sor Bucket DUMP PPC pressure sensor P05 • The disconnected pres-
Arm IN PPC pressure sensor P04 sure sensor is defective.
• Replace the disconnected
Boom RAISE PPC pressure sensor P06 NO
pressure sensor.
Swing RIGHT PPC pressure sensor P07 • Proceed to "Repair
Arm OUT PPC pressure sensor P08 check".
Swing LEFT PPC pressure sensor P03
F pump pressure sensor P25
R pump pressure sensor P26
a Measure voltage before the controller stops outputting.
2. Disconnect connectors P01 to P08, P25, and P26. occur in the wiring har-
3. Connect the T-adapter to the female side of either of the YES ness.
disconnected connectors (e.g. P07). • Proceed to the next
Hot short cir- 4. Turn the starting switch ON (with connectors P01 to P08, inspection item.
2 cuit in wiring P25, and P26 disconnected).
ground ing harness.
check".
1. Starting switch: OFF • No ground fault occurs in
2. Disconnect connectors C01, P01 to P08, P25, and P26. the wiring harness.
YES
3. Connect the T-adapter to the female side of connector • Proceed to the next
C01. inspection item.
Ground fault
Between C01 (female) (9) and Resis- • Repair or replace the wir-
Min. 1 Mz NO
check".
PC200, 200LC, 220, 220LC-8M0 40-303 15

SEN06135-01 Failure code [DA25KP]
Inspection
item
item ler.
check".
YES
5 Repair check
40-303 16 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to 5 V sensor power supply 1
PC200, 200LC, 220, 220LC-8M0 40-303 17

Failure code [DA26KP]

Detail of failure Voltage of 5 V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V.
Action level -
• Stops output of power from 5 V sensor power supply output 2.
Action of con-
troller
Problem on
Machine does not run stably.
machine
Inspection
item
2. Disconnect the following connectors one by one, and turn • The state of the pressure
the starting switch to ON position each time. sensor is normal.
YES
a If this failure code is cleared, the disconnected sensor is • Proceed to the next
defective. inspection item.
3. Each time troubleshooting is finished, return to step 1.
Sensor Connector
Pressure sen- L.H. travel forward PPC pressure
1 P09
sor sensor • The disconnected pres-
sure sensor is defective.
L.H. travel reverse PPC pressure
P10 • Replace the disconnected
sensor NO
pressure sensor.
R.H. travel forward PPC pressure • Proceed to "Repair
P11
sensor check".
R.H. travel reverse PPC pressure
P12
sensor
a Measure voltage before the controller stops outputting.
2. Disconnect connectors P09 to P12. occur in the wiring har-
3. Connect the T-adapter to the female side of one of the YES ness.
disconnected connectors (e.g. P09). • Proceed to the next
Hot short cir- 4. Turn the starting switch ON (with connectors P09 to P12 inspection item.
2 cuit in wiring disconnected).
ground ing harness.
check".
2. Disconnect connectors C01 and P09 to P12. the wiring harness.
YES
C01. inspection item.
Ground fault
Min. 1 Mz NO
check".
40-303 18 PC200, 200LC, 220, 220LC-8M0

Inspection
item
item ler.
check".
YES
5 Repair check
PC200, 200LC, 220, 220LC-8M0 40-303 19

Circuit diagram related to 5 V sensor power supply 2
40-303 20 PC200, 200LC, 220, 220LC-8M0

Failure code [DA29KQ] SEN06135-01
Failure code [DA29KQ]

Detail of failure Model code signal for model which is not registered in controller is input.
Action level L01
• Treats it as a default-set model (PC200).
Action of con-
troller
Problem on
The pump controller recognizes the machine as "PC200", so there are no particular problems.
machine
• Machine model code of pump controller can be checked via the monitoring function.
Related infor- (Code: 00200 Controller machine model code)
mation • Signal state of machine model selection can be checked via the monitoring function. (Code: 02201
Switch input 2)
q PC200-8M0, PC200LC-8M0
Inspection
item
• The state of the model
1. Starting switch: OFF selection connector is nor-
2. Disconnect connector S30, and connect the T-adapter to YES mal.
inspection item.
Resis-
Between S30 (female) (1) and (2) Min. 1 Mz
tance
Resis-
tance
Model selec- Resis-
1 • The model selection con-
tion connector Between S30 (female) (2) and (3) tance
Min. 1 Mz
nector is defective.
Resis- • Replace the model selec-
Between S30 (female) (3) and (4) Min. 1 Mz NO
tance tion connector.
Between S30 (female) (4) and (7) Min. 1 Mz check".
tance
Resis-
tance
Resis-
Between S30 (female) (3) and (8) Max. 1 z
tance
2. Disconnect connector C01, and connect the T-adapter to YES ness.
Max. 1 z NO
check".
PC200, 200LC, 220, 220LC-8M0 40-303 21

SEN06135-01 Failure code [DA29KQ]
Inspection
item
the wiring harness.
2. Disconnect connector C01, and connect the T-adapter to YES
the female side.
inspection item.
Between C01 (female) (21) and C01 Resis-
Short circuit in (female) (77) Min. 1 Mz
tance
Between C01 (female) (39) and C01 Resis- the wiring harness.
ness Min. 1 Mz
(female) (77) tance • Repair or replace the wir-
NO
Between C01 (female) (40) and C01 Resis- ing harness.
Min. 1 Mz • Proceed to "Repair
(female) (77) tance
check".
Min. 1 Mz
(female) (77) tance
the wiring harness.
the female side.
inspection item.
Between C01 (female) (21) and Resis-
Ground fault Min. 1 Mz
ground tance
Between C01 (female) (40) and Resis- wiring harness.
ness Min. 1 Mz
ground tance • Repair or replace the wir-
NO
Between C01 (female) (58) and Resis- ing harness.
ground tance
check".
Min. 1 Mz
ground tance
item ler.
check".
YES
6 Repair check
40-303 22 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to model selection connector (PC200-8M0, 200LC-8M0)
PC200, 200LC, 220, 220LC-8M0 40-303 23

SEN06135-01 Failure code [DA29KQ]
Failure code [DA29KQ]

q PC220-8M0, PC220LC-8M0
Inspection
item
• The state of the model
1. Starting switch: OFF selection connector is nor-
2. Disconnect connector S30, and connect the T-adapter to YES mal.
inspection item.
Resis-
tance
Resis-
tance
Model selec- Resis-
1 • The model selection con-
tion connector Between S30 (female) (3) and (4) tance
Min. 1 Mz
nector is defective.
Resis- • Replace the model selec-
Between S30 (female) (4) and (7) Min. 1 Mz NO
tance tion connector.
Between S30 (female) (7) and (8) Min. 1 Mz check".
tance
Resis-
tance
Resis-
tance
2 in wiring har- Between C01 (female) (40) and Resis- • An open circuit occurs in
ness Max. 1 z
ground tance the wiring harness.
NO
ground tance
check".
the wiring harness.
the female side.
inspection item.
Short circuit in Between C01 (female) (21) and C01 Resis-
3 wiring har- Min. 1 Mz • A short circuit occurs in
ness
Between C01 (female) (39) and C01 Resis- • Repair or replace the wir-
Min. 1 Mz NO
Between C01 (female) (58) and C01 Resis- • Proceed to "Repair
Min. 1 Mz check".
(female) (77) tance
the wiring harness.
the female side.
inspection item.
Ground fault Between C01 (female) (21) and Resis-
ground tance wiring harness.
ness
Min. 1 Mz NO
Between C01 (female) (58) and Resis- • Proceed to "Repair
Min. 1 Mz check".
ground tance
40-303 24 PC200, 200LC, 220, 220LC-8M0

Inspection
item
item ler.
check".
YES
6 Repair check
Circuit diagram related to model selection connector (PC220-8M0, PC220LC-8M0)
PC200, 200LC, 220, 220LC-8M0 40-303 25

SEN06135-01 Failure code [DA2QKR]
Failure code [DA2QKR]

The machine monitor does not recognize the pump controller through the CAN communication 2 line
Detail of failure
(KOMNET/c).
Action level L03
Action of con-
Retains information when the failure occurred.
troller
Information to be obtained from the pump controller is not displayed and special functions that need
Problem on
information do not work. Otherwise, updating of received data is stopped (failure code or monitoring
machine
code sent from the pump controller).
switch is received.
Related infor- the air conditioner is also operated through CAN communication.
mation • This can be activated even when the power supply to the pump controller is turned off.
timeter.
Inspection
item
is normal.
2. Disconnect fusible link F05 and connect the T-adapter to YES
the female side.
inspection item.
1 Fusible link Resis- • A ground fault may occur
Between F05 (female) (1) and (2) Max. 1 z
tance in the fusible link.
NO • Replace the fusible link.
a If fusible link has blown, the circuit may have a ground • Proceed to "Repair
fault. check".
YES
2. Remove fuse No. 17 in fuse box F01. • Proceed to the next
inspection item.
2 Fuse • The fuse may have a
ground fault.
a If fuse has blown, the circuit may have a ground fault. NO • Replace the fuse.
check".
a Check ground terminal T04 for looseness and rust.
pump controller is normal.
the female side.
inspection item.
Power supply 3. Starting switch: OFF
3 to pump con- Between C01 (female) (1) and (2) 20 to 30 V • The power supply to the
troller pump controller is insuffi-
cient.
Voltage NO
Between C01 (female) (4) and (5) 20 to 30 V • Repair the defective part.
check".
40-303 26 PC200, 200LC, 220, 220LC-8M0

Failure code [DA2QKR] SEN06135-01
Inspection
item
a If the result of Inspection item 3 is normal, this check is • An open circuit does not
not required. occur in the wiring har-
2. Disconnect connectors F05 and C01, and connect the • Proceed to the next
T-adapter to each female side. inspection item.
Between terminal R04 and F05
Open circuit Max. 1 z
4 in wiring har- (female) (1)
• An open circuit occurs in
ness Between F05 (female) (2) and the wiring harness.
Max. 1 z
Resis- F01-16E • Repair or replace the wir-
NO
tance Between F01-17 and C01 (female) ing harness.
(1)
check".
Between F01-17 and C01 (female)
Max. 1 z
(4)
• The state of the CAN
Communication 2 system
YES is normal.
CAN commu- inspection item.
Perform checks on inspection items 4 to 9 in troubleshooting
5 nication 2
for failure code [DB2QKR]. • The CAN communication
system
check".
• The pump controller or
Recheck of machine monitor may be
6 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the pump control-
item
ler or machine monitor.
check".
YES
7 Repair check
PC200, 200LC, 220, 220LC-8M0 40-303 27

SEN06135-01 Failure code [DA2QKR]
Circuit diagram related to pump controller power supply
40-303 28 PC200, 200LC, 220, 220LC-8M0

Failure code [DAF0MB] SEN06135-01
Failure code [DAF0MB]

Detail of failure Machine monitor program is rewritten (program error).
Action level -
Action of con-
-
troller
Problem on • Machine monitor display is unreliable.
machine • It can neither transmit the data to controllers nor receive the data from them.
Related infor-
-
mation
Inspection
item
be defective.
Defective machine monitor
Machine • Replace the machine
1 (Since this is an internal defect, troubleshooting cannot be -
monitor monitor.
performed.)
check".
YES
2 Repair check
Failure code [DAF0MC]

Detail of failure Malfunction of machine monitor
Action level -
Action of con-
-
troller
Problem on • Machine monitor display is unreliable.
machine • It can neither transmit the data to controllers nor receive the data from them.
Related infor-
-
mation
Inspection
item
be defective.
Machine • Replace the machine
1 (Since this is an internal defect, troubleshooting cannot be -
monitor monitor.
performed.)
check".
YES
2 Repair check
PC200, 200LC, 220, 220LC-8M0 40-303 29

SEN06135-01 Failure code [DAF8KB]
Failure code [DAF8KB]

Output power supply voltage (rating: 8 V) from the machine monitor to the camera falls below 6.0 V or
Detail of failure
exceeds 10 V.
Action level L03
Action of • Stops output power supply voltage (rating: 8 V) to the camera.
machine moni- • Even if the cause of a failure is removed, the state of the machine does not return to normal until the
tor starting switch is turned to OFF position.
Problem on
Camera image is not displayed on the monitor screen.
machine
Related infor-
-
mation
Inspection
item
1. Starting switch: OFF • The camera is normal.
2. Disconnect the camera connector, and turn the starting YES • Proceed to the next
switch to ON position. inspection item.
1 Camera • The battery is defective.
If the failure code disappears after disconnecting the camera
• Replace the camera.
in order to perform the operation to reproduce the procedure, NO
an internal defect of the camera will be detected.
check".
• The state of the machine
2. Disconnect connector CM04.
monitor is normal.
3. Connect the T-adapter to the male side of connector YES
CM04.
inspection item.
Machine
2 • The machine monitor is
monitor
defective.
Between CM04 (male) (1) and • Replace the machine
Voltage 6 to 10 V NO
ground monitor.
check".
2. Disconnect the camera connector from connector CM04. the wiring harness.
YES
CM04. inspection item.
Ground fault
Min. 1 Mz NO
check".
2. Disconnect the camera connector. occur in the wiring har-
3. Insert the T-adapter into connector CM04. YES ness.
Hot short cir- (Disconnect camera and check that it is normal, in advance.) inspection item.
Between CM04 (1) and (5) Voltage Max. 10 V NO
ing harness.
check".
YES
5 Repair check
40-303 30 PC200, 200LC, 220, 220LC-8M0

Failure code [DAF8KB] SEN06135-01
Circuit diagram related to camera power supply
PC200, 200LC, 220, 220LC-8M0 40-303 31

SEN06135-01 Failure code [DAF9KQ]
Failure code [DAF9KQ]

The model in the machine monitor program differs from that in the pump controller program (the
Detail of failure
replaced machine monitor or pump controller has the wrong part No.).
Action level L03
Action of con-
-
troller
Problem on
Machine does not operate normally.
machine
• The assembly part No. of the pump controller program can be checked via the monitoring function.
Related infor- (Code: 20229)
mation • The assembly part No. of the machine monitor program can be checked via the monitoring function.
(Code: 20227)
Inspection
item
monitor is normal.
YES
inspection item.
1. Use the monitoring function to display the assembly part
No. and check whether it is identical to that listed in the • The machine monitor is
Machine defective (the pro-
1 Parts Book.
monitor grammed model is differ-
(The wrong machine model has been programmed.) ent).
NO
• Replace the machine
monitor.
check".
• The pump controller is
normal.
YES
inspection item.
1. Use the monitoring function to display the assembly part
No. and check whether it is identical to that listed in the • The pump controller is
Pump control- defective (the pro-
2 Parts Book.
ler grammed model is differ-
Defective pump controller
(The wrong machine model has been programmed.) ent).
NO
• Replace the pump control-
ler.
check".
YES
3 Repair check
40-303 32 PC200, 200LC, 220, 220LC-8M0

Failure code [DAFGMC] SEN06135-01
Failure code [DAFGMC]

No position data is sent from the GPS module (inside of the KOMTRAX terminal) to the KOMTRAX ter-
Detail of failure
minal 50 seconds or more after the KOMTRAX started.
Action level -
Action of
• None in particular
machine moni-
tor
Problem on
-
machine
Related infor-
-
mation
Inspection
item
• The KOMTRAX terminal
The GPS module of the KOMTRAX terminal may be defec- may be defective.
KOMTRAX tive. • Replace the KOMTRAX
1 -
terminal (Since this is an internal defect, troubleshooting cannot be terminal.
performed.) • Proceed to "Repair
check".
YES
2 Repair check 3. Turn the starting switch on.
4. Is this failure code displayed? (50 seconds after starting NO Repairs are completed.
switch was turned on)
PC200, 200LC, 220, 220LC-8M0 40-303 33

SEN06135-01 Failure code [DAFQKR]
Failure code [DAFQKR]

Detail of failure KOMTRAX terminal does not recognize machine monitor through CAN communication 2 line.
Action level -
Action of con-
-
troller
Problem on
System may not operate normally.
machine
switch is received.
• Failure code is transmitted to and displayed on machine monitor by CAN communication. Accord-
ingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is not displayed on
Related infor-
machine monitor and it can be observed only through KOMTRAX system.
mation
• Since each controller and machine monitor are connected directly to the battery, they are supplied
with power even after the starting switch is turned OFF.
timeter.
Inspection
item
machine monitor is nor-
YES mal.
1 to machine Perform troubleshooting for "E-5" in E mode. • The power supply to the
monitor machine monitor is insuffi-
cient.
NO
check".
• The CAN communication
item for failure code [DB2QKR].
check".
YES
3 Repair check
40-303 34 PC200, 200LC, 220, 220LC-8M0

Failure code [DAZ9KQ] SEN06135-01
Failure code [DAZ9KQ]

The model in the machine monitor program differs from that in the air conditioner controller program
Detail of failure
(the replaced machine monitor or air conditioner controller has the wrong part No.)
Action level -
Action of con-
-
troller
Problem on
Machine does not operate normally.
machine
• The model code specified by the air conditioner controller program cannot be checked via the moni-
toring function.
• Machine model code of machine monitor program can be checked via the monitoring function.
(Code: 00500)
Related infor-
• Air conditioner control data (model and series) of machine monitor can be checked via the monitor-
mation
ing function.
(Code: 55200)
• Air conditioner control data (model and series) can be checked via the monitoring function.
(Code: 55201) (OK if control data is 01 (which means PC))
Inspection
item
monitor is normal.
YES
inspection item.
• The machine monitor is
Machine Defective machine monitor defective (the pro-
1
monitor (The wrong machine model has been programmed.) grammed model is differ-
ent).
NO
• Replace the machine
monitor.
check".
• The state of the air condi-
tioner controller is normal.
YES
inspection item.
Air condi- • The air controller is defec-
Defective air conditioner controller
2 tioner control- tive (the programmed
(The wrong machine model has been programmed.)
ler model is different).
NO • Replace the air condi-
tioner controller.
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-303 35

SEN06135-01 Failure code [DAZQKR]
Failure code [DAZQKR]

In CAN communication 2 line (KOMNET/c), machine monitor cannot recognize air conditioner control-
Detail of failure
ler.
Action level L01
Action of con- • Retains information when the failure occurred.
• Failure codes related to the air conditioner controller are not displayed.
Problem on • Monitoring data related to the air conditioner controller are not updated.
machine • Air conditioner cannot be controlled (air does not blow out).
• Air conditioner operation screen of the machine monitor is not displayed properly.
switch is received.
• 4 different failure codes, [D8AQKR], [DA2QKR], [DAZQKR], and [DB2QKR] are used for defective
Related infor- codes are displayed simultaneously on screen, ground fault, short circuit, or hot short circuit may
mation occur in the wiring harness (CAN communication line).
timeter.
Inspection
item
air conditioner controller is
YES normal.
to air condi- a Perform Chapter 80 "Troubleshooting for power supply
1 • The power supply to the
tioner control- system".
ler air conditioner controller is
insufficient.
NO
check".
• The state of the CAN2
communication system is
YES normal.
CAN2 com-
a Perform Inspection items 4 to 9 for failure code inspection item.
2 munication
[DB2QKR]. • The CAN2 communica-
system
tion system is defective.
check".
• The air conditioner con-
troller or machine monitor
3 inspection • Replace the air condi-
item tioner controller or
machine monitor.
check".
YES
4 Repair check
40-303 36 PC200, 200LC, 220, 220LC-8M0

Failure code [DB2QKR] SEN06135-01
Failure code [DB2QKR]

The machine monitor does not recognize the pump controller through the CAN communication 2 line
Detail of failure
(KOMNET/c).
Action level L03
Action of con-
Retains information when the failure occurred.
troller
Information to be obtained from the engine controller is not displayed and special functions that need
Problem on
information do not work. Otherwise, updating of received data is stopped (failure code or monitoring
machine
code sent from the engine controller).
switch is received.
Related infor-
the air conditioner is also operated through CAN communication.
mation
timeter.
Inspection
item
normal.
YES
inspection item.
1. Starting switch: OFF • If the fuse has burnt out,

Fuse (for proceed to "Engine con-
2. Remove fuse-19 (30A) from fuse box F01.
1 engine controller power supply cir-
a If fuse has blown, the engine controller may have short
troller) cuit".
circuit.
NO • If the fuse has not burnt
replace the fuse.
check".
a If fuse is not blown out, this check is not required. • The engine controller is
YES
2. Disconnect connector CE03, and connect the T-adapter to • Proceed to the next
the male side. inspection item.
Engine con- • The engine controller may
2
troller be defective.
Resis- • Replace the engine con-
Between CE03 (male) (3) and (1) Min. 10 z NO
tance troller.
check".
PC200, 200LC, 220, 220LC-8M0 40-303 37

SEN06135-01 Failure code [DB2QKR]
Inspection
item
a Check ground terminal T12 for looseness and rust.
engine controller is nor-
2. Disconnect connector CE03, and connect the T-adapter to
YES mal.
the female side.
Power supply 3. Turn the starting switch to ON position. inspection item.
3 to engine con- a If abnormal, perform troubleshooting for [CA441].
troller • The power supply to the
engine controller is abnor-
Between CE03 (female) (3) and (1) Voltage 20 to 30 V NO mal.
• Perform troubleshooting
for failure code [CA441].
• The CAN terminating
resistor is normal.
2. Disconnect connectors CM02 and K02, and connect the YES
inspection item.
CAN termi- Resis- • The CAN terminating
4 120±12 z
nating resistor Between K02 (male) (A) and (B) tance resistor is defective.
• Replace CAN terminating
NO
Resis- resistor.
Between CM02 (male) (7) and (9)
tance 120±12 z • Proceed to "Repair
check".
• CAN communication line
a The 120 Ω CAN terminating resistor is also located in the
machine monitor. That is, 2 CAN terminating resistors of
120 Ω are connected in parallel. When the circuit resis-
tance is measured at the connector of a controller other
than the machine monitor, if the combined resistance is
60 Ω, the wiring harness does not have an open circuit. circuit does not occur in
YES the wiring harness.
ground cable.
2. Disconnect the related connector, and connect the
inspection item.
T-adapter to the connector to be measured.
a If short circuit is found (resistance between 2 terminals is
1 Ω and below), disconnect all CAN communication con-
Open circuit nectors of every controller, and check whether short
or short circuit circuiting occurs between wiring harnesses or inside the
5
in wiring har- controller.
ness Resis- Approx. 120
Between CM02 (female) (8) and (9)
tance z
Between CE02 (female) (46) and Resis-
Approx. 60 z
(47) tance
Resis- • An open circuit or short
Between C01 (female) (45) and (64) Approx. 60 z circuit occurs in the wiring
tance
NO harness.
Resis-
Between AC01 (female) (1) and (2) Approx. 60 z • Proceed to "Open circuit in
tance wiring harness".
Between CK01 (female) (10) and Resis-
Approx. 60 z
(11) tance
Resis- Approx. 120
Between K02 (female) (A) and (B)
tance z
40-303 38 PC200, 200LC, 220, 220LC-8M0

Inspection
item
• ACC signal of starting switch (start of CAN communication
is not recognized) • An open circuit does not
1. Turn the starting switch off, and disconnect the battery occur in the wiring har-
ground cable. YES ness.
2. Insert the T-adapter into the connector to be measured. • Proceed to the next
3. Connect the battery ground cable, and turn the starting inspection item.
switch ON.
Between CM01 (10) and (3) Voltage 20 to 30 V
Between CE02 (39) and CE03 (1) Voltage 20 to 30 V
Between C01 (2) and each of (24),
Voltage 20 to 30 V
(43), and (79)
Between AC02 (4) and (1) Voltage 20 to 30 V
Between CK02 (3) and (1) Voltage 20 to 30 V
a If the result of Inspection item 5 is normal, this check is
not required.
1. Turn the starting switch off, and disconnect the battery
ground cable.
T-adapter to the connector of each female side to be
Open circuit measured.
6 in wiring har- Between CM02 (female) (8) and C01 Resis-
ness Max. 1 z
(female) (45) tance • An open circuit occurs in
Between CM02 (female) (9) and C01 Resis- the wiring harness.
Max. 1 z • Repair or replace the wir-
(female) (64) tance NO
ing harness.
Between CM02 (female) (8) and Resis-
CE02 (female) (46) tance check".
Max. 1 z
CE02 (female) (47) tance
Max. 1 z
AC01 (female) (2) tance
Max. 1 z
AC01 (female) (1) tance
Max. 1 z
CK01 (female) (10) tance
Max. 1 z
CK01 (female) (11) tance
Max. 1 z
K02 (female) (A) tance
Max. 1 z
K02 (female) (B) tance
PC200, 200LC, 220, 220LC-8M0 40-303 39

Inspection
item
a If no failure (no open circuit) is found by Inspection item 5,
measure resistance at any one place in each case.
the wiring harness.
ground cable. YES
inspection item.
T-adapter to the connector of each female side to be
Ground fault measured.
7 in wiring har- Between ground and any one of C01 • Ground fault occurs in the
ness Resis-
(female) (45), CM02 (female) (7), Min. 1 Mz wiring harness.
tance
(8), and CE02 (female) (46) • Repair or replace the wir-
ing harness.
NO
Between ground and any of C01 • Replace fuse if it has
Resis- blown out.
(female) (64), CM02 (female) (9) and Min. 1 Mz
CE02 (female) (47)
check".
a If no failure (no open circuit) is found by Inspection item 5,
measure resistance at any one place in each case.
ground cable. • A short circuit or hot short
2. Disconnect connectors to be measured and insert circuit does not occur in
T-adapters into them. YES the wiring harness.
3. Connect the battery ground cable. • Proceed to the next
Open circuit a Voltage of CAN H and CAN L is 2.5 ± 1 V including dur-
or hot short ing communication, so regard wiring harness as normal if
8
circuit in wir- measured voltage is 1 to 4 V.
ing harness
Between ground and any of CM02
(female) (8), C01 (female) (45), • A short circuit or hot short
Voltage 1 to 4 V circuit occurs in the wiring
CK01 (female) (10), AC01 (female)
(2), and CE02 (female) (46) harness.
Between ground and any of CM02 ing harness.
(female) (9), C01 (female) (64), • Proceed to "Repair
Voltage 1 to 4 V
CK01 (female) (11), AC01 (female) check".
(1), and CE02 (female) (47)
• If all four failure codes [DA2QKR], [DB2QKR], [D8AQKR],
and [DAZQKR] are displayed:
a To identify defective controller, repeat following steps 1
• If the number of failure
through 3 to disconnect controllers one by one from CAN
codes decreases from 4,
communication line.
the disconnected control-
ler is defective.
ground cable.
• Replace the engine con-
2. Disconnect each CAN communication connector of engine YES
Engine controller, pump controller, air
controller (connector CE02), pump controller (connector
troller, pump conditioner unit, or
C01), air conditioner unit (connector AC01) and
controller, air KOMTRAX terminal.
KOMTRAX terminal (connector CK01) one by one in
9 conditioner • Proceed to "Repair
order.
unit, check".
3. Connect the battery ground cable, and turn the starting
KOMTRAX switch ON for troubleshooting.
terminal 4. Return to step 1. to check next controller.
• If the number of failure
codes does not decrease
If YES, the discon- from 4, the state of the dis-
Has the number of displayed failure
nected controller is NO connected controller is
codes decreased from 4?
defective. normal.
inspection item.
40-303 40 PC200, 200LC, 220, 220LC-8M0

Inspection
item
• The engine controller or
10 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the engine con-
item
troller or machine monitor.
check".
YES
11 Repair check
PC200, 200LC, 220, 220LC-8M0 40-303 41

Circuit diagram related to CAN communication
40-303 42 PC200, 200LC, 220, 220LC-8M0

Failure code [DGH2KB] SEN06135-01
Failure code [DGH2KB]

The signal voltage of the hydraulic oil temperature sensor circuit is below 1 V, so the pump controller
Detail of failure
determines that the circuit has a ground fault.
Action level L01
Action of con-
If the cause of the failure is eliminated, the state of the machine returns to normal by itself.
troller
Problem on The hydraulic oil temperature gauge is set to 50°C or equivalent regardless of the hydraulic oil tem-
machine perature.
Related infor- Signal voltage of hydraulic oil temperature sensor can be checked via the monitoring function. (Code:
mation 04402 hydraulic oil temperature sensor voltage)
Inspection
item
ture sensor is normal.
the male side.
inspection item.
Resis- Approx. 90
10°C tance kz
Hydraulic oil Between P22 (male) (1) Resis- Approx. 35
1 temperature and (2) 30°C • The hydraulic oil tempera-
tance kz ture sensor is defective.
sensor a Oil temperature sensor
temperature and resis- Resis- Approx. 6.5 • Replace the hydraulic oil
80°C NO
tance characteristics tance kz temperature sensor.
Resis- Approx. 3.5 • Proceed to "Repair
100°C tance kz check".
Resis-
Between P22 (male) (2) and ground Min. 1 Mz
tance
the female side. • No open circuit, short cir-
3. Turn the starting switch to ON position. cuit, ground fault, or hot
a If voltage is 0 V, wiring harness has open circuit, ground short circuit occurs in the
YES
Open circuit, fault, or short circuit, and if voltage is 24 V, wiring harness wiring harness.
short circuit, has hot short circuit. • Proceed to the next
ground fault, a Voltage of approximately 5 V is applied to temperature inspection item.
2 sensor signal circuits through resistance in pump control-
or hot short
circuit in wir- ler.
ing harness • An open circuit, short cir-
cuit, ground fault, or hot
short circuit occurs in the
Between P22 (female) (1) and (2) Voltage Approx. 5 V NO
wiring harness.
• Proceed to "Ground fault
in wiring harness".
PC200, 200LC, 220, 220LC-8M0 40-303 43

SEN06135-01 Failure code [DGH2KB]
Inspection
item
2. Disconnect connector C01, and connect the T-adapter to
the female side.
fault occurs in the wiring
a Use the temperature and resistance characteristics table
YES harness.
for check on Inspection item 1 as resistance criteria.
a If resistance is 1 MΩ or higher, wiring harness has an inspection item.
Short circuit
open circuit. If it is 1 Ω or lower, wiring harness has a
or ground short circuit.
3
fault in wiring
harness Resis- • A short circuit or ground
Between C01 (female) (29) and (46) 3.5 to 90 kz
harness.
Min. 1 Mz
ground tance • Proceed to "Repair
check".
required.
the wiring harness.
2. Disconnect connectors C01 and P22, and connect the
inspection item.
Between ground and C01 (female) Resis- • Repair or replace the wir-
Min. 1 Mz NO
check".
item ler.
check".
YES
6 Repair check
Circuit diagram related to hydraulic oil temperature sensor
40-303 44 PC200, 200LC, 220, 220LC-8M0

Failure code [DHA4KA] SEN06135-01
Failure code [DHA4KA]

When starting switch is turned to ON position, signal voltage from air cleaner clogging switch is not 1 V
Detail of failure or below, and machine monitor detects open circuit (sensor contacts open) of air cleaner clogging sen-
sor.
Action level L01
Action of con-
Displays the air cleaner clogging monitor in yellow on the machine monitor.
troller
Problem on If machine is used as it is, clogging of air cleaner cannot be detected correctly, and engine may be
machine damaged.
Related infor- Input state (ON/OFF) from air cleaner clogging sensor can be checked via the monitoring function.
Inspection
item
Air cleaner • Repairs are completed.
1 clogging sys- Perform troubleshooting for failure code [AA10NX]. - • Proceed to "Repair
tem check".
YES
2 Repair check
PC200, 200LC, 220, 220LC-8M0 40-303 45

SEN06135-01 Failure code [DHPAMA]
Failure code [DHPAMA]

Detail of failure Signal voltage of front pump pressure sensor circuit is 0.3 V and below or 4.5 V and above.
Action level L01
Action of con- • Controls the front pump pressure to be 0 MPa {0 kg/cm2}.
Problem on • Automatic gear shift function of travel does not work.
machine • Straight travel performance becomes poor or it is hard to steer.
• If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will break. Accordingly, take extreme care when checking.
Related infor- • As the T-adapter for the pump controller connector is the "socket-type box", operating voltage cannot
• The front pump pressure can be checked via the monitoring function. (Code: 01100 F pump pres-
sure)
Inspection
item
If failure code [DA25KP] is also displayed, perform trouble-
shooting for it first.
• The state of the 5 V sen-
1. Starting switch: OFF sor power supply 1 system
2. Disconnect connector P25, and connect the T-adapter to YES is normal.
5 V sensor
a If the power supply voltage is abnormal, proceed to
1 power supply
Inspection item 3 and after.
1 system
• The 5 V sensor power
supply 1 system is defec-
Between P25 (female) Power sup- tive.
(3) and (1) ply • Repair the defective part.
wiring harness".
• The front pump pressure
sensor is normal.
2. Insert the T-adapter into the connector P25. YES
inspection item.
Between P25 (2) and Sensor out-
Voltage 0.5 to 4.5 V
(1) put
a If the power supply voltage is normal and the sensor out-
put voltage is abnormal, it is difficult to judge whether the
Front pump cause of the failure is a defective sensor, a ground fault or
2 pressure sen- • The front pump pressure
hot short circuit in the wiring harness. Check as below. sensor is defective.
sor 1. Starting switch: OFF • Replace the front pump
2. Interchange connector P25 with connector P26 of the rear NO
pressure sensor.
pump PPC pressure sensor. • Proceed to "Repair
3. Turn the starting switch to ON position and display the check".
Electrical Systems Abnormality Record screen of the
machine monitor.
4. If E mark is no longer displayed in this failure code column,
the front pump pressure sensor is defective.
a After completing the test, restore the connector.
40-303 46 PC200, 200LC, 220, 220LC-8M0

Failure code [DHPAMA] SEN06135-01
Inspection
item
2. Disconnect connectors C01 and P25, and connect the YES ness.
inspection item.
a If power supply voltage in
Inspection item 1 is normal, this
Resis-
Open circuit check is not required. Max. 1 z
tance
3 in wiring har- Between C01 (female) (18) and P25 • An open circuit occurs in
ness (female) (1) the wiring harness.
Between C01 (female) (49) and P25 Resis- • Repair or replace the wir-
Max. 1 z NO
a If power supply voltage in • Proceed to "Repair
Inspection item 1 is normal, this check".
Resis-
check is not required. Max. 1 z
tance
Between C01 (female) (9) and P25
(female) (3)
the wiring harness.
2. Disconnect connectors C01 and P25, and connect the YES
inspection item.
Ground fault
Min. 1 Mz NO
check".
2. Disconnect connector P25.
YES ness.
3. Connect the T-adapter to female side of connector P25.
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
PC200, 200LC, 220, 220LC-8M0 40-303 47

SEN06135-01 Failure code [DHPAMA]
Circuit diagram related to front pump pressure sensor
40-303 48 PC200, 200LC, 220, 220LC-8M0

Failure code [DHPBMA] SEN06135-01
Failure code [DHPBMA]

Detail of failure Signal voltage of rear pump pressure sensor circuit is 0.3 V and below or 4.5 V and above.
Action level L01
Action of con- • Controls the rear pump pressure to be 0 MPa {0 kg/cm2}.
Problem on • Automatic gear shift function of travel does not work.
machine • Straight travel performance becomes poor or it is hard to steer.
• The rear pump pressure can be checked via the monitoring function. (Code: 01101 R pump pres-
sure)
Inspection
item
• The state of the 5 V sen-
1. Starting switch: OFF sor power supply 1 system
2. Disconnect connector P26, and connect the T-adapter to YES is normal.
5 V sensor
a If the power supply voltage is abnormal, proceed to
1 power supply
Inspection item 3 and after.
1 system
• The 5 V sensor power
supply 1 system is defec-
Between P26 (female) Power sup- tive.
(3) and (1) ply • Repair the defective part.
wiring harness".
• The rear pump pressure
sensor is normal.
2. Insert the T-adapter into the connector P26. YES
inspection item.
(1) put
a If the power supply voltage is normal and the sensor out-
put voltage is abnormal, it is difficult to judge whether the
Rear pump cause of the failure is a defective sensor, a ground fault or
2 pressure sen- • The rear pump pressure
hot short circuit in the wiring harness. Check as below. sensor is defective.
sor 1. Starting switch: OFF • Replace the rear pump
2. Interchange connector P26 with connector P25 of front NO
pressure sensor
pump PPC pressure sensor. • Proceed to "Repair
machine monitor.
4. If E mark is no longer displayed for this failure code
column, the rear pump pressure sensor is defective.
PC200, 200LC, 220, 220LC-8M0 40-303 49

SEN06135-01 Failure code [DHPBMA]
Inspection
item
inspection item.
a If power supply voltage in
Resis-
tance
Max. 1 z NO
a If power supply voltage in • Proceed to "Repair
Resis-
tance
(female) (3)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
2. Disconnect connector P26. occur in the wiring har-
3. Connect the T-adapter to the female side of connector YES ness.
P26. • Proceed to the next
Hot short cir- 4. Turn the starting switch to ON position. inspection item.
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
40-303 50 PC200, 200LC, 220, 220LC-8M0

Failure code [DHPBMA] SEN06135-01
Circuit diagram related to rear pump pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-303 51

SEN06135-01
© 2018 KOMATSU
All Rights Reserved
40-303 52
SEN06136-01
SEN06136-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
Failure code [DHS3MA] .................................................................................................................................. 2

Failure code [DHS9MA] .................................................................................................................................11
Failure code [DHSAMA]................................................................................................................................ 14
Failure code [DHSBMA]................................................................................................................................ 17
Failure code [DHSCMA]................................................................................................................................ 20
Failure code [DHSDMA]................................................................................................................................ 23
Failure code [DHSFMA] ................................................................................................................................ 26
Failure code [DHSGMA] ............................................................................................................................... 29
Failure code [DHSHMA]................................................................................................................................ 32
Failure code [DHSJMA] ................................................................................................................................ 35
Failure code [DHX1MA] ................................................................................................................................ 38
Failure code [DR21KX] ................................................................................................................................. 39
Failure code [DR31KX] ................................................................................................................................. 41
Failure code [DV20KB] ................................................................................................................................. 42
Failure code [DW43KA] ................................................................................................................................ 44
Failure code [DW43KB] ................................................................................................................................ 46
PC200, 200LC, 220, 220LC-8M0 40-304 1

SEN06136-01 Failure code [DHS3MA]
Failure code [DHS3MA]

Detail of failure Signal voltage of arm IN PPC pressure sensor circuit is 0.3 V and below or 4.5 V and above.
Action level L01
Action of con- • Fixes arm IN PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem on • Auto-deceleration function cannot be reset.
machine • Poor operability of arm IN
• Arm IN PPC pressure can be checked via the monitoring function. (Code: 07200 Arm IN PPC pres-
sure)
Inspection
item
• The state of the 5V sensor
1. Starting switch: OFF power supply 1 system is
2. Disconnect connector P04, and connect the T-adapter to YES normal.
5V sensor 3. Turn the starting switch to ON position. inspection item.
1 power supply a If the power supply voltage is abnormal, proceed to
1 system Inspection item 3 and after.
• The 5V sensor power sup-
ply 1 system is defective.
Between P04 (female) Power sup-
Voltage 4.5 to 5.5 V NO • Repair the defective part.
(3) and (1) ply
wiring harness".
• The state of the arm IN
1. Starting switch: OFF PPC pressure sensor is
2. Insert the T-adapter into connector P04. YES normal.
inspection item.
(1) put
a If the power supply voltage is normal and sensor output
Arm IN PPC voltage is abnormal, it is difficult to judge whether the
2 pressure sen- cause of the failure is a defective sensor, a ground fault or • The arm IN PPC pressure
sor a hot short circuit in the wiring harness. Check as below. sensor is defective.
1. Starting switch: OFF • Replace the arm IN PPC
2. Interchange connector P04 with a connector of another NO
pressure sensor.
PPC pressure sensor. • Proceed to "Repair
machine monitor.
4. If an E mark is not displayed again for this failure code, the
arm IN PPC pressure sensor is defective.
40-304 2 PC200, 200LC, 220, 220LC-8M0

Failure code [DHS3MA] SEN06136-01
Inspection
item
inspection item.
a If the power supply voltage by
Resis-
tance
Max. 1 z NO
a If the power supply voltage by • Proceed to "Repair
Resis-
tance
(female) (2)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
PC200, 200LC, 220, 220LC-8M0 40-304 3

Circuit diagram related to arm IN PPC pressure sensor
40-304 4 PC200, 200LC, 220, 220LC-8M0


Detail of failure Signal voltage of bucket CURL PPC pressure sensor circuit is 0.3 V and below or 4.5 V and above.
Action level L01
Action of con- • Fixes bucket CURL PPC pressure at 0 MPa {0 kg/cm2} and continues control.
machine • Poor operability of bucket CURL
• Bucket CURL PPC pressure can be checked via the monitoring function. (Code: 07300 Bucket
CURL PPC Pressure)
Inspection
item
(3) and (1) ply
wiring harness".
• The state of the bucket
1. Starting switch: OFF CURL PPC pressure sen-
2. Insert the T-adapter into connector P01. YES sor is normal.
inspection item.
(1) put
Bucket CURL voltage is abnormal, it is difficult to judge whether the
2 PPC pres- cause of the failure is a defective sensor, a ground fault or • The bucket CURL PPC
sure sensor a hot short circuit in the wiring harness. Check as below. pressure sensor is defec-
1. Starting switch: OFF tive.
2. Interchange connector P01 with a connector of another NO • Replace the bucket CURL
PPC pressure sensor. PPC pressure sensor.
3. Turn the starting switch to ON position and display the • Proceed to "Repair
Electrical Systems Abnormality Record screen of the check".
machine monitor.
bucket CURL PPC pressure sensor is defective.
PC200, 200LC, 220, 220LC-8M0 40-304 5

Inspection
item
inspection item.
Resis-
tance
Max. 1 z NO
Resis-
tance
(female) (3)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
40-304 6 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to bucket CURL PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 7


Detail of failure Signal voltage of boom RAISE PPC pressure sensor circuit is 0.3 V and below or 4.5 V and above.
Action level L01
Action of con- • Fixes boom RAISE PPC pressure at 0 MPa {0 kg/cm2} and continues control.
machine • Poor operability of boom RAISE
• Boom RAISE PPC pressure can be checked via the monitoring function. (Code: 07400 Boom RAISE
PPC Pressure)
Inspection
item
(3) and (1) ply
wiring harness".
• The state of the boom
1. Starting switch: OFF RAISE PPC pressure sen-
2. Insert T-adapter in connector P06. YES sor is normal.
inspection item.
(1) put
Boom RAISE voltage is abnormal, it is difficult to judge whether the
2 PPC pres- cause of the failure is a defective sensor, a ground fault or • The boom RAISE PPC
2. Interchange connector P06 with a connector of another NO • Replace the boom RAISE
machine monitor.
boom RAISE PPC pressure sensor is defective.
40-304 8 PC200, 200LC, 220, 220LC-8M0

Inspection
item
inspection item.
Resis-
tance
Max. 1 z NO
Resis-
tance
(female) (3)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
PC200, 200LC, 220, 220LC-8M0 40-304 9

Circuit diagram related to boom RAISE PPC pressure sensor
40-304 10 PC200, 200LC, 220, 220LC-8M0


Detail of failure Signal voltage of boom LOWER pressure sensor circuit is 0.3 V and below or 4.5 V and above.
Action level L01
Action of con-
troller
machine • Poor operability of boom LOWER
• Boom LOWER PPC pressure can be checked via the monitoring function. (Code: 07500 Boom
LOWER PPC Pressure)
Inspection
item
(3) and (1) ply
wiring harness".
• The state of the boom
1. Starting switch: OFF LOWER PPC pressure
2. Insert the T-adapter into connector P02. YES sensor is normal.
inspection item.
(1) put
Boom voltage is abnormal, it is difficult to judge whether the
LOWER PPC cause of the failure is a defective sensor, a ground fault or • The boom LOWER PPC
2 a hot short circuit in the wiring harness. Check as below. pressure sensor is defec-
pressure sen-
sor 1. Starting switch: OFF tive.
2. Interchange connector P02 with a connector of another • Replace the boom
NO
PPC pressure sensor. LOWER PPC pressure
3. Turn the starting switch to ON position and display the sensor.
Electrical Systems Abnormality Record screen of the • Proceed to "Repair
machine monitor. check".
4. If an E mark is not displayed again in this failure code
column, the boom LOWER PPC pressure sensor is defec-
tive.
PC200, 200LC, 220, 220LC-8M0 40-304 11

Inspection
item
inspection item.
Resis-
tance
Max. 1 z NO
Resis-
tance
(female) (3)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
40-304 12 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to boom LOWER PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 13

SEN06136-01 Failure code [DHSAMA]
Failure code [DHSAMA]

Detail of failure Signal voltage of swing RIGHT PPC pressure sensor circuit is 0.3 V and below or 4.5 V and above.
Action level L01
Action of con- • Fixes swing RIGHT PPC pressure at 0 MPa {0 kg/cm2} and continues control.
machine • Poor operability of swing RIGHT
• Swing RIGHT PPC pressure can be checked via the monitoring function. (Code: 09002 Swing
RIGHT PPC pressure)
Inspection
item
(3) and (1) ply
wiring harness".
• The state of the swing
1. Starting switch: OFF RIGHT PPC pressure sen-
2. Insert T-adapter into connector P07. YES sor is normal.
inspection item.
(1) put
voltage is abnormal, it is difficult to judge whether the
Swing RIGHT cause of the failure is a defective sensor, a ground fault or
2 PPC pres- • The swing RIGHT PPC
a hot short circuit in the wiring harness. Check as below. pressure sensor is defec-
sure sensor 1. Starting switch: OFF tive.
2. Interchange connector P07 with a connector of another NO • Replace the swing RIGHT
machine monitor.
column, the swing RIGHT PPC pressure sensor is defec-
tive.
40-304 14 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSAMA] SEN06136-01
Inspection
item
inspection item.
Resis-
tance
Max. 1 z NO
Resis-
tance
(female) (3)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
PC200, 200LC, 220, 220LC-8M0 40-304 15

SEN06136-01 Failure code [DHSAMA]
Circuit diagram related to swing RIGHT PPC pressure sensor
40-304 16 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSBMA] SEN06136-01
Failure code [DHSBMA]

Detail of failure Signal voltage of swing LEFT PPC pressure sensor circuit is 0.3 V and below or 4.5 V and above.
Action level L01
Action of con- • Fixes swing LEFT PPC pressure at 0 MPa {0 kg/cm2} and continues control.
machine • Poor operability of swing LEFT
• Swing LEFT PPC pressure can be checked via the monitoring function. (Code: 09001 Swing LEFT
PPC pressure)
Inspection
item
(3) and (1) ply
wiring harness".
1. Starting switch: OFF LEFT PPC pressure sen-
inspection item.
(1) put
voltage is abnormal, it is difficult to judge whether the
Swing LEFT cause of the failure is a defective sensor, a ground fault or
2 PPC pres- • The swing LEFT PPC
a hot short circuit in the wiring harness. Check as below. pressure sensor is defec-
sure sensor 1. Starting switch: OFF tive.
2. Interchange connector P03 with a connector of another NO • Replace the swing LEFT
machine monitor.
column, the swing LEFT PPC pressure sensor is defec-
tive.
PC200, 200LC, 220, 220LC-8M0 40-304 17

SEN06136-01 Failure code [DHSBMA]
Inspection
item
inspection item.
Resis-
tance
Max. 1 z NO
Resis-
tance
(female) (3)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
40-304 18 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSBMA] SEN06136-01
Circuit diagram related to swing LEFT PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 19

SEN06136-01 Failure code [DHSCMA]
Failure code [DHSCMA]

Detail of failure Signal voltage of arm OUT PPC pressure sensor circuit is 0.3 V and below or 4.5 V and above.
Action level L01
Action of con-
troller
machine • Poor operability of arm OUT
• Arm OUT PPC pressure can be checked via the monitoring function. (Code: 07600 Arm OUT PPC
Pressure)
Inspection
item
(3) and (1) ply
wiring harness".
• The state of the arm OUT
1. Starting switch: OFF PPC pressure sensor is
2. Insert the T-adapter into connector P08. YES normal.
inspection item.
(1) put
Arm OUT voltage is abnormal, it is difficult to judge whether the
2 PPC pres- cause of the failure is a defective sensor, a ground fault or • The arm OUT PPC pres-
sure sensor a hot short circuit in the wiring harness. Check as below. sure sensor is defective.
1. Starting switch: OFF • Replace the arm OUT
2. Interchange connector P08 with a connector of another NO
PPC pressure sensor.
PPC pressure sensor. • Proceed to "Repair
machine monitor.
arm OUT PPC pressure sensor is defective.
40-304 20 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSCMA] SEN06136-01
Inspection
item
inspection item.
Resis-
tance
Max. 1 z NO
Resis-
tance
(female) (3)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
PC200, 200LC, 220, 220LC-8M0 40-304 21

SEN06136-01 Failure code [DHSCMA]
Circuit diagram related to arm OUT PPC pressure sensor
40-304 22 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSDMA] SEN06136-01
Failure code [DHSDMA]

Detail of failure Signal voltage of bucket DUMP PPC pressure sensor circuit is 0.3 V and below or 4.5 V and above.
Action level L01
Action of con- • Fixes bucket DUMP PPC pressure at 0 MPa {0 kg/cm2} and continues control.
machine • Poor operability of bucket DUMP
• Bucket DUMP PPC pressure can be checked via the monitoring function.
(Code: 07301 Bucket DUMP PPC Pressure)
Inspection
item
Between P05 (3) and Power sup-
(1) ply
wiring harness".
1. Starting switch: OFF DUMP PPC pressure sen-
inspection item.
(1) put
Bucket DUMP voltage is abnormal, it is difficult to judge whether the
2 PPC pres- cause of the failure is a defective sensor, a ground fault or • The bucket DUMP PPC
2. Interchange connector P05 with a connector of another NO • Replace the bucket DUMP
machine monitor.
bucket DUMP PPC pressure sensor is defective.
PC200, 200LC, 220, 220LC-8M0 40-304 23

SEN06136-01 Failure code [DHSDMA]
Inspection
item
inspection item.
Resis-
tance
Max. 1 z NO
Resis-
tance
(female) (3)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
40-304 24 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSDMA] SEN06136-01
Circuit diagram related to bucket DUMP PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 25

SEN06136-01 Failure code [DHSFMA]
Failure code [DHSFMA]

Detail of failure Signal voltage of travel left-forward PPC pressure sensor is below 0.3 V or above 4.5 V.
Action level L01
Action of con- • Controls machine by regarding travel left-forward PPC pressure sensor as 0 MPa {0 kg/cm2}.
machine • Poor operability of travel
• Travel left-forward PPC pressure can be checked via the monitoring function. (Code: 07102 Travel
left-forward PPC pressure)
Inspection
item
(3) and (1) ply
wiring harness".
• The state of the travel
1. Starting switch: OFF left-forward PPC pressure
inspection item.
(1) put
Travel left-for- voltage is abnormal, it is difficult to judge whether the
ward PPC cause of the failure is a defective sensor, a ground fault or • The travel left-forward
2 a hot short circuit in the wiring harness. Check as below. PPC pressure sensor is
pressure sen-
sor 1. Starting switch: OFF defective.
2. Interchange connector P09 with a connector of another • Replace the travel left-for-
NO
PPC pressure sensor. ward PPC pressure sen-
3. Turn the starting switch to ON position and display the sor.
column, the travel left-forward PPC pressure sensor is
defective.
40-304 26 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSFMA] SEN06136-01
Inspection
item
inspection item.
Resis-
tance
Max. 1 z NO
Resis-
tance
(female) (3)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
PC200, 200LC, 220, 220LC-8M0 40-304 27

SEN06136-01 Failure code [DHSFMA]
Circuit diagram related to travel PPC pressure sensor
40-304 28 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSGMA] SEN06136-01
Failure code [DHSGMA]

Detail of failure Signal voltage of travel right-forward PPC pressure sensor is 0.3 V and below or 4.5 V and above.
Action level L01
Action of con- • Controls machine by regarding travel right-forward PPC pressure sensor as 0 MPa {0 kg/cm2}.
• Travel right-forward PPC pressure can be checked via the monitoring function. (Code: 07103 Travel
right-forward PPC pressure)
Inspection
item
(3) and (1) ply
wiring harness".
1. Starting switch: OFF right-forward PPC pres-
2. Insert the T-adapter into connector P11. YES sure sensor is normal.
inspection item.
(1) put
Travel voltage is abnormal, it is difficult to judge whether the
right-forward cause of the failure is a defective sensor, a ground fault or • The travel right-forward
PPC pres-
sure sensor 1. Starting switch: OFF defective.
2. Interchange connector P11 with a connector of another • Replace the travel
NO
PPC pressure sensor. right-forward PPC pres-
3. Turn the starting switch to ON position and display the sure sensor.
column, the travel right-forward PPC pressure sensor is
defective.
PC200, 200LC, 220, 220LC-8M0 40-304 29

SEN06136-01 Failure code [DHSGMA]
Inspection
item
inspection item.
Resis-
tance
Max. 1 z NO
Resis-
tance
(female) (3)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
40-304 30 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSGMA] SEN06136-01
PC200, 200LC, 220, 220LC-8M0 40-304 31

SEN06136-01 Failure code [DHSHMA]
Failure code [DHSHMA]

Detail of failure Signal voltage of travel left-reverse PPC pressure sensor is below 0.3 V or above 4.5 V.
Action level L01
Action of con- • Controls machine by regarding travel left-reverse PPC pressure sensor as 0 MPa {0 kg/cm2}.
• Travel left-reverse PPC pressure can be checked via the monitoring function. (Code: 07104 Travel
left-reverse PPC pressure)
Inspection
item
(3) and (1) ply
wiring harness".
1. Starting switch: OFF left-reverse PPC pressure
inspection item.
(1) put
left-reverse cause of the failure is a defective sensor, a ground fault or • The travel left-reverse
PPC pres-
NO
PPC pressure sensor. left-reverse PPC pressure
3. Turn the starting switch to ON position and display the sensor.
column, the travel left-reverse PPC pressure sensor is
defective.
40-304 32 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSHMA] SEN06136-01
Inspection
item
inspection item.
Resis-
tance
Max. 1 z NO
Resis-
tance
(female) (3)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
PC200, 200LC, 220, 220LC-8M0 40-304 33

SEN06136-01 Failure code [DHSHMA]
40-304 34 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSJMA] SEN06136-01
Failure code [DHSJMA]

Detail of failure Signal voltage of travel right-reverse PPC pressure sensor is below 0.3 V or above 4.5 V.
Action level L01
Action of con- • Controls machine by regarding travel right-reverse PPC pressure sensor as 0 MPa {0 kg/cm2}.
• Travel right-reverse PPC pressure can be checked via the monitoring function. (Code: 07105 Travel
right-reverse PPC pressure)
Inspection
item
(3) and (1) ply
wiring harness".
1. Starting switch: OFF right-reverse PPC pres-
2. Insert the T-adapter into connector P12. YES sure sensor is normal.
inspection item.
(1) put
right-reverse cause of the failure is a defective sensor, a ground fault or • The travel right-reverse
PPC pres-
NO
PPC pressure sensor. right-reverse PPC pres-
3. Turn the starting switch to ON position and display the sure sensor.
column, the travel right-reverse PPC pressure sensor is
defective.
PC200, 200LC, 220, 220LC-8M0 40-304 35

SEN06136-01 Failure code [DHSJMA]
Inspection
item
inspection item.
Resis-
tance
Max. 1 z NO
Resis-
tance
(female) (3)
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
check".
Voltage Max. 1 V NO
ground ing harness.
check".
item ler.
check".
YES
7 Repair check
40-304 36 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSJMA] SEN06136-01
PC200, 200LC, 220, 220LC-8M0 40-304 37

SEN06136-01 Failure code [DHX1MA]
Failure code [DHX1MA]

The display setting is enabled for the monitor (overload alarm monitor) with no display setting config-
Detail of failure
ured.
Action level L04
Problem on
-
machine
Related infor-
-
mation
Inspection
item
be defective.
Pump control- The pump controller may be defective. (Since this is an inter- • Replace the pump control-
1 -
ler nal defect, troubleshooting cannot be performed.) ler.
check".
YES
2 Repair check
40-304 38 PC200, 200LC, 220, 220LC-8M0

Failure code [DR21KX] SEN06136-01
Failure code [DR21KX]

Voltage that is different from output voltage of the machine monitor is detected in the camera 2 picture
Detail of failure
reverse drive circuit (pin 6 of connector CM04).
Action level L01
Action of con-
Does not display the camera 2 image.
troller
Problem on
Camera 2 image is not displayed.
machine
• When the camera 2 picture reverse drive circuit (pin 6 of connector CM04) is set to 0 V, a normal
Related infor- image is displayed. When it is set to 8 V, a mirror image is displayed (the camera power supply is 8 V,
mation so 8 V is commanded for the mirror image).
• Check connector A41 to identify camera 2.
Inspection
item
2. Disconnect connectors CM04 and A46, and connect the YES ness.
1 in wiring har- Between CM04 (female) (6) and A46 Resis- • An open circuit occurs in
ness Max. 1 z
NO
Between CM04 (female) (5) and A46 Resis- ing harness.
(female) (4) tance
check".
the wiring harness.
2. Disconnect connectors CM04 and A46, and connect the YES
inspection item.
Ground fault
Min. 1 Mz NO
(6) or A46 (female) (3) tance ing harness.
check".
2. Disconnect connector A46, and connect the T-adapter to occur in the wiring har-
the female side. YES ness.
Hot short cir- a Check that normal image setting is selected for camera 2. inspection item.
Between A46 (female) (3) and (4) or • Repair or replace the wir-
Voltage Max. 1 V NO
ground ing harness.
check".
the wiring harness.
2. Disconnect connectors CM04 and A46, and connect the YES
T-adapter to the female side of the CM04.
inspection item.
Short circuit in
Max. 1 z NO
each pin other than pin (6) tance ing harness.
check".
PC200, 200LC, 220, 220LC-8M0 40-304 39

SEN06136-01 Failure code [DR21KX]
Inspection
item
• The camera 2 or the
5 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the camera 2 or
item
the machine monitor.
check".
YES
6 Repair check
Circuit diagram related to camera 2
40-304 40 PC200, 200LC, 220, 220LC-8M0

Failure code [DR31KX] SEN06136-01
Failure code [DR31KX]

q Since camera 3 is not installed in this machine, it has no effect on the machine body. This failure code is ready for
case that camera 3 is installed in future.
q If this failure codes is displayed, see "Classification and procedures of troubleshooting" to clear the failure code.
PC200, 200LC, 220, 220LC-8M0 40-304 41

SEN06136-01 Failure code [DV20KB]
Failure code [DV20KB]

Detail of failure Abnormal current flows when power is output to the travel alarm circuit.
Action level L01
• Stops driving the travel alarm circuit.
Action of con-
• Even if the cause of the failure disappears, the state of the machine does not return to normal until
troller
the starting switch is set to OFF position.
Problem on
Travel alarm does not sound.
machine
• The travel alarm operating condition (ON/OFF) can be checked via the monitoring function.
Related infor- (Code: 03701 Controller Output 2)
mation • As the T-adapter for the pump controller connector is the "socket-type box", operating voltage cannot
Inspection
item
2. Disconnect connector M14, and connect the T-adapter to
alarm is normal.
the female side. YES
inspection item.
4. Operate the travel lever to perform troubleshooting.
1 Travel alarm Travel lever:
Voltage Max. 1 V • The travel alarm is defec-
Between M14 (female) Neutral
(1) and (2) tive.
Travel lever:
Voltage 20 to 30 V NO • Replace the travel alarm.
Operated
a If the voltage above is normal but the travel alarm does check".
not sound, the travel alarm is defective.
the wiring harness.
2. Disconnect connectors C02 and M14, and connect the YES
inspection item.
Ground fault
Min. 1 Mz NO
(107) or M14 (female) (1) tance ing harness.
check".
item ler.
check".
YES
4 Repair check
40-304 42 PC200, 200LC, 220, 220LC-8M0

Failure code [DV20KB] SEN06136-01
Circuit diagram related to travel alarm
PC200, 200LC, 220, 220LC-8M0 40-304 43

SEN06136-01 Failure code [DW43KA]
Failure code [DW43KA]

No current flows when the pump controller drives the travel speed solenoid, so the pump controller
Detail of failure
determines that an open circuit exists in the travel speed solenoid circuit.
Action level L01
Action of con- • None in particular (Since no current flows, solenoid is not energized.)
Problem on The machine travels slowly when the Hi travel speed is set (the machine monitor shows Hi setting but
machine the speed is kept at around Mi).
The controller's command (ON/OFF) to the travel speed solenoid can be checked via the monitoring
Related infor- function. (As long as the controller's command to the solenoid is ON, the sensor state displayed on the
mation monitoring screen is ON even if the solenoid is not energized due to an open circuit.) (Code: 02300
Solenoid 1)
Inspection
item
1. Starting switch: OFF speed selector solenoid is
2. Disconnect connector V04, and connect the T-adapter to YES normal.
Travel speed inspection item.
1 selector sole- • The travel speed selector
noid solenoid is defective.
Resis- • Replace the travel speed
Between V04 (male) (1) and (2) 20 to 60 z NO
tance selector solenoid.
check".
inspection item.
20 to 60 z
(115), (117), or (120) tance
Open circuit
a If no failure is found by the above checks, this check is not
required.
2. Disconnect connectors C02 and V04 and connect the • Repair or replace the wir-
NO
T-adapter to each female side. ing harness.
Between C02 (female) (87) and V04 Resis-
Max. 1 z check".
(female) (1) tance
Between V04 (female) (2) and C02 Resis-
Max. 1 z
(female) (115), (117), or (120) tance
item ler.
check".
YES
4 Repair check
4. Set travel speed Hi.
5. Operate the travel lever. NO Repairs are completed.
40-304 44 PC200, 200LC, 220, 220LC-8M0

Failure code [DW43KA] SEN06136-01
Circuit diagram related to travel speed Hi/Lo solenoid
PC200, 200LC, 220, 220LC-8M0 40-304 45

SEN06136-01 Failure code [DW43KB]
Failure code [DW43KB]

An abnormal current flows when the pump controller drives the travel speed solenoid, so the pump con-
Detail of failure
troller determines that a short circuit exists in the travel speed solenoid circuit.
Action level L01
• Stops driving travel speed solenoid.
Action of con-
• Even if the cause of the failure is removed, the state of the machine does not return to normal until
troller
the starting switch is turned to OFF position once.
Problem on The machine travels slowly when the Hi travel speed is set (the machine monitor shows Hi setting but
machine the speed is kept at around Mi).
Related infor- The controller's command (ON/OFF) to the travel speed solenoid can be checked via the monitoring
mation function. (Code: 02300 Solenoid 1)
Inspection
item
1. Starting switch: OFF speed selector solenoid is
Travel speed inspection item.
1 selector sole- Resis- • The travel speed selector
noid Between V04 (male) (1) and (2) 20 to 60 z
tance solenoid is defective.
• Replace the travel speed
NO
Resis- selector solenoid.
Between V04 (male) (1) and ground Min. 1 Mz • Proceed to "Repair
tance
check".
2. Disconnect connector C02, and connect the T-adapter to YES harness.
2
fault in wiring Between C02 (female) (87) and Resis- • A short circuit or ground
harness 20 to 60 z
each of (115), (117), and (120) tance fault occurs in the wiring
NO harness.
Between C02 (female) (87) and Resis- • Proceed to "Ground fault
Min. 1 Mz
ground tance in wiring harness".
a If no failure is found by Inspection item 2 this check is not
required.
the wiring harness.
2. Disconnect connectors C02 and V04, and connect the
inspection item.
Min. 1 Mz NO
(87) or V04 (female) (1) tance ing harness.
check".
item ler.
check".
40-304 46 PC200, 200LC, 220, 220LC-8M0

Failure code [DW43KB] SEN06136-01
Inspection
item
YES
5 Repair check
4. Set travel speed Hi.
5. Operate the travel lever. NO Repairs are completed.
Circuit diagram related to travel speed Hi/Lo solenoid
PC200, 200LC, 220, 220LC-8M0 40-304 47


When the controller does not drive the swing parking brake solenoid, the solenoid output voltage of the
Detail of failure
controller is higher than specified value, and an open circuit is detected.
Action level L03
• None in particular (Since no current flows, the solenoid is not energized. Accordingly, the swing park-
Action of con-
ing brake is still effective.)
troller
Problem on
Swing is not enabled (swing parking brake is not canceled).
machine
• If no failure is identified in the solenoid or wiring harness, set the swing parking brake cancel switch
to CANCEL position to enable swing operation. (However, the swing parking brake cannot be
released when the operation is stopped. Accordingly, the swing parking brake is still effective.)
• Set the swing parking brake cancel switch to CANCEL position during diagnosis. If the state of the
Related infor- swing parking brake solenoid is normal, current flows to it after turning the starting switch to ON posi-
mation tion in this condition, and the brake is released.
• The controller's command (ON/OFF) to the swing parking brake solenoid can be checked via the
monitoring function (Code: 02300: Solenoid 1).
• Power for the swing parking brake solenoid circuit is supplied from pin (101) of pump controller con-
nector C02 or fuse -1 in fuse box F01.
Inspection
item
normal.
YES
inspection item.
If fuse No.1 (in the upper-right side) in fuse box F01 has • If the fuse has burnt out,
1 Fuse see [DW45KB].
blown, see [DW45KB].
NO out but it has no continuity,
replace the fuse.
check".
1. Starting switch: OFF parking brake solenoid is
Swing parking inspection item.
2 brake sole- • The swing parking brake
noid solenoid is defective.
Resis- • Replace the swing parking
tance brake solenoid.
check".
1. Starting switch: OFF • The state of the diode
2. Remove diode arrays D01 and D03, and connect the array is normal.
YES
T-adapter to the male side. • Proceed to the next
3 Diode array Between D01 (male) (3) (+) and (7) (-) No continuity • The diode array is defec-
Between D01 (male) (7) (+) and (3) (-) Continuity tive.
NO • Replace the diode array.
Between D03 (male) (3) (+) and (7) (-) No continuity • Proceed to "Repair
Between D03 (male) (7) (+) and (3) (-) Continuity check".
40-304 48 PC200, 200LC, 220, 220LC-8M0

Inspection
item
1. Starting switch: OFF • An open circuit does not
2. Remove diode D01. occur in the wiring har-
female side. • Proceed to the next
a Swing lock switch OFF inspection item.
Max. 1 z
D01 (female) (7) tance
Between D01 (female) (3) and C02 Resis-
Open circuit 20 to 60 z
(female) (115) tance
ness a If no failure is found by the above checks, this check is not
the wiring harness.
required.
1. Starting switch: OFF NO
ing harness.
2. Disconnect connectors D01, C02, and V03, and connect
inspection item.
Between D01 (female) (3) and V03 Resis-
Max. 1 z
(female) (1) tance
Between V03 (female) (2) and C02 Resis-
Max. 1 z
(female) (115), (117), or (120) tance
item ler.
check".
YES
6 Repair check
PC200, 200LC, 220, 220LC-8M0 40-304 49

Circuit diagram related to swing parking brake
40-304 50 PC200, 200LC, 220, 220LC-8M0


An abnormal current flows when the pump controller drives the swing parking brake solenoid, so a
Detail of failure
short circuit is detected.
Action level L03
• Stops driving swing parking brake solenoid.
Action of con-
troller
Problem on
Swing is not enabled (swing parking brake is not canceled).
machine
• If no failure is identified in the solenoid or wiring harness, set the swing parking brake cancel switch
to CANCEL position to enable swing operation. (However, the swing parking brake cannot be
released when the operation is stopped. Accordingly, the swing parking brake is still effective.)
• Set the swing parking brake cancel switch to CANCEL position during diagnosis. If the state of the
Related infor- swing parking brake solenoid is normal, current flows to it after turning the starting switch to ON posi-
mation tion in this condition, and the brake is released.
• The controller's command (ON/OFF) to the swing parking brake solenoid can be checked via the
monitoring function (Code: 02300: Solenoid 1).
• Power for the swing parking brake solenoid circuit is supplied from pin (101) of pump controller con-
nector C02 or fuse -1 in fuse box F01.
Inspection
item
normal.
YES
inspection item.
Troubleshoot in order to identify the cause of the failure even • If the fuse has burnt out,
1 Fuse if fuse No.1 (in the upper-right side) in fuse box F01 is burnt proceed to the next
out. inspection item.
NO
replace the fuse.
check".
1. Starting switch: OFF parking brake solenoid is
Swing parking inspection item.
2 brake sole- Resis- • The swing parking brake
tance solenoid is defective.
• Replace the swing parking
NO
Resis- brake solenoid.
tance
check".
YES
3 Diode array Between D01 (male) (3) (+) and (7) (-) No continuity • The diode array is defec-
Between D01 (male) (7) (+) and (3) (-) Continuity tive.
Between D03 (male) (3) (+) and (7) (-) No continuity • Proceed to "Repair
Between D03 (male) (7) (+) and (3) (-) Continuity check".
PC200, 200LC, 220, 220LC-8M0 40-304 51

Inspection
item
2. Remove fuse No.1 (upper right, 10 A) in fuse box F01 and • No ground fault occurs in
diode D01. the wiring harness.
YES
3. Disconnect connectors C02, D01, and V03. • Proceed to the next
4. Connect the T-adapter to the female sides of connectors inspection item.
C02 and D01.
Ground fault
4 in wiring har- Between C02 (female) (101) and Resis- • Ground fault occurs in the
Min. 1 Mz
ness ground tance wiring harness.
ing harness.
NO
Between D01 (female) (3) and Resis- • Replace the fuse if it has
ground tance
check".
2. Remove fuse No.1 (upper right, 10 A) in fuse box F01 and
diode D01.
the wiring harness.
3. Disconnect connector C02. YES
4. Connect the T-adapter to the female sides of connectors
inspection item.
D01 and C02.
Short circuit in a Swing lock switch: Check that this switch is turned OFF.
Between D01 (female) (3) and each
of C02 (female) (115), (117), and
Resis- ing harness.
(120) 20 to 60 z NO
tance • Replace the fuse if it has
a Swing parking brake solenoid
blown out.
coil resistance
check".
item ler.
check".
YES
7 Repair check
40-304 52 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-304 53


The controller output voltage to the solenoid is above the standard value when the pump controller
Detail of failure does not drive the travel junction solenoid, so the pump controller determines that an open circuit exists
in the travel junction solenoid circuit.
Action level L01
Problem on
It is difficult to steer the machine when the machine travels.
machine
The controller's command (ON/OFF) to the travel junction solenoid can be checked via the monitoring
mation monitoring screen is ON even if the solenoid is not energized due to an open circuit.) (Code: 02300
Solenoid 1)
Inspection
item
1. Starting switch: OFF junction solenoid valve is
Travel junc- inspection item.
1 tion solenoid • The travel junction sole-
valve noid valve is defective.
Resis- • Replace the travel junction
tance solenoid valve.
check".
2. Disconnect connector C02, and connect the T-adapter to YES the wiring harness.
2
ness circuit occurs in the wiring
(115), (117), or (120) tance
wiring harness".
2. Disconnect connectors C02 and V05 and connect the • Proceed to the next
ness Max. 1 z
V05 (female) (1) tance the wiring harness.
NO
Between V05 (female) (2) and C02 Resis- ing harness.
(female) (115), (117), or (120) tance
check".
item ler.
check".
40-304 54 PC200, 200LC, 220, 220LC-8M0

Inspection
item
YES
5 Repair check
4. Perform steering operation using R.H. and L.H. travel
levers. NO Repairs are completed.
Circuit diagram related to travel junction solenoid valve
PC200, 200LC, 220, 220LC-8M0 40-304 55


An abnormal current flows when the pump controller drives the travel junction solenoid, so the pump
Detail of failure
controller determines that a short circuit exists in the travel junction solenoid circuit.
Action level L01
• Stops driving travel junction solenoid.
Action of con-
troller
Problem on
It is difficult to steer the machine when the machine travels.
machine
The controller's command (ON/OFF) to the travel junction solenoid can be checked via the monitoring
mation monitoring screen is ON even if the solenoid is not energized due to a short circuit.) (Code: 02300 Sole-
noid 1)
Inspection
item
1. Starting switch: OFF junction solenoid valve is
Travel junc- inspection item.
1 tion solenoid Resis- • The travel junction sole-
valve Between V05 (male) (1) and (2) 20 to 60 z
tance noid valve is defective.
• Replace the travel junction
NO
Resis- solenoid valve.
tance
check".
2
harness 20 to 60 z
(115), (117), or (120) tance fault occurs in the wiring
NO harness.
Min. 1 Mz
required.
the wiring harness.
inspection item.
Min. 1 Mz NO
check".
item ler.
check".
40-304 56 PC200, 200LC, 220, 220LC-8M0

Inspection
item
YES
5 Repair check
4. Perform steering operation using R.H. and L.H. travel
levers. NO Repairs are completed.
Circuit diagram related to travel junction solenoid valve
PC200, 200LC, 220, 220LC-8M0 40-304 57

SEN06136-01
© 2018 KOMATSU
All Rights Reserved
40-304 58
SEN06137-01
SEN06137-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
Failure code [DWA2KA] .................................................................................................................................. 2

Failure code [DWA2KB] .................................................................................................................................. 4
Failure code [DWK0KA] .................................................................................................................................. 6
Failure code [DWK0KB] .................................................................................................................................. 8
Failure code [DWK2KA] ................................................................................................................................ 10
Failure code [DWK2KB] ................................................................................................................................ 12
Failure code [DXA8KA] ................................................................................................................................. 14
Failure code [DXA8KB] ................................................................................................................................. 17
Failure code [DXA9KA] ................................................................................................................................. 20
Failure code [DXA9KB] ................................................................................................................................. 23
Failure code [DXE0KA] ................................................................................................................................. 26
Failure code [DXE0KB] ................................................................................................................................. 28
Failure code [DY20KA] ................................................................................................................................. 42
Failure code [DY20MA]................................................................................................................................. 45
Failure code [DY2CKB]................................................................................................................................. 48
Failure code [DY2DKB]................................................................................................................................. 51
Failure code [DY2EKB] ................................................................................................................................. 53
PC200, 200LC, 220, 220LC-8M0 40-305 1

SEN06137-01 Failure code [DWA2KA]
Failure code [DWA2KA]

When output to the attachment return selector solenoid is OFF, the output terminal voltage of the con-
Detail of failure
troller exceeds the standard value, resulting in the detection of an open circuit.
Action level L03
Problem on
Hydraulic circuit for attachment is not changed to single-acting circuit.
machine
The controller's command (ON/OFF) to the attachment return selector solenoid can be checked via the
Related infor- monitoring function. (As long as the controller's command to solenoid is ON, the sensor state displayed
mation on the monitoring screen is ON even if the solenoid is not energized due to an open circuit.) (Code:
02301 Solenoid 2)
Inspection
item
• The state of the attach-
1. Starting switch: OFF ment return selector sole-
2. Disconnect connector V06, and connect the T-adapter to YES noid is normal.
inspection item.
Attachment
1 return selec- • The attachment return
tor solenoid selector solenoid is defec-
tive.
Resis-
Between V06 (male) (1) and (2) 20 to 60 z NO • Replace the attachment
tance
return selector solenoid.
check".
2
fault in wiring • An open circuit or ground
harness fault occurs in the wiring
ground tance
wiring harness".
• No open circuit occurs in
required.
the wiring harness.
inspection item.
Open circuit T-adapter to each female side.
3 in wiring har- Between C02 (female) (86) and V06 Resis- • An open circuit occurs in
ness Max. 1 z
NO
Between V06 (female) (2) and Resis- ing harness.
ground tance
check".
item ler.
check".
40-305 2 PC200, 200LC, 220, 220LC-8M0

Failure code [DWA2KA] SEN06137-01
Inspection
item
YES
4. Set to a mode other than breaker mode (B). NO Repairs are completed.
Circuit diagram related to ATT single/multiple selector solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 3

SEN06137-01 Failure code [DWA2KB]
Failure code [DWA2KB]

An abnormal current flows when the pump controller drives the attachment return selector solenoid, so
Detail of failure the pump controller determines that a short circuit has occurred in the attachment return selector sole-
noid circuit.
Action level L03
• Turns the output to the attachment return selector solenoid OFF.
Action of con-
troller
Problem on
Hydraulic circuit for attachment is not changed to single-acting circuit.
machine
The controller's command (ON/OFF) to the attachment return selector solenoid can be checked via the
Related infor- monitoring function. (As long as the controller's command to solenoid is ON, the sensor state displayed
mation on the monitoring screen is ON even if the solenoid is not energized due to a short circuit.) (Code:
02301 Solenoid 2)
Inspection
item
inspection item.
Attachment
Resis- • The attachment return
1 return selec- Between V06 (male) (1) and (2) 20 to 60 z
tor solenoid tance selector solenoid is defec-
tive.
NO • Replace the attachment
Resis- return selector solenoid.
Between V06 (male) (1) and ground Min. 1 Mz
check".
2
ground tance
in wiring harness".
required.
the wiring harness.
inspection item.
Min. 1 Mz NO
check".
item ler.
check".
40-305 4 PC200, 200LC, 220, 220LC-8M0

Failure code [DWA2KB] SEN06137-01
Inspection
item
YES
4. Set to breaker mode (B). NO Repairs are completed.
Circuit diagram related to ATT single/multiple selector solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 5

SEN06137-01 Failure code [DWK0KA]
Failure code [DWK0KA]

Controller output voltage to solenoid is above standard value when pump controller does not drive
Detail of failure
2-stage relief solenoid, so pump controller determines that open circuit exists.
Action level L01
troller • If the cause of the failure disappears by itself, the state of the machine returns to normal.
Problem on • Traveling force is weak (main relief valve is not switched to high pressure setting).
machine • One-touch power maximizing function does not operate.
• The controller's command (ON/OFF) to the 2-stage relief solenoid can be checked via the monitoring
function. (As long as the controller's command to the solenoid is ON, the sensor state displayed on
the monitoring screen is ON even if solenoid is not energized due to an open circuit.) (Code: 02300
Related infor-
Solenoid 1)
mation
• Controller detects open circuit only if solenoid output is OFF.
Inspection
item
• The state of the 2-stage
relief solenoid is normal.
2. Disconnect connector V02, and connect the T-adapter to YES
the male side.
inspection item.
2-stage relief • The 2-stage relief solenoid
1
solenoid is defective.
Resis- • Replace the 2-stage relief
tance solenoid.
check".
1. Starting switch: OFF • No open circuit or short
2. Disconnect connector C02, and connect the T-adapter to circuit occurs in the wiring
the female side. YES harness.
Open circuit a If resistance is 1 Mz or higher, the harness has an open • Proceed to the next
or short circuit circuit. If it is 1 z or below, the harness has a short circuit. inspection item.
2
each of (115), (117), and (120) tance
wiring harness".
required.
the wiring harness.
inspection item.
ness Max. 1 z
Wiring harness between C02 NO
Resis- ing harness.
(female) (115), (117), or (120) and Max. 1 z • Proceed to "Repair
tance
V02 (female) (2) check".
item ler.
check".
40-305 6 PC200, 200LC, 220, 220LC-8M0

Failure code [DWK0KA] SEN06137-01
Inspection
item
YES
5 Repair check
Circuit diagram related to 2-stage relief solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 7

SEN06137-01 Failure code [DWK0KB]
Failure code [DWK0KB]

Detail of failure When driving 2-stage relief solenoid, abnormal current flows and a short circuit is detected.
Action level L01
• Shuts off power supply to 2-stage relief solenoid.
Action of con-
troller
starting switch is set to OFF position.
Problem on • Traveling force is weak (main relief valve is not switched to high pressure setting).
machine • One-touch power maximizing function does not operate.
• The controller's command (ON/OFF) to the 2-stage relief solenoid can be checked via the monitoring
function. (As long as the controller's command to the solenoid is ON, the sensor state displayed on
the monitoring screen is ON even if solenoid is not energized due to a short circuit.) (Code: 02300
Related infor-
Solenoid 1)
mation
• Controller detects open circuit only if solenoid output is OFF.
Inspection
item
relief solenoid is normal.
the male side.
inspection item.
2-stage relief Resis- • The 2-stage relief solenoid
1
solenoid Between V02 (male) (1) and (2) 20 to 60 z
tance is defective.
• Replace the 2-stage relief
NO
Between V02 (female) (1) and Resis- solenoid.
ground tance
check".
the wiring harness.
2. Disconnect connectors C02 and V02, and connect the YES
T-adapter to the female side of the V02.
inspection item.
Ground fault
Min. 1 Mz NO
check".
the wiring harness.
2. Disconnect connectors C02 and V02, and connect the YES
T-adapter to the female side of the V02.
inspection item.
Short circuit in
Between V02 (female) (1) and (2) Min. 1 Mz NO
tance ing harness.
check".
item ler.
check".
40-305 8 PC200, 200LC, 220, 220LC-8M0

Failure code [DWK0KB] SEN06137-01
Inspection
item
YES
5 Repair check
PC200, 200LC, 220, 220LC-8M0 40-305 9

SEN06137-01 Failure code [DWK2KA]
Failure code [DWK2KA]

When output to variable back pressure solenoid is ON, no current flows in the circuit, so the open circuit
Detail of failure
is detected.
Action level L01
Problem on
Fuel consumption lowers.
machine
• The controller's command (ON/OFF) to the variable back pressure solenoid can be checked via the
monitoring function. (As long as the controller's command to the solenoid is ON, the sensor state dis-
Related infor-
played on the monitoring screen is ON even if solenoid is not energized due to an open circuit.)
mation
(Code: 02301 Solenoid 2)
• When controller's command to solenoid is ON, back pressure valve set pressure falls.
Inspection
item
• The state of the variable
1. Starting switch: OFF back pressure solenoid is
Variable back inspection item.
1 pressure • The variable back pres-
solenoid sure solenoid is defective.
Resis- • Replace the variable back
tance pressure solenoid.
check".
2
(female) (115), (117), or (120) tance
wiring harness".
required.
the wiring harness.
inspection item.
ness Max. 1 z
NO
Between C02 (female) (115), (117), Resis- ing harness.
or (120) and V25 (female) (2) tance
check".
item ler.
check".
40-305 10 PC200, 200LC, 220, 220LC-8M0

Failure code [DWK2KA] SEN06137-01
Inspection
item
YES
5 Repair check
Circuit diagram related to variable back pressure solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 11

SEN06137-01 Failure code [DWK2KB]
Failure code [DWK2KB]

Abnormal current flows when the pump controller drives the variable back pressure solenoid, so the
Detail of failure
pump controller determines that a short circuit exists in the variable back pressure solenoid circuit.
Action level L01
• Stops driving variable back pressure solenoid.
Action of con-
troller
Problem on
Fuel consumption lowers.
machine
• The controller's command (ON/OFF) to the variable back pressure solenoid can be checked via the
monitoring function. (As long as the controller's command to the solenoid is ON, the sensor state dis-
Related infor-
played on the monitoring screen is ON even if solenoid is not energized due to a short circuit.)
mation
(Code: 02301 Solenoid 2)
• When controller's command to solenoid is ON, back pressure valve set pressure falls.
Inspection
item
• The state of the variable
1. Starting switch: OFF back pressure solenoid is
Variable back inspection item.
1 pressure Resis- • The variable back pres-
tance sure solenoid is defective.
• Replace the variable back
NO
Resis- pressure solenoid.
tance
check".
2
(115), (117), or (120) tance
in wiring harness".
a If no failure is found by Inspection item 2, this check is not • No ground fault occurs in
required. the wiring harness.
YES
1. Starting switch: OFF • Proceed to the next
2. Disconnect connectors C02 and V25, and connect the inspection item.
Between ground and C02 (female) Resis- NO
Min. 1 Mz ing harness.
(85) or V25 (female) (1) tance
check".
item ler.
check".
40-305 12 PC200, 200LC, 220, 220LC-8M0

Failure code [DWK2KB] SEN06137-01
Inspection
item
YES
5 Repair check
Circuit diagram related to variable back pressure solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 13

SEN06137-01 Failure code [DXA8KA]
Failure code [DXA8KA]

No current flows when the pump controller drives the PC-EPC (front) solenoid, so the pump controller
Detail of failure
determines an open circuit exists in the PC-EPC (F) solenoid circuit.
Action level L03
Problem on
If pump load increases, engine speed largely decreases and engine may stop.
machine
• When the states of the solenoid and wiring harness are normal, the engine can be prevented from
Related infor- stopping by setting emergency pump drive switch to ON position.
mation • Drive current of PC-EPC (F) solenoid can be checked via the monitoring function.
(Code: 01300 PC-EPC (F) Solenoid Current)
Inspection
item
• The state of the PC-EPC
(F) solenoid is normal.
the male side.
inspection item.
PC-EPC (F) • The PC-EPC (F) solenoid
1
Resis- • Replace the PC-EPC (F)
tance solenoid.
check".
• The state of the emer-
1. Starting switch: OFF gency pump drive switch
2. Disconnect connector S25, and connect the T-adapter to YES is normal.
inspection item.
Switch position: Nor- Resis-
Emergency Between S25 Max. 1 z
2 pump drive mal tance
(male) (3) and • The emergency pump
switch (2) Switch position: Resis- drive switch is defective.
Min. 1 Mz
Abnormal tance • Replace the emergency
NO
Switch position: Nor- Resis- pump drive switch.
Between S25 Max. 1 z • Proceed to "Repair
mal tance
(male) (6) and check".
(5) Switch position: Resis-
Min. 1 Mz
Abnormal tance
Open circuit a Check that the emergency pump drive switch is turned to • Proceed to the next
or short circuit the normal position (bottom side). inspection item.
3
(115), (117), or (120) tance
wiring harness".
40-305 14 PC200, 200LC, 220, 220LC-8M0

Failure code [DXA8KA] SEN06137-01
Inspection
item
required.
the wiring harness.
2. Disconnect connectors C02, S25 and V11, and connect
inspection item.
Between C02 (female) (96) and S25 Resis-
4 in wiring har- (female) (3) tance
ness Between S25 (female) (2) and V11 Resis- the wiring harness.
Max. 1 z
NO
Between S25 (female) (6) and C02 Resis- ing harness.
(female) (115), (117), or (120) tance
check".
Between S25 (female) (5) and V11 Resis-
Max. 1 z
(female) (2) tance
item ler.
check".
YES
6 Repair check
PC200, 200LC, 220, 220LC-8M0 40-305 15

Circuit diagram related to PC-EPC solenoid
40-305 16 PC200, 200LC, 220, 220LC-8M0

Failure code [DXA8KB] SEN06137-01
Failure code [DXA8KB]

Abnormal current flows when the pump controller drives the PC-EPC (front) solenoid, so the pump con-
Detail of failure
troller determines that a short circuit exists in the PC-EPC (F) solenoid circuit.
Action level L03
• Stops output to PC–EPC (front) solenoid.
Action of con-
troller
Problem on
machine
mation • Drive current of PC-EPC (F) solenoid can be checked via the monitoring function.
(Code: 01300 PC-EPC (F) Solenoid Current)
Inspection
item
(F) solenoid is normal.
the male side.
inspection item.
PC-EPC (F) Resis- • The PC-EPC (F) solenoid
1
tance is defective.
• Replace the PC-EPC (F)
NO
Resis- solenoid.
tance
check".
Emergency inspection item.
2 pump drive Between S25 (male) • The emergency pump
switch Resis-
(2) and each of (3) to Min. 1 Mz drive switch is defective.
tance
(5) Switch posi- • Replace the emergency
NO
tion: Normal pump drive switch.
Between ground and Resis- • Proceed to "Repair
Min. 1 Mz
S25 (male) (2) or (3) tance check".
1. Starting switch: OFF • No short circuit or ground
2. Disconnect connector C02, and connect the T-adapter to fault occurs in the wiring
Short circuit a Check that the emergency pump drive switch is turned to • Proceed to the next
or ground the normal position (bottom side). inspection item.
3
harness 3 to 14 z
NO harness.
Min. 1 Mz
PC200, 200LC, 220, 220LC-8M0 40-305 17

SEN06137-01 Failure code [DXA8KB]
Inspection
item
required.
the wiring harness.
inspection item.
Ground fault the T-adapter to any female side.
4 in wiring har- Between ground and C02 (female) Resis- • Ground fault occurs in the
ness Min. 1 Mz
(96) or S25 (female) (3) tance wiring harness.
NO
Between ground and S25 (female) Resis- ing harness.
check".
item ler.
check".
YES
6 Repair check
40-305 18 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-305 19

Failure code [DXA9KA]

No current flows when the pump controller drives the PC-EPC (rear) solenoid, so the pump controller
Detail of failure
determines that an open circuit exists in the PC-EPC (R) solenoid circuit.
Action level L03
Problem on
machine
mation • Drive current of PC-EPC (R) solenoid can be checked via the monitoring function.
(Code: 01300 PC-EPC (R) Solenoid Current)
Inspection
item
(R) solenoid is normal.
the male side.
inspection item.
PC-EPC (R) • The PC-EPC (R) solenoid
1
Resis- • Replace the PC-EPC (R)
tance solenoid.
check".
inspection item.
Switch posi- Resis-
Max. 1 z
Emergency tion: Normal tance
Between S25 (male)
2 pump drive (3) and (2) Switch posi- • The emergency pump
Resis-
switch tion: Emer- Min. 1 Mz drive switch is defective.
tance
gency • Replace the emergency
NO
Switch posi- Resis- pump drive switch.
tion: Normal tance
Between S25 (male) check".
(6) and (5) Switch posi-
Resis-
tion: Emer- Min. 1 Mz
tance
gency
Open circuit a Check that the emergency pump drive switch is turned to • Proceed to the next
or short circuit the normal position (bottom side). inspection item.
3
(115), (117), or (120) tance
wiring harness".
40-305 20 PC200, 200LC, 220, 220LC-8M0

Failure code [DXA9KA] SEN06137-01
Inspection
item
required.
the wiring harness.
2. Disconnect connectors C02, S25, and V12, and connect
inspection item.
Between C02 (female) (96) and S25 Resis-
4 in wiring har- (female) (3) tance
ness Between S25 (female) (2) and V12 Resis- the wiring harness.
Max. 1 z
NO
(female) (115), (117), or (120) tance
check".
Between S25 (female) (5) and V12 Resis-
Max. 1 z
(female) (2) tance
item ler.
check".
YES
6 Repair check
PC200, 200LC, 220, 220LC-8M0 40-305 21

40-305 22 PC200, 200LC, 220, 220LC-8M0

Failure code [DXA9KB]

Abnormal current flows when the pump controller drives the PC-EPC (rear) solenoid, so the pump con-
Detail of failure
troller determines that a short circuit exists in the PC-EPC (R) solenoid circuit.
Action level L03
• Stops output to PC–EPC (rear) solenoid.
Action of con-
troller
Problem on
machine
mation • Drive current of PC-EPC (R) solenoid can be checked via the monitoring function.
(Code: 01300 PC-EPC (R) Solenoid Current)
Inspection
item
(R) solenoid is normal.
the male side.
inspection item.
PC-EPC (R) Resis- • The PC-EPC (R) solenoid
1
tance is defective.
• Replace the PC-EPC (R)
NO
Resis- solenoid.
tance
check".
Emergency inspection item.
2 pump drive Between S25 (male) • The emergency pump
switch Resis-
(2) and each of (3) to Min. 1 Mz drive switch is defective.
tance
(5) Switch posi- • Replace the emergency
NO
tion: Normal pump drive switch.
Between ground and Resis- • Proceed to "Repair
Min. 1 Mz
S25 (male) (2) or (3) tance check".
1. Starting switch: OFF • No short circuit or ground
Short circuit a Check that the emergency pump drive switch is turned to • Proceed to the next
or ground the normal position (bottom side). inspection item.
3
harness 3 to 14 z
NO harness.
Min. 1 Mz
PC200, 200LC, 220, 220LC-8M0 40-305 23

SEN06137-01 Failure code [DXA9KB]
Inspection
item
required.
the wiring harness.
inspection item.
Ground fault the T-adapter to any female side.
4 in wiring har- Between ground and C02 (female) Resis- • Ground fault occurs in the
ness Min. 1 Mz
(96) or S25 (female) (3) tance wiring harness.
NO
check".
item ler.
check".
YES
6 Repair check
40-305 24 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-305 25

SEN06137-01 Failure code [DXE0KA]
Failure code [DXE0KA]

No current flows when the pump controller drives the LS-EPC solenoid, so the pump controller deter-
Detail of failure
mines that an open circuit exists in the LS-EPC solenoid circuit.
Action level L01
Problem on • Travel speed is high when travel speed selection is Lo. and Mi.
machine • Operation speed of work equipment and swing is high in fine control mode (L).
Related infor- Drive current of LS-EPC solenoid can be checked via the monitoring function.
mation (Code: 01500 LS-EPC Solenoid Current)
Inspection
item
• The state of the LS-EPC
solenoid is normal.
the male side.
inspection item.
LS-EPC sole- • The LS-EPC solenoid is
1
noid defective.
Resis- • Replace the LS-EPC sole-
tance noid.
check".
• No open circuit or short
1. Starting switch: OFF circuit occurs in the wiring
2. 2. Disconnect connector C02, and connect T-adapter to YES harness.
2
(115), (117), or (120) tance
wiring harness".
required.
the wiring harness.
inspection item.
ness Max. 1 z
NO
Between C02 (female) (115), (117), Resis- ing harness.
or (120) and V19 (female) (2) tance
check".
item ler.
check".
YES
5 Repair check
40-305 26 PC200, 200LC, 220, 220LC-8M0

Failure code [DXE0KA] SEN06137-01
Circuit diagram related to LS-EPC solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 27

SEN06137-01 Failure code [DXE0KB]
Failure code [DXE0KB]

Abnormal current flows when the pump controller drives the LS-EPC solenoid, so the pump controller
Detail of failure
determines that a short circuit exists in the LS-EPC solenoid circuit.
Action level L01
• Stops output to LS-EPC solenoid.
Action of con-
troller
Problem on • Travel speed is high when travel speed selection is Lo. and Mi.
machine • Operation speed of work equipment and swing is high in fine control mode (L).
Related infor- Drive current of LS-EPC solenoid can be checked via the monitoring function.
mation (Code: 01500 LS-EPC Solenoid Current)
Inspection
item
solenoid is normal.
the male side.
inspection item.
LS-EPC sole- Resis- • The LS-EPC solenoid is
1
tance defective.
• Replace the LS-EPC sole-
NO
Resis- noid.
tance
check".
2
harness 3 to 14 z
NO harness.
Min. 1 Mz
required.
the wiring harness.
inspection item.
Min. 1 Mz NO
check".
item ler.
check".
YES
5 Repair check
40-305 28 PC200, 200LC, 220, 220LC-8M0

Failure code [DXE0KB] SEN06137-01
Circuit diagram related to LS-EPC solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 29


No current flows when the pump controller drives the attachment (ATT) flow rate adjustment (service
Detail of failure current) EPC solenoid, so the pump controller determines that an open circuit exists in the attachment
(ATT) flow rate adjustment (service current) EPC solenoid circuit.
Action level -
Problem on
Attachment does not operate.
machine
Drive current of attachment flow rate adjustment (service current) EPC solenoid can be checked via the
Related infor-
monitoring function.
mation
(Code: 01700 Service Solenoid Current)
Inspection
item
1. Starting switch: OFF ment flow rate adjustment
2. Disconnect connector V30, and connect the T-adapter to YES EPC solenoid is normal.
inspection item.
Attachment
flow rate • The attachment flow rate
1 adjustment EPC solenoid
adjustment
EPC solenoid is defective.
Resis- • Replace the attachment
tance flow rate adjustment EPC
solenoid.
check".
2
(115), (117), or (120) tance
wiring harness".
required.
the wiring harness.
2. Disconnect connectors C02 and V30 and connect the
inspection item.
ness Max. 1 z
NO
BetweenV30 (female) (2) and C02 Resis- ing harness.
(female) (115), (117), or (120) tance
check".
item ler.
check".
40-305 30 PC200, 200LC, 220, 220LC-8M0

Inspection
item
YES
Circuit diagram related to attachment flow rate orifice EPC solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 31


When the pump controller drives the attachment (ATT) flow rate adjustment EPC solenoid, abnormal
Detail of failure
current flows through the circuit, so a short circuit is detected.
Action level -
• Stops driving the attachment flow rate adjustment EPC solenoid.
Action of con-
troller
Problem on
Attachment does not operate.
machine
Drive current of attachment flow rate adjustment (service current) EPC solenoid can be checked via the
Related infor-
monitoring function.
mation
(Code: 01700 Service Solenoid Current)
Inspection
item
1. Starting switch: OFF ment flow rate adjustment
2. Disconnect connector V30, and connect the T-adapter to YES EPC solenoid is normal.
inspection item.
Attachment
Resis- • The attachment flow rate
1
flow rate Between V30 (male) (1) and (2) 3 to 14 z
adjustment tance adjustment EPC solenoid
EPC solenoid is defective.
• Replace the attachment
NO
Resis- flow rate adjustment EPC
Between V30 (male) (1) and ground Min. 1 Mz solenoid.
tance
check".
2
harness 3 to 14 z
NO harness.
Min. 1 Mz
required.
the wiring harness.
inspection item.
Min. 1 Mz NO
check".
item ler.
check".
40-305 32 PC200, 200LC, 220, 220LC-8M0

Inspection
item
YES
Circuit diagram related to attachment flow rate orifice EPC solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 33


No current flows when the pump controller drives the merge-divider (main) EPC solenoid, so the pump
Detail of failure
controller determines that an open circuit exists in the merge-divider (main) EPC solenoid circuit.
Action level L01
• None in particular (Since no current flows, merge-divider main solenoid is not energized.
Action of con- Merge-divider LS solenoid is also not energized because no current flows.)
troller • Even if the cause of a failure is removed, the state of the machine does not return to normal until the
Problem on • Single operation speed of work equipment and swing is high in fine control mode (L).
machine • It is difficult to steer during travel.
Related infor- Drive current to merge-divider (main) EPC solenoid can be checked via the monitoring function.
mation (Code: 08000 Merge-divider (Main) Solenoid Current)
Inspection
item
1. Starting switch: OFF merge-divider (main) EPC
2. Disconnect connector V23, and connect the T-adapter to YES solenoid is normal.
Merge-divider inspection item.
1 (main) EPC • The merge-divider (main)
solenoid EPC solenoid is defective.
Resis- • Replace the merge-divider
tance (main) EPC solenoid.
check".
2
(115), (117), or (120) tance
wiring harness".
required.
the wiring harness.
inspection item.
ness Max. 1 z
NO
(female) (115), (117), or (120) tance
check".
item ler.
check".
40-305 34 PC200, 200LC, 220, 220LC-8M0

Inspection
item
YES
5 Repair check
Circuit diagram related to merge-divider main solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 35


Abnormal current flows when the pump controller drives the merge-divider (main) EPC solenoid, so the
Detail of failure
pump controller determines that a short circuit exists in the merge-divider (main) EPC solenoid circuit.
Action level L01
• Stops driving merge-divider (main) EPC solenoid (merge-divider LS solenoid is also not energized
Action of con- because no current flows).
Related infor- Drive current to merge-divider (main) EPC solenoid can be checked via the monitoring function.
mation (Code: 08000 Merge-divider (Main) Solenoid Current)
Inspection
item
1. Starting switch: OFF merge-divider (main) EPC
1 (main) EPC Resis- • The merge-divider (main)
tance EPC solenoid is defective.
• Replace the merge-divider
NO
Resis- (main) EPC solenoid.
tance
check".
2
harness 3 to 14 z
NO harness.
Min. 1 Mz
required.
the wiring harness.
inspection item.
Min. 1 Mz NO
check".
item ler.
check".
40-305 36 PC200, 200LC, 220, 220LC-8M0

Inspection
item
YES
5 Repair check
Circuit diagram related to merge-divider main solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 37


No current flows when the pump controller drives the merge-divider (LS) EPC solenoid, so the pump
Detail of failure
controller determines that an open circuit exists in the merge-divider (LS) EPC solenoid circuit.
Action level L01
• None in particular (Since no current flows, merge-divider LS solenoid is not energized. Merge-divider
Action of con- main solenoid is also not energized because no current flows.)
Related infor- Drive current to merge-divider (LS) EPC solenoid can be checked via the monitoring function.
mation (Code: 08001 Merge-divider (LS) Solenoid Current)
Inspection
item
1. Starting switch: OFF merge-divider (LS) EPC
1 (LS) EPC • The merge-divider (LS)
solenoid EPC solenoid is defective.
Resis- • Replace the merge-divider
tance (LS) EPC solenoid.
check".
2
(115), (117), or (120) tance
wiring harness".
required.
the wiring harness.
inspection item.
ness Max. 1 z
NO
(female) (115), (117), or (120) tance
check".
item ler.
check".
40-305 38 PC200, 200LC, 220, 220LC-8M0

Inspection
item
YES
5 Repair check
Circuit diagram related to merge-divider LS solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 39


Abnormal current flows when the pump controller drives the merge-divider (LS) EPC solenoid, so the
Detail of failure
pump controller determines that a short circuit exists in the merge-divider (LS) EPC solenoid circuit.
Action level L01
• Stops driving merge-divider (LS) EPC solenoid (merge-divider main solenoid is also not energized
Action of con- because no current flows).
Related infor- Drive current to merge-divider (LS) EPC solenoid can be checked via the monitoring function.
mation (Code: 08000 Merge-divider (LS) Solenoid Current)
Inspection
item
1. Starting switch: OFF merge-divider (LS) EPC
1 (LS) EPC Resis- • The merge-divider (LS)
tance EPC solenoid is defective.
NO
Resis- (LS) EPC solenoid.
tance
check".
2
harness 3 to 14 z
NO harness.
Min. 1 Mz
required.
the wiring harness.
inspection item.
Min. 1 Mz NO
check".
item ler.
check".
40-305 40 PC200, 200LC, 220, 220LC-8M0

Inspection
item
YES
5 Repair check
Circuit diagram related to merge-divider LS solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 41

SEN06137-01 Failure code [DY20KA]
Failure code [DY20KA]

Detail of failure When wiper is operated, W signal at both edges of wiper operating range is not input.
Action level -
Action of con- • Does not drive wiper motor.
Problem on
Wiper motor does not operate.
machine
• Signal input (ON/OFF) of the W contact signal that indicates the wiper working area end can be
checked via the monitoring function.
(Code: 02204 Switch input 5)
Related infor-
mation
• The single wiper does not provide a lower wiper for the double wiper (the upper wiper is referred to
as "wiper").
Inspection
item
• The state of the wiper
motor is normal.
2. Disconnect connector M05, and connect the T-adapter to YES
the female side.
inspection item.
Windshield
wiper posi-
tion: Both Resis-
Max. 1 z
edges of tance
wiper oper-
ating range
Between M05 (female)
1 Wiper motor Windshield • The wiper motor is defec-
(6) and (5)
wiper positive.
tion: Other NO • Replace the wiper motor.
Resis-
than both Min. 1 Mz • Proceed to "Repair
tance
edges of check".
wiper oper-
ating range
Windshield
Between M05 (female) wiper posi- Resis-
Max. 20 z
(1) and (3) tion: Entire tance
area
40-305 42 PC200, 200LC, 220, 220LC-8M0

Failure code [DY20KA] SEN06137-01
Inspection
item
2. Disconnect connectors C01 and C02, and connect the YES harness.
inspection item.
Windshield
wiper posi-
tion: Both Resis-
Max. 1 z
edges of tance
Open circuit wiper oper-
or short circuit ating range
2 Between C01 (female)
in wiring har- Windshield • An open circuit or short
(56) and ground
ness wiper posi- circuit occurs in the wiring
tion: Other NO harness.
Resis-
than both Min. 1 Mz • Proceed to "Open circuit in
tance
edges of wiring harness".
wiper oper-
ating range
Windshield
Between C02 (female) wiper posi- Resis-
Max. 20 z
area
required. • No open circuit occurs in
YES
2. Disconnect connectors C01, C02, and M05. • Proceed to the next
C01 and C02, and the male side of connector M05.
Open circuit Between C01 (female) (56) and M05 Resis-
3 in wiring har- Max. 1 z
(male) (6) tance
ness • An open circuit occurs in
Between M05 (male) (5) and ground Resis- the wiring harness.
Max. 1 z
(T05) tance • Repair or replace the wir-
NO
M05 (male) (1) tance
check".
Max. 1 z
item ler.
check".
YES
4. Turn the wiper switch to INT or ON. NO Repairs are completed.
PC200, 200LC, 220, 220LC-8M0 40-305 43

SEN06137-01 Failure code [DY20KA]
Circuit diagram related to windshield wiper
40-305 44 PC200, 200LC, 220, 220LC-8M0

Failure code [DY20MA] SEN06137-01
Failure code [DY20MA]

Detail of failure When wiper is stowed, P signal of wiper stowing range is not input.
Action level -
Action of con- • Stops power used to stow wiper motor.
Problem on
Wiper motor is not stowed.
machine
• Condition of P contact signal of wiper resting area can be checked via the monitoring function.
Related infor- (Code: 02204 Switch input 5)
mation • As the T-adapter for the pump controller connector is the "socket-type box", operating voltage cannot
Inspection
item
motor is normal.
the female side.
inspection item.
Windshield
wiper posi- Resis-
Max. 1 z
tion: Stowing tance
Between M05 (female) range
1 Wiper motor • The wiper motor is defec-
(4) and (5) Windshield
tive.
wiper posi- Resis-
Min. 1 Mz NO • Replace the wiper motor.
tion: Work- tance
ing area
check".
Windshield
Between M05 (female) wiper posi- Resis-
Max. 20 z
area
2. Disconnect connectors C01 and C02, and connect the YES harness.
inspection item.
Windshield
wiper posi- Resis-
tion: Stowing tance
or short circuit
2 Between C01 (female) range
(75) and ground Windshield
wiper posi- Resis-
Min. 1 Mz NO harness.
tion: Work- tance
ing area
wiring harness".
Windshield
Between C02 (female) wiper posi- Resis-
Max. 20 z
area
PC200, 200LC, 220, 220LC-8M0 40-305 45

SEN06137-01 Failure code [DY20MA]
Inspection
item
YES
2. Disconnect connectors C01, C02, and M05. • Proceed to the next
C01 and C02, and the male side of connector M05.
Open circuit Between C01 (female) (75) and M05 Resis-
(male) (4) tance
ness • An open circuit occurs in
Between M05 (male) (5) and ground Resis- the wiring harness.
Max. 1 z
(T05) tance • Repair or replace the wir-
NO
check".
Max. 1 z
item ler.
check".
YES
5 Repair check
4. Turn the wiper switch to INT or ON.
5. Turn the wiper switch off. NO Repairs are completed.
40-305 46 PC200, 200LC, 220, 220LC-8M0

Failure code [DY20MA] SEN06137-01
PC200, 200LC, 220, 220LC-8M0 40-305 47

SEN06137-01 Failure code [DY2CKB]
Failure code [DY2CKB]

When outputting current to the window washer motor (GND connection), abnormal current flows and a
Detail of failure
short circuit is detected.
Action level -
• Stops output to washer motor.
Action of con-
troller
Problem on
Window washer does not operate.
machine
Related infor-
-
mation
Inspection
item
normal.
YES
inspection item.
1 Fuse If fuse No.4 has blown, the circuit may have a ground fault. proceed to "Ground fault
in wiring harness".
NO
replace the fuse.
check".
• The state of the washer
motor is normal.
the male side.
inspection item.
Resis- • The washer motor is
2 Washer motor Between M06 (male) (1) and (2) 5 to 20 z
tance defective.
• Replace the washer
Between M06 (male) (1) and ground, NO
Resis- motor.
or between M06 (male) (2) and Min. 1 Mz • Proceed to "Repair
tance
ground check".
2. Disconnect connector D02, and connect the T-adapter to array is normal.
YES
3 Diode array Between D02 (male) (7) (+) and (3) • The diode array is defec-
Continuity
(-) tive.
Between D02 (male) (3) (+) and (7) • Proceed to "Repair
No continuity
(-) check".
2. Remove fuse No.4. the wiring harness.
YES
3. Disconnect connectors M06, C01 and D02, and connect • Proceed to the next
the T-adapter to any female side. inspection item.
Ground fault Between ground and any one of F01 • Ground fault occurs in the
Resis-
4 in wiring har- (4), M06 (female) (2), and D02 Min. 1 Mz wiring harness.
tance
ness (female) (3) • Repair or replace the wir-
ing harness.
NO
Between ground and any one of C01 • Replace fuse if it has
Resis- blown out.
(female) (3), M06 (female) (1), and Min. 1 Mz
D02 (female) (7)
check".
40-305 48 PC200, 200LC, 220, 220LC-8M0

Failure code [DY2CKB] SEN06137-01
Inspection
item
2. Disconnect connectors C01 and M06, and connect the • No hot short circuit occurs
T-adapter to the female side of the C01. in the wiring harness.
YES
3. Remove fuse No.4. • Proceed to the next
a Ignore failure codes displayed on machine monitor.
Hot short cir-
Between C01 (female) (3) and ing harness.
Voltage Max. 1 V NO
ground • Replace fuse if it has
blown out.
check".
item ler.
check".
YES
4. Turn the washer switch on. NO Repairs are completed.
PC200, 200LC, 220, 220LC-8M0 40-305 49

SEN06137-01 Failure code [DY2CKB]
Circuit diagram related to window washer
40-305 50 PC200, 200LC, 220, 220LC-8M0

Failure code [DY2DKB] SEN06137-01
Failure code [DY2DKB]

When power to the normal rotation side of the wiper motor drive is supplied, a short circuit was detected
Detail of failure
as a result of the abnormal current that flowed to the circuit.
Action level -
• Stops output to wiper motor drive normal rotation side.
Action of con-
troller
Problem on
Wiper does not operate.
machine
Inspection
item
motor is normal.
the female side.
inspection item.
1 Wiper motor Between M05 (female) (3) and (1) Continuity • The wiper motor is defec-
tive.
Between M05 (female) (3) and Resis- NO • Replace the wiper motor.
ground tance
check".
the wiring harness.
T-adapter to either harness side.
inspection item.
Short circuit in
Between C02 (female) (119) and
(114), or between M05 (male) (1) Min. 1 Mz NO
tance ing harness.
and (3)
check".
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
(119) or M05 (male) (3) tance ing harness.
check".
item ler.
check".
YES
PC200, 200LC, 220, 220LC-8M0 40-305 51

SEN06137-01 Failure code [DY2DKB]
40-305 52 PC200, 200LC, 220, 220LC-8M0

Failure code [DY2EKB] SEN06137-01
Failure code [DY2EKB]

When driving the reverse side of the wiper motor drive circuit, a short circuit was detected as a result of
Detail of failure
the abnormal current that flowed to the circuit.
Action level -
• Stops output to wiper motor drive reverse side.
Action of con-
troller
Problem on
Wiper does not operate.
machine
Inspection
item
motor is normal.
the female side.
inspection item.
1 Wiper motor Between M05 (female) (1) and (3) Continuity • The wiper motor is defec-
tive.
Between M05 (female) (1) and Resis- NO • Replace the wiper motor.
ground tance
check".
the wiring harness.
inspection item.
Short circuit in
Between C02 (female) (119) and
(114), or between M05 (male) (1) Min. 1 Mz NO
tance ing harness.
and (3)
check".
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
(114) or M05 (male) (1) tance ing harness.
check".
item ler.
check".
YES
PC200, 200LC, 220, 220LC-8M0 40-305 53

SEN06137-01 Failure code [DY2EKB]
40-305 54 PC200, 200LC, 220, 220LC-8M0

Failure code [DY2EKB] SEN06137-01
PC200, 200LC, 220, 220LC-8M0 40-305 55

SEN06137-01
© 2018 KOMATSU
All Rights Reserved
40-305 56
SEN06138-02
SEN06138-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
400 Troubleshooting of electrical system
(E-mode)
Before troubleshooting for electrical system ................................................................................................... 3

Information described in troubleshooting table ............................................................................................... 5
E-1 Engine does not start (engine does not rotate) ........................................................................................ 7
E-2 Preheating system does not work .......................................................................................................... 16
E-3 Machine monitor displays nothing when starting switch is turned to ON position .................................. 22
E-4 When starting switch is turned to ON position (with engine stopped), basic check items light up ......... 25
E-5 Caution item lights up while the engine is running ................................................................................. 26
E-6 Caution item lights up while the engine is running ................................................................................. 31
E-7 Fuel gauge does not indicate correct level............................................................................................. 34
E-8 Engine coolant temperature gauge does not indicate correct temperature............................................ 37
E-9 Hydraulic oil temperature gauge does not indicate correct temperature................................................ 39
E-10 Contents of display on machine monitor are different from actual machine model .............................. 42
E-11 Some areas of machine monitor screen are not displayed .................................................................. 44
E-12 Function switch does not work ............................................................................................................. 44
E-13 Automatic warm-up system does not work (in cold weather) ............................................................... 45
E-14 Auto-deceleration function does not work properly .............................................................................. 47
E-15 Working mode does not change........................................................................................................... 49
E-16 Travel speed does not change ............................................................................................................. 50
E-17 Alarm buzzer does not stop sounding .................................................................................................. 52
E-18 Service meter is not displayed while starting switch is in OFF position................................................ 52
E-19 Service mode cannot be selected ........................................................................................................ 53
E-20 All work equipment, swing and travel do not work, or lock is not available .......................................... 54
PC200, 200LC, 220, 220LC-8M0 40-400 1

400 Troubleshooting of electrical system (E-mode)
SEN06138-02
E-21 Swing parking brake does not work properly........................................................................................ 57

E-22 One-touch power maximizing function does not work properly ............................................................ 61
E-23 Travel alarm does not sound or does not stop sounding...................................................................... 64
E-24 Horn does not sound or does not stop sounding.................................................................................. 66
E-25 Wiper or window washer does not operate .......................................................................................... 70
E-26 "Boom LOWER" is not displayed correctly via monitoring function ...................................................... 73
E-27 "Arm OUT" is not displayed correctly via monitoring function .............................................................. 73
E-28 "Arm IN" is not displayed correctly via monitoring function .................................................................. 74
E-29 "Boom RAISE" is not displayed correctly via monitoring function ........................................................ 74
E-30 "Bucket CURL" is not displayed correctly via monitoring function ........................................................ 74
E-31 "Bucket DUMP" is not displayed correctly via monitoring function ....................................................... 75
E-32 "Swing" is not displayed correctly via monitoring function .................................................................... 75
E-33 "Travel" is not displayed correctly via monitoring function.................................................................... 75
E-34 "Service" is not displayed correctly via monitoring function.................................................................. 76
E-35 Attachment hydraulic circuit cannot be changed .................................................................................. 79
E-36 KOMTRAX system does not operate normally..................................................................................... 80
E-37 Breaker clogging caution lamp lights up when breaker is not used...................................................... 82
40-400 2 PC200, 200LC, 220, 220LC-8M0

Before troubleshooting for electrical system SEN06138-02
Before troubleshooting for electrical system
Connection table of fuse box

a This connection table shows the devices that receive the power from each fuse in the fuse box (the switch
power supply refers to the power that is supplied while the starting switch is in ON position and the contin-
uous power supply refers to the power that is supplied while the starting switch is in OFF and ON positions).
a When performing troubleshooting related to the electrical system, check the fuses and fusible links to see
if the power is being supplied correctly.
Power sup- Fusible Fuse
Fuse No. Destination of power
ply type link capacity
Light relay, rear light relay, cab light relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve
1 10A [When emergency pump drive switch is operated]
Swing parking brake solenoid valve
[When swing parking brake cancel switch is operated]
Switch 2 30A Pump controller (solenoid power supply)

F04
power sup- PPC oil pressure lock solenoid valve
(60A)
ply
3 10A Starting motor cut-off relay (PPC lock)
Starting motor cut-off relay (personal code)
Cigarette lighter
4 10A
Window washer motor
5 10A Horn relay, horn
6 10A Electrical intake air heater relay
7 10A Revolving lamp
Switch 8 20A R.H. headlamp, working lamp (boom), working lamp (rear)
F04
power sup-
(60A) Radio
ply
9 10A
L.H. knob switch (pump controller input)
10 5A Air conditioner controller power supply
11 20A
Air conditioner compressor solenoid clutch
12 10A (Spare)
Switch
F04
power sup- 13 10A Headlamp
(60A)
ply
14 10A Optional power supply (1)
Travel alarm
15 10A
Optional power supply (2)
Radio (Backup power supply)
16 10A
Room lamp
Starting switch
Continu-
F05
ous power 17 20A Machine monitor
(30A)
supply
Pump controller
18 5A Air conditioner controller backup
19 30A Engine controller
Switch
Starting switch
power sup- 20 5A Engine controller (ACC signal)
ACC
ply
PC200, 200LC, 220, 220LC-8M0 40-400 3

SEN06138-02 Before troubleshooting for electrical system
Locations of fusible links
Locations of fuse boxes and fuse No.
40-400 4 PC200, 200LC, 220, 220LC-8M0

Information described in troubleshooting table SEN06138-02
Information described in troubleshooting table

q The following types of information are described in the troubleshooting list and related circuit diagram.
Be sure you have a full understanding of the description before performing troubleshooting.
Failure Failure symptom that appears on machine
Related infor-
Information on occurred failure or troubleshooting
mation
Inspection
item
<Description>
• Procedure to determine the probable cause, and standard
value when it is normal
• Remarks for determination of probable cause
<Failures in wiring harness>

1 • Open circuit failure
Connection of connector is defective or wiring harness is
broken.
• Ground failure
A wiring harness that is not to be connected to the ground
(earth) circuit accidentally comes into contact with the Remedy when criterion is
ground (earth) circuit. YES
judged to be "YES"
• Hot short circuit failure
A wiring harness not to be connected to the power (24 V)
circuit accidentally comes into contact with the power (24
Probable V) circuit.
causes • Short circuit failure
2 (Given num- In an independent circuit and as an abnormal event, a spe-
bers are refer- cific wiring harness comes into contact with another one.
ence
numbers, <Precautions for troubleshooting>
which do not 1) Connector number indication method and handling of
indicate prior- T-adapter
ity.)
For troubleshooting, insert or connect T-adapters as follows
unless otherwise specified.
• When "male" or "female" is not indicated with a connec-
tor number, disconnect the connector, and insert
3
T-adapter between the male and female connectors.
• When "male" or "female" is indicated with a connector
number, disconnect the connector, and connect
T-adapter to the indicated side of connector. Remedy when criterion is
NO
judged to be "NO"
2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-)
leads as shown below unless otherwise specified.
4
• Connect the positive (+) lead to pin or wiring harness
indicated first.
• Connect the negative (-) lead to a pin or wiring harness
indicated second.
PC200, 200LC, 220, 220LC-8M0 40-400 5

SEN06138-02 Information described in troubleshooting table
Related circuit diagram
This is the excerpted circuit diagram related to trouble-

shooting
q The circuit diagram contains the connector No., pin No.,
and connector color related to the failure.
q The slash "/" in the connector number is used in the fol-
lowing two cases.
1) Case to use an abbreviation (abbreviated with three
characters in many cases)
Example: T/C: Stands for Torque Converter.
2) Case in which the connector number is different in
the male and female sides
Example: BREAK OUT / E24
q The circuit diagram contains the destination or source of
the branch line in a wiring harness.
q Arrow (io): Approximate installation portion on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed
40-400 6 PC200, 200LC, 220, 220LC-8M0

E-1 Engine does not start (engine does not rotate) SEN06138-02
E-1 Engine does not start (engine does not rotate)

Failure Engine does not start (engine does not rotate)
• The engine start circuit is equipped with the start lock function of the following two systems.
1) Start lock by password of machine monitor
Related infor-
2) Start lock by lock lever
mation
• If the failure symptom is "Battery relay operation sound is not heard" when the starting switch is
turned to ON position, perform troubleshooting for E-1 as well.
Inspection
item
1. Starting switch: OFF is normal.
YES
2. Remove fusible links F04 and F05. • Proceed to the next
inspection item.
1 Fusible link • The fusible link is defec-
tive.
Resis-
Between terminals F04 and F05 Max. 1 z NO • Replace the fusible link.
tance
check".
normal.
YES
inspection item.
• If the fuses have burnt out,
If fuses No.3 and 17 in fuse box F01 are blown, the circuit proceed to "Ground fault
2 Fuse in wiring harness".
may have a ground fault. (See Inspection item 16.)
• If the fuses have not burnt
NO out but they have no resis-
tance value, replace the
fuses.
check".
• No terminal looseness or
open circuit occurs.
inspection item.
Loose termi-
nal or open • If any terminal has
3 become loose, re-mount it.
circuit at ter-
minal • If an open circuit is
Check the terminals of the starting motor, alternator, battery
NO detected, carry out the
relay, and ground terminals T04, T07, T08, etc.
appropriate replacement.
check".
PC200, 200LC, 220, 220LC-8M0 40-400 7

SEN06138-02 E-1 Engine does not start (engine does not rotate)
Inspection
item
• The state of the ground
between the battery relay
bracket and frame is nor-
mal.
inspection item.
Between battery relay (terminal R01)
and ground Resis-
Max. 1 z
Contact a Check the ground state using the tance
(ground) frame.
between bat- a If an abnormality (ground failure) is found in the above,
4 • The ground comes into
tery relay perform the following procedure (see the figures below).
bracket and contact with the frame.
1. Disconnect the battery ground cable. • Repair the contact part
frame 2. Remove the battery relay (BAT RL). NO between the ground and
3. Remove the battery relay bracket (BKT). frame.
• Check the contact face (A) between the battery relay • Proceed to "Repair
bracket (BKT) and the frame for rust and adhesion of for- check".
eign substances. (Also check the frame side.)
a If the face is rusty, polish it.
• Check the mounting bolt (B) for rust.
a If it is rusty, be sure to replace it with a plating bolt.
• Tighten the mounting bolt (B) to the specified torque.
a Be ready with the starting switch in OFF position, then
normal.
perform the troubleshooting with the starting switch YES
stayed in OFF position.
inspection item.
5 Battery
Battery voltage (2 • The battery is defective.
Min. 24 V
cells) • Replace the battery.
NO
Gravity of battery Min. 1.26 check".
q Battery relay bracket (BKT), battery relay (BAT RL)
40-400 8 PC200, 200LC, 220, 220LC-8M0

Inspection
item
controller system is nor-
YES mal.
Defects of the engine controller power supply and ACC signal inspection item.
Engine con-
6 are indicated with failure code [DB2QKR]. If this code
troller system • The engine controller sys-
appears, perform troubleshooting for it first.
tem is defective.
check".
• The state of the starting
1. Starting switch: OFF switch, starting motor
2. Remove fuse No. 19 (30 A) in fuse box F01. (To prevent cut-off relay R06, per-
the engine from starting during the check) sonal code relay R07, bat-
YES
3. Insert the T-adapter into connector E10. tery relay, and wiring
4. Turn the starting switch to START position and hold it (Two harness are normal.
Starting people are required to carry out this check). • Proceed to the inspection
switch, start- item for the starting motor.
ing motor
cut-off relay Between E10 (1) and ground Voltage 20 to 30 V • The starting switch, start-
R06, per- ing motor cut-off relay
7 R06, personal code relay
sonal code
relay R07, R07, battery relay, or wir-
battery relay, ing harness are defective.
wiring har- • Replace the starting
ness NO switch, starting motor
a If voltage is normal, go to Inspection item 14 and after. cut-off relay R06, per-
sonal code relay R07, bat-
tery relay, or wiring
harness.
check".
2. Disconnect connector H15, and connect the T-adapter to
switch is normal.
the male side. YES
3. After troubleshooting, turn the starting switch to
inspection item.
ON/START position and perform troubleshooting again.
Between Resis-
Starting switch: OFF Min. 1 Mz
H15 tance
(male)
(1) and Turn the starting switch to Resis-
Max. 1 z
(2) ON position. tance
Starting
8 • The starting switch is
switch Between Resis-
Starting switch: OFF Min. 1 Mz defective.
H15 tance
• Replace the starting
(male) NO
switch.
Max. 1 z
ON position. tance • Proceed to "Repair
(5)
check".
Between Resis-
Starting switch: OFF Min. 1 Mz
H15 tance
(male)
Max. 1 z
(4) START position. tance
PC200, 200LC, 220, 220LC-8M0 40-400 9

Inspection
item
• The state of the lock lever
switch is normal.
2. Disconnect connector S14, and connect the T-adapter to YES
the female side.
inspection item.
Lock lever Resis- • The lock lever switch is
9 Between Lock lever: FREE Min. 1 Mz
switch tance defective.
S14
• Replace the lock lever
(female) NO
Resis- switch.
(1) and Lock lever: LOCK Max. 1 z • Proceed to "Repair
(3) tance
check".
motor cut-off relay is nor-
2. Replace the starting motor cut-off relay R06 with the horn
YES mal.
relay R08.
inspection item.
Starting motor
10 • The starting motor cut-off
cut-off relay
relay is defective.
If the engine starts, the original starting motor cut-off relay • Replace the starting motor
NO
(R06) is defective. cut-off relay.
check".
1. Starting switch: OFF • The state of the personal
2. Replace the personal code relay R07 with the horn relay code relay is normal.
YES
R08. • Proceed to the next
3. Start the engine. inspection item.
Personal • The personal code relay is
11
code relay defective.
If the engine starts, the original personal code relay is defec- • Replace the personal
NO
tive. code relay.
check".
2. Disconnect diode D01 and connect the T-adapter to the normal.
YES
diode. • Proceed to the next
a Measure it with diode range of multimeter. inspection item.
Between D01 (male) (1) (+) and (5)
No continuity
(-)
12 Diode
Between D01 (male) (5) (+) and (1) • The diode is defective.
Continuity
(-) • Replace the diode.
NO
No continuity check".
(-)
Continuity
(-)
40-400 10 PC200, 200LC, 220, 220LC-8M0

Inspection
item
1. Starting switch: OFF • The state of the starting
2. Disconnect the starting motor safety relay terminal C only. motor safety relay is nor-
3. Insert the T-adapter into R17. YES mal.
4. Turn the starting switch to START position to perform trou- • Proceed to the next
bleshooting. inspection item.
Between safety relay Power sup-
Voltage 20 to 30 V
terminals B and E ply
Between safety relay
Power gen-
terminal R (R17-2) and Voltage Max. 1 V
Starting motor safety relay terminal E eration input
13 • The starting motor safety
safety relay
Between safety relay relay is defective.
Input for
terminal S (R17-1) and Voltage 20 to 30 V • Replace the starting motor
starting NO
safety relay terminal E safety relay.
Between safety relay • Proceed to "Repair
Starting out- check".
terminal C (R28) and Voltage 20 to 30 V
put
safety relay terminal E
If the states of the power supply, power generation input, and
starting input are normal while the state of the starting output
is abnormal, the starting motor safety relay is defective.
motor is normal.
2. Turn the starting switch to START position to perform trou- YES
bleshooting.
inspection item.
Between starting
Power sup-
motor terminal B (SB) Voltage 20 to 30 V • The starting motor is
14 Starting motor and ground ply
defective.
Between starting • Replace the starting
Input for NO
motor terminal C (SC) Voltage 20 to 30 V motor.
starting
and ground • Proceed to "Repair
If the power supply and input for starting are normal but the check".
starting motor does not rotate, the starting motor is defective.
is normal.
inspection item.
15 Alternator
• The alternator is defective.
Between E12 (1) and Power gen- • Replace the alternator.
Voltage Max. 1 V NO
ground eration input • Proceed to "Repair
check".
PC200, 200LC, 220, 220LC-8M0 40-400 11

Inspection
item
• Battery relay
Between terminal R01 and ground Resis-
Max. 1 z
(T08) tance
• Battery relay
a Check how far the 24 V comes and identify the point of
the open circuit in the wiring harness.
Between terminals R04 and R01 Voltage 20 to 30 V
Between terminal R01 and ground Voltage Max. 1 V
• Alternator and starting motor
2. Disconnect the battery ground cable. • No open circuit occurs in
Open circuit
3. Insert the T-adapter into connectors H15, S14, R07, R17, YES the wiring harness.
16 in wiring har-
E10, and E12. • Proceed to the next
ness
4. Connect the battery ground cable. inspection item.
5. Turn the starting switch to START position to perform trou-
bleshooting.
a Check how far the 24 V comes and identify the point of
the open circuit in the wiring harness.
Between H15 (4) and ground Voltage 20 to 30 V
Between S14 (1) and ground Voltage 20 to 30 V
Between S14 (3) and ground Voltage 20 to 30 V
Between R07 (4) and ground Voltage 20 to 30 V
Between R17 (1) and ground Voltage 20 to 30 V
Between E10 (1) and ground Voltage 20 to 30 V
Between alternator terminal B and
Voltage 20 to 30 V
ground
Between starting motor terminal B
Voltage 20 to 30 V
and ground
40-400 12 PC200, 200LC, 220, 220LC-8M0

Inspection
item
a If the fuse or fusible link is burnt out, replace it with a new
one.
2. Disconnect H15, S14, R06, and R07.
3. Connect the T-adapter to each female side of H15, R06
and R07, as well as to the male side of S14.
4. Remove fuse F01-3.
Between H15 (female) (4) and R06 Resis-
Max. 1 z
(female) (5) tance
Between R06 (female) (3) and R07 Resis-
Max. 1 z
(female) (4) tance
Between R07 (female) (1) and S14 Resis-
Max. 1 z
(male) (1) tance
Between R07 (female) (2) and CM01 Resis- • An open circuit occurs in
Max. 1 z
Open circuit
Between R07 (female) (3) and start- Resis- • Repair or replace the wir-
16 in wiring har- Max. 1 z NO
ing harness.
ness ing motor safety relay terminal S tance
Between alternator B and starting Resis-
Max. 1 z check".
motor B tance
Between starting motor B and bat- Resis-
Max. 1 z
tery relay R03 tance
Between starting motor safety relay Resis-
Max. 1 z
terminal R and alternator terminal L tance
Between alternator L and D01 Resis-
Max. 1 z
(female) (6) tance
Resis-
Between F01-3 and S14 (male) (1) Max. 1 z
tance
Between S14 (male) (3) and R06 Resis-
Max. 1 z
(female) (1) tance
Between R06 (female) (2) and Resis-
Max. 1 z
ground (T04) tance
relay is normal.
YES
inspection item.
If the voltage of terminal R03 only is unusual as measured by • When only the voltage of
17 Battery relay battery relay checks by Inspection item 16, the battery relay is terminal R03 is abnormal,
defective. the battery relay is defec-
NO tive.
• Replace the battery relay.
check".
PC200, 200LC, 220, 220LC-8M0 40-400 13

Inspection
item
2. Disconnect H15, S14, R06, and R07.
the wiring harness.
3. Connect the T-adapter to each female side of H15, R06 YES
and R07, as well as to the male side of S14.
inspection item.
Between ground and H15 (female) Resis-
Min. 1 Mz
(4) or R06 (female) (5) tance
Between ground and R06 (female) Resis-
Min. 1 Mz
Ground fault Between ground and R07 (female) Resis-
Between ground and starting motor Resis-
Min. 1 Mz • Repair or replace the wir-
safety relay B or battery relay R03 tance NO
ing harness.
Between ground and starting motor • Proceed to "Repair
Resis-
safety relay C or starting motor C Min. 1 Mz check".
tance
(SC)
Between F01-3 or S14 (male) (1) Resis-
Min. 1 Mz
and ground tance
Between ground and S14 (male) (3) Resis-
Min. 1 Mz
or R06 (female) (1) tance
• No hot short circuit occurs
2. Insert the T-adapter to R17 or E08. YES
inspection item.
Hot short cir-
Between ground and R17 (2) or E08 • Repair or replace the wir-
Voltage Max. 1 V NO
(1) ing harness.
check".
item troller.
check".
YES
21 Repair check
4. Does this failure recur? NO Repairs are completed.
40-400 14 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to engine start
PC200, 200LC, 220, 220LC-8M0 40-400 15

SEN06138-02 E-2 Preheating system does not work
E-2 Preheating system does not work

Failure 1) Manual preheating does not work.
• This troubleshooting describes procedures to be followed when manual preheating does not func-
tion to heat the electrical intake air heater mounting part.
• This machine has "Automatic preheating" and "Manual preheating" functions. When either preheat-
ing function works, the preheating monitor lights up. (When only the preheating monitor does not
light up, perform troubleshooting for failure "3) While preheating is working, preheating monitor does
Related infor-
not light up").
mation
• If failure symptom "Machine monitor does not light up" or "Battery relay does not make operating
sound" appears when the starting switch is turned to ON position, the main electric power supply
system may be defective. In these cases, perform troubleshooting for E-3 and E-1 respectively.
• Before performing troubleshooting, check that no related failure code is displayed. (If failure code
[D110KB] is displayed, perform troubleshooting for it first.)
Inspection
item
normal.
YES
inspection item.
If fuse No.17 in fuse box F01 has blown out, it is highly proba-
1 Fuse ble that the circuit has a ground fault. In this case, perform • If fuse No.17 in fuse box
Inspection item 8 first. F01 has blown out, the cir-
cuit may have a ground
NO
fault.
in wiring harness".
• The states of the heater
relay, battery relay, and
electrical intake air heater
terminals are normal.
inspection item.
Loose termi- • The states of the heater

nal or open relay, battery relay, and
2 electrical intake air heater
circuit in ter-
minal terminals are normal.
• If the terminal has become
Check the heater relay, battery relay, and electrical intake air
NO loose, attach it correctly.
heater terminals.
• If an open circuit is
detected, repair or replace
the terminal.
check".
40-400 16 PC200, 200LC, 220, 220LC-8M0

E-2 Preheating system does not work SEN06138-02
Inspection
item
2. Disconnect connectors CM01 and H15, and connect the YES harness.
T-adapter to the female side of the H15. • Proceed to the next
inspection item.
a Heater relay coil resistance
Resis-
Between H15 (female) (3) and Approx. 20 z
tance
ground
Open circuit 1. Starting switch: OFF
or short circuit 2. Turn the starting switch to ON position. • An open circuit or short
3
ness, Between input terminal on contact
Voltage 20 to 30 V harness.
side of heater relay and ground
1. Starting switch: OFF ing harness.
2. Disconnect heater relay terminal R16. • Proceed to "Repair
a To prevent current from flowing through the heater when check".
the starting switch is turned to HEAT position
3. Turn the starting switch to HEAT position (R1 connected).
Between heater relay terminal R15
Voltage 20 to 30 V
and ground
• The state of the heater
relay is normal.
YES
Heater relay inspection item.
(does not turn If no failure is found by Inspection item 3 and no heater relay
4 • The heater relay is defec-
ON) (terminal operation sound is heard, the heater relay is defective.
R16) tive.
NO • Replace the heater relay.
check".
2. Disconnect connector D02, and connect the T-adapter to normal.
YES
the diode. • Proceed to the next
a Measure it with diode range of multimeter. inspection item.
5 Diode
Between D02 (male) (1) (+) and (5) • The diode is defective.
No continuity
(-) • Replace the diode.
NO
Continuity check".
(-)
• The state of the electrical
1. Starting switch: OFF intake air heater is normal.
YES
2. Disconnect terminal E01. • Proceed to the next
Electrical inspection item.
intake air
6 heater (elec- • The electrical intake air
trical intake heater is defective.
air heater) • Replace the electrical
Between E01 terminal and ground Continuity NO
intake air heater.
check".
PC200, 200LC, 220, 220LC-8M0 40-400 17

Inspection
item
2. Disconnect the battery ground cable. • The state of the starting
3. Disconnect connector H15, and connect the T-adapter to switch is normal.
YES
4. Turn the starting switch to OFF and the HEAT positions to inspection item.
Starting perform troubleshooting.
7
switch Resis- • The starting switch is
OFF Min. 1 Mz
tance defective.
Between H15 (male) • Replace the starting
NO
(1) and (3) Resis- switch.
HEAT Min. 1 Mz • Proceed to "Repair
tance
check".
required.
the wiring harness.
2. Disconnect connectors H15, CM01, terminal R15, E01 and
inspection item.
starting motor terminal B.
Ground fault
8 in wiring har- Between heater relay terminal R15 Resis- • Ground fault occurs in the
Min. 1 Mz
ness (wiring harness side) and ground tance wiring harness.
Between input terminal on contact Resis- • Repair or replace the wir-
Min. 1 Mz NO
side of heater relay and ground tance ing harness.
Between heater terminal E01 (wir- Resis- • Proceed to "Repair
Min. 1 Mz check".
ing harness side) and ground tance
item monitor.
check".
YES
10 Repair check
3. Turn the starting switch to the HEAT position.
40-400 18 PC200, 200LC, 220, 220LC-8M0

Failure 2) Automatic preheating function does not work.

• Automatic preheating starts when boost temperature is -4°C and below (Monitoring code boost
temperature: 18500)
• If automatic preheating function does not work, check whether the manual preheating function
Related infor- works first.
mation • Engine controller checks the primary (coil) side of the preheat relay (connector R18) and generates
failure code [CA2555] or [CA2556] if it is defective.
• Engine controller checks the charge (boost) temperature sensor and generates failure code
[CA153] or [CA154] if it is defective.
Inspection
item
normal.
YES
inspection item.
If fuse No.6 in fuse box F01 has blown out, it is highly proba-
1 Fuse ble that the circuit has a ground fault. In this case, perform • If fuse No.6 in fuse box
Inspection item 5 first. F01 has blown out, the cir-
cuit may have a ground
NO
fault.
in wiring harness".
1. Starting switch: OFF • The state of the auto pre-
2. Replace the auto preheat relay (connector R18) with, for heat relay is normal.
YES
instance, the horn relay (connector R08). • Proceed to the next
Auto preheat • The auto preheat relay is
2
relay defective.
If automatic preheating functions when the charge (boost)
• Replace the auto preheat
temperature is below -4°C, the original auto preheat relay is NO
relay R18.
defective.
check".
2. Disconnect connectors CM01 and R18, and connect the • No open circuit or ground
T-adapter to the female side of the R18. fault occurs in the wiring
a If resistance is 1 Mz or higher, the harness has an open YES harness.
Open circuit circuit. If it is 1 z or below, the harness has an short cir- • Proceed to the next
or ground cuit. inspection item.
3
fault in wiring a Coil resistance of heater relay
harness • An open circuit or ground
fault occurs in the wiring
Approx. 20 z NO harness.
ground tance
wiring harness".
1. Starting switch: OFF • No open circuit occurs in
2. Disconnect connectors R18 and CM01, and connect the the wiring harness.
YES
T-adapter to the female side of connector R18. • Proceed to the next
3. Remove fuse No. 6 in fuse box F01. inspection item.
Open circuit
4 in wiring har- Between R18 (female) (3) and F01-6 Max. 1 z
NO
Between R18 (female) (5) and Resis- ing harness.
heater relay terminal R15 tance
check".
PC200, 200LC, 220, 220LC-8M0 40-400 19

Inspection
item
If the fuse has not blown out, this check is not required.
the wiring harness.
2. Disconnect connectors CM01 and R18, disconnect cable YES
from starting motor terminal B, and connect the T-adapter
inspection item.
Ground fault to female side of R18.
Between R18 (female) (3) and Resis- • Repair or replace the wir-
Min. 1 Mz NO
check".
item monitor.
check".
YES
7 Repair check
Failure 3) While preheating is working, the preheating monitor does not light up.
• This machine has "Automatic preheating" and "Manual preheating" functions. When either preheat-
Related infor-
ing function works, the preheating monitor lights up.
mation
• Check whether the manual preheating function starts first.
Inspection
item
the wiring harness.
2. Disconnect the connectors H15, CM01 and R18, and YES
connect the T-adapter to each female side.
inspection item.
Open circuit
Between H15 (female) (3) and CM01 Resis- • An open circuit occurs in
ness (female) (16) tance the wiring harness.
NO
Between R18 (female) (5) and CM01 Resis- ing harness.
(female) (16) tance
check".
item monitor.
check".
YES
3 Repair check
40-400 20 PC200, 200LC, 220, 220LC-8M0

Circuit diagram related to engine preheating
PC200, 200LC, 220, 220LC-8M0 40-400 21

SEN06138-02 E-3 Machine monitor displays nothing when starting switch is turned to ON position
E-3 Machine monitor displays nothing when starting switch is turned

to ON position
Failure When the starting switch is turned to ON position, nothing is displayed on the machine monitor.
• When the starting switch is turned to ON position, the machine monitor displays the KOMATSU
logo, screen to input password (if set), screen to check breaker mode (if set), pre-start screen,
screen to check working mode, screen to check travel speed, and standard screen in order.
Related infor-
• When starting the engine, the battery voltage may suddenly drop depending on the temperature
mation
and battery condition.
If this happens, the display on the machine monitor may momentarily go out, but this does not indi-
cate any abnormality.
Inspection
item
• The battery ground is con-
nected correctly.
YES
inspection item.
Battery
1 ground cable Check whether battery ground 60B is connected. • The battery ground is not
connection connected correctly.
• Connect the battery
NO
ground cable.
check".
a Be ready with the starting switch in OFF position, then
normal.
perform the troubleshooting with the starting switch YES
stayed in OFF position.
inspection item.
2 Battery
Battery voltage (2 cells) Min. 24 V • The battery is defective.
NO
Gravity of battery (1 piece) Min. 1.26 • Proceed to "Repair
check".
• The states of the fusible
link and fuse are normal.
YES
inspection item.
Fusible link, If fusible link F05 or fuse F01-17 is blown, the circuit may proceed to "Ground fault
3 in wiring harness".
fuse have a ground fault. (See Inspection item 7.)
NO out but it has no resis-
tance, replace the fusible
link and fuse.
check".
ness, starting switch, and
ground cable.
machine monitor are nor-
2. Insert the T-adapter into connector CM01. YES
mal.
3. Connect the battery ground cable, and turn the starting
Wiring har- switch ON (connect the ACC).
inspection item.
ness, starting
4 switch, or Between CM01 (1) and (3) Voltage 20 to 30 V • The wiring harness, start-
machine mon- Between CM01 (2) and (4) Voltage 20 to 30 V ing switch, or machine
itor monitor is defective.
• Replace the wiring har-
NO
ness, starting switch, or
Between CM01 (10) and (4) Voltage 20 to 30 V machine monitor.
inspection item.
40-400 22 PC200, 200LC, 220, 220LC-8M0

E-3 Machine monitor displays nothing when starting switch is turned to ON position SEN06138-02
Inspection
item
2. Disconnect connector H15, and connect the T-adapter to
switch is normal.
the male side. YES
3. Turn the starting switch to ON position and perform trou-
inspection item.
bleshooting again.
Starting
5 Starting Resis- • The starting switch is
switch Min. 1 Mz
switch: OFF tance defective.
Between H15 (male) Turn the • Replace the starting
NO
(1) and (5) starting Resis- switch.
switch to ON tance
position. check".
If no failure is found by Inspection item 4, this check is not
required.
1. Turn the starting switch OFF, and disconnect the battery • No open circuit occurs in
ground cable. the wiring harness.
YES
2. Disconnect fusible link F05, fuse No. 17 in fuse box F01, • Proceed to the next
and connectors H15 and CM01. inspection item.
3. Connect the T-adapter to connectors F05 (male side), H15
(female side), and CM01 (female side).
Resis-
Between battery (-) and ground Max. 1 z
tance
Open circuit Between battery (+) and F05 (male) Resis-
Max. 1 z
6 in wiring har- (1) tance
ness Between F05 (male) (2) and Resis-
F01-16E tance the wiring harness.
Between F01-17 and CM01 (female) Resis- • Repair or replace the wir-
Max. 1 z NO
(1), (2) tance ing harness.
Between ground (T05) and each of Resis- • Proceed to "Repair
Max. 1 z check".
CM01 (female) (3) and (4) tance
Between F01-17 and H15 (female) Resis-
Max. 1 z
(1) tance
Between H15 (female) (5) and CM01 Resis-
Max. 1 z
(female) (10) tance
If no failure is found by Inspection item 4, this check is not
required.
1. Turn the starting switch OFF, and disconnect the battery • No ground fault occurs in
ground cable. the wiring harness.
YES
2. Disconnect fusible link F05, fuse No. 17 in fuse box F01, • Proceed to the next
20E terminal, and connectors H15, CM01, and C01. inspection item.
3. Connect the T-adapter to connectors F05 (male side), H15
Ground fault (female side), and CM01 (female side).
7 in wiring har- Between ground and battery (+) or Resis-
ness Min. 1 Mz
F05 (male) (1) tance
• Ground fault occurs in the
Between ground and F05 (male) (2) Resis- wiring harness.
Min. 1 Mz
or F01-16E tance • Repair or replace the wir-
NO
Between ground and F01-17, CM01 Resis- ing harness.
(female) (1), (2), or H15 (female) (1) tance
check".
Between ground and H15 (female) Resis-
Min. 1 Mz
(5) or CM01 (female) (14) tance
PC200, 200LC, 220, 220LC-8M0 40-400 23

SEN06138-02 E-3 Machine monitor displays nothing when starting switch is turned to ON position
Inspection
item
item monitor.
check".
YES
9 Repair check
Circuit diagram related to machine monitor power supply
40-400 24 PC200, 200LC, 220, 220LC-8M0

E-4 When starting switch is turned to ON position (with engine stopped), basic check items light up SEN06138-02
E-4 When starting switch is turned to ON position (with engine

stopped), basic check items light up
1) When the starting switch is turned to ON position (with engine stopped), engine oil level monitor
Failure
lights up yellow.
Related infor-
-
mation
Inspection
item
Engine oil
1 Perform troubleshooting for failure code [B@BAZK]. - • Proceed to "Repair
level
check".
YES
2 Repair check
Failure 2) The radiator coolant level monitor lights up yellow.

Related infor-
-
mation
Inspection
item
Radiator • Repairs are completed.
1 sub-tank Perform troubleshooting for failure code [B@BCZK]. - • Proceed to "Repair
switch system check".
YES
2 Repair check
PC200, 200LC, 220, 220LC-8M0 40-400 25

SEN06138-02 E-5 Caution item lights up while the engine is running
E-5 Caution item lights up while the engine is running

Failure 1) The engine coolant temperature monitor lights up white.
• A signal from the coolant temperature sensor is input to the engine controller, and then transmitted
Related infor- to the machine monitor through the CAN communication system.
ant temperature)
Inspection
item
perature is appropriate.
YES
If the monitor lights up white, the engine coolant temperature • Proceed to the next
may be low (approximately 30°C and below). Warm up the inspection item.
Engine cool-
engine. • The engine coolant tem-
1 ant tempera-
• Lights up white: The engine coolant temperature is low. perature is low.
ture
• Lights up blue: The engine coolant temperature is appropri- • Perform warm-up opera-
ate. NO
tion.
check".
perature system may be
defective.
Recheck of • Perform troubleshooting
2 inspection for "Engine coolant tem-
item perature gauge does not
indicate correct tempera-
ture." in E mode.
check".
YES
3 Repair check
Failure 2) The hydraulic oil temperature monitor lights up white.

• A signal from hydraulic oil temperature sensor is input to the pump controller and then transmitted to
Related infor- the machine monitor through the CAN communication system.
mation • Hydraulic oil temperature can be checked via the monitoring function. (Code: 04401: Hydraulic oil
temperature)
Inspection
item
ture is appropriate.
YES
If the monitor lights up white, the hydraulic oil temperature inspection item.
may be low (below approximately 20°C). Warm up the
Hydraulic oil • The hydraulic oil tempera-
1 engine.
temperature ture is low.
• Lights up white: Hydraulic oil temperature is low.
• Lights up blue: Hydraulic oil temperature is appropriate. • Perform warm-up opera-
NO
tion.
check".
40-400 26 PC200, 200LC, 220, 220LC-8M0

E-5 Caution item lights up while the engine is running SEN06138-02
Inspection
item
ture gauge system may be
defective.
2 inspection for "Hydraulic oil tempera-
item ture gauge does not indi-
cate correct temperature."
in E mode.
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-400 27

Failure 3) Charge level monitor lights up while the engine is running.

Related infor- The generated signal condition of the alternator can be checked via the monitoring function. (Code:
mation 04300 Battery Charge)
Inspection
item
Alternator
1 Perform troubleshooting for failure code [AB00KE]. - • Proceed to "Repair
system
check".
YES
2 Repair check
Failure 4) The fuel level monitor lights up red.

Related infor- Signal voltage of fuel sensor can be checked via the monitoring function. (Code: 04200 Fuel sensor
mation voltage)
Inspection
item
• The fuel level is normal.
inspection item.
1 Fuel level The fuel level may decrease. Check it. If it drops, refill with oil. • The fuel level is insuffi-
cient.
NO • Replenish fuel.
check".
• The fuel gauge system
may be defective.
2 inspection for "Fuel level gauge does
item not indicate correct level."
in E mode.
check".
YES
3 Repair check
40-400 28 PC200, 200LC, 220, 220LC-8M0

Failure 5) The air cleaner clogging monitor lights up yellow.

Related infor- The signal status of the air cleaner clogging switch can be checked via the monitoring function. (Code:
mation 04501 Monitor Input 2)
Inspection
item
• The state of the air cleaner
is normal.
YES
inspection item.
Air cleaner may be clogged. Check it for clogging and then
1 Air cleaner • Air cleaner is clogged.
clean or replace if clogged.
• Clean or replace the air
NO cleaner.
check".
• The state of the air cleaner
clogging switch is normal.
YES
inspection item.
Air cleaner
2 clogging Perform troubleshooting for failure code [AA10NX]. • The air cleaner clogging
switch switch is defective.
• Replace the air cleaner
NO
clogging switch.
check".
item monitor.
check".
YES
4 Repair check
PC200, 200LC, 220, 220LC-8M0 40-400 29

6) The engine state monitor lights up yellow by the water separator sensor (the water level in the water
Failure
separator rises).
Related infor- The condition of water detected by the fuel filter sensor can be checked via the monitoring function.
mation (Code: 18800 WIF Sensor status)
Inspection
item
• The water level of the
water separator is normal.
YES
inspection item.
Water level in
Since full water capacity in the water separator is detected, • The water separator is
1 water separa-
check the water separator and drain the water in it. filled with water.
tor
• Drain water in the water
NO
separator.
check".
water-in-fuel sensor is nor-
YES mal.
If no failure is found by Inspection item 1, the water-in-fuel inspection item.
Water-in-fuel
2 sensor system may be defective. Perform troubleshooting for • The water-in-fuel sensor is
sensor
"failure codes [CA428] and [CA429] Water sensor error". defective.
• Replace the water-in-fuel
NO
sensor.
check".
item monitor.
check".
YES
4 Repair check
40-400 30 PC200, 200LC, 220, 220LC-8M0

E-6 Caution item lights up while the engine is running

Failure 1) The engine coolant temperature monitor lights up red.
• A signal from the engine coolant temperature sensor is input to the engine controller, and then
Related infor- transmitted to the machine monitor through the CAN communication system.
ant temperature)
Inspection
item
If the monitor is lit in red, the coolant temperature may be high
(above approximately 102°C). Cool down the coolant. (Run
the engine at low idle.)
perature is normal.
• Lights up red: The engine coolant temperature is high YES
(overheat).
inspection item.
Engine cool- • Lights up blue: The engine coolant temperature is appropri-
1 ant tempera- ate.
ture • The engine coolant over-
heats.
Perform troubleshooting for "S-14 Coolant temperature rises • Cool the engine coolant
NO
too high (overheating)". temperature. (Low idle)
check".
perature system may be
defective.
Recheck of perature system may be
2 inspection defective. Perform trouble-
item shooting "E-8 Engine cool-
ant temperature gauge
does not indicate correct
temperature.".
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-400 31

Failure 2) The hydraulic oil temperature monitor lights up red.

• A signal from the hydraulic oil temperature sensor is input to the pump controller and then transmit-
Related infor- ted to the machine monitor through the CAN communication system.
temperature)
Inspection
item
ture is normal.
YES
inspection item.
If the monitor is lit in red, the hydraulic oil temperature may be
high (above approximately 102°C). Cool down the hydraulic • Hydraulic oil temperature
Hydraulic oil overheats.
1 oil. (Run the engine at low idle or stop the engine.)
temperature • Cool the hydraulic oil tem-
• Lights up red: Hydraulic oil temperature is high (overheat).
• Lights up blue: Hydraulic oil temperature is appropriate. perature. (Run the engine
NO
at a low idle or stop the
engine)
check".
ture gauge system may be
defective.
2 inspection for "E-9 Hydraulic oil tem-
item perature gauge does not
indicate correct tempera-
ture."
check".
YES
3 Repair check
40-400 32 PC200, 200LC, 220, 220LC-8M0

Failure 3) The engine oil pressure monitor lights up red.

• The engine oil pressure switch signal is input to the engine controller.
Related infor-
• If the engine oil pressure switch turns ON while the engine is running, failure code [B@BAZG] is
mation
transmitted from the engine controller to the machine monitor through the CAN communication.
Inspection
item
• The engine oil pressure is
normal.
YES
inspection item.
Engine oil pressure may have dropped. Check it and if it is • The engine oil pressure
Engine oil
1 has dropped, perform troubleshooting "S-12 Oil pressure drops.
pressure
drops". • Perform troubleshooting
NO for "S-12 Oil pressure
drops".
check".
• The engine oil pressure
Recheck of switch system may be
2 inspection
2. Can you identify the cause after carrying out a recheck? NO • Perform troubleshooting
item
for failure code [CA435].
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-400 33

SEN06138-02 E-7 Fuel gauge does not indicate correct level
E-7 Fuel gauge does not indicate correct level

1) When fuel is added, the fuel gauge indicator does not rise above the red range (E).
Failure
2) When the fuel level is low, the fuel gauge indicator does not fall below the green range top (F)
mation voltage)
Inspection
item
• The state of the fuel level
sensor is normal.
the male side.
inspection item.
Fuel level Fuel level Resis- • The fuel level sensor is
1
sensor 7 to 11 z
FULL tance defective.
Between P21 (male) • Replace the fuel level sen-
NO
(1) and ground Fuel level Resis- sor.
85 to 95 z • Proceed to "Repair
EMPTY tance
check".
2. Disconnect connector CM01, and connect the T-adapter to YES harness.
Open circuit the female side. • Proceed to "Ground fault
or short circuit in wiring harness".
2
in wiring har- Fuel level Resis- • An open circuit or short
ness 7 to 11 z
Between CM01 FULL tance circuit occurs in the wiring
(female) (15) and NO harness.
Fuel level Resis-
ground 85 to 95 z • Proceed to "Open circuit in
EMPTY tance wiring harness".
required.
the wiring harness.
2. Disconnect connectors CM01 and P21, and connect the
inspection item.
Max. 1 z NO
P21 (female) (1) tance ing harness.
check".
the wiring harness.
2. Disconnect connectors CM01 and P21, and connect the YES
inspection item.
Ground fault
Min. 1 Mz NO
check".
40-400 34 PC200, 200LC, 220, 220LC-8M0

E-7 Fuel gauge does not indicate correct level SEN06138-02
Inspection
item
3. Insert the T-adapter into connector CM01, or connect the YES
T-adapter to female side of P21.
inspection item.
Hot short cir- 4. Turn the starting switch to ON position.
Between ground and CM01 (15) or • Repair or replace the wir-
Voltage Approx. 3.3 V NO
P21 (female) (1) ing harness.
check".
item monitor.
check".
YES
7 Repair check
Circuit diagram related to fuel level sensor
PC200, 200LC, 220, 220LC-8M0 40-400 35

SEN06138-02 E-7 Fuel gauge does not indicate correct level
3) The fuel level indicated by the fuel gauge differs from the actual fuel level.
Failure
4) The fuel gauge indication does not match the indication shown on the fuel level monitor.
mation voltage)
Inspection
item
a Perform troubleshooting when the starting switch is in ON
position or the engine starts.
Color of mon-
Fuel level Fuel gauge level • The machine monitor may
itor light (a)
be defective.
289l 6
Machine mon- • Replace the machine
1 244.5l 5 -
itor monitor.
200l 4 Blue • Proceed to "Repair
check".
100l 3
60l 2
41l 1 Red
YES
2 Repair check
Fuel gauge and fuel level monitor
40-400 36 PC200, 200LC, 220, 220LC-8M0

E-8 Engine coolant temperature gauge does not indicate correct temperature SEN06138-02
E-8 Engine coolant temperature gauge does not indicate correct

temperature
1) When the engine coolant temperature is rising normally, it does not rise above the white range (C).
Failure
2) When the engine coolant temperature has stabilized normally, it rises to the red range (H).
• A signal from the coolant temperature sensor is input to the engine controller, and then transmitted
Related infor- to the machine monitor through the communication system.
ant temperature)
Inspection
item
coolant temperature sen-
YES sor is normal.
inspection item.
Engine cool- The coolant temperature sensor system may be defective.
1 ant tempera- Perform troubleshooting for failure codes [CA144] and • The engine coolant tem-
ture sensor [CA145]. perature sensor is defec-
tive.
NO • Replace the engine cool-
ant temperature sensor.
check".
item monitor.
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-400 37

SEN06138-02 E-8 Engine coolant temperature gauge does not indicate correct temperature
3) The temperature of the engine coolant differs from the temperature shown on the coolant tempera-
ture gauge.
Failure
4) The temperature shown on the engine coolant temperature gauge differs from the temperature
shown on the engine coolant temperature monitor.
• A signal voltage from the coolant temperature sensor is input to the engine controller, and then
Related infor- transmitted to the machine monitor through the CAN communication system.
ant temperature)
Inspection
item
Engine coolant tem- Coolant temperature Color of mon-
perature gauge level itor light (a) • The machine monitor may
be defective.
105°C 6
Machine mon- Red • Replace the machine
1 5 -
itor 102°C monitor.
100°C 4 • Proceed to "Repair
check".
85°C 3 Blue
60°C 2
30°C 1 White
YES
2. Start the engine to raise the temperature of the engine item.
2 Repair check
coolant.
Engine coolant temperature gauge and monitor
40-400 38 PC200, 200LC, 220, 220LC-8M0

E-9 Hydraulic oil temperature gauge does not indicate correct temperature SEN06138-02
E-9 Hydraulic oil temperature gauge does not indicate correct

temperature
1) When the hydraulic oil temperature is rising normally, it does not rise above the white range (C).
Failure
2) When the hydraulic oil temperature has stabilized normally, it rises to the red range (H).
temperature)
Inspection
item
• The state of the hydraulic
1. Starting switch: OFF oil temperature sensor is
inspection item.
Resis- Approx. 90
10°C tance kz
Hydraulic oil
Between P22 (male) Resis- Approx. 35
1 temperature • The hydraulic oil tempera-
(1) and (2) 30°C tance kz
sensor ture sensor is defective.
a Oil temperature
sensor thermal Resis- Approx. 6.5 • Replace the hydraulic oil
80°C NO
characteristics tance kz temperature sensor.
Resis- Approx. 3.5 • Proceed to "Repair
100°C tance kz check".
Resis-
Between P22 (male) (2) and ground Min. 1 Mz
tance
the female side. • Proceed to "Hot short cir-
Open circuit cuit in wiring harness".
or short circuit Between C01 (female) (29) and (46) • An open circuit or short
2
in wiring har- a Use the thermal characteristics Resis- circuit occurs in the wiring
ness, 3.5 to 90 kz
table in Inspection item 1 as tance harness.
resistance criteria. NO • Proceed to "Short circuit in
wiring harness" or
Between C01 (female) (29) and Resis- "Ground fault in wiring har-
Min. 1 Mz
ground tance ness".
required.
the wiring harness.
inspection item.
3 in wiring har- Between C01 (female) (29) and P22 Resis- • An open circuit occurs in
ness Max. 1 z
NO
Between C01 (female) (46) and P22 Resis- ing harness.
(female) (1) tance
check".
PC200, 200LC, 220, 220LC-8M0 40-400 39

SEN06138-02 E-9 Hydraulic oil temperature gauge does not indicate correct temperature
Inspection
item
required.
the wiring harness.
inspection item.
Min. 1 Mz NO
check".
3. Insert the T-adapter into connector C01, or connect the YES
T-adapter to the female side of the P22.
inspection item.
Hot short cir- 4. Turn the starting switch to ON position.
Between ground and C01 (29) or • Repair or replace the wir-
Voltage Approx. 5 V NO
P22 (female) (2) ing harness.
check".
item ler.
check".
YES
7 Repair check
Circuit diagram related to hydraulic oil temperature sensor
40-400 40 PC200, 200LC, 220, 220LC-8M0

E-9 Hydraulic oil temperature gauge does not indicate correct temperature SEN06138-02
3) The temperature of hydraulic oil differs from the temperature shown on the hydraulic oil temperature
gauge.
Failure
4) The temperature of hydraulic oil shown on the hydraulic oil temperature gauge differs from the tem-
perature shown on the hydraulic oil temperature monitor.
temperature)
Inspection
item
Check that there is no consistency between "hydraulic oil
temperature" and hydraulic oil temperature gauge level" and
between "hydraulic oil temperature gauge level" and "monitor
light-up color". • The machine monitor may
Hydraulic oil tempera- Hydraulic oil tempera- Color of mon- be defective.
Machine mon- ture ture level itor light (a) • Replace the machine
1 -
itor monitor.
105°C 6
Red • Proceed to "Repair
102°C 5 check".
100°C 4
85°C 3 Blue
40°C 2
20°C 1 White
YES
2 Repair check 2. Start the engine to raise the hydraulic oil temperature. item.
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
PC200, 200LC, 220, 220LC-8M0 40-400 41

SEN06138-02 E-10 Contents of display on machine monitor are different from actual machine model
E-10 Contents of display on machine monitor are different from actual

machine model
q PC200-8M0, PC200LC-8M0
Failure Contents of display on machine monitor is different from actual machine condition.
Related infor-
-
mation
Inspection
item
model code signal is nor-
a Turn the starting switch ON and perform troubleshooting
YES mal.
(via the monitoring function).
inspection item.
Machine
Model selection 1: OFF
1 model code • The machine model code
00201 Model selection 2: OFF
signal Monitor- Monitoring signal is defective.
Switch input Model selection 3: ON
ing code display • Perform troubleshooting
2 Model selection 4: OFF NO
Model selection 5: OFF for failure code [DA29KQ].
If the display on the monitor is not correct, perform trouble- check".
shooting for failure code [DA29KQ].
item monitor.
check".
YES
3 Repair check
q PC220-8M0, PC220LC-8M0
Failure Contents of display on machine monitor is different from actual machine condition.
Related infor-
-
mation
Inspection
item
model code signal is nor-
a Turn the starting switch ON and perform troubleshooting
YES mal.
(via the monitoring function).
inspection item.
Machine
Model selection 1: ON
1 model code • The machine model code
00201 Model selection 2: OFF
signal Monitor- Monitoring signal is defective.
Switch input Model selection 3: ON
ing code display • Perform troubleshooting
2 Model selection 4: OFF NO
Model selection 5: OFF for failure code [DA29KQ].
If the display on the monitor is not correct, perform trouble- check".
shooting for failure code [DA29KQ].
40-400 42 PC200, 200LC, 220, 220LC-8M0

E-10 Contents of display on machine monitor are different from actual machine model SEN06138-02
Inspection
item
item monitor.
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-400 43

SEN06138-02 E-11 Some areas of machine monitor screen are not displayed
E-11 Some areas of machine monitor screen are not displayed

Failure Some areas of machine monitor screen are not displayed.
One of the features of liquid crystal display panels is that there may be black spots (spots that do not
Related infor-
light up) or white spots (spots that stay lit) on the screen. If the number of white spots and black spots
mation
does not exceed 10, this is not a failure or a defect.
Inspection
item
monitor (liquid crystal dis-
a Turn the starting switch to ON position, then perform trou-
YES play panel) is normal.
bleshooting.
Machine mon- inspection item.
itor (Liquid • The machine monitor (Liq-
1
crystal dis- When all the lights on the liquid crystal display panel are on uid crystal display panel)
play panel) (entirely white) as a result of the following switch operation is defective.
being implemented, the state of the machine monitor is nor- NO • Replace the machine
mal. monitor.
• Switch operation: [4] + [F2] (Press them simultaneously.) • Proceed to "Repair
check".
item monitor.
check".
YES
3 Repair check
E-12 Function switch does not work

Failure Function switch does not work.
Related infor- The signal status of the function switch can be checked via the monitoring function.
mation (Code: 04503 Monitor function switch)
Inspection
item
be defective.
Machine mon- The machine monitor may be defective. (Because this is an • Replace the machine
1 -
itor internal defect, troubleshooting cannot be performed.) monitor.
check".
YES
2 Repair check
40-400 44 PC200, 200LC, 220, 220LC-8M0

E-13 Automatic warm-up system does not work (in cold weather) SEN06138-02
E-13 Automatic warm-up system does not work (in cold weather)
Failure Automatic warm-up system does not operate (in cold season).
• The automatic warm-up function increases engine speed to 1,200 rpm when the coolant tempera-
ture is below 30°C.
• With the starting switch at ON position or after the engine is started, if the fuel control dial is kept at
70% or more of the full open range for 3 seconds, automatic warm-up operation is canceled.
Related infor- • For the machine equipped with an air conditioner, the warm-up function of the heater increases the
mation engine speed to 1,300 rpm under the following conditions; blower is ON, ambient temperature is 5°C
and below, engine coolant temperature is below 55°C. When the engine coolant temperature
reaches 60°C, the warm-up function of heater is canceled.
• When the engine coolant temperature is below 10°C, the turbo protect function works to keep
engine speed 1,000 rpm and below for a maximum of 5 seconds after engine is started.
Inspection
item
coolant temperature signal
YES system is normal.
inspection item.
Coolant tem-
Engine coolant tem-
Monitoring code perature
perature
gauge level
Engine cool- • The engine coolant tem-
105°C 6 (a: red) perature signal system is
ant tempera-
1 102°C 5 (a: red) defective.
ture signal
system 04107 4 (a: blue) • Perform troubleshooting
100°C
Engine coolant tem- for "E-8 Engine coolant
85°C 3 (a: blue) NO
perature temperature gauge does
60°C 2 (a: blue) not indicate correct tem-
perature.".
30°C 1 (a: white)
When the engine coolant temperature does not match the check".
coolant temperature gauge level, perform troubleshooting
"E-8 Engine coolant temperature gauge does not indicate cor-
rect temperature.".
item troller.
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-400 45

SEN06138-02 E-13 Automatic warm-up system does not work (in cold weather)
Engine coolant temperature gauge and engine coolant temperature monitor
40-400 46 PC200, 200LC, 220, 220LC-8M0

E-14 Auto-deceleration function does not work properly SEN06138-02
E-14 Auto-deceleration function does not work properly

1) When the auto-deceleration switch is operated, the auto-deceleration monitor does not light up or
Failure
does not go off.
Related infor- The signal status of the auto-deceleration switch can be checked via the monitoring function.
mation (Code: 04504 Monitor 1st & 2nd Row SW)
Inspection
item
be defective.
1 -
check".
YES
2 Repair check
Failure 2) The auto-deceleration function does not operate or is not canceled while the lever is operated.
• The set speed of auto-deceleration is 1,050 rpm. Unless the fuel control dial is set higher than this
Related infor- value, the auto-deceleration is not activated and canceled.
mation • The auto-deceleration function does not work in arm crane mode (L) of the arm crane specifica-
tions.
Inspection
item
• The state of the PPC oil
a Start the engine and perform troubleshooting (via the pressure signal is normal.
YES
monitoring function). • Proceed to the next
inspection item.
Normal dis-
Monitoring code Item
play
Swing
Travel When lever
Boom LOWER operated:
01900 • The PPC oil pressure sig-
ON, When
PPC oil pres- Pressure switch 1 Boom RAISE nal is defective.
1 lever in NEU-
sure signal • Perform troubleshooting
Arm IN TRAL: OFF
for "E-26 to 34 "***" is not
Arm OUT NO
displayed correctly via
Bucket CURL When lever monitoring function.".
operated: • Proceed to "Repair
01901 Bucket DUMP
ON, When check".
Pressure switch 2
Service lever in NEU-
TRAL: OFF
If the monitor display is not correct, perform troubleshooting
for "E-26 to 34 "***" is not displayed correctly via monitoring
function.".
PC200, 200LC, 220, 220LC-8M0 40-400 47

SEN06138-02 E-14 Auto-deceleration function does not work properly
Inspection
item
• The machine monitor,
pump controller, or engine
Recheck of controller may be defec-
1. Recheck the preceding troubleshooting. tive.
2 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the machine
item
monitor, pump controller,
or engine controller.
check".
YES
3 Repair check
40-400 48 PC200, 200LC, 220, 220LC-8M0

E-15 Working mode does not change SEN06138-02
E-15 Working mode does not change

1) The working mode selection screen is not displayed while the working mode selector switch is oper-
Failure
ated.
Related infor- The signal status of the working mode switch can be checked via the monitoring function.
Inspection
item
be defective.
1 -
check".
YES
2 Repair check
Failure 2) The setting of the engine and hydraulic pump is not changed while working mode is changed.
Related infor-
-
mation
Inspection
item
be defective.
1 -
check".
item ler.
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-400 49

SEN06138-02 E-16 Travel speed does not change
E-16 Travel speed does not change

1) When the travel speed switch is operated, the travel speed on the travel speed monitor does not
Failure
change.
Related infor- The signal status of the travel speed switch can be checked via the monitoring function.
Inspection
item
be defective.
1 -
check".
YES
2 Repair check
Failure 2) Travel speed does not change after the travel speed is changed.
• If a machine monitor failure occurs, actual travel speed does not drop when the travel speed selec-
Related infor- tion is changed to Lo.
mation • As the T-adapter for the pump controller connector is the "socket-type box", operating voltage can-
not be measured at the pump controller connector.
Inspection
item
1. Starting switch: OFF • No hot short circuit occurs
2. Disconnect connector V04, and connect the T-adapter to in the wiring harness.
YES
Hot short cir-
Between V04 (female) (2) and • Repair or replace the wir-
Voltage Max. 3 V NO
ground ing harness.
check".
• The machine monitor or
pump controller may be
item monitor or pump control-
ler.
check".
YES
3 Repair check
40-400 50 PC200, 200LC, 220, 220LC-8M0

E-16 Travel speed does not change SEN06138-02
Circuit diagram related to travel speed solenoid
PC200, 200LC, 220, 220LC-8M0 40-400 51

SEN06138-02 E-17 Alarm buzzer does not stop sounding
E-17 Alarm buzzer does not stop sounding

Failure Alarm buzzer does not stop sounding.
Related infor- The signal status of the alarm buzzer stop switch can be checked via the monitoring function.
Inspection
item
be defective.
1
check".
YES
2 Repair check
E-18 Service meter is not displayed while starting switch is in OFF

position
Failure Service meter is not displayed while starting switch is in OFF position.
The following switch operation with the starting switch set to OFF position displays a service meter in
Related infor-
the upper middle of the screen.
mation
Operation of switches: [4] + [1] (pressed simultaneously)
Inspection
item
• The state of the backup
power supply system is
YES normal.
inspection item.
When the starting switch is turned to ON position, if nothing is
displayed on the machine monitor, the backup power supply • The backup power supply
Backup power system is defective.
1 system may be defective. Perform troubleshooting for "E-3
supply system • Perform troubleshooting
Machine monitor displays nothing when starting switch is
turned to ON position.". for "E-3 Machine monitor
NO displays nothing when
starting switch is turned to
ON position.".
check".
item monitor.
check".
YES
3 Repair check
3. Press function switches [4] and [1] simultaneously.
40-400 52 PC200, 200LC, 220, 220LC-8M0

E-19 Service mode cannot be selected SEN06138-02
E-19 Service mode cannot be selected

Failure Service mode cannot be selected.
Related infor- Service mode is enabled with the following switch operation:
mation Operation of switches: [4] + [1]o[2]o[3] (While pressing [4], press [1], [2] and [3] in this order.)
Inspection
item
be defective.
1 -
check".
YES
2 Repair check 3. Operation of function switches: [4] + [1]o[2]o[3] (While
pressing [4], press [1], [2] and [3] in this order.) NO Repairs are completed.
4. Does this failure recur?
PC200, 200LC, 220, 220LC-8M0 40-400 53

SEN06138-02 E-20 All work equipment, swing and travel do not work, or lock is not available
E-20 All work equipment, swing and travel do not work, or lock is not
available
Failure 1) All work equipment, swing and travel do not work.
Related infor-
-
mation
Inspection
item
normal.
YES
inspection item.
If fuse F01-3 has blown, the circuit may have a ground fault. proceed to "Ground fault
1 Fuse
(See check on Inspection item 6.) in wiring harness".
NO
out but it has no resis-
tance, replace the fuse.
check".
switch is normal.
the female side.
inspection item.
Lock lever Lock lever: Resis- • The lock lever switch is
2 Min. 1 Mz
switch LOCK tance defective.
Between S14 (female) • Replace the lock lever
NO
(1) and (2) Lock lever: Resis- switch.
FREE tance
check".
• The state of the PPC lock
solenoid is normal.
the male side.
inspection item.
PPC lock Resis- • The PPC lock solenoid is
3
tance defective.
• Replace the PPC lock
NO
Resis- solenoid.
tance
check".
2. Remove diode array D01 and connect the T-adapter to the array is normal.
YES
male side. • Proceed to the next
4 Diode array Between D01 (male) (8) (+) and (4) • The diode array is defec-
Continuity
(-) tive.
No continuity
(-) check".
40-400 54 PC200, 200LC, 220, 220LC-8M0

E-20 All work equipment, swing and travel do not work, or lock is not available SEN06138-02
Inspection
item
the wiring harness.
2. Set the lock lever to FREE position. YES
inspection item.
Between F01-3 and ground (Coil Resis-
20 to 60 z
resistance of PPC lock solenoid) tance
a If no failure is found in the above, this check is not
required.
5 in wiring har- 2. Remove fuse F01-3. • An open circuit occurs in
ness 3. Disconnect connectors S14 and V01, and then connect the wiring harness.
the T-adapter to the male side of the S14 or the female • Repair or replace the wir-
NO
side of the V01. ing harness.
Resis-
Between F01-3 and S14 (male) (1) Max. 1 z check".
tance
Between S14 (male) (2) and V01 Resis-
Max. 1 z
(female) (1) tance
Between V01 (female) (2) and Resis-
Max. 1 z
ground (T09) tance
the wiring harness.
3. Disconnect connectors S14, V01, and D01, and then YES
connect the T-adapter to the male side of the S14, or the
inspection item.
Ground fault female side of the V01 or D01.
6 in wiring har- Between F01-3 or S14 (male) (1) Resis- • Ground fault occurs in the
ness Min. 1 Mz
and ground tance wiring harness.
NO
Between ground and S14 (male) (2), Resis- ing harness.
V01 (female) (1), or D01 (female) (4) tance
check".
YES
7 Repair check
Failure 2) All work equipment, swing and travel cannot be locked.

Related infor-
-
mation
Inspection
item
switch is normal.
the male side.
inspection item.
Lock lever Lock lever: Resis- • The lock lever switch is
1 Min. 1 Mz
switch LOCK tance defective.
Between S14 (female) • Replace the lock lever
NO
(1) and (2) Lock lever: Resis- switch.
FREE tance
check".
PC200, 200LC, 220, 220LC-8M0 40-400 55

SEN06138-02 E-20 All work equipment, swing and travel do not work, or lock is not available
Inspection
item
YES
Hot short cir-
Between V01 (female) (1) and (2) Voltage Max. 1 V NO
ing harness.
check".
YES
3 Repair check
40-400 56 PC200, 200LC, 220, 220LC-8M0

E-21 Swing parking brake does not work properly SEN06138-02
E-21 Swing parking brake does not work properly

1) Upper structure does not swing while the swing parking brake cancel switch is set to CANCEL posi-
Failure
tion.
Related infor- The signal status of the swing lock switch can be checked via the monitoring function.
mation (Pump controller system code: 02200 Switch input 1)
Inspection
item
normal.
YES
inspection item.
If fuse F01-1 has blown out, the circuit may have a ground proceed to "Ground fault
1 Fuse
fault. In this case, perform Inspection item 6 first. in wiring harness".
NO
check".
1. Starting switch: OFF parking brake cancel
2. Disconnect connector S25, and connect the T-adapter to YES switch is normal.
inspection item.
Swing park-
Swing parking brake
Resis-
2 ing brake can- cancel Min. 1 Mz • The swing parking brake
tance
cel switch switch: Nor- cancel switch is defective.
Between S25 (male) mal • Replace the swing parking
NO
(13) and (14) Swing park- brake cancel switch.
ing brake • Proceed to "Repair
Resis-
cancel Max. 1 z check".
tance
switch: Can-
cel
YES
Continuity
(-)
3 Diode array • The diode array is defec-
No continuity tive.
(-)
Continuity
(-) check".
No continuity
(-)
PC200, 200LC, 220, 220LC-8M0 40-400 57

SEN06138-02 E-21 Swing parking brake does not work properly
Inspection
item
1. Starting switch: OFF • The state of the wiring har-
2. Disconnect connector V03, and connect the T-adapter to ness is normal.
YES
Swing park-
ing brake
Wiring har- cancel Voltage 20 to 30 V • The wiring harness is
4
ness switch: Can- defective.
Between V03 (female) cel • Repair or replace the wir-
NO
(1) and (2) Swing parking harness.
cancel Voltage Max. 1 V check".
switch: Nor-
mal
required.
the wiring harness.
2. Disconnect connectors V03 and S25, and connect the
inspection item.
5 in wiring har- Between V03 (female) (1) and S25 Resis- • An open circuit occurs in
ness Max. 1 z
NO
Between V03 (female) (2) and C02 Resis- ing harness.
(female) (115) tance
check".
required.
the wiring harness.
2. Disconnect connectors S25, V03, D01 and D03, and
inspection item.
Ground fault connect the T-adapter to the female side of the V03.
Between V03 (female) (1) and Resis- • Repair or replace the wir-
Min. 1 Mz NO
check".
item monitor.
check".
YES
4. Turn the swing lock switch on/off. NO Repairs are completed.
40-400 58 PC200, 200LC, 220, 220LC-8M0

E-21 Swing parking brake does not work properly SEN06138-02
2) Swing brake does not operate while the swing parking brake cancel switch is set to NORMAL posi-
Failure
tion.
Related infor-
-
mation
Inspection
item
1. Starting switch: OFF parking brake cancel
2. Disconnect connector S25, and connect the T-adapter to YES switch is normal.
inspection item.
Swing park-
Swing parking brake
Resis-
1 ing brake can- cancel Min. 1 Mz • The swing parking brake
tance
cel switch switch: Nor- cancel switch is defective.
Between S25 (male) mal • Replace the swing parking
NO
(13) and (14) Swing park- brake cancel switch.
Resis-
cancel Max. 1 z check".
tance
switch: Can-
cel
2. Disconnect connector V03, and connect the T-adapter to
inspection item.
Hot short cir- 4. Swing lock switch ON
Voltage Max. 1 V NO
ground ing harness.
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-400 59

SEN06138-02 E-21 Swing parking brake does not work properly
40-400 60 PC200, 200LC, 220, 220LC-8M0

E-22 One-touch power maximizing function does not work properly SEN06138-02
E-22 One-touch power maximizing function does not work properly

1) One-touch power maximizing function monitor is not displayed when the L.H. knob switch is
Failure pressed.
2) Work equipment power is not increased when the L.H. knob switch is pressed.
• One-touch power maximizing function does not operate when working mode is other than power
Related infor- mode (P) or economy mode (E).
mation • The condition of L.H. knob switch signal can be checked via the monitoring function (Code: 02200
Switch input 1)
Inspection
item
monitor is normal.
YES
If work equipment power is increased when the L.H. knob inspection item.
Machine mon- switch is pressed but not displayed on the monitor, the • The machine monitor is
1
itor machine monitor may be defective. (Since this is an internal defective.
defect, troubleshooting cannot be performed.) • Replace the machine
NO
monitor.
check".
normal.
YES
inspection item.
If fuse No.9 has blown, the circuit may have a ground fault. proceed to "Ground fault
2 Fuse
(See check on Inspection item 6.) in wiring harness".
NO
check".
• The state of the L.H.knob
switch is normal.
the male side.
inspection item.
L.H. knob L.H.knob • The L.H.knob switch is
3 Resis-
switch switch: Min. 1 Mz defective.
tance
Between S11 (female) Release • Replace the L.H.knob
NO
(1) and (2) L.H.knob switch.
Resis-
switch: Max. 1 z • Proceed to "Repair
tance check".
Press
1. Starting switch: OFF • No open circuit or ground
Open circuit a Ignore displayed failure codes. inspection item.
or ground L.H.knob • An open circuit or ground
4
fault in wiring switch: Voltage Max. 1 V fault occurs in the wiring
harness Release harness.
Between C01 (female)
NO • Proceed to "Short circuit in
(41) and ground L.H.knob wiring harness" or
switch: Voltage 20 to 30 V "Ground fault in wiring har-
Press ness".
PC200, 200LC, 220, 220LC-8M0 40-400 61

SEN06138-02 E-22 One-touch power maximizing function does not work properly
Inspection
item
YES
2. Remove fuse F01-9. • Proceed to the next
3. Disconnect connectors C01 and S11 and connect the inspection item.
5 in wiring har-
ness Between F01-9 and S11 (female) (1) Max. 1 z
tance the wiring harness.
NO
(female) (41) tance
check".
YES
2. Remove fuse F01-9. • Proceed to the next
3. Disconnect connectors C01 and S11, and connect the inspection item.
Ground fault T-adapter to the female side of the S11.
6 in wiring har-
ness Between ground and F01-9 or S11 Resis- • Ground fault occurs in the
Min. 1 Mz
(female) (1) tance wiring harness.
NO
(2) or C01 (female) (41) tance
check".
item ler.
check".
YES
8 Repair check
Circuit diagram related to L.H. knob switch
40-400 62 PC200, 200LC, 220, 220LC-8M0

E-22 One-touch power maximizing function does not work properly SEN06138-02
Failure 3) Work equipment power does not return to normal when the L.H. knob switch is released.
Related infor- The condition of L.H. knob switch signal can be checked via the monitoring function (Code: 02200
mation Switch input 1)
Inspection
item
YES
Hot short cir-
Between V02 (female) (1) and (2) Voltage Max. 3 V NO
ing harness.
check".
item ler.
check".
YES
3 Repair check
PC200, 200LC, 220, 220LC-8M0 40-400 63

SEN06138-02 E-23 Travel alarm does not sound or does not stop sounding
E-23 Travel alarm does not sound or does not stop sounding
Failure 1) The alarm does not sound during travel.
Related infor- Condition of output to the travel alarm can be checked via the monitoring function (Code: 03701 Con-
mation troller Output 2)
Inspection
item
alarm is normal.
the male side.
inspection item.
1 Travel alarm • The travel alarm is defec-
tive.
Between M14 (male) (1) and (2) Continuity NO • Replace the travel alarm.
check".
the wiring harness.
2. Disconnect connectors M14 and C02, and connect the YES
T-adapter to each female side.
inspection item.
Open circuit
Between C02 (female) (107) and Resis- • An open circuit occurs in
ness M14 (female) (1) tance the wiring harness.
NO
M14 (female) (2) tance
check".
the wiring harness.
inspection item.
Ground fault
Min. 1 Mz NO
(107) or M14 (female) (1) tance ing harness.
check".
YES
4 Repair check
4. Turn the travel lever to FORWARD or REVERSE (put in a
little). NO Repairs are completed.
40-400 64 PC200, 200LC, 220, 220LC-8M0

E-23 Travel alarm does not sound or does not stop sounding SEN06138-02
Failure 2) The alarm does not stop sounding while machine is stopped.
Related infor-
-
mation
Inspection
item
1. Starting switch: OFF • A hot short circuit may
2. Disconnect connector M14, and connect the T-adapter to occur in the wiring har-
Hot short cir- the female side. ness.
1 cuit in wiring 3. Turn the starting switch to ON position. - • Repair or replace the wir-
harness ing harness.
Between M14 (female) (1) and • Proceed to "Repair
Voltage Max. 3 V
ground check".
YES
2 Repair check
Circuit diagram related to travel alarm
PC200, 200LC, 220, 220LC-8M0 40-400 65

SEN06138-02 E-24 Horn does not sound or does not stop sounding
E-24 Horn does not sound or does not stop sounding

Failure 1) Horn does not sound.
Related infor-
-
mation
Inspection
item
normal.
YES
inspection item.
If fuse F01-5 has blown out, the circuit may have a ground proceed to "Ground fault
1 Fuse
fault. In this case, perform Inspection item 7 first. in wiring harness".
NO
check".
1. Starting switch: OFF • The state of the horn relay
2. Replace horn relay (connector: R08) with another relay. is normal.
YES
4. Press the L.H. knob switch. inspection item.
2 Horn relay • The changed horn relay is

defective.
• Replace the changed horn
If horn sounds, original horn relay is defective. NO
relay.
check".
• The state of the horn
switch is normal.
male side.
inspection item.
3 Horn switch Resis- • The horn switch is defec-
Switch: OFF Min. 1 Mz
tance tive.
Between S10 (male)
NO • Replace the horn switch.
(1) and (2) Resis-
Switch: ON Max. 1 z • Proceed to "Repair
tance check".
• The treble tone and bass
1. Starting switch: OFF tone of the horn are nor-
2. Disconnect connectors M07 and M08, and connect the YES mal.
inspection item.
Treble tone
4 and bass tone Between M07 (male) (1) and (2) Continuity • The treble tone and bass
of horn tone of the horn are defec-
tive.
NO • Replace the treble tone
Between M08 (male) (1) and (2) No continuity and bass tone of the horn.
check".
40-400 66 PC200, 200LC, 220, 220LC-8M0

E-24 Horn does not sound or does not stop sounding SEN06138-02
Inspection
item
2. Disconnect connector R08, and connect the T-adapter to
ness is normal.
inspection item.
4. Press the L.H. knob switch.
Wiring har-
5 Between R08 (female) (1) and (2) Voltage 20 to 30 V • The wiring harness is
ness
defective.
• Replace the wiring har-
NO
Between R08 (female) (3) and (2) Voltage 20 to 30 V ness.
check".
the wiring harness.
2. Disconnect connector R08, and connect the T-adapter to YES
the female side.
inspection item.
Between R08 (female) (5) and
Continuity
ground
Between R08 (female) (1) and
Continuity
ground
required.
2. Remove fuse F01-5. the wiring harness.
ness 3. Disconnect connectors R08 and S10 and connect the • Repair or replace the wir-
T-adapter to each female side. NO
ing harness.
Between F01-5 and S10 (female) (1) Max. 1 z
tance check".
Between S10 (female) (2) and R08 Resis-
Max. 1 z
(female) (1) tance
Max. 1 z
ground tance
Resis-
Between R08 (female) (3) and F01-5 Max. 1 z
tance
a If the fuse has not blown out, this check is not required.
the wiring harness.
2. Remove fuse F01-5. YES
3. Disconnect connectors R08, M07, and M08, and connect
inspection item.
the T-adapter to the female side of the R08.
Ground fault
7 in wiring har- Between R08 (female) (1) and Resis- • Ground fault occurs in the
Min. 1 Mz
ness ground tance wiring harness.
Between R08 (female) (3) and Resis- • Repair or replace the wir-
Min. 1 Mz NO
Between R08 (female) (5) and Resis- • Proceed to "Repair
Min. 1 Mz check".
ground tance
Recheck of • The horn may be defec-

1. Recheck the preceding troubleshooting. tive.
8 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the horn.
item
check".
YES
9 Repair check
PC200, 200LC, 220, 220LC-8M0 40-400 67

SEN06138-02 E-24 Horn does not sound or does not stop sounding
Failure 2) Horn does not stop sounding.

Related infor-
-
mation
Inspection
item
• The state of the horn relay
is normal.
2. Remove horn relay (connector R08). YES
inspection item.
1 Horn relay • The horn relay is defec-
tive.
If horn stops sounding, original horn relay is defective. NO • Replace the horn relay.
check".
2. Disconnect connectors M07 and M08, and connect the in the wiring harness.
YES
T-adapter to each female sides. • Proceed to the next
Hot short cir-
2 cuit in wiring Between M07 (female) (2) and (1) Voltage Max. 1 V • A hot short circuit occurs
NO
Between M08 (female) (2) and (1) Voltage Max. 1 V ing harness.
check".
YES
3 Repair check
40-400 68 PC200, 200LC, 220, 220LC-8M0

E-24 Horn does not sound or does not stop sounding SEN06138-02
Circuit diagram related to horn
PC200, 200LC, 220, 220LC-8M0 40-400 69

SEN06138-02 E-25 Wiper or window washer does not operate
E-25 Wiper or window washer does not operate

Failure 1) The wiper monitor does not light up, or does not go out, while the wiper switch is operated.
Related infor- The signal status of the wiper switch can be checked via the monitoring function.
Inspection
item
be defective.
1 -
check".
YES
4. Operate the wiper switch. NO Repairs are completed.
Failure 2) The wiper does not work while the wiper switch is operated.
• The state of window rear limit switch signal can be checked via the monitoring function.
Related infor- (Code: 02204 Switch input 5)
mation • As for wiper motor system, troubleshooting is performed by failure codes [DY20KA], [DY20MA],
[DY2DKB], and [DY2EKB].
Inspection
item
• The state of the window
1. Starting switch: OFF rear limit switch is normal.
YES
2. Disconnect connector W03. • Proceed to the next
inspection item.
Front win-
Window rear dow: When Resis- • The window rear limit
1 Min. 1 Mz
limit switch the front tance switch is defective.
Between W03 (male) mounting • Replace the window rear
NO
(1) and (2) Front win- limit switch.
dow: When Resis- • Proceed to "Repair
Max. 1 z check".
the rear tance
stowage
motor is normal.
the female side.
inspection item.
2 Wiper motor • The wiper motor is defec-
tive.
Between M05 (female) (1) and (3) Continuity NO • Replace the wiper motor.
check".
40-400 70 PC200, 200LC, 220, 220LC-8M0

E-25 Wiper or window washer does not operate SEN06138-02
Inspection
item
a See troubleshooting for failure codes [DY20KA], the wiring harness.
YES
[DY20MA], and [DY2DKB], [DY2EKB]. • Proceed to the next
inspection item.
Open circuit a Rear limit switch system
3 in wiring har- 1. Starting switch: OFF • An open circuit occurs in
ness 2. Disconnect connector C01, and connect the T-adapter to the wiring harness.
the female side. • Repair or replace the wir-
NO
3. Front window rear stowage ing harness.
Max. 1 z check".
ground tance
2. Disconnect connector C01, and connect the T-adapter to the wiring harness.
YES
3. Front window front mounting inspection item.
Ground fault
Min. 1 Mz NO
check".
item ler.
check".
YES
4. Operate the wiper switch. NO Repairs are completed.
Failure 3) The window washer does not operate when the window washer switch is operated.
• The state of the window washer switch signal can be checked via the monitoring function.
Related infor-
(Code: 04504 Monitor 1st & 2nd Row SW)
mation
• Failure in window washer is expressed by failure codes [DY2CKA] and [DY2CKB].
Inspection
item
be defective.
1 -
check".
YES
4. Operate the window washer switch. NO Repairs are completed.
PC200, 200LC, 220, 220LC-8M0 40-400 71

SEN06138-02 E-25 Wiper or window washer does not operate
Circuit diagram related to wiper and window washer
40-400 72 PC200, 200LC, 220, 220LC-8M0

E-26 "Boom LOWER" is not displayed correctly via monitoring function SEN06138-02
E-26 "Boom LOWER" is not displayed correctly via monitoring function

Failure "Boom LOWER" is not displayed correctly via the monitoring function.
Related infor-
Monitoring code: 01900 Pressure Switch 1
mation
Inspection
item
Boom
LOWER PPC
1 Perform troubleshooting for failure code [DHS9MA]. - • Proceed to "Repair
oil pressure
check".
sensor
YES
2 Repair check
4. Perform boom LOWER operation (push in a little) using
the work equipment control lever. NO Repairs are completed.
E-27 "Arm OUT" is not displayed correctly via monitoring function

Failure "Arm OUT" is not displayed correctly via the monitoring function.
Related infor-
mation
Inspection
item
Arm OUT • Repairs are completed.
1 PPC oil pres- Perform troubleshooting for failure code [DHSCMA]. - • Proceed to "Repair
sure sensor check".
YES
2 Repair check
4. Perform arm OUT operation (push in a little) using the work
equipment control lever. NO Repairs are completed.
PC200, 200LC, 220, 220LC-8M0 40-400 73

SEN06138-02 E-28 "Arm IN" is not displayed correctly via monitoring function
E-28 "Arm IN" is not displayed correctly via monitoring function

Failure "Arm IN" is not displayed correctly via the monitoring function.
Related infor-
mation
Inspection
item
Arm IN PPC • Repairs are completed.
1 oil pressure Perform troubleshooting for failure code [DHS3MA]. - • Proceed to "Repair
sensor check".
YES
2 Repair check
4. Perform arm IN operation (push in a little) using the work
equipment control lever. NO Repairs are completed.
E-29 "Boom RAISE" is not displayed correctly via monitoring function

Failure "Boom RAISE" is not displayed correctly via the monitoring function.
Related infor-
mation
Inspection
item
Boom RAISE • Repairs are completed.
1 PPC oil pres- Perform troubleshooting for failure code [DHS8MA]. - • Proceed to "Repair
sure sensor check".
YES
2 Repair check
4. Perform boom RAISE operation (push in a little) using the
work equipment control lever. NO Repairs are completed.
E-30 "Bucket CURL" is not displayed correctly via monitoring function

Failure "Bucket CURL" is not displayed correctly via the monitoring function.
Related infor-
mation
Inspection
item
Bucket CURL • Repairs are completed.
1 PPC oil pres- Perform troubleshooting for failure code [DHS4MA]. - • Proceed to "Repair
sure sensor check".
YES
2 Repair check
4. Perform bucket CURL operation (push in a little) using the
40-400 74 PC200, 200LC, 220, 220LC-8M0

E-31 "Bucket DUMP" is not displayed correctly via monitoring function SEN06138-02
E-31 "Bucket DUMP" is not displayed correctly via monitoring function

Failure "Bucket DUMP" is not displayed correctly via the monitoring function.
Related infor-
mation
Inspection
item
Bucket DUMP • Repairs are completed.
1 PPC oil pres- Perform troubleshooting for failure code [DHSDMA]. - • Proceed to "Repair
sure sensor check".
YES
2 Repair check
4. Perform bucket DUMP operation (push in a little) using the
E-32 "Swing" is not displayed correctly via monitoring function

Failure "Swing" is not displayed correctly via the monitoring function.
Related infor-
mation
Inspection
item
Swing PPC oil • Repairs are completed.
Perform troubleshooting for failure codes [DHSAMA] and
1 pressure sen- - • Proceed to "Repair
[DHSBMA].
sor check".
YES
2 Repair check
4. Perform swing LEFT or RIGHT operation (push in a little)
using the work equipment control lever. NO Repairs are completed.
E-33 "Travel" is not displayed correctly via monitoring function

Failure "Travel" is not displayed correctly via the monitoring function.
Related infor-
mation
Inspection
item
Travel PPC oil • Repairs are completed.
Perform troubleshooting for failure code [DHSFMA], [DHS-
1 pressure sen- - • Proceed to "Repair
GMA], [DHSHMA], or [DHSJMA].
sor check".
YES
2 Repair check
4. Turn the travel control lever to FORWARD or REVERSE
(push in a little). NO Repairs are completed.
PC200, 200LC, 220, 220LC-8M0 40-400 75

SEN06138-02 E-34 "Service" is not displayed correctly via monitoring function
E-34 "Service" is not displayed correctly via monitoring function

Failure "Service" is not displayed correctly via the monitoring function.
• Monitoring code: 01901 Pressure Switch 2
Related infor- • For safety, use "short socket adapter" 799-601-7230 for 2-pin X connector in tests of Inspection
k While the engine is running, do not check the oil pressure switch connector.
mation items 1 and 2.
Inspection
item
A. If the monitoring function does not indicate that the "Ser-
vice" is "ON" when engine is started and attachment control
pedal is depressed at front end
1. Starting switch: OFF • The state of the service
2. Disconnect connector P14, and connect the "short socket front PPC oil pressure
adapter" to the male side. YES switch (P14) is normal.
a After finishing test, restore the connector. inspection item.
Service front If the monitoring function indicates that "Service" is "ON", the
PPC oil pres- service front PPC oil pressure switch (P14) is defective (Note
1
sure switch 1).
(P14)
B. If the monitoring function indicates that the "Service" is • The service front PPC oil
"ON" when the starting switch is turned to ON position pressure switch (P14) is
1. Starting switch: OFF defective.
2. Disconnect connector P14. • Replace the service front
3. Turn the starting switch to ON position. NO
PPC oil pressure switch
If the monitoring function indicates that "Service" is "OFF", the (P14).
service front PPC oil pressure switch (P14) is defective (Note • Proceed to "Repair
2). check".
A. If the monitoring function does not indicate that the "Ser-
vice" is "ON" when the engine is started and the attachment
control pedal is depressed at the rear end.
1. Starting switch: OFF • The state of the service
2. Disconnect connector P15, and connect the "short socket rear PPC oil pressure
adapter" to the male side. YES switch (P15) is normal.
a After finishing test, restore the connector. inspection item.
Service rear If the monitoring function indicates that "Service" is "ON", the
PPC oil pres- service rear PPC oil pressure switch (P15) is defective (Note
2
sure switch 1).
(P15)
B. If the monitoring function indicates that the "Service" is • The service rear PPC oil
"ON" when the starting switch is turned to ON position pressure switch (P15) is
1. Starting switch: OFF defective.
2. Disconnect connector P15. • Replace the service rear
3. Turn the starting switch to ON position. NO
PPC oil pressure switch
If the monitoring function indicates that "Service" is "OFF", the (P15).
service rear PPC oil pressure switch (P15) is defective (Note • Proceed to "Repair
2). check".
40-400 76 PC200, 200LC, 220, 220LC-8M0

E-34 "Service" is not displayed correctly via monitoring function SEN06138-02
Inspection
item
1. Starting switch: OFF • The state of the wiring har-
2. Insert the T-adapter into the P13. ness or pump controller is
3. Start the engine. YES normal.
4. Depress the attachment control pedal and perform trouble- • Proceed to the next
shooting. inspection item.
Attachment
Wiring har-
Between P13 (1) and control • The wiring harness or
3 ness or pump Voltage Approx. 7 V
(2) pedal: NEU- pump controller is defec-
controller
TRAL tive.
Attachment NO • Replace the wiring har-
control ness or pump controller.
Between P13 (1) and • Proceed to "Repair
pedal: FOR- Voltage Max. 1 V
(2) check".
WARD or
REVERSE
the wiring harness.
2. Disconnect C01, P14, and P15 and connect the T-adapter YES
to each female side.
inspection item.
Between C01 (female) (76) and P14 Resis-
(female) (1) tance
Between C01 (female) (76) and P15 Resis- the wiring harness.
ness Max. 1 z
NO
Between P14 (female) (2) and Resis- ing harness.
ground (T06) tance
check".
Between P15 (female) (2) and Resis-
Max. 1 z
ground (T06) tance
the wiring harness.
2. Disconnect connectors C01, P14, and P15, and connect YES
the T-adapter to any of the female sides.
inspection item.
Ground fault
Between ground and each of C01
(female) (76), P14 (female) (1) or Min. 1 Mz NO
tance ing harness.
P15 (female) (1)
check".
2. Disconnect connectors P14 and P15, and connect the the wiring harness.
YES
T-adapter to any of the female sides. • Proceed to the next
Short circuit in
Between ground and P14 (female) • Repair or replace the wir-
Voltage Approx. 7 V NO
(1) or P15 (female) (1) ing harness.
check".
item ler.
check".
PC200, 200LC, 220, 220LC-8M0 40-400 77

SEN06138-02 E-34 "Service" is not displayed correctly via monitoring function
Inspection
item
YES
4. Operate the service control lever (put in a little). NO Repairs are completed.
Note 1: If the monitoring function indicates that "attachment control pedal" is "OFF" while voltage between
C01 (52) and ground is below 1 V, pump controller is defective.
Note 2: If the monitoring function indicates that "attachment control pedal" is "ON" while the voltage between
C01 (52) and the ground is approximately 7 V, the pump controller is defective.
Circuit diagram related to service oil pressure switch
40-400 78 PC200, 200LC, 220, 220LC-8M0

E-35 Attachment hydraulic circuit cannot be changed SEN06138-02
E-35 Attachment hydraulic circuit cannot be changed

Attachment circuit cannot be changed.
Failure 1) When working mode P or E is selected, the crusher circuit (2-way circuit) is not selected.
2) When working mode B is selected, breaker circuit (one-way circuit) is not selected.
Related infor- The troubleshooting for the attachment return selector solenoid (open circuit/short circuit) is performed
mation via failure code [DWA2KA] or [DWA2KB].
Inspection
item
• The stare of the attach-
inspection item.
Attachment
Resis- • The attachment return
1 return selec- Between V06 (male) (1) and (2) 20 to 60 z
tor solenoid tance selector solenoid is defec-
tive.
NO • Replace the attachment
Resis- return selector solenoid.
Between V06 (male) (1) and ground Min. 1 Mz
check".
YES
Hot short cir-
Voltage Max. 3 V NO
ground ing harness.
check".
YES
3 Repair check
Circuit diagram related to attachment return selector solenoid
PC200, 200LC, 220, 220LC-8M0 40-400 79

SEN06138-02 E-36 KOMTRAX system does not operate normally
E-36 KOMTRAX system does not operate normally

Failure q KOMTRAX system does not operate normally.
q Perform the following troubleshooting if the administrator of the KOMTRAX system requests check-
Related infor- ing of whether a failure is occurring in the system on the machine.
mation q Even when the KOMTRAX system is defective, no problem appears on the machine.
q Check all results of troubleshooting on the service menu display of the machine monitor.
No. Cause Procedure, measuring location, criteria and remarks Criterion and remedy
• The KOMTRAX transmis-
1. Turn the starting switch to ON position. sion function is normal.
YES
2. Display "Terminal status" screen. • Proceed to the next
inspection item.
Communica- • The KOMTRAX transmis-
1
tion 1 sion function is defective.
Monitor-
Check item: • Contact the KOMTRAX
ing dis- To be completed NO
Station set-up check service hot-line.
play
check".
KOMTRAX GPS position-
YES ing function is normal.
2. Display "GPS & Communication Status" screen. • Proceed to the next
inspection item.
Positioning by N ###.##.## (Latitude)

2 Monitor- • The KOMTRAX GPS posi-
GPS Check item: E ###.##.## (Longi- tioning function is defec-
ing dis-
Positioning tude) tive.
play
In positioning NO • Contact the KOMTRAX
service hot-line.
If latitude and longitude are not displayed within 5 minutes
when the machine is outdoor under clear skies, contact
check".
KOMTRAX service hot line.
• The KOMTRAX communi-
cation environment is nor-
YES mal.
inspection item.
Communica-
Monitor- • The KOMTRAX communi-
3 tion environ- Check item: Satellite in View or No
ing dis- cation environment is
ment Communication Satellite in View
play defective.
If Communication Status does never display "Satellite in NO • Contact the KOMTRAX
View" within 15 minutes with machine stayed outdoor where service hot-line.
opens clearly for sky, check if connector of TC330 or antenna • Proceed to "Repair
on top of cab are properly connected. check".
• The KOMTRAX transmis-
1. Turn the starting switch to ON position. sion function is normal.
YES
inspection item.
Communica- • The KOMTRAX transmis-
4
tion 2 sion function is defective.
Monitor- Check item:
• Contact the KOMTRAX
ing dis- Number of message not 0 to 60 (normally 0) NO
service hot-line.
play yet sent
check".
40-400 80 PC200, 200LC, 220, 220LC-8M0

E-36 KOMTRAX system does not operate normally SEN06138-02
No. Cause Procedure, measuring location, criteria and remarks Criterion and remedy
YES
5 Repair check
a Select "02 GPS & Communication Status" from

a Select "01 Terminal Status" from "11 KOMTRAX
"11 KOMTRAX settings" in the service menu of
settings" in service menu of machine monitor.
the machine monitor.
PC200, 200LC, 220, 220LC-8M0 40-400 81

SEN06138-02 E-37 Breaker clogging caution lamp lights up when breaker is not used
E-37 Breaker clogging caution lamp lights up when breaker is not used
Failure The lamp lights up when the breaker is not used.
Related infor-
-
mation
Inspection
item
• The state of the breaker
clogging lamp is normal.
the male side.
inspection item.
Breaker clog- • The breaker clogging lamp
1
ging lamp is defective.
• Replace the breaker clog-
Between P72 (2) and (3) No continuity NO
ging lamp.
check".
2. Disconnect connector P72, and connect the T-adapter to YES harness.
2
ness harness.
Between P72 (3) and P71 (1) No continuity NO • Repair or replace the wir-
ing harness.
check".
YES
3 Repair check
Circuit diagram related to breaker clogging caution lamp
40-400 82 PC200, 200LC, 220, 220LC-8M0

E-37 Breaker clogging caution lamp lights up when breaker is not used SEN06138-02
PC200, 200LC, 220, 220LC-8M0 40-400 83

SEN06138-02
© 2018 KOMATSU
All Rights Reserved
40-400 84
SEN06139-01
SEN06138-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
500 Troubleshooting of hydraulic and
mechanical system (H-mode)
System diagram of hydraulic and mechanical system .................................................................................... 4

Failure mode and cause table......................................................................................................................... 6
Information in troubleshooting table ................................................................................................................ 8
H-1 All work equipment, swing and travel speed are all slow, or there is no force ......................................... 9
H-2 Engine speed drops significantly or engine stalls................................................................................... 12
H-3 All work equipment, swing and travel do not work ................................................................................. 14
H-4 Unusual noise is heard from the vicinity of the hydraulic pump ............................................................. 15
H-5 Fine control performance or response is poor ....................................................................................... 16
H-6 Boom speed is low or power is insufficient ............................................................................................ 17
H-7 Arm speed is low or power is insufficient ............................................................................................... 21
H-8 Bucket speed is low or power is insufficient ........................................................................................... 25
H-9 Work equipment does not move in single operation .............................................................................. 27
H-10 Hydraulic drift of work equipment is large ............................................................................................ 28
H-11 Time lag of work equipment is large..................................................................................................... 32
H-12 When certain work equipment is relieved hydraulically, other work equipment moves........................ 33
H-13 One-touch power maximization function does not work....................................................................... 34
H-14 When combining operations of work equipment, equipment subject to heavier loads moves slower.. 35
H-15 Boom RAISE is slow in Swing + Boom RAISE operation .................................................................... 36
H-16 When combining swing and travel operations, travel speed drops significantly .................................. 37
H-17 Travel deviation is detected.................................................................................................................. 38
H-18 Travel speed is slow............................................................................................................................. 40
H-19 Machine does not steer well or steering power is low .......................................................................... 43
PC200, 200LC, 220, 220LC-8M0 40-500 1

500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN06139-01
H-20 Travel speed does not change, or travel speed is too slow or too fast................................................. 47
H-21 One track does not move ..................................................................................................................... 49
H-22 Machine does not swing....................................................................................................................... 51
H-23 Swing acceleration or swing speed is low ............................................................................................ 54
H-24 Upper structure overruns excessively when it stops swinging ............................................................. 57
H-25 Shock is significant when upper structure stops swinging ................................................................... 60
H-26 An unusual loud noise is heard when the upper structure stops swinging ........................................... 61
H-27 Swing drift on a slope is significant ...................................................................................................... 62
H-28 Attachment circuit cannot be changed ................................................................................................. 65
H-29 Oil flow in the attachment circuit cannot be changed ........................................................................... 66
40-500 2 PC200, 200LC, 220, 220LC-8M0

SEN06139-01
PC200, 200LC, 220, 220LC-8M0 40-500 3

SEN06139-01 System diagram of hydraulic and mechanical system
System diagram of hydraulic and mechanical system
40-500 4 PC200, 200LC, 220, 220LC-8M0

System diagram of hydraulic and mechanical system SEN06139-01
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, 220, 220LC-8M0 40-500 5

SEN06139-01 Failure mode and cause table
Failure mode and cause table

Failed parts Tank Hydraulic pump Control valve
Pump merge-divider main EPC valve

Pump merge-divider LS-EPC valve
Pump merge-divider main valve
Pressure compensation valve
Self-pressure reducing valve
Pump merge-divider LS valve

Boom throttle EPC solenoid
Pump swash plate sensor
Boom regeneration valve

Boom lock valve
Main relief valve
Engine system
LS line throttle
PC-EPC valve
LS-EPC valve
Unload valve
Piston pump
Servo piston
Hydraulic oil
PC valve
PC valve
Damper
stainer
Spool
Cap
Failure mode
All of work equipment, swing and travel work slow or
Any of work equipment,
q q q q q q q q q q q q
lack power
swing and travel
Engine speed lowers extremely or engine stalls q q q q q q q q

All work equipment, travel, and swing systems do not
q q q q
work.
Unusual sound is heard from around hydraulic pump q q q q
Fine control performance or response is poor q q q q
Speed or power of boom is low q q q q q q q q q

Speed or power of arm is low q q q q q q
Speed or power of bucket is low q q
Work equipment does not move in single operation q
Work equipment
Boom q q
Hydraulic drift of work
Arm q q
equipment is large
Bucket q q
Time lag of work equipment operation is large q q q
Other wok equipment moves when one of work equip-
q
ment is relieved
One-touch power maximization function does not work. q
When combining operations of work equipment, equip-
q
ment subject to heavier loads moves slower
Swing Swing
travel boom
In combined operations of swing and boom RAISE,

and
boom rising speed is low
Travel speed drops largely in combined operation of

and
swing and travel

Machine does not travel straight q q q q q
Travel speed is low. q q q q
Travel
Machine is hard to steer or travel power is low q q q q q q

Travel speed does not change or travel speed is too
q
low or high
One track does not run
Upper structure swings
q
Upper structure does not neither to the right nor left
swing Upper structure does not
q
swing in only one direction
Poor or low for both of the
q
Swing acceleration is poor right and left
or swing speed is low Poor or low for only in one
q q
direction
Swing
Largely for both of the right

Upper structure overruns
and left
considerably when it stops
Largely for only in one
swinging q
direction
Shock is significant when upper structure stops swing-
ing
An unusual loud noise is heard when the upper struc-
ture stops swinging
Swing drift on a slope is When swing brake works
significant When swing brake works q q
Attachment circuit is not changed
Attach
-ment
Oil flow in attachment circuit cannot be changed
40-500 6 PC200, 200LC, 220, 220LC-8M0

q
q
q
q
Safety valve
q
Suction valve
q
q q
q q
q
q q q
q q q
LS shuttle valve
q
Arm regeneration valve
Arm quick return valve
q q q q q q
q
Arm lock valve
q
Swing LS select valve
Control valve
q
q
Travel junction valve
q
Back pressure valve
Failure mode and cause table
q
Service valve (safety valve)
q
q
PPC valve (right lever)
q
q
q
q
q q
PPC valve (left lever)
PC200, 200LC, 220, 220LC-8M0

q
q
q
PPC valve (travel lever)
q
PPC valve (service)
q
q
Swing PPC slow return valve
q
Oil flow adjuster EPC valve for attachment
q
Work equipment lock solenoid
q
2-stage relief solenoid
q
q
Travel interconnection solenoid
q
Travel speed selector solenoid
q
q
Swing holding brake solenoid
Solenoid valve
q
ATT return selector solenoid
Piston motor
q
q q
q q
q q
Safety valve
q q
Check valve
q
q q
q q
Suction valve
q q q q
q
Shockless valve
Swing motor
q
Parking brake
q
q q
q q
Swing machinery
Center swivel joint
q q
q
q
q
Piston motor
Counterbalance valve
q q q q
Check valve
q q
Safety valve
Parking brake
Travel motor
q q q q
q
Final drive
Hydraulic cylinder
q
q
q
q
q
40-500
Diagnosis codes
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
q H-10
7
SEN06139-01

a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting,
understand that information fully.
Failure Description of failure code
Related infor-
Information related to detected failure or troubleshooting
mation
No. Cause Criteria and troubleshooting procedure Criterion and remedy

Probable
1 causes of Remedy when criterion is
trouble YES
judged to be "YES"
2 (Given num- <Contents of description>
bers are ref- q Standard value in normal condition to judge
erence probable causes
3 numbers, q Remarks on judgment
Remedy when criterion is
which do not NO
judged to be "NO"
4 indicate pri-
ority)
40-500 8 PC200, 200LC, 220, 220LC-8M0

H-1 All work equipment, swing and travel speed are all slow, or there is no force SEN06139-01
H-1 All work equipment, swing and travel speed are all slow, or there is
no force
Failure All work equipment, swing and travel operation lack speed or power.
Related infor-
Perform all troubleshooting with the working mode set in the power mode (P).
mation
Inspection
item
• The state of the unload
a Prepare by stopping the engine, then perform trouble- valve is normal.
YES
shooting with the engine running at a high idle speed. • Proceed to the next
inspection item.
1 Unload valve Control lever Unload pressure • The unload valve is defec-
tive.
3.5±1.0 MPa NO • Replace the unload valve.
All control levers in NEUTRAL • Proceed to "Repair
{36 ± 10 kg/cm2}
check".
• The state of the main relief
YES
inspection item.
Control lever Main relief pressure • The main relief valve is
33.3 to 37.2 MPa defective.
Main relief Arm IN relief • Adjust the main relief
2 {340 to 380 kg/cm2}
valve valve.
• If the correct oil pressure
NO
If pressure cannot be adjusted to a normal level, a malfunc- is not obtained after
tion and an internal defect of the main relief valve may occur. adjustment, replace the
Check it. valve.
check".
• The state of the self-pres-
sure reducing valve is nor-
a Prepare by stopping the engine, then perform trouble-
YES mal.
shooting with the engine running at a high idle speed.
Self-pressure inspection item.
3 reducing Control circuit source pres- • The self-pressure reduc-
valve Control lever
sure ing valve is defective.
• Replace the self-pressure
NO
2.84 to 3.43 MPa reducing valve.
All control levers in NEUTRAL
{29 to 35 kg/cm2} • Proceed to "Repair
check".
a Be ready with engine stopped, then perform troubleshoot- valve is normal.
YES
ing with engine at low idle and high idle. • Proceed to the next
inspection item.
PC-EPC valve out-
PC-EPC Engine Control lever • The PC-EPC valve is
4 put pressure
valve defective.
Approx. 2.9 MPa
• Replace the PC-EPC
Low idle {Approx. 30 NO
All control levers in valve.
kg/cm2}
NEUTRAL • Proceed to "Repair
0.52 to 0.91 MPa check".
High idle
{5.3 to 9.3 kg/cm2}
PC200, 200LC, 220, 220LC-8M0 40-500 9

SEN06139-01 H-1 All work equipment, swing and travel speed are all slow, or there is no force
Inspection
item
• The state of the PC valve
a Prepare by stopping the engine, then perform trouble- is normal.
YES
inspection item.
Oil pressure to be Measurement con-
Oil pressure ratio
measured dition • The PC valve is defective.
5 PC valve Pump discharged • Adjust the PC valve.
Swing lock switch: 1 • If the correct oil pressure
pressure
ON is not obtained after
PC valve output Approx. 0.6 NO
Arm IN relief adjustment, replace the
pressure (Approx. 3/5) PC valve.
If oil pressure cannot be adjusted to a normal level, a mal- • Proceed to "Repair
function and an internal defect of the PC valve may occur. check".
Check it.
YES
inspection item.
LS-EPC valve out-
Travel speed Travel lever • The LS-EPC valve is
6 LS-EPC valve put pressure
defective.
Approx. 2.9 MPa
• Replace the LS-EPC
Lo NEUTRAL {Approx. 30 NO
valve.
kg/cm2}
0 MPa check".
Hi Operation
{0 kg/cm2}
• The state of the LS valve
YES
inspection item.
Lever operation and oil pressure ratio
Oil pressure to be Running track idle

measured All control levers in off ground • The LS valve is defective.
NEUTRAL (Lever moved half- • Adjust the LS valve.
7 LS valve way) • If the correct oil pressure
Pump discharged is not obtained after
1 NO
pressure Almost same pres- adjustment, replace the
PC valve output sure Approx. 0.6 valve.
pressure (Approx. 3/5) • Proceed to "Repair
check".
If oil pressure cannot be adjusted to a normal level, a mal-
function or an internal defect of the LS valve may occur.
Check it.
• The state of the servo pis-
ton is normal.
YES
inspection item.
8 Servo piston Servo piston may malfunction. Check it. • The servo piston is defec-
tive.
NO • Replace the servo piston.
check".
40-500 10 PC200, 200LC, 220, 220LC-8M0

H-1 All work equipment, swing and travel speed are all slow, or there is no force SEN06139-01
Inspection
item
Recheck of • The piston pump may be

9 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the piston pump.
item
check".
YES
4. Set the working mode to the power mode (P). NO Repairs are completed.
PC200, 200LC, 220, 220LC-8M0 40-500 11

SEN06139-01 H-2 Engine speed drops significantly or engine stalls
H-2 Engine speed drops significantly or engine stalls

Failure Engine speed drops significantly or engine stalls.
Related infor-
mation
Inspection
item
• The state of the main relief
YES
inspection item.
L.H. work equipment control • The main relief valve is
Main relief pressure
lever defective.
Main relief • Adjust the main relief
1 33.3 to 37.2 MPa
valve Arm IN relief valve.
{340 to 380 kg/cm2}
NO
is not obtained after
If pressure cannot be adjusted to a normal level, a malfunc- adjustment, replace the
tion and an internal defect of the main relief valve may occur. valve.
Check it. • Proceed to "Repair
check".
a Be ready with engine stopped, then perform troubleshoot- valve is normal.
YES
ing with engine at low idle and high idle. • Proceed to the next
inspection item.
PC-EPC valve out-
PC-EPC Engine Control lever • The PC-EPC valve is
2 put pressure
valve defective.
Approx. 2.9 MPa
• Replace the PC-EPC
Low idle {Approx. 30 NO
All control levers in valve.
kg/cm2}
NEUTRAL • Proceed to "Repair
0.52 to 0.91 MPa check".
High idle
{5.3 to 9.3 kg/cm2}
• The state of the PC valve
YES
inspection item.
Oil pressure to be Measurement con-
Oil pressure ratio
measured dition • The PC valve is defective.
3 PC valve Pump discharged • Adjust the PC valve.
Swing lock switch: 1 • If the correct oil pressure
pressure
ON is not obtained after
PC valve output Approx. 0.6 NO
Arm IN relief adjustment, replace the
pressure (Approx. 3/5) PC valve.
If oil pressure cannot be adjusted to a normal level, a mal- • Proceed to "Repair
function and an internal defect of the PC valve may occur. check".
Check it.
40-500 12 PC200, 200LC, 220, 220LC-8M0

H-2 Engine speed drops significantly or engine stalls SEN06139-01
Inspection
item
YES
inspection item.

1 NO
check".
Check it.
• The state of the orifice or
filter in the servo device is
YES normal.
Orifice or fil- inspection item.
The orifice or filter in the pump servo device may be clogged.
5 ter in servo • The orifice or filter in the
Check it.
device servo device is defective.
• Replace the orifice or filter
NO
in the servo device.
check".
Recheck of • The servo piston may be

6 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the servo piston.
item
check".
YES
PC200, 200LC, 220, 220LC-8M0 40-500 13

SEN06139-01 H-3 All work equipment, swing and travel do not work
H-3 All work equipment, swing and travel do not work

Failure All work equipment, swing and travel do not work.
Related infor-
mation
Inspection
item
• The state of the PPC lock
a Prepare by stopping the engine, then perform trouble- solenoid valve is normal.
YES
inspection item.
PPC lock PPC lock solenoid valve out- • The PPC lock solenoid
1 Lock lever
solenoid valve put pressure valve is defective.
0 MPa • Replace the PPC lock
LOCK NO
{0 kg/cm2} solenoid valve.
Approx. 2.9 MPa • Proceed to "Repair
FREE check".
{Approx. 30 kg/cm2}
YES mal.
valve Control lever
NO
check".
• The state of the piston
The piston pump may malfunction or may have an internal pump is normal.
YES
defect. Check it according to the following method. • Proceed to the next
1. Remove the inspection plugs (F and R) for pump inspection item.
3 Piston pump discharged pressure. • The piston pump is defec-
2. Crank (manual rotation) the flywheel. tive.
3. Oil flowing out of the inspection plug hole is a normal NO • Replace the piston pump.
occurrence and should not cause concern. • Proceed to "Repair
check".
Recheck of • The damper may be

4 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the damper.
item
check".
YES
40-500 14 PC200, 200LC, 220, 220LC-8M0

H-4 Unusual noise is heard from the vicinity of the hydraulic pump SEN06139-01
H-4 Unusual noise is heard from the vicinity of the hydraulic pump
Failure Unusual noise is heard from around hydraulic pump.
Related infor-
-
mation
Inspection
item
• The level of hydraulic oil is
normal.
YES
inspection item.
Hydraulic oil
1 The hydraulic oil level may fall. Check it. • The level of hydraulic oil is
level
not appropriate.
NO • Replenish hydraulic oil.
check".
oil is normal.
YES
inspection item.
2 Hydraulic oil Air may be mixed in hydraulic oil. Check it. • The hydraulic oil is defec-
tive.
NO • Replace hydraulic oil.
check".
tank cap is normal.
YES
inspection item.
Hydraulic tank The hydraulic tank cap may be clogged and the pressure • The hydraulic tank cap is
3
cap inside the tank may become negative. Check it. defective.
• Clean the hydraulic tank
NO
cap.
check".
tank strainer is normal.
YES
inspection item.
Hydraulic tank The hydraulic tank strainer may be clogged and the pressure • The hydraulic tank strainer
4
strainer of the suction circuit may become negative. Check it. is defective.
• Clean the hydraulic tank
NO
strainer.
check".
Recheck of • The piston pump may be

5 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the piston pump.
item
check".
YES
6 Repair check
PC200, 200LC, 220, 220LC-8M0 40-500 15

SEN06139-01 H-5 Fine control performance or response is poor
H-5 Fine control performance or response is poor

Failure Fine control performance or response is poor.
Related infor-
mation
Inspection
item
YES
inspection item.
LS-EPC valve out-
defective.
Approx. 2.9 MPa
valve.
kg/cm2}
0 MPa check".
Hi Operation
{0 kg/cm2}
• The state of the LS circuit
orifice is normal.
YES
inspection item.
LS circuit ori- The orifice in the LS circuit (pump - piping - control valve) may
2 • The LS circuit orifice is
fice be clogged. Check it.
defective.
NO • Clean the LS circuit orifice.
check".
YES
inspection item.

1 NO
check".
Check it.
Recheck of • The servo piston may be

4 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the servo piston.
item
check".
YES
40-500 16 PC200, 200LC, 220, 220LC-8M0

H-6 Boom speed is low or power is insufficient SEN06139-01
H-6 Boom speed is low or power is insufficient

Failure Boom speed or power is low.
Related infor-
mation
Inspection
item
• The state of the R.H. PPC
YES
inspection item.
R.H. PPC R.H. work equipment control
1 valve (Boom PPC valve output pressure • The R.H. PPC valve is
lever defective.
circuit)
0 MPa • Replace the R.H. PPC
NEUTRAL NO
{0 kg/cm2} valve.
Boom RAISE 2.84 to 3.43 MPa • Proceed to "Repair
Boom LOWER {29 to 35 kg/cm2} check".

merge-divider main EPC
YES valve is normal.
The merge-divider main EPC valve may malfunction. Check
2 main EPC • The merge-divider main
it.
valve EPC valve is defective.
NO
main EPC valve.
check".
merge-divider LS-EPC
inspection item.
Merge-divider
3 The merge-divider LS-EPC valve may malfunction. Check it. • The merge-divider
LS-EPC valve
LS-EPC valve is defective.
NO
LS-EPC valve.
check".
merge-divider main valve
YES is normal.
inspection item.
Merge-divider
4 The merge-divider main valve may malfunction. Check it. • The merge-divider main
main valve
valve is defective.
NO
main valve.
check".
PC200, 200LC, 220, 220LC-8M0 40-500 17

SEN06139-01 H-6 Boom speed is low or power is insufficient
Inspection
item
merge-divider LS valve is
YES normal.
inspection item.
Merge-divider
5 The merge-divider LS valve may malfunction. Check it. • The merge-divider LS
LS valve
valve is defective.
NO
LS valve.
check".
• The state of the spool of
the boom control valve is
YES normal.
inspection item.
Boom control The spool of the boom control valve may malfunction. Check
6 • The spool of the boom
valve (Spool) it.
control valve is defective.
• Replace the spool of the
NO
boom control valve.
check".
compensation valve of the
boom control valve is nor-
YES
mal.
Boom control inspection item.
valve (Pres- The pressure compensation valve of the boom control valve • The pressure compensa-
7
sure compen- may malfunction. Check it. tion valve of the boom
sation valve) control valve is defective.
• Replace the pressure
NO
boom control valve.
check".
• The state of the regenera-
tion valve of the boom
YES control valve is normal.
inspection item.
Boom control • The regeneration valve of
The regeneration valve of the boom control valve may mal-
8 valve (Regen- the boom control valve is
function. Check it.
eration valve) defective.
• Replace the regeneration
NO
valve of the boom control
valve.
check".
40-500 18 PC200, 200LC, 220, 220LC-8M0

H-6 Boom speed is low or power is insufficient SEN06139-01
Inspection
item
• The state of the lock valve
of the boom control valve
YES is normal.
inspection item.
Boom control
The lock valve of the boom control valve may malfunction. • The lock valve of the
9 valve (Lock
Check it. boom control valve is
valve)
defective.
NO • Replace the lock valve of
the boom control valve.
check".
• The state of the safety
valve for the lock valve, or
the state of the seal is nor-
YES
mal.
inspection item.
Safety valve
The safety valve for the lock valve may malfunction, or the • The safety valve for the
10 for lock valve,
seal may be defective. Check it. lock valve or the seal is
seal
defective.
• Replace the safety valve
NO
for the lock valve or the
seal.
check".
• The state of the suction
valve of the boom control
valve, or the state of the
YES
seal is normal.
valve (suc- The suction valve of the boom control valve may malfunction, • The suction valve of the
11
tion valve), or the seal may be defective. Check it. boom control valve or the
seal seal is defective.
• Replace the suction valve
NO
of the boom control valve
or the seal.
check".
• The state of the safety &
suction valve of the boom
control valve, or the state
YES
of the seal is normal.
valve (safety The safety & suction valve of the boom control valve may • The safety & suction valve
12
& suction malfunction, or the seal may be defective. Check it. of the boom control valve
valve), seal or the seal is defective.
• Replace the safety & suc-
NO
tion valve of the boom
control valve or the seal.
check".
PC200, 200LC, 220, 220LC-8M0 40-500 19

SEN06139-01 H-6 Boom speed is low or power is insufficient
Inspection
item
• The state of the LS shuttle
valve of the L.H. travel
control valve, bucket con-
YES trol valve, or service con-
trol valve is normal.
inspection item.
Each control The LS shuttle valve of the L.H. travel control valve, the valve of the L.H. travel
13 valve (LS bucket control valve, or the service control valve may mal- control valve, bucket con-
shuttle valve) function. Check it. trol valve, or service con-
trol valve is defective.
• Replace the LS shuttle
NO
control valve, bucket con-
trol valve, or service con-
trol valve.
check".
• The boom cylinder may be
14 inspection • Replace the boom cylin-
item der.
check".
YES
40-500 20 PC200, 200LC, 220, 220LC-8M0

H-7 Arm speed is low or power is insufficient SEN06139-01
H-7 Arm speed is low or power is insufficient

Failure Arm speed or power is low.
Related infor-
mation
Inspection
item
• The state of the L.H. PPC
YES
inspection item.
L.H. PPC L.H. work equipment control
1 valve (Arm PPC valve output pressure • The L.H. PPC valve is
lever defective.
circuit)
0 MPa • Replace the L.H. PPC
NEUTRAL NO
{0 kg/cm2} valve.
Arm IN 2.84 to 3.43 MPa • Proceed to "Repair
Arm OUT {29 to 35 kg/cm2} check".

it.
NO
main EPC valve.
check".
inspection item.
Merge-divider
LS-EPC valve
NO
LS-EPC valve.
check".
YES is normal.
inspection item.
Merge-divider
main valve
valve is defective.
NO
main valve.
check".
PC200, 200LC, 220, 220LC-8M0 40-500 21

SEN06139-01 H-7 Arm speed is low or power is insufficient
Inspection
item
YES normal.
inspection item.
Merge-divider
LS valve
valve is defective.
NO
LS valve.
check".
the arm control valve is
YES normal.
inspection item.
Arm control
6 The spool of the arm control valve may malfunction. Check it. • The spool of the arm con-
valve (Spool)
trol valve is defective.
NO
arm control valve.
check".
arm control valve is nor-
YES
mal.
Arm control inspection item.
valve (Pres- The pressure compensation valve of the arm control valve • The pressure compensa-
7
sure compen- may malfunction. Check it. tion valve of the arm con-
sation valve) trol valve is defective.
NO
arm control valve.
check".
tion valve of the arm con-
YES trol valve is normal.
inspection item.
Arm control • The regeneration valve of
The regeneration valve of the arm control valve may malfunc-
8 valve (Regen- the arm control valve is
tion. Check it.
eration valve) defective.
• Replace the regeneration
NO
valve of the arm control
valve.
check".
40-500 22 PC200, 200LC, 220, 220LC-8M0

H-7 Arm speed is low or power is insufficient SEN06139-01
Inspection
item
• The state of the quick
return valve of the arm
inspection item.
Arm control • The quick return valve of
The quick return valve of the arm control valve may malfunc-
9 valve (Quick the arm control valve is
tion. Check it.
return valve) defective.
• Replace the quick return
NO
valve.
check".
valve for the lock valve, or
YES
mal.
inspection item.
Safety valve
The safety valve for the lock valve may malfunction, or the • The safety valve for the
10 for lock valve,
seal may be defective. Check it. lock valve or the seal is
seal
defective.
NO
for the lock valve or the
seal.
check".
valve, or the state of the
YES
seal is normal.
valve (suc- The suction valve of the arm control valve may malfunction, • The suction valve of the
11
tion valve), or the seal may be defective. Check it. arm control valve or the
seal seal is defective.
• Replace the suction valve
NO
of the arm control valve or
the seal.
check".
suction valve of the arm
YES
valve (safety The safety & suction valve of the arm control valve may mal- • The safety & suction valve
12
& suction function, or the seal may be defective. Check it. of the arm control valve or
valve), seal the seal is defective.
NO
tion valve of the arm con-
trol valve or the seal.
check".
PC200, 200LC, 220, 220LC-8M0 40-500 23

SEN06139-01 H-7 Arm speed is low or power is insufficient
Inspection
item
valve of the R.H. travel
control valve, the arm con-
trol valve, the L.H. travel
control valve, the bucket
YES
control valve, or the ser-
vice control valve is nor-
mal.
inspection item.
The LS shuttle valve of the R.H. travel control valve, the valve of the R.H. travel
Each control control valve, the arm con-
boom control valve, the L.H. travel control valve, the bucket
13 valve (LS trol valve, the L.H. travel
control valve, or the service control valve may malfunction.
shuttle valve) control valve, the bucket
Check it.
control valve, or the ser-
vice control valve is defec-
tive.
NO • Replace the LS shuttle
valve of the R.H. travel
control valve, arm control
valve, L.H. travel control
valve, bucket control
valve, or service control
valve.
check".
Recheck of • The arm cylinder may be

14 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the arm cylinder.
item
check".
YES
40-500 24 PC200, 200LC, 220, 220LC-8M0

H-8 Bucket speed is low or power is insufficient SEN06139-01
H-8 Bucket speed is low or power is insufficient

Failure Bucket speed or power is low.
Related infor-
mation
Inspection
item
• The state of the R.H. PPC
YES
inspection item.
R.H. PPC R.H. work equipment control
1 valve (Bucket PPC valve output pressure • The R.H. PPC valve is
lever defective.
circuit)
0 MPa • Replace the R.H. PPC
NEUTRAL NO
{0 kg/cm2} valve.
Bucket CURL 2.84 to 3.43 MPa • Proceed to "Repair
Bucket DUMP {29 to 35 kg/cm2} check".

the bucket control valve is
YES normal.
inspection item.
Bucket control The spool of the bucket control valve may malfunction. Check
2 • The spool of the bucket
valve (Spool) it.
NO
bucket control valve.
check".
bucket control valve is nor-
YES
mal.
Bucket control inspection item.
valve (Pres- The pressure compensation valve of the bucket control valve • The pressure compensa-
3
sure compen- may malfunction. Check it. tion valve of the bucket
NO
bucket control valve.
check".
suction valve of the bucket
YES
Bucket control inspection item.
valve (safety The safety & suction valve of the bucket control valve may • The safety & suction valve
4
& suction malfunction, or the seal may be defective. Check it. of the bucket control valve
valve), seal or the seal is defective.
NO
tion valve of the bucket
control valve or the seal.
check".
PC200, 200LC, 220, 220LC-8M0 40-500 25

SEN06139-01 H-8 Bucket speed is low or power is insufficient
Inspection
item
valve of the service control
inspection item.
Service con- • The LS shuttle valve of the
The LS shuttle valve of the service control valve may mal-
5 trol valve (LS service control valve is
function. Check it. (With service valve mounted)
shuttle valve) defective.
NO
valve of the service control
valve.
check".
• The bucket cylinder may
6 inspection • Replace the bucket cylin-
item der.
check".
YES
40-500 26 PC200, 200LC, 220, 220LC-8M0

H-9 Work equipment does not move in single operation SEN06139-01
H-9 Work equipment does not move in single operation

(1) Boom does not move in a single operation.
Failure (2) Arm does not move in a single operation.
(3) Bucket does not move in a single operation
Related infor-
mation
Inspection
item
• The state of the PPC valve
YES
inspection item.
1 PPC valve Work equipment control lever PPC valve output pressure • The PPC valve is defec-
0 MPa tive.
NEUTRAL
{0 kg/cm2} NO • Replace the PPC valve.
2.84 to 3.43 MPa • Proceed to "Repair
Operation check".
{29 to 35 kg/cm2}
• The spool of the control
Recheck of valve may be defective.
2 inspection • Replace the spool of the
item control valve.
check".
YES
PC200, 200LC, 220, 220LC-8M0 40-500 27

SEN06139-01 H-10 Hydraulic drift of work equipment is large
H-10 Hydraulic drift of work equipment is large

Failure (1) Hydraulic drift of boom is significant.
Related infor-
mation
Inspection
item
• The state of the boom cyl-
a Prepare by stopping the engine, then perform trouble- inder is normal.
YES
inspection item.
1 Boom cylinder R.H. work equipment control Boon cylinder leakage • The boom cylinder is
lever amount defective.
• Replace the boom cylin-
NO
der.
Boom RAISE relief 20 cc/min • Proceed to "Repair
check".
• The state of the seal of the
lock valve of the boom
inspection item.
Seal of boom • The seal of the lock valve
The seal of the lock valve of the boom control valve may be
2 control valve of the boom control valve
defective. Check it.
(lock valve) is defective.
• Replace the seal of the
NO
lock valve of the boom
control valve.
check".
• The seal of the safety
valve for the lock valve
3 inspection • Replace the seal of the
item safety valve for the lock
valve.
check".
YES
40-500 28 PC200, 200LC, 220, 220LC-8M0

H-10 Hydraulic drift of work equipment is large SEN06139-01
Failure (2) Hydraulic drift of arm is significant.

Related infor-
mation
Inspection
item
• The state of the arm cylin-
a Prepare by stopping the engine, then perform trouble- der is normal.
YES
inspection item.
1 Arm cylinder L.H. work equipment control • The arm cylinder is defec-
Arm cylinder leakage amount
lever tive.
NO • Replace the arm cylinder.
Arm IN relief 20 cc/min • Proceed to "Repair
check".
spool of the arm control
inspection item.
Seal of arm • The seal of the spool of
The seal of the spool of the arm control valve may be defec-
2 control valve the arm control valve is
tive. Check it.
(spool) defective.
NO
spool of the arm control
valve.
check".
pressure compensation
YES
valve is normal.
inspection item.
Seal of arm
control valve • The seal of the pressure
The seal of the pressure compensation valve of the arm con- compensation valve of the
3 (pressure
trol valve may be defective. Check it. arm control valve is defec-
compensa-
tion valve) tive.
NO
valve.
check".
The seal of the suction valve of the arm control valve may be inspection item.
Seal of arm
defective. Check it. • The seal of the suction
control valve
4 a Interchange with the suction valve of a control valve other valve of the arm control
(suction
than the arm control valve. Check the phenomenon since valve is defective.
valve)
it changes, then make an appropriate judgment. • Replace the seal of the
NO
control valve.
check".
PC200, 200LC, 220, 220LC-8M0 40-500 29

SEN06139-01 H-10 Hydraulic drift of work equipment is large
Inspection
item
• The seal of the safety
valve for the lock valve
item safety valve for the lock
valve.
check".
YES
Failure (3) Hydraulic drift of bucket is significant.

Related infor-
mation
Inspection
item
a Prepare by stopping the engine, then perform trouble- cylinder is normal.
YES
inspection item.
Bucket cylin- L.H. work equipment control • The bucket cylinder is
1 Leakage of bucket cylinder
der lever defective.
• Replace the bucket cylin-
NO
der.
Bucket CURL relief 20 cc/min • Proceed to "Repair
check".
spool of the bucket con-
YES trol valve is normal.
inspection item.
Seal of bucket • The seal of the spool of
The seal of the spool of the bucket control valve may be
2 control valve the bucket control valve is
(spool) defective.
NO
spool of the bucket con-
trol valve.
check".
40-500 30 PC200, 200LC, 220, 220LC-8M0

H-10 Hydraulic drift of work equipment is large SEN06139-01
Inspection
item
valve of the bucket control
YES
valve is normal.
inspection item.
Seal of bucket
The seal of the pressure compensation valve of the bucket compensation valve of the
3 (pressure
control valve may be defective. Check it. bucket control valve is
compensa-
tion valve) defective.
NO
valve.
check".
• The seal of the safety &
suction valve of the bucket
Recheck of control valve is defective.
item safety & suction valve of
the bucket control valve.
check".
YES
PC200, 200LC, 220, 220LC-8M0 40-500 31

SEN06139-01 H-11 Time lag of work equipment is large
H-11 Time lag of work equipment is large

Failure Time lag of work equipment is large.
Related infor-
mation
Inspection
item
YES
inspection item.
LS-EPC valve out-
defective.
Approx. 2.9 MPa
• Clean or replace the
LS-EPC valve.
kg/cm2}
0 MPa check".
Hi Operation
{0 kg/cm2}
tion valve of the control
valve (Regen-
The regeneration valve of the control valve may malfunction. • The regeneration valve of
2 eration valve)
Check it. the control valve is defec-
[Boom and
arm only] tive.
NO • Replace the regeneration
valve of the control valve.
check".
suction valve of the control
The safety & suction valve of the control valve may malfunc- • Proceed to the next
tion. Check it. inspection item.
Control valve a Interchange with the safety & suction valve of the appro- • The safety & suction valve
3 (Safety & suc- priate control valve. Check the phenomenon since it of the control valve is
tion valve) changes, then make an appropriate judgment. (However, defective.
the set pressure is only different for the boom head cir- • Replace the safety & suc-
cuit.) NO
valve.
check".
• The pressure compensa-
Recheck of valve may be defective.
4 inspection • Replace the pressure
item compensation valve of the
control valve.
check".
1. Turn the starting switch off. YES Repairs are completed.
2. Connect all the component parts.
5 Repair check 3. Start the engine. Return to the first inspection
4. Set the working mode to the power mode (P). NO
item.
40-500 32 PC200, 200LC, 220, 220LC-8M0

H-12 When certain work equipment is relieved hydraulically, other work equipment moves SEN06139-01
H-12 When certain work equipment is relieved hydraulically, other work

equipment moves
Failure When single work equipment is relieved hydraulically, other work equipment will move.
Related infor-
-
mation
Inspection
item
• The state of the seal of
valve of the control valve
YES in the operating side is
normal.
Seal of con- inspection item.
trol valve
(pressure The seal of the pressure compensation valve of the control • The seal of the pressure
1 compensation valve of the
compensa- valve in the operating side may be defective. Check it.
tion valve) in control valve in the operat-
operating side ing side is defective.
NO
valve of the control valve
in the operating side.
check".
YES
2 Repair check
PC200, 200LC, 220, 220LC-8M0 40-500 33

SEN06139-01 H-13 One-touch power maximization function does not work
H-13 One-touch power maximization function does not work

Failure One-touch power maximization function does not operate.
Related infor-
mation
Inspection
item
relief solenoid valve is nor-
YES mal.
inspection item.
2-stage relief 2-stage relief solenoid valve
1 Swing lock switch • The 2-stage relief solenoid
solenoid valve output pressure valve is defective.
0 MPa • Replace the 2-stage relief
OFF NO
ON check".
{Approx. 30 kg/cm2}
• The main relief valve may
2 inspection • Replace the main relief
item valve.
check".
item.
40-500 34 PC200, 200LC, 220, 220LC-8M0

H-14 When combining operations of work equipment, equipment subject to heavier loads moves slower SEN06139-01
H-14 When combining operations of work equipment, equipment

subject to heavier loads moves slower
Failure When combining operations of work equipment, equipment subject to heavier loads moves slower.
Related infor-
-
mation
Inspection
item
The pressure compensation valve of the control valve in the control valve in the
YES
low-load side may malfunction. Check it. low-load side is normal.
inspection item.
High-load Low-load
Combination of multi-operations
Control valve side side
(pressure • The pressure compensa-
Boom
1 compensa- Boom RAISE + Arm IN Arm IN tion valve of the control
RAISE
tion valve) in valve in the low-load side
Boom is defective.
low-load side Boom RAISE + Arm OUT Arm OUT
RAISE • Replace the pressure
NO
Boom Bucket compensation valve of the
Boom RAISE + Bucket CURL control valve in the
RAISE CURL
low-load side.
Bucket
Arm OUT + Bucket CURL Arm OUT • Proceed to "Repair
CURL
check".
Boom
Boom LOWER + Arm OUT Arm OUT
LOWER
YES
2 Repair check
PC200, 200LC, 220, 220LC-8M0 40-500 35

SEN06139-01 H-15 Boom RAISE is slow in Swing + Boom RAISE operation
H-15 Boom RAISE is slow in Swing + Boom RAISE operation

Failure Boom RAISE is slow during the Swing + Boom RAISE operation.
Related infor- If a single operation of boom RAISE is also slow, first perform troubleshooting for "H-6 Boom speed or
mation power is low".
Inspection
item
• The state of the LS selec-
tor valve of the swing con-
trol valve, or the state of
YES
the seal is normal.
Swing control inspection item.
valve (LS LS selector valve of swing control valve may malfunction or • The LS selector valve of
1
selector sealing may be defective. Check it. the swing control valve or
valve), seal the seal is defective.
• Replace the LS selector
NO
valve of the swing control
valve or the seal.
check".
YES
2 Repair check
40-500 36 PC200, 200LC, 220, 220LC-8M0

H-16 When combining swing and travel operations, travel speed drops significantly SEN06139-01
H-16 When combining swing and travel operations, travel speed drops
significantly
Failure When combining swing and travel operations, travel speed drops significantly.
Related infor- If the single operation of travel is also slow, first perform troubleshooting for "H-18 Travel speed is
mation slow.".
Inspection
item
control valve or the swing
YES
control valve is normal.
inspection item.
Each control • The state of the LS shuttle

The LS shuttle valve of the L.H. travel control valve or the valve of the L.H. travel
1 valve (LS
swing control valve may malfunction. Check it. control valve or the swing
shuttle valve)
NO
control valve or the swing
control valve.
check".
2 Repair check Return to the first inspection
3. Start the engine. NO
4. Does this failure recur? item.
PC200, 200LC, 220, 220LC-8M0 40-500 37

SEN06139-01 H-17 Travel deviation is detected
H-17 Travel deviation is detected

Failure Travel deviation is detected.
Related infor-
mation
Inspection
item
a Prepare by stopping the engine, then perform trouble- PPC valve is normal.
YES
inspection item.
Travel PPC Travel lever PPC valve output pressure • The travel PPC valve is
1
valve defective.
0 MPa
NEUTRAL • Replace the travel PPC
{0 kg/cm2} NO
valve.
Forward 2.84 to 3.43 MPa • Proceed to "Repair
Reverse {29 to 35 kg/cm2} check".
YES mal.
valve Control lever
NO
check".
YES
inspection item.

1 NO
check".
Check it.
junction solenoid valve is
YES normal.
inspection item.
Travel junc-
4 tion solenoid Travel junction solenoid valve • The travel junction sole-
Travel lever
valve output pressure noid valve is defective.
0 MPa • Replace the travel junction
Both NEUTRAL NO
Single operation check".
{Approx. 30 kg/cm2}
40-500 38 PC200, 200LC, 220, 220LC-8M0

H-17 Travel deviation is detected SEN06139-01
Inspection
item
junction valve is normal.
YES
inspection item.
Travel junc- • The travel junction valve is
5 The travel junction valve may malfunction. Check it.
tion valve defective.
NO
valve.
check".
the travel control valve is
YES normal.
inspection item.
Travel control The spool of the travel control valve may malfunction. Check
6 • The spool of the travel
valve (Spool) it.
NO
travel control valve.
check".
a Prepare by stopping the engine, then perform trouble- motor is normal.
YES
inspection item.
7 Travel motor Travel lever Leakage from travel motor • The travel motor is defec-
tive.
NO • Replace the travel motor.
Travel relief 27.2 l/min • Proceed to "Repair
check".
Recheck of • The final drive may be

8 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the final drive.
item
check".
item.
PC200, 200LC, 220, 220LC-8M0 40-500 39

SEN06139-01 H-18 Travel speed is slow
H-18 Travel speed is slow

Failure Travel speed is slow.
Related infor-
mation
Inspection
item
YES
inspection item.
Travel PPC Travel lever PPC valve output pressure • The travel PPC valve is
1
valve defective.
0 MPa
NEUTRAL • Replace the travel PPC
{0 kg/cm2} NO
valve.
Forward 2.84 to 3.43 MPa • Proceed to "Repair
Reverse {29 to 35 kg/cm2} check".
YES mal.
valve Control lever
NO
check".
YES
inspection item.
LS-EPC valve out-
defective.
Approx. 2.9 MPa
valve.
kg/cm2}
0 MPa check".
Hi Operation
{0 kg/cm2}
YES normal.
inspection item.
valve (Spool) it.
NO
check".
40-500 40 PC200, 200LC, 220, 220LC-8M0

H-18 Travel speed is slow SEN06139-01
Inspection
item
travel control valve is nor-
YES
mal.
Travel control inspection item.
valve (Pres- Check as operation of the pressure compensation valve of • The pressure compensa-
5
sure compen- the travel control valve may be defective. tion valve of the travel
NO
check".
valve of the travel control
inspection item.
Travel control
The suction valve of the travel control valve may malfunction. • The suction valve of the
6 valve (Suc-
Check it. travel control valve is
tion valve)
defective.
NO • Replace the suction valve
of the travel control valve.
check".
inspection item.
Travel control • The LS shuttle valve of the
The LS shuttle valve of the travel control valve may malfunc-
7 valve (LS travel control valve is
tion. Check it.
NO
valve.
check".
YES
inspection item.
tive.
check".

9 inspection
item
check".
PC200, 200LC, 220, 220LC-8M0 40-500 41

SEN06139-01 H-18 Travel speed is slow
Inspection
item
YES
40-500 42 PC200, 200LC, 220, 220LC-8M0

H-19 Machine does not steer well or steering power is low SEN06139-01
H-19 Machine does not steer well or steering power is low

Failure Machine does not steer well or steering power is low.
Related infor-
mation
Inspection
item
• The state of the steering
spool of the travel PPC
inspection item.
Travel PPC
1 valve (Steer- PPC valve output pressure • The steering spool of the
Travel lever
ing spool) (Steering) travel PPC valve is defec-
0 MPa tive.
Both NEUTRAL NO • Replace the steering spool
{0 kg/cm2}
of the travel PPC valve.
2.84 to 3.43 MPa • Proceed to "Repair
Single operation
{29 to 35 kg/cm2} check".
junction solenoid valve is
YES normal.
inspection item.
Travel junc-
2 tion solenoid Travel junction solenoid valve • The travel junction sole-
Travel lever
valve output pressure noid valve is defective.
0 MPa • Replace the travel junction
Both NEUTRAL NO
Single operation check".
{Approx. 30 kg/cm2}
junction valve is normal.
YES
inspection item.
Travel junc- • The travel junction valve is
3 The travel junction valve may malfunction. Check it.
tion valve defective.
NO
valve.
check".
it.
NO
main EPC valve.
check".
PC200, 200LC, 220, 220LC-8M0 40-500 43

SEN06139-01 H-19 Machine does not steer well or steering power is low
Inspection
item
inspection item.
Merge-divider
LS-EPC valve
NO
LS-EPC valve.
check".
YES is normal.
inspection item.
Merge-divider
main valve
valve is defective.
NO
main valve.
check".
YES normal.
inspection item.
Merge-divider
LS valve
valve is defective.
NO
LS valve.
check".
YES normal.
inspection item.
valve (Spool) it.
NO
check".
40-500 44 PC200, 200LC, 220, 220LC-8M0

H-19 Machine does not steer well or steering power is low SEN06139-01
Inspection
item
travel control valve is nor-
YES
mal.
Travel control inspection item.
9
sure compen- the travel control valve may be defective. tion valve of the travel
NO
check".
inspection item.
Travel control
The suction valve of the travel control valve may malfunction. • The suction valve of the
10 valve (Suc-
Check it. travel control valve is
tion valve)
defective.
NO • Replace the suction valve
of the travel control valve.
check".
inspection item.
Bucket control • The LS shuttle valve of the
The LS shuttle valve of the bucket control valve may malfunc-
11 valve (LS bucket control valve is
tion. Check it.
NO
valve.
check".
LS pressure pickup port
(control valve side) check
YES
valve is normal.
Seal of the LS inspection item.
pressure • The seal of the LS pres-
pickup port The seal of the LS pressure pickup port (control valve side) sure pickup port (control
12
(control valve check valve may be defective. Check it. valve side) check valve is
side) check defective.
valve • Replace the seal of the LS
NO
pressure pickup port (con-
trol valve side) check
valve.
check".
PC200, 200LC, 220, 220LC-8M0 40-500 45

SEN06139-01 H-19 Machine does not steer well or steering power is low
Inspection
item
safety valve for the travel
YES motor is normal.
The seal of the safety valve for travel motor may be defective. inspection item.
Check it.
Seal of travel • The seal of the safety
a If necessary, you can replace the safety valve between
13 motor (safety valve for the travel motor
the forward and reverse sides of the same motor or
valve) is defective.
between the left and right motors to check the phenome-
non as it changes and make an appropriate judgment. • Replace the seal of the
NO
motor.
check".
• The seal of the check
valve for the travel motor
item check valve for the travel
motor.
check".
YES
40-500 46 PC200, 200LC, 220, 220LC-8M0

H-20 Travel speed does not change, or travel speed is too slow or too fast SEN06139-01
H-20 Travel speed does not change, or travel speed is too slow or too
fast
Failure Travel speed does not change, or travel speed is too slow or too fast.
Related infor-
mation
Inspection
item
a Perform troubleshooting when the engine is running at a valve is normal.
YES
high idle speed. • Proceed to the next
inspection item.
Monitoring code:
Travel speed Travel lever
01500
663 mA
(PC200-8M0)
Lo (*)
578 mA
(PC220-8M0)
Operation 424 mA
(PC200-8M0)
Mi
641 mA
(PC220-8M0)
1 LS-EPC valve • The LS-EPC valve is
Hi 0 mA defective.
a Travel speed of the Lo setting can be adjusted using • Replace the LS-EPC
NO
adjustment function of the machine monitor. If it is valve.
changed from the default value, the value changes • Proceed to "Repair
slightly. check".
LS-EPC valve out-
Travel speed Travel lever
put pressure
Approx. 2.9 MPa
Lo NEUTRAL {Approx. 30
kg/cm2}
0 MPa
Hi Operation
{0 kg/cm2}
speed selector solenoid
inspection item.
Travel speed Travel speed selec-
2 selector sole- Travel speed Travel lever tor solenoid valve • The travel speed selector
noid valve output pressure solenoid valve is defec-
tive.
0 MPa
Lo NEUTRAL NO • Replace the travel speed
{0 kg/cm2}
selector solenoid valve.
Hi Operation {Approx. 30 check".
kg/cm2}
PC200, 200LC, 220, 220LC-8M0 40-500 47

SEN06139-01 H-20 Travel speed does not change, or travel speed is too slow or too fast
Inspection
item
• The speed selector part of
the travel motor may be
item speed selector part of the
travel motor.
check".
YES
40-500 48 PC200, 200LC, 220, 220LC-8M0

H-21 One track does not move SEN06139-01
H-21 One track does not move

Failure One track does not move.
Related infor-
mation
Inspection
item
suction valve of the travel
inspection item.
Seal of travel
control valve The seal of the suction valve of the travel control valve may • The seal of the suction
1 valve of the travel control
(Suction be defective. Check it.
valve) valve is defective.
NO
suction valve of the travel
control valve.
check".
The seal of the safety valve for travel motor may be defective. inspection item.
Check it.
Seal of travel • The seal of the safety
a If necessary, you can replace the safety valve between
2 motor (safety valve for the travel motor
NO
motor.
check".
check valve for the travel
The seal of the check valve for the travel motor may be defec- inspection item.
tive. Check it.
Seal of travel • The seal of the check
a If necessary, you can replace the check valve between
3 motor (check valve for the travel motor
NO
check valve for the travel
motor.
check".
• The state of the parking
brake of the travel motor is
YES normal.
Travel motor inspection item.
The parking brake of the travel motor may malfunction. Check
4 (Parking • The parking brake of the
it.
brake) travel motor is defective.
• Replace the parking brake
NO
of the travel motor.
check".
PC200, 200LC, 220, 220LC-8M0 40-500 49

SEN06139-01 H-21 One track does not move
Inspection
item
YES
inspection item.
tive.
check".

6 inspection
item
check".
item.
40-500 50 PC200, 200LC, 220, 220LC-8M0

H-22 Machine does not swing SEN06139-01
H-22 Machine does not swing

Failure (1) Upper structure does not swing to the right or left
Related infor-
mation
Inspection
item
parking brake solenoid
inspection item.
Swing park- Swing parking
L.H. work equip- • The swing parking brake
1 ing brake Travel lever brake solenoid out-
ment control lever solenoid valve is defec-
solenoid valve put pressure
tive.
0 MPa
NEUTRAL NEUTRAL NO • Replace the swing parking
{0 kg/cm2}
brake solenoid valve.
Swing LEFT
Operation {Approx. 30 check".
Swing RIGHT
kg/cm2}
the swing control valve is
YES normal.
inspection item.
Swing control The spool of the swing control valve may malfunction. Check
2 • The spool of the swing
valve (Spool) it.
NO
swing control valve.
check".
brake of the swing motor
YES is normal.
Swing motor inspection item.
The parking brake of the swing motor may malfunction.
Check it.
brake) swing motor is defective.
NO
of the swing motor.
check".
valve for the swing motor
YES is normal.
inspection item.
L.H. work equip- Swing relief pres- • The safety valve for the
Swing lock switch
Swing motor ment control lever sure swing motor is defective.
4 • Adjust the safety valve for
(Safety valve) Swing hydraulic 28.9 to 32.9 MPa
ON the swing motor.
relief {295 to 335 kg/cm2}
NO
If oil pressure cannot be adjusted to a normal level, a mal- adjustment, replace the
function and an internal defect of the safety valve for the valve.
swing motor may occur. Check it. • Proceed to "Repair
check".
PC200, 200LC, 220, 220LC-8M0 40-500 51

SEN06139-01 H-22 Machine does not swing
Inspection
item
YES
inspection item.
5 Swing motor L.H. work equip- Leakage from • The swing motor is defec-
Swing lock switch
ment control lever swing motor tive.
NO • Replace the swing motor.
Swing hydraulic
ON Max. 10 l/min • Proceed to "Repair
relief check".
• The swing machinery may
6 inspection • Replace the swing
item machinery.
check".
YES
Failure (2) The upper structure only swing to the right or left
Related infor-
mation
Inspection
item
YES
inspection item.
Swing PPC L.H. work equipment control • The swing PPC valve is
1 PPC valve output pressure
valve lever defective.
0 MPa • Replace the swing PPC
NEUTRAL NO
{0 kg/cm2} valve.
Swing LEFT 2.84 to 3.43 MPa • Proceed to "Repair
Swing RIGHT {29 to 35 kg/cm2} check".

YES normal.
inspection item.
valve (Spool) it.
NO
check".
40-500 52 PC200, 200LC, 220, 220LC-8M0

H-22 Machine does not swing SEN06139-01
Inspection
item
valve of the swing motor is
YES normal.
The suction valve of the swing motor may malfunction. Check • Proceed to the next
it. inspection item.
Swing motor
a If necessary, you can interchange the suction valves of
3 (Suction • The suction valve of the
the swing motors in the left and right sides to check the
valve) swing motor is defective.
phenomenon as it changes and make an appropriate
judgment. • Replace the suction valve
NO
of the swing motor.
check".
• The check valve of the
Recheck of swing motor may be
4 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the check valve
item
of the swing motor.
check".
YES
PC200, 200LC, 220, 220LC-8M0 40-500 53

SEN06139-01 H-23 Swing acceleration or swing speed is low
H-23 Swing acceleration or swing speed is low

Failure (1) Swing acceleration or swing speed is low in both directions (right and left).
Related infor-
mation
Inspection
item
YES normal.
inspection item.
valve (Spool) it.
NO
check".
• The states of the LS shut-
tle valves of all the control
YES valves are normal.
inspection item.
All control • The LS shuttle valves of
The LS shuttle valves of all the control valves may malfunc-
2 valves (LS all the control valves are
tion. Check them.
NO
valves of all the control
valves.
check".
brake of the swing motor
YES is normal.
Swing motor inspection item.
The parking brake of the swing motor may malfunction.
Check it.
brake) swing motor is defective.
NO
of the swing motor.
check".
YES is normal.
inspection item.
Swing lock switch
ON the swing motor.
NO
check".
40-500 54 PC200, 200LC, 220, 220LC-8M0

H-23 Swing acceleration or swing speed is low SEN06139-01
Inspection
item
YES
inspection item.
5 Swing motor L.H. work equip- Leakage from • The swing motor is defec-
Swing lock switch
ment control lever swing motor tive.
NO • Replace the swing motor.
Swing hydraulic
ON Max. 10 l/min • Proceed to "Repair
relief check".
item machinery.
check".
YES
Failure (2) The swing acceleration performance is poor or the swing speed is slow in only one direction.
Related infor-
mation
Inspection
item
YES
inspection item.
NEUTRAL NO
{0 kg/cm2} valve.

YES normal.
inspection item.
valve (Spool) it.
NO
check".
PC200, 200LC, 220, 220LC-8M0 40-500 55

SEN06139-01 H-23 Swing acceleration or swing speed is low
Inspection
item
swing control valve is nor-
YES
mal.
Swing control inspection item.
3
sure compen- swing control valve may be defective. tion valve of the swing
NO
check".
YES normal.
Swing motor
NO
of the swing motor.
check".
5 inspection
item
of the swing motor.
check".
item.
40-500 56 PC200, 200LC, 220, 220LC-8M0

H-24 Upper structure overruns excessively when it stops swinging SEN06139-01
H-24 Upper structure overruns excessively when it stops swinging

Failure (1) Upper structure overruns excessively when it stops swinging (both right and left).
Related infor-
mation
Inspection
item
YES is normal.
inspection item.
Swing lock switch
ON the swing motor.
NO
check".
Recheck of • The swing motor may be

2 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the swing motor.
item
check".
YES
PC200, 200LC, 220, 220LC-8M0 40-500 57

SEN06139-01 H-24 Upper structure overruns excessively when it stops swinging
(2) The upper structure overruns excessively when it stops swinging (only one direction either right or
Failure
left).
Related infor-
mation
Inspection
item
YES
inspection item.
NEUTRAL NO
{0 kg/cm2} valve.

PPC slow return valve is
YES normal.
The swing PPC slow return valve may malfunction. Check it. • Proceed to the next
Swing PPC a If necessary, you can interchange the swing PPC slow inspection item.
2 slow return return valves in the left and right sides to check the phe- • The swing PPC slow
valve nomenon as it changes and make an appropriate judg- return valve is defective.
ment. • Replace the swing PPC
NO
slow return valve.
check".
YES normal.
inspection item.
valve (Spool) it.
NO
check".
YES normal.
Swing motor
NO
of the swing motor.
check".
40-500 58 PC200, 200LC, 220, 220LC-8M0

H-24 Upper structure overruns excessively when it stops swinging SEN06139-01
Inspection
item
5 inspection
item
of the swing motor.
check".
item.
PC200, 200LC, 220, 220LC-8M0 40-500 59

SEN06139-01 H-25 Shock is significant when upper structure stops swinging
H-25 Shock is significant when upper structure stops swinging

Failure Shock is significant when upper structure stops swinging.
Related infor-
mation
Inspection
item
YES
inspection item.
NEUTRAL NO
{0 kg/cm2} valve.

PPC slow return valve is
YES normal.
The swing PPC slow return valve may malfunction. Check it. • Proceed to the next
Swing PPC a If necessary, you can interchange the swing PPC slow inspection item.
2 slow return return valves in the left and right sides to check the phe- • The swing PPC slow
valve nomenon as it changes and make an appropriate judg- return valve is defective.
ment. • Replace the swing PPC
NO
slow return valve.
check".
• The shockless valve of the
3 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the shockless
item
valve of the swing motor.
check".
YES
40-500 60 PC200, 200LC, 220, 220LC-8M0

H-26 An unusual loud noise is heard when the upper structure stops swinging SEN06139-01
H-26 An unusual loud noise is heard when the upper structure stops
swinging
Failure An unusual loud noise is heard when the upper structure stops swinging.
Related infor-
mation
Inspection
item
• The state of the back pres-
sure valve is normal.
YES
inspection item.
Back pres- • The back pressure valve is
1 The back pressure valve may malfunction. Check it.
sure valve defective.
• Replace the back pres-
NO
sure valve.
check".
YES is normal.
inspection item.
Swing motor The safety valve of the swing motor may malfunction. Check
2 • The safety valve for the
(Safety valve) it.
swing motor is defective.
NO
for the swing motor.
check".
YES normal.
Swing motor it. inspection item.
3 (Suction a Interchange the suction valves of the swing motors in the • The suction valve of the
valve) left and right sides. Check the phenomenon since it swing motor is defective.
changes, then make an appropriate judgment. • Replace the suction valve
NO
of the swing motor.
check".
item machinery.
check".
YES
PC200, 200LC, 220, 220LC-8M0 40-500 61

SEN06139-01 H-27 Swing drift on a slope is significant
H-27 Swing drift on a slope is significant

Failure (1) Swing drift on a slope is significant (while parking brake is applied).
• When the swing lock switch is set to ON position or swing parking brake cancel switch is set to
Related infor- NORMAL position, the swing parking brake is applied and the swing system is locked by the disc
mation brake.
• Perform all troubleshooting with the working mode set in the power mode (P).
Inspection
item
parking brake solenoid
inspection item.
Swing park-
1 ing brake L.H. work equipment control Swing parking brake solenoid • The swing parking brake
solenoid valve lever output pressure solenoid valve is defec-
0 MPa tive.
NEUTRAL NO • Replace the swing parking
{0 kg/cm2}
brake solenoid valve.
Swing LEFT Approx. 2.9 MPa • Proceed to "Repair
Swing RIGHT {Approx. 30 kg/cm2} check".
• The parking brake of the
2 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the parking brake
item
of the swing motor.
check".
YES
40-500 62 PC200, 200LC, 220, 220LC-8M0

H-27 Swing drift on a slope is significant SEN06139-01
Failure (2) Swing drift on a slope is significant (while swing parking brake is released).
• The swing parking brake is released and the swing is held only with oil pressure while the swing
Related infor-
parking brake is released.
mation
• Perform all troubleshooting with the working mode set in the power mode (P).
Inspection
item
the swing control valve or
YES
mal.
inspection item.
Swing control
The spool of swing control valve may malfunction, or the seal • The spool of the swing
1 valve (spool),
may be defective. Check it. control valve or the seal is
seal
defective.
• Replace the seal or the
NO
spool of the swing control
valve.
check".
YES
valve is normal.
inspection item.
Seal of swing
The seal of the pressure compensation valve of the swing compensation valve of the
2 (pressure
control valve may be defective. Check it. swing control valve is
compensa-
tion valve) defective.
NO
valve.
check".
safety valve for the swing
inspection item.
Seal of swing • The seal of the safety
The seal of the safety valve for the swing motor may be
3 motor (safety valve for the swing motor
NO
safety valve for the swing
motor.
check".
PC200, 200LC, 220, 220LC-8M0 40-500 63

SEN06139-01 H-27 Swing drift on a slope is significant
Inspection
item
suction valve for the swing
inspection item.
Seal of swing • The seal of the suction
The seal of the suction valve for the swing motor may be
4 motor (suction valve for the swing motor
NO
suction valve for the swing
motor.
check".
check valve for the swing
inspection item.
Seal of swing • The seal of the check
The seal of the check valve for the swing motor may be
5 motor (check valve for the swing motor
NO
check valve for the swing
motor.
check".
• The seal of the shockless
item shockless valve for the
swing motor.
check".
YES
40-500 64 PC200, 200LC, 220, 220LC-8M0

H-28 Attachment circuit cannot be changed SEN06139-01
H-28 Attachment circuit cannot be changed

Attachment mounting specification
Failure Attachment circuit cannot be changed.
• In the attachment mounting specification, the service circuit switches as follows according to the
selected working mode.
1) In ATT mode: The circuit switches to the double-acting circuit and the safety valve becomes the
Related infor- low pressure set.
mation 2) In B mode: The circuit switches to the single-acting circuit and the safety valve becomes the
high pressure set.
• The set pressure of the safety valve switches only in the B port and that of the A port remains in the
low pressure set at all times.
Inspection
item
• The state of the ATT return
selector solenoid valve is
YES normal.
inspection item.
ATT return
1 selector sole- ATT return selector solenoid • The ATT return selector
Working mode
noid valve valve output pressure solenoid valve is defec-
0 MPa tive.
ATT mode NO • Replace the ATT return
{0 kg/cm2}
selector solenoid valve.
B mode
{Approx. 30 kg/cm2} check".
• The state of the ATT return
selector valve is normal.
YES
inspection item.
ATT return • The ATT return selector
2 The ATT return selector valve may malfunction. Check it.
selector valve valve is defective.
• Replace the ATT return
NO
selector valve.
check".
• The safety valve (in the B
port side) of the service
Recheck of control valve may be
3 inspection
2. Can you identify the cause after carrying out a recheck? NO • Replace the safety valve
item
(in the B port side) of the
service control valve.
check".
YES
4 Repair check
PC200, 200LC, 220, 220LC-8M0 40-500 65

SEN06139-01 H-29 Oil flow in the attachment circuit cannot be changed
H-29 Oil flow in the attachment circuit cannot be changed

Attachment mounting specification
Failure Oil flow in the attachment circuit cannot be changed.
• In the attachment mounting specification, the flow rate of the service circuit switches according to
Related infor- the selected user mode.
mation • The flow rate adjustment procedure is different between the ATT mode and the B mode of the work-
ing mode. For details, refer to the "Operation and Maintenance Manual".
Inspection
item
• The state of the ATT oil
flow adjustment EPC
inspection item.
ATT oil flow
The ATT oil flow adjustment EPC valve may malfunction. • The ATT oil flow adjust-
1 adjustment
Check it. ment EPC valve is defec-
EPC valve
tive.
NO • Replace the ATT oil flow
adjustment EPC valve.
check".
• The service PPC valve
2 inspection • Replace the service PPC
item valve.
check".
YES
3 Repair check
40-500 66 PC200, 200LC, 220, 220LC-8M0

H-29 Oil flow in the attachment circuit cannot be changed SEN06139-01
PC200, 200LC, 220, 220LC-8M0 40-500 67

SEN06139-01
© 2018 KOMATSU
All Rights Reserved
40-500 68
SEN06140-00
SEN05991-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
600 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart........................................................................................................ 2

S-1 Startability is poor ................................................................................................................................. 6
S-2 Engine does not start ........................................................................................................................... 7
S-3 Engine does not pick up smoothly........................................................................................................ 10
S-4 Engine stops during operation.............................................................................................................. 11
S-5 Engine runs rough or is unstable.......................................................................................................... 12
S-6 Engine lacks 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 (coolant or fuel in oil).................................................................................................... 20
S-14 Coolant temperature rises too high (overheating) .............................................................................. 21
S-15 Unusual noise is made ....................................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................................... 23
PC200, 200LC, 220, 220LC-8M0 40-600 1

SEN06140-00 Method of using troubleshooting chart
Method of using troubleshooting chart
The troubleshooting chart consists of the "Ques-

tions", "Check items", "Causes", and "Troubleshoot-
ing" blocks.
The Questions and Check items are used to narrow
down high probability causes by simple inspection
or from symptoms without using troubleshooting
tools.
Next, use troubleshooting tools or perform direct in-
spection to check the selected Causes in the order
of probability to determine the real cause according
to the troubleshooting procedure.
Questions:
Questions placed in the sections A and B in the
table on the right are those to be answered by
the customer or operator.
Questions in section A are for basic information
about the failure. Depth and accuracy of their an-
swers to the questions in section B may depend
on their concerns on the machine condition.
Check items:
Check items placed in the section C in the table
on the right are to be simply checked by the tech-
nician to select highly probable causes.
Causes:
Various causes are listed is this block.
The technician will be able to narrows down the
probable causes by taking the actions listed in
the blocks A, B, and C.
Troubleshooting:
This section includes various items of trouble-
shooting that are performed in order to verify the
results of the diagnosis made by asking the
questions and inspecting the machine. The trou-
bleshooting is performed in order from the most
probable one by applying troubleshooting tools
or direct inspection.
40-600 2 PC200, 200LC, 220, 220LC-8M0

Method of using troubleshooting chart SEN06140-00
This troubleshooting chart marks the content of the questions and check items with E, Q or w according to
their closer relationship with the causes.
E: Reference information for estimation of the cause
Q: Information and inspection result that indicate the cause of the failure
w: A cause particularly probable among those marked with Q above.
a Count the priority level of each marking as w > Q when determining the cause.
Don't count E when determining the cause. The item with this marking may be counted, however, if no
difference is present than this and the cause cannot be determined.
PC200, 200LC, 220, 220LC-8M0 40-600 3

SEN06140-00 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 3 items to be the causal symptoms; [Color of exhaust gas gradually became
black], [Power was lost gradually], and [Dust indicator indicates a red zone].
40-600 4 PC200, 200LC, 220, 220LC-8M0

Method of using troubleshooting chart SEN06140-00
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
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, 220, 220LC-8M0 40-600 5

SEN06140-00 S-1 Startability is poor
S-1 Startability is poor
General causes why startability is poor Cause
Leakage or clogging of fuel piping or air in the fuel piping

q Defective electrical system
q Insufficient supply of fuel
q Insufficient intake of air
q Improper selection of fuel
a The common rail fuel injection system (CRI) controls the fuel injection timing
Clogged air breather hole in fuel tank cap

Defective contact of valve with valve seat
electrically. Accordingly, even if the engine is cranked properly, the engine
Defective alternator (generator section)

Defective alternator (regulator section)
may not start until the crankshaft rotates two turns under the most disadvan-
Stuck or seized supply pnmp pluger

tageous condition. This phenomenon does not mean a problem, however.
Defective intake air heater system
Defective or deteriorated battery

Clogged air cleaner element
Worn piston ring or cylinder
Clogging of fuel filter
Defective injector
Check recent repair history.
Machine opera-
Operated for long period E E E
tion hours
Starting perfor- Became worse gradually Q w w Q
w w
Questions
mance Engine starts easily when warm.

Fuel other than specified one is used Q Q Q
Filters are not replaced as indicated in the Operation and Maintenance Man-
w w Q Q
ual.
Engine oil must be added more frequently. w
When engine is preheated or when temperature is low, preheating monitor
w
does not indicate proper functioning of preheating system.
During operation, charge level monitor indicates abnormal charge. w w
Dust indicator indicates a red zone w
Air breather hole in fuel tank cap is clogged. w
Fuel leaks from fuel piping. w Q
If priming pump is operated, no resistance is felt or it is heavy. w Q
Starting motor cranks engine slowly. w
When engine is Even if air bleeding plug in fuel filter head is removed, fuel
w
cranked with does not flow out.
Check items
starting motor, If spill hose from injector is disconnected, little fuel spills. w
When exhaust manifold is touched immediately after starting engine, temper-
w
ature 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
Check air cleaner. q
When compression pressure is measured, it is found to be low. q q
When air is bled from fuel system, air comes out. q
q
Troubleshooting
Check fuel filter.

Perform troubleshooting for "Supply pump pressure low error” according to
q
failure code (*1).
Even if a cylinder is cut out, engine speed does not change. q
Even if starting switch is turned to HEAT, intake air heater mount does not
q
become warm.
Is voltage 20 – 30 V between alternator terminal B and terminal E Yes q
when engine is running at low idle speed? None q
Specific gravity of electrolyte and voltage of battery are low. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Remedy
*1: Failure codes [CA559] and [CA2249]
40-600 6 PC200, 200LC, 220, 220LC-8M0

S-2 Engine does not start SEN06140-00
S-2 Engine does not start
a) Engine does not crank Cause
General causes why engine does not crank
Defective connection of battery cable terminal

q Internal parts of engine seized.
oSee "S-4 Engine stops during operations"
Defective starting motor (motor section)

q Defective electrical system
q Defect in hydraulic pump
Defective starting circuit wiring

Broken flywheel ring gear
Defective hydraulic pump

Defective starting switch
Defective battery relay
Defective safety relay

Machine operation
Questions
Operated for long period EE

hours
Condition of horn Horn does not sound. Q Q w
when starting switch
Horn volume is low. w
is turned ON
Battery electrolyte level is low. w
Battery cable terminal is loose w
When starting switch is turned ON, no operating sound is heard from battery relay. Q w
When starting switch is turned to START, starter pinion does not plunge. Q Q w
Check items
When starting switch Rotation speed is low. w

is turned to START, Unusual noise is heard around ring gear. w w
starter pinion Pinion returns halfway. w
plunges, but: Unusual noise is heard around relay and engine does not rotate. Q QQ Q
Check flywheel ring gear. q
Perform H-mode troubleshooting

Perform E-mode troubleshooting
Voltage (20 – 30 V) between battery relay terminal B and termi-
q
Troubleshooting
nal E is not found.

Turn starting switch to When terminal B and terminal C of starting switch are connected, q
OFF position and engine cranks.
connect cable, and When terminal B at safety relay outlet and terminal C are con-
q
perform troubleshoot- nected, engine cranks.
Even if terminal B at safety relay outlet and terminal C are con-
ing with starting q
switch at ON. nected, engine will not crank.
When terminal at safety switch and terminal B at starting motor
q
are connected, engine cranks.
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Remedy
–
–
PC200, 200LC, 220, 220LC-8M0 40-600 7

SEN06140-00 S-2 Engine does not start
b) Engine cranks but no exhaust smoke comes out Cause

General causes why engine cranks but no exhaust smoke comes out
q Fuel is not being supplied.
Malfunction of overflow valve (Does not close)

q Supply of fuel is extremely small.
q Improper selection of fuel (particularly in winter)
Seized or prematurely worn feed pump
Defective common rail pressure limiter

Stuck or seized supply pump plunger
Defective IMV for supply pump
Broken supply pump shaft
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Machine opera-
Questions
Operated for long period EE

tion hours
Exhaust smoke suddenly stopped coming out (at restarting after short time
w Q w w
stoppage).
Fuel other than specified one is used w
Filters are not replaced as indicated in the Operation and Maintenance
w E
Manual.
Fuel tank is found to be empty. w
Rust and water are found when fuel tank is drained. QE EE
There is no fuel in the removal fuel filter. w w
Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. w Q
Check items
Even if air bleeding plug in fuel filter head is removed, fuel

When engine is Q Q w Q
does not flow out.
cranked with
Even if spill hose from injector is disconnected, little fuel
starting motor, Q w w w Q
spills.
Check fuel filter. q
Troubleshooting
Check feed pump. q

q q
failure code (*1).
Perform troubleshooting for the error "IMV/IMA short or open circuit" accord-
q
ing to failure code (*2).
Check pressure relief valve. q
Fuel flows out when pressure limiter return piping is disconnected. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Add
Remedy

40-600 8 PC200, 200LC, 220, 220LC-8M0

S-2 Engine does not start SEN06140-00
c) Exhaust smoke comes out but engine will not start (fuel is injected) Cause
Leakage or clogging of fuel piping or air in the fuel system
Defective coolant temperature sensor or 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 lever, etc.)
Clogged injection nozzle, or defective spray


Defective intake air heater system


Use of improper fuel
Machine operation
hours
Suddenly become unstartable. w w Q
Questions
Fuel other than specified one is used Q Q

Filters are not replaced as indicated in the Operation and Maintenance Man-
w w
ual.
Oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor
w
does not indicate proper function of preheating system.
Air breather hole of fuel tank cap is clogged. Q
Rust and water are found when fuel tank is drained. w
There is no fuel in the removal fuel filter. w
When priming pump is operated, no resistance is felt or it is heavy. wQ
Starting motor cranks engine slowly. w
When engine is running, unusual noise is heard around cylinder head. w
Even if air bleeding plug in fuel filter head is removed, fuel
Check items
When engine is Q w
does not flow out.
cranked with start-
Even if spill hose from injector is disconnected, little fuel
ing motor, w
spills.
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low.
Check valve system. q
When compression pressure is measured, it is found to be low. q
Troubleshooting

q
failure code (*1).
Coolant temperature gauge indication is not correct. q
Even if starting switch is turned to HEAT, intake air heater mount does not
q
become warm.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Remedy
PC200, 200LC, 220, 220LC-8M0 40-600 9

SEN06140-00 S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly
General causes why engine will not pick up smoothly Cause
Leaking or clogging of fuel piping or air in the fuel piping

q Improper of fuel injection
Clogged injection nozzle, or defective spray

q Controller is controlling in derate mode

(limiting injection rate (power) because of an error in electrical system)
Seizure or interference at turbocharger


Improper valve clearance

Machine opera-
Operated for long period EE E E
Questions
tion hours
Engine pickup suddenly became worse. w QQ Q
Fuel other than specified one is used www
Filters are not replaced as indicated in the Operation and Maintenance Manual. w w
Rust and water are found when fuel tank is drained. w
When priming pump is operated, no resistance is felt or it is heavy. wQ
When exhaust manifold is touched immediately after starting engine, temperature of
Qw
some cylinders is low.
Color of exhaust Blue under light load. w
Check items
smoke Black. wQ w w
While engine is running, unusual noise is heard around cylinder head. w
While engine is running, interference sound is heard around turbocharger. w
High idle speed is normal, but speed suddenly drops when load is applied. Q w
Engine hunts. Q Q Q
Blowby gas is excessive. w
Troubleshooting
Check valve clearance. q

When turbocharger is rotated by hand, it is found to be heavy. q
Perform troubleshooting for "Supply pump pressure low error” according to failure
q
code (*1).
When a certain cylinder is cut out, engine speed does not change. q
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Clean
Clean
Remedy
40-600 10 PC200, 200LC, 220, 220LC-8M0

S-4 Engine stops during operation SEN06140-00
S-4 Engine stops during operation
General causes why engine stops during operation Cause
Broken auxiliary equipment (pump or air compressor, etc.)

q Internal parts of engine seized
Damage of valve system (valve, rocker lever, etc.)

q Engine overheating
Defective engine controller power supply wiring

q Defect in hydraulic pump

Broken or seized piston connecting rod
Broken or seized crankshaft bearing

Clogging of feed pnmp gauze filter
Defective starting switch wiring

Clogged or leaking fuel piping
Broken or seized feed pump

Broken or seized gear train
Broken supply pump shaft
Defective hydraulic pump


Machine operation
Operated for long period. EE
hours
Unusual noise was heard and engine
wwww QwQw w
Questions
Condition when stopped suddenly.

engine stopped
Engine overheated and stopped. wQ Q
Engine stopped slowly. w Q Q QQ
Engine hunted and stopped. wQ Q QQ QQ
Fuel other than specified one is used Q QQ Q
Filters are not replaced as indicated in the Operation and Mainte-
w w
nance Manual.
Fuel level monitor indicates low level. w
When priming pump is operated, no resistance is felt or it is wQQ
Rust and water are found when fuel tank is drained. ww
Metal particles are found in oil drained from oil pan. ww QQ
Check items
It does not rotate at all. ww

When engine is It rotates only in opposite direction. w
Crankshaft moves by amount of gear
rotated by hand: w w
backlash.
Supply pump shaft does not turn. w
Engine operates, but stops when load is applied from machine. w
Perform H-mode trouble-
Check piston and connecting rod. q

Check crankshaft bearing. q
Check gear train. q
Troubleshooting
shooting

Check feed pump gauze filter. q
Check the feed pump. q
Perform troubleshooting for "Supply pump pressure low error”
qq
according to failure code (*1).
Engine operates if auxiliary equipment (pump, air compressor,
q
etc.) is removed.
Check engine controller power supply wiring. q
Check starting switch wiring. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Clean
Clean
Add
Remedy
–
PC200, 200LC, 220, 220LC-8M0 40-600 11

SEN06140-00 S-5 Engine runs rough or is unstable
S-5 Engine runs rough or is unstable
General causes why engine runs rough or is unstable Cause

q Air in fuel system
q Defective engine speed sensor (error at degree that does not generate failure code)
Clogged injector or defective spray (dirt in injector)

Defective Ne speed sensor, or wiring harness
Defective Ne speed sensor, or wiring harness

Machine operation
Operated for long period E
hours
Questions
Occurs at a certain speed range. Q Q

Occurs at low idle. Q Q Q Q Q
Hunting:
Occurs even when speed is raised. Q Q Q
Occurs on slope. w
Filters are not replaced as indicated in the Operation and Maintenance Manual. w
Troubleshooting Check items
Rust and water are found when fuel tank is drained. Q

When priming pump is operated, no resistance is felt or it is heavy. w Q
Perform troubleshooting for "Eng Ne Speed Sensor Error" according to failure code (*1). q
Perform troubleshooting for "Eng Backup Speed Sensor Error" according to failure code (*2). q
Replace
Replace
Replace
Replace
Replace
Clean
Add
Remedy
*1: Failure code [CA689]

*2: Failure code [CA778]
40-600 12 PC200, 200LC, 220, 220LC-8M0

S-6 Engine lacks power SEN06140-00
S-6 Engine lacks power

General causes why engine lacks power Causes
Clogged injector nozzle, or defective spray (dirt in injector)

Defective installation of boost pressure sensor (air leak)

q Improper fuel injection
Defective boost pressure sensor or wiring harness

Air leakage from air intake piping and aftercooler

oSee “S-14 Coolant temperature becomes too high (overheating)“.
Defective injector drive (signal or solenoid)

q

Controller is controlling in derate mode.


Clogged or leaking fuel piping
Clogged fuel spill piping


Machine operation
hours
Operated for long period E E E E
Q w Q Q Q Q
Questions
suddenly
Power was lost
gradually Q Q Q Q Q Q
Fuel other than specified one is used QQ Q
Filters are not replaced as indicated in the Operation and Maintenance Manual. w w
Oil must be added more frequently. Q Q
Dust indicator indicates a red zone w w
Power becomes insufficient after short stop of operation. w
Color of exhaust black w w
smoke blue under light load w
w w
w
Check items
While engine is running, interference sound is heard around turbocharger.

High idle speed is too high. Q
High idle speed is normal, but speed suddenly drops when load is applied. Q wQ Q
Engine does not pick up smoothly and combustion is irregular. w w QQ w
Engine hunts. QQQ Q Q
Blowby gas is excessive w w
Check air intake piping. q
When boost pressure is measured, it is found to be low. q q q
Troubleshooting
Check fuel piping. q

Check spill port check valve. q
Perform troubleshooting for "Supply pump pressure low error” according to failure
code (*1).
q
When a certain cylinder is cut out, engine speed does not change. q q
Check boost air pressure sensor mount. q
Perform troubleshooting for "Charge pressure sensor error" according to failure code
(*2).
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Adjust
Clean
Clean
Remedy

PC200, 200LC, 220, 220LC-8M0 40-600 13

SEN06140-00 S-7 Exhaust smoke is black (incomplete combustion)
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black Cause
Air leak at tubing between turbocharger and cylinder head

q Improper fuel injection
oSee “S-14 Coolant temperature becomes too high (overheating)“.

q Controller is controlling in derate mode.

Improper fuel injection pressure

Improper fuel injection timing

Crushed or clogged muffler
Prematurely worn injector

Cloggedor seized injector
Machine opera-
Operated for long period E E E E
tion hours
w w QQQ
Questions
Color of exhaust Suddenly became black.

smoke
Gradually became black. w Q Q
Is blue under light load. w
Fuel other than specified one is used QQ
Power was lost
Suddenly w Q QQ
Gradually Q Q Q Q
Muffler is crushed. w
Air leaks at tubing between turbocharger and cylinder head, and loose
w
clamp.
Engine is operated in low-temperature mode at normal temperature. QQQ
When exhaust manifold is touched immediately after starting engine, tem-
Qw
perature of some cylinders is low.
w
Check items
While engine is running, interference sound is heard around turbocharger.

Torque converter stall speed or pump relief speed is high (Fuel is injected
Q
excessively).
Exhaust noise is unusual. Q w Q
Engine does not pick up smoothly and combustion is irregular. Q QQQ Qw
When spill hose from injector is disconnected, fuel spills excessibly. w
When turbocharger is rotated by hand, it is fount to be heavy. q
Troubleshooting

If muffler is removed, exhaust sound improves. q
q q
failure code (*1).
Perform troubleshooting for "Coolant sensor error" according to failure code
q
(*2).
Check the condition by using monitoring function of the machine monitor. qq
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Clean
Remedy

40-600 14 PC200, 200LC, 220, 220LC-8M0

S-8 Oil consumption is excessive (or exhaust smoke is blue) SEN06140-00
S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive Cause
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

q Excessive oil carry-over
Worn/damaged valve (stem, guide, seal)

q Long-time operation of engine at low idle or high idle
(Do not idle the engine for more than 20 minutes continuously)
Dust sucked in at air intake system

q External leakage of oil
Clogged breather or breather hose

q Wear of parts in lubrication system
Worn or damaged rear oil seal
Oil leakage from oil drain plug

Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Machine operation
Questions
Operated for long period EEE E

hours
Oil consumption suddenly increased. w Q
Engine 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
Loose hose clamps are found in air intake system. w
Inside of air outlet pipe at turbo compressor side is dirty with oil. w
Inside of turbo exhaust outlet pipe is dirty with oil. Q w
Check items
Oil in coolant w
Oil level in damper chamber is increasing. w
Exhaust smoke is blue under light load. w w
Excessive Q Q w w
Amount of blowby gas
None w
When intake manifold is removed, dust is found inside. q
When intake manifold is removed, inside is abnormally dirty. q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather or breather hose. q
Check rear oil seal. q
Pressure tightness test result of oil cooler shows oil leakage. q q
External leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Repair
Repair
Clean
Remedy
PC200, 200LC, 220, 220LC-8M0 40-600 15

SEN06140-00 S-9 Oil becomes contaminated early
S-9 Oil becomes contaminated early
General causes why oil becomes contaminated early Cause
Clogged turbocharger lubrication oil drain tube

Defective sealing at turbocharger turbine end
q Entry of exhaust gas into oil due to internal wear
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather or breather hose

q Operation under excessive load
Defective oil filter safety valve

Worn valve or valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions
Machine operation hours Operated for long period EEE

Fuel other than specified one is used Q Q
Oil must be added more frequently. w
Metal particles are found in the removed oil filter. Q Q w
Inside of exhaust pipe is dirty with oil. w
Engine oil temperature rises quickly. w
Blue under light load w
Check items
Color of exhaust smoke

Black w
Excessive Q Q w Q
Amount of blowby gas
None w
Excessive play of turbocharger shaft q
Troubleshooting

q
See S-7
Check breather or breather hose.
Check oil cooler. q
Check oil filter. q
Spring of oil filter safety valve is stuck or broken. q
Check turbocharger lubrication oil drain tube. q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
–
40-600 16 PC200, 200LC, 220, 220LC-8M0

S-10 Fuel consumption is excessive SEN06140-00
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Cause

q Leakage of fuel
q Improper fuel injection (fuel pressure or injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective atomization by injector

Improper common rail pressure
Defective supply pump plunger
Defective operation of injector

Fuel leakage at cylinder head
Defective feed pump oil seal
Improper injection timing

Machine opera-
Questions
Operated for long period EE E

tion hours
is more than that on other machines of same model. Q QQQ
Fuel consump-
Gradually increased. Q Q
tion:
Suddenly increased. QQ
External leakage of fuel from engine w
Combustion is irregular. w
Engine oil level rises and oil smells of diesel fuel. w w
w
Check items

Low idle speed is high. Q
Pump relief speed is high. Q
Color of exhaust Black QQ QQ
smoke White Q
Remove head cover and check for fuel leak. q
Check oil seal of feed pump. q
Troubleshooting
Perform troubleshooting for "Supply pump pressure low error” according to failure code
q
(*1).
Too much fuel is returned from injector. q
Perform troubleshooting for "Coolant sensor error" according to failure code (*2). q
Check the condition by using monitoring function of machine monitor. q q
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy

PC200, 200LC, 220, 220LC-8M0 40-600 17

SEN06140-00 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 present in coolant Cause
Broken cylinder head or cylinder head gasket

q Internal leakage in lubrication system
q Internal leakage in cooling system
Internal cracks in cylinder block
Broken oil cooler core or O-ring

Holes caused by pitting
Machine operation
EE
Questions
Operated for long period

hours
suddenly Q Q
Oil level rose:
gradually Q Q
Hard water is being used as coolant. Q Q
Oil level has risen and oil is milky. Q Q w
Check items
Unusual air bubbles are found in radiator, or coolant spurts. w

Troubleshooting
Pressure tightness test result of cylinder head shows oil leakage. q
Check cylinder block. q q
Pressure tightness test result of oil cooler shows oil leakage. q

Replace
Replace
Replace
Replace
Remedy
40-600 18 PC200, 200LC, 220, 220LC-8M0

S-12 Oil pressure drops SEN06140-00
S-12 Oil pressure drops
General causes why oil pressure drops Cause

q Leakage, clogging, or wear on lubrication system
q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Operation and Maintenance
Manual is not observed.
q Deterioration of oil due to overheating
Leaking, crushed, clogged oil piping

Clogged or broken pipe in oil pan
Clogged strainer in oil pan
Defective regulator valve

Coolant or fuel in oil
Lack of oil in oil pan
Worn main hearing
Defective oil pump
Clogged oil filter

Machine opera-
Questions

tion hours
Oil pressure monitor indicates low oil pressure. Qw
Oil other than specified one is used Q Q
Filters are not replaced as indicated in the Operation and Maintenance Manual. w
Indicates pressure drop at low idle. w
Oil pressure
Indicates pressure drop at low and high idle. Q wwwQ
monitor:
Indicates pressure drop on slope. w
(if installed)
Sometimes indicates pressure drop. w Q
Oil pressure monitor indicates low oil pressure. w w
Oil level in oil pan is low. w
External lubrication piping is leaking or crushed. w
Troubleshooting Check items
Oil is milky or smells of diesel fuel. w

Metal particles are found in oil drained from oil pan. w
Metal particles are found in the removed oil filter. w Q
Metal particles are found in oil filter. q
Inspect oil pan strainer and pipe. qq
See S-13
Oil pump rotation is heavy or there is play in oil pump. q

Valve and spring of regulator valve are fatigued or damaged. q
Check oil filter. q
If oil level sensor is replaced, oil level monitor indicates correct oil level. q
Replace
Replace
Replace
Repair
Adjust
Adjust
Clean
Clean
Add
Remedy
–
PC200, 200LC, 220, 220LC-8M0 40-600 19

SEN06140-00 S-13 Oil level rises (coolant or fuel in oil)
S-13 Oil level rises (coolant or fuel in oil)
General causes why oil level rises Causes
Defective seal of auxiliaries (water pump or air compressor)

q Coolant in oil (milky)
q Fuel in oil (oil smell of diluted diesel fuel)
a If oil is in coolant, perform troubleshooting for “S-11 Oil is in coolant”.
Internal cracks in cylinder block
Broken oil cooler core or O-ring

Worn or damaged rear oil seal
Defects in supply pump

Broken injector O-ring
Questions
Machine opera-
Operated for long period E EE E
tion hours
Fuel must be added more frequently. w w
Coolant must be added more frequently. Q Q
Oil in coolant QQQQ w
Oil smells of diesel fuel w w
Oil is milky. Q Q
While engine is running, drops of water come from muffler. Q
If radiator cap is removed and engine is run at low idle, an unusual number of bubbles
Check items
w Q
appears, or coolant spurts.
Exhaust smoke is white. Q
Oil level in damper chamber decreases. w
Troubleshooting
Remove injector and check O-ring. q

Check cylinder block. qq
Check rear oil seal. q
Pressure tightness test result of oil cooler shows oil leakage. q
Remove and check supply pump. q
Check seal of auxiliaries. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
40-600 20 PC200, 200LC, 220, 220LC-8M0

S-14 Coolant temperature rises too high (overheating) SEN06140-00
S-14 Coolant temperature rises too high (overheating)
General causes why coolant temperature rises too high Causes

q Lack of cooling air (deformation or damage of fan)
q Drop in heat dissipation efficiency
q Problem in coolant circulation system
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Slipping fan belt or worn fan pulley
Rise in hydraulic oil temperature

Clogged or crushed radiater fins
Clogged or broken oil cooler
Malffunction of water pump

Malfunction of thermostat
Clogged radiator core

Lack of coolant
Machine opera-
Operated for long period EE EE
Questions
tion hours
Suddenly occurred. Q w Q
Overheating
Tends to occur always. Q w w Q
Coolant temper- Indiacates quick temperature rise. Q w
ature gauge: Does not go down from red range. w
Radiator coolant level monitor indicates drop of coolant level. w
Engine oil level has risen and oil is milky. w Q
Fan belt tension is low. w
When fan pulley is turned, it has play. w
Milky oil is floating on coolant. w
Unusual air bubbles are found in radiator or coolant spurts. w
Check items
When light bulb is held behind radiator core, no light passes through. w
Radiator shroud and inside of underguard are clogged with dirt or mud. w w
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 gauge enters red range faster than engine coolant
w
temperature gauge.

q
Perform H-mode troubleshooting.
Check cylinder.
Check oil cooler. q
q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large.

When operation of thermostat is tested, it does not open at specified opening
q
temperature.
Temperature difference between upper and lower tanks of radiator is slight. q
Check radiator core. q
When operation of radiator cap is tested, its opening pressure is low. q
Check fan belt and pulley. q
When coolant temperature is measured, it is found to be normal. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Add
Remedy
–
PC200, 200LC, 220, 220LC-8M0 40-600 21

SEN06140-00 S-15 Unusual noise is made
S-15 Unusual noise is made
General causes why unusual noise is heard Cause
(defect in low coolant temperature sensor or boost temperature sensor)

q Abnormality due to defective parts
q Abnormal combustion
q Air sucked in from air intake system
a Judge if the noise is an internal noise or an external noise before starting troubleshoot-
Deformed cooling fan, loose fan belt, interference of fan belt

ing.
Defective inside of muffler (partition board out of position)

Air leak at tubing between turbocharge and cylinder head
a The engine is operated in the low-temperature mode while it is not warmed up suffi-
ciently. Accordingly, the engine sound becomes a little larger. This does not indicate
abnormality, however.
Damage of valve system (valve or rocker lever)

a When the engine is accelerated, it is operated in the acceleration mode and its sound
becomes a little larger for up to about three seconds. This does not indicate abnormal-
ity, however.
Excessively worn piston ring or cylinder

Dislocated or seized bushing
Improper fuel injection timing

Improper gear train backlash
Clogged or seized injector

Dirt caught in injector

Machine opera-
Operated for long period E
Questions
tion hours
Gradually occurred. Q Q
Abnormal noise
Sudden occurred. QQ Q
Fuel other than specified one is used Q
Metal particles are found in the removed oil filter. w w
Air leaks at tubing between turbocharger and cylinder head. w
While engine is running, interference sound is heard from turbocharger. w
While engine is running, unusual noise is heard around cylinder head. w w
While engine is running, beat noise is heard around muffler. w
Check items

wQ
Color of exhaust Blue under light load w
smoke: Black Qw Q
Engine does not pick up smoothly and combustion is irregular. w
Unusual noise is loud when engine is accelerated Q Q QQ
When turbocharger is rotated by hand, it is found to be heavy. q
If muffler is removed, unusual noise disappears. q
Troubleshooting

When compression pressure measured, it is found to be low. q
Check gear train. qq
Check fan and fan belt. q
Even if a cylinder is cut out, engine speed does not change. qq
Unusual noise is heard only when engine is cranked. q
Check the condition by using monitoring function of machine monitor. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Remedy
40-600 22 PC200, 200LC, 220, 220LC-8M0

S-16 Vibration is excessive SEN06140-00
S-16 Vibration is excessive
General causes why vibration is excessive Cause
Improper injection timing (Problem with coolant or boost temperature sensor)

q Defective parts (premature wear or breakage)
q Misalignment between engine snd hydraulic pump
q Abnormal combustion
a If unusual noise is made and vibration is excessive, perform troubleshooting also
for “S-15 Unusual noise is made”.
Worn main bearing and connecting rod bearing
Loose engine mount bolts or broken cushions

Stuck valve system (valve, rocker arm, etc.)
Misalignment of engine and hydraulic pump

Broken parts in damper chamber
Improper gear train backlash
Worn camshaft bushing
Machine opera-
Questions

tion hours
Suddenly increased. Q Q
Vibration
Gradually increased. Q Q Q
Oil other than specified one is used Q Q
Metal particles are found in the removed oil filter. w w
Metal particles are found in oil drained from oil pan. w w
Oil pressure is low at low idle. Q Q
Check items
Vibration occurs at mid-range speed. Q Q

Vibration follows engine speed. Q Q Q Q
Exhaust smoke is black. w Q
Check main bearing and connecting rod bearing. q
Troubleshooting
Check gear train. q

Check camshaft bushing. q
Check the condition by using monitoring function of machine monitor. q
Check engine mounting bolts and cushions. q
When radial runout and facial runout are checked, misalignment is found. q
Check inside of damper chamber. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
PC200, 200LC, 220, 220LC-8M0 40-600 23

SEN06140-00
© 2012 KOMATSU
All Rights Reserved
40-600 24
SEN06142-01
HYDRAULIC EXCAVATOR
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
50 Disassembly and assembly 1
100 General information on disassembly

and assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools .............................................................................................................................. 12
PC200, 200LC, 220, 220LC-8M0 50-100 1

100 General information on disassembly and assembly
SEN06142-01 How to read this manual
How to read this manual (Rev. 2009.1)1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
6:
model. They have a new part num-
Amount of oil or coolant to be drained
ber respectively.
R: Tools made available by redesign- 4: Weight of part or component
ing the existing tools which were
developed for other models. Each
of them has a new part number Installation
assigned by setting forward the q Unless otherwise instructed, installation of
part number of the existing tool. parts is to be done in the reverse order to
Blank : Tools already available for other removal.
models. They can be used without q Instructions and precautions for parts installa-
any modification. tion is shown with the mark ([*1], [*2]...) which
3) Circle mark Q in sketch column: corresponds to the mark in “Removal” section.
q The sketch of the special tool is pre- q Common tools that are necessary for installa-
sented in the section of “Sketches of tion are described as [1], [2]••• etc. and their
special tools”. part numbers, part names and quantities are
q Part No. of special tools starting with not described.
79 T- - : q Marks shown in the “Installation” section stand
* *** ****
means that they are not available for the following.
from Komatsu Ltd. (i.e. tools to be
made locally). k: Precautions related to work safety
a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
50-100 2 PC200, 200LC, 220, 220LC-8M0

How to read this manual SEN06142-01
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
6:
2) Distinction of new and existing special
Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num-
ber respectively. Assembly
R: Tools made available by redesign- q In “Assembly” section, the work procedures,
ing the existing tools which were precautions and know-how to do the work, and
developed for other models. Each the amount of oil and coolant to be replenished
of them has a new part number are described.
assigned by setting forward the q Common tools that are necessary for assem-
part number of the existing tool. bly are described as [1], [2]••• etc. and their
Blank : Tools already available for other part numbers, part names and quantities are
models. They can be used without not described.
any modification. q The meanings of the symbols used in “Assem-
3) Circle mark Q in sketch column: bly” section are as follows.
q The sketch of the special tool is pre-
sented in the section of “Sketches of k : Precautions related to work safety
special tools”. a : Guidance or precautions for the work
q Part No. of special tools starting with 2 : Type of coating material
79 T- - : 3 : Tightening torque
* *** ****
means that they are not available 5 : Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
PC200, 200LC, 220, 220LC-8M0 50-100 3

SEN06142-01 Coating materials list
Coating materials list 1

(Rev. 2009.08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
q Use to prevent rubber gaskets, rubber cushions,

LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropy-
20 g Polyethylene lene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.
Polyethylene q Features: Resistance to heat and chemicals.
LT-2 790-129-9040 50 g
container q Use to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Use to bond and seal metal, glass and plastics.
sive and hard- Hardener:
ener) 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g q Use to seal plugs for blank holes
container
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instantaneous adhesive.
ThreeBond Polyethylene q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Use mainly to bond metals, rubbers, plastics, and
woods.
q Instantaneous adhesive.
Aron-alpha Polyethylene q Quick-curing type (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes)
q Use mainly to bond rubbers, plastics, and metals.
q Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc q Use for fitted portions subjected to high tempera-
648-50 container
ture.
q Use to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container q Use to seal taper plugs, elbows, and nipples for
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube
q Use to seal flange surfaces and threaded portions.
Liquid gasket
q Use to seal oil pan, final drive case, etc.

q Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat and cold-resistant,
ThreeBond 419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the
ThreeBond 790-129-9310 200 g Tube
weld which must be caulked, etc.
1206D
q Can be coated with paint.
50-100 4 PC200, 200LC, 220, 220LC-8M0

Coating materials list SEN06142-01
Cate- Komatsu
gory code
LG-10 q Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket
1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steer-
1121 ing case etc.
ThreeBond
790-129-9090 100 g Tube q Liquid gasket used to repair engine.
1211
q Use to prevent galling and seizure of press-fitted
Molybdenum disulfide
portions, shrinkage-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
lubricant
q Use to lubricate linkages, bearings, etc.

q Spray type
q Thin molybdenum disulphide films are made on
— 09995-00250 190 g Can metal surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound
q Feature: Seizure and galling prevention com-

Seizure
LC-G pound with metallic super-fine-grain, etc.

NEVER- — — Can q Use for the mounting bolt in the high temperature
SEEZ area of the exhaust manifold and the turbocharger,
etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold brication performance, general purpose type.
SYG0-400LI-A
district
(*)
SYG0-160CNLI
(*)
q Use for parts under heavy load.
Molybde- Caution:
num disul- SYG2-400M 400 g × 10 Bellows-type q Do not use this grease for rolling bearings like
fide grease SYG2-400M-A 400 g × 20 container swing circle bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg Can q Use this grease for work equipment pins only
(G2-M) when installing them, but do not use it after-
ward.
SYG2-400T-A
Grease
Hyper White
SYG0-400T-A q Seizure resistance, heat resistance and water re-
G2-T, Bellows-type
(*) 400 g sistance higher than molybdenum disulfide
G0-T (*) container
SYG2-16CNT grease.
*: For cold 16 kg Can
SYG0-16CNT q Not conspicuous on machine since color is white.
district
(*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT
Bellows-type q Since this grease is biodegradable in short period,
*: For use at (*) 400 g
container it has less impact on microorganisms, animals,
high temper- SYGA-16CNB
16 kg Can and plants.
ature and SYGA-16CNBT
under high (*)
load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond — 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
PC200, 200LC, 220, 220LC-8M0 50-100 5

SEN06142-01 Coating materials list
Cate- Komatsu
gory code
q Feature: Urea (organic system) grease with heat
Grease
resistance and long life, can be packed into the

G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
20 ml
PRIMER tainer (Effective period: four months after date of
580 SUPER manufacture)
417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
20 ml (Effective period: four months after date of
For adhered window glass

PRIMER tainer
manufacture)
580 SUPER
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
Primer
22M-54-27230 20 ml
435-95 manufacture)
q Use as primer for black ceramic-coated
SUNSTAR
glass surface and for hard polycarbonate-
GLASS
22M-54-27240 150 ml Can coated surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
GP-402 manufacture)
SUNSTAR q Use "S" in high-temperature season and "W"
PENGUINE in low-temperature season as adhesive for
Polyethylene
SEAL580 417-926-3910 320 ml glass.
container
SUPER "S" (Effective period: four months after date of
Adhesive
or "W" manufacture)
Sika Japan, q Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
container
For adhered window glass
256HV manufacture)
SUNSTAR q Use as adhesive for glass.
Ecocart (Spe-
PENGUINE 22M-54-27210 320 ml (Effective period: six months after date of
cial container)
SUPER 560 manufacture)
SUNSTAR
q Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
Caulking material
2505
SEKISUI q Use to seal front window.
Polyethylene
SILICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE
q Use to seal glass-to-glass joint. Translucent
TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL
manufacture)
381
50-100 6 PC200, 200LC, 220, 220LC-8M0

Special tools list SEN06142-01
Special tools list 1
a Tools with part number 79 T- - means that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
* *** ****
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
“Sketches of special tools”).
Necessity
Sym-
Sketch
Work item Part number Part name Work content
bol
Q'ty
N/R
Installation of engine front oil
Engine front oil seal 1 795-799-6400 Seal puller t 1 N
seal
Installation of engine rear oil
Engine rear oil seal 2 795-799-6500 Seal puller t 1 N
seal
3 795-799-6700 Primer t 1 N Removal of fuel injector
Cylinder head assembly, Positioning with 3RD and
4 795-799-1131 Gear t 1
fuel injector assembly 4TH cylinder top
5 795-799-8150 Remover q 1 N Removal of inlet connector
Wrench
6 790-331-1120 q 1 Angle tightening of bolt
(Angle)
Cylinder head assembly
A Judgment of cylinder head
7 795-790-4510 Gauge q 1 N
bolt length
8 796T-401-1110 Plate q 1 N Q Removal and installation of
Engine and hydraulic
engine and hydraulic pump
pump assembly 9 795-790-9300 Lifting tool q 1 N assembly
Hydraulic pump assembly,
Engine and hydraulic 10 796-460-1210 Oil stopper q 1
pump assembly, Control Stopping oil
valve assembly, Center 11 796-770-1320 Adapter q 1
swivel joint assembly
Fuel supply pump Removal and installation of
12 795-799-6130 Support t 1
assembly gear
1 796T-426-1410 Push tool t 1 Q Press fit of main bearing
2 796-426-1120 Push tool t 1 Press fit of sub bearing
Swing motor and swing
F 796T-426-1130 Plate t 1 Q
machinery assembly
3 790-101-5421 Grip t 1 Press fit of oil seal
01010-81240 Bolt t 1
796-427-1400 Wrench assembly t 1 N
796-427-1410 • Wrench 1 N Removal and installation of
Final drive assembly J 1
796-427-1140 • Pin 3 nut
01314-20612 • Screw 3
PC200, 200LC, 220, 220LC-8M0 50-100 7

SEN06142-01 Special tools list
Necessity
Sym-
Sketch
bol
Q'ty
N/R
796T-427-1510 Push tool t 1 N Q
790-101-2510 Block t 1
790-101-3310 Block t 1
790-101-2610 Rod t 2
790-101-2730 Adapter t 2
2 Installation of bearing
01580-11613 Nut t 2
790-101-2570 Plate t 2
01643-31645 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
3 796-427-1520 Installer t 1 N Installation of floating seal
Removal and installation of
4 796-427-1400 Wrench assembly t 1
Final drive assembly J ring nut
5 796-427-1520 Installer t 1 Installation of floating seal
796T-427-1510 Push tool t 1 Q
790-101-2510 Block t 1
790-101-3310 Plate t 1
790-101-2610 Leg t 2
790-101-2730 Adapter t 2
6 Installation of hub assembly
01580-11613 Nut t 2
790-101-2570 Plate t 2
01643-31645 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
7 790-331-1110 Wrench t 1 Angle tightening of bolt
Carrier roller assembly 1 790-434-1660 Installer t 1
Track roller assembly L 2 796-670-1020 Installer t 1 Installation of floating seal
Idler assembly 3 791-530-1510 Installer t 1
50-100 8 PC200, 200LC, 220, 220LC-8M0

Necessity
Sym-
Sketch
bol
Q'ty
N/R
791-600-2001 Compressor (A) t 1
or
791-685-8006 Compressor (B) t 1
790-201-2780 Spacer t 1
1 791-635-3160 Extension t 1
Cylinder
790-101-1600 t 1
(686 kN {70 ton})
790-101-1102 Pump t 1
Recoil spring assembly M 791-640-2180 Guide bolt t 1 Disassembly and assembly
of recoil spring assembly
790-101-5201 Push tool kit (B) q 1
790-101-5241 • Plate 1
2
790-101-5221 • Grip 1
01010-51225 • Bolt 2
790-201-1500 Push tool kit q 1
790-201-1620 • Plate 1
3
790-101-5021 • Grip 1
01010-50816 • Bolt 1
791-630-3000 Remover and installer t 1
Cylinder Separation and installation of
Track shoe assembly R 790-101-1300 t 1
(980 kN {100 ton}) track shoe assembly
790-101-1102 Pump t 1
1 796T-467-2410 Push tool t 1 N Q Press fit of input shaft oil seal
2 796T-416-1010 Push tool t 1 N Q
Hydraulic pump assembly S Press fitting of bushing
3 796T-416-1030 Push tool t 1 N Q
4 796T-416-1020 Push tool t 1 N Q Press fitting of pin
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
Disassembly and assembly
Center swivel joint
T 1 790-101-2540 • Washer 1 of center swivel joint
assembly
assembly
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2
PC200, 200LC, 220, 220LC-8M0 50-100 9

SEN06142-01 Special tools list
Necessity
Sym-
Sketch
bol
Q'ty
N/R
796-946-1310 Guide f21.8 mm
t 1
(For 723-46-40100)
796-946-1610 Guide f21.4 mm
t 1
(For 723-46-41100)
796-946-1810 Guide f21.2 mm
2 t 1
(For 723-46-43100 and 723-46-43400)
796-946-1910 Guide f21.0 mm
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2210 Guide f20.6 mm
t 1
(For 723-46-45100 and 723-46-45700)
796-946-1320 Guide f21.8 mm
t 1
(For 723-46-40100)
796-946-1620 Guide f21.4 mm
t 1
(For 723-46-41100)
796-946-1820 Guide f21.2 mm
t 1
(For 723-46-43100 and 723-46-43400)
3
796-946-1920 Guide f21.0 mm Replacement of pressure
Control valve assembly T t 1
(For 723-46-46101 and 723-46-46300) compensation valve seal
796-946-2220 Guide f20.6 mm
t 1
(For 723-46-45100)
796-946-1420 Guide f21.6 mm
t 1
(For 723-46-42700)
796-946-1330 Sleeve
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
t 1
(For 723-46-43100 and 723-46-43400)
4
796-946-1930 Sleeve
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)
50-100 10 PC200, 200LC, 220, 220LC-8M0

Necessity
Sym-
Sketch
bol
Q'ty
N/R
790-502-1003 Cylinder repair stand q 1 Disassembly and assembly
1 of hydraulic cylinder
790-101-1102 Pump q 1 assembly
790-102-4300 Wrench assembly t 1 Removal and installation of
2
790-102-4310 Pin t 2 piston assembly
3 790-720-1000 Expander q 1
Rubber band
796-720-1670 q 1
(for boom and arm)
07281-01279 Clamp q 1 Installation of piston ring
4
Rubber band
796-720-1680 q 1
(for bucket)
07281-01589 Clamp q 1
Hydraulic cylinder 790-201-1702 Push tool kit t 1
U
assembly • Push tool
790-201-1841 1
(for boom and bucket)
5 • Push tool Press fit of bushing
790-201-1851 1
(for arm)
790-101-5021 • Grip 1
01010-50816 • Bolt 2
• Push tool
790-201-1650 1
6 Plate Press fit of dust seal
790-201-1660 1
(for arm)
790-101-5021 Grip 1
01010-50816 Bolt 2
796-900-1200 Remover t 1
796-900-1210 • Sleeve 1
792-900-1520 • Plate 1
799-900-1230 • Screw 1
Work equipment 796-900-1240 • Adapter 1
V Removal of foot pin
assembly
01643-33080 • Washer 1
01803-13034 • Nut 1
Puller
790-101-4000 t 1
(490 kN {50 ton} long)
790-101-1102 Pump (294 kN {30 ton}) t 1
Operator cab glass 2 793-498-1210 Lifter (Suction cup) t 2 Installation of operator cab
X
(stuck glass) 3 20Y-54-13180 Stopper rubber t 2 glass (stuck glass)
Commercially
Impact wrench q 1 Removal and installation of
available
Counterweight assembly Z the counterweight mounting
Commercially Socket wrench
q 1 bolt
available (width across flats: 41 mm)
PC200, 200LC, 220, 220LC-8M0 50-100 11

SEN06142-01 Sketches of special tools
Sketches of special tools 1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A8 Plate
F1 Push tool
50-100 12 PC200, 200LC, 220, 220LC-8M0

Sketches of special tools SEN06142-01
F3 Plate
J2, J6 Push tool
PC200, 200LC, 220, 220LC-8M0 50-100 13

SEN06142-01 Sketches of special tools
S1 Push tool
S2 Push tool
50-100 14 PC200, 200LC, 220, 220LC-8M0

Sketches of special tools SEN06142-01
S3 Push tool
S4 Push tool
PC200, 200LC, 220, 220LC-8M0 50-100 15

SEN06142-01

© 2019 KOMATSU
All Rights Reserved
50-100 16
SEN06143-01
HYDRAULIC EXCAVATOR
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
50 Disassembly and assembly1

Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 9
Removal and installation of engine front oil seal........................................................................................... 19
Removal and installation of engine rear oil seal ........................................................................................... 26
Removal and installation of cylinder head assembly .................................................................................... 31
Removal and installation of radiator assembly ............................................................................................. 52
Removal and installation of hydraulic oil cooler assembly ............................................................................ 57
Removal and installation of aftercooler assembly......................................................................................... 62
Removal and installation of fuel cooler assembly ......................................................................................... 67
Removal and installation of engine and hydraulic pump assembly .............................................................. 70
PC200, 200LC, 220, 220LC-8M0 50-200 1

SEN06143-01 Removal and installation of fuel supply pump assembly
Removal and installation of fuel supply pump assembly 1
Standard tools list

Tools below are shown for reference. Tools other than them may be used if the purposes are the same.
No. Part name Part No. Specifications Q'ty Remarks
1 Socket wrench (Commercially available) 19 mm 1
2 Torque wrench set (socket) (Commercially available) 98 to 123 Nm 1
3 1/2-inch spinner handle (Commercially available) 1
4 Puller (Commercially available) 1
Special tools list

Symbol Part name Part No. Specifications Q'ty Remarks
A 1 Support 795-799-6130 1
k Park the machine on a level ground, swing the upper structure by 90 degrees, lower the work
equipment to the ground in a stable posture, and move the lock lever to LOCK position.
k Disconnect the cable from the negative (-) terminal of the battery.
NOTICE
q Check and record the connector numbers and installed positions before disconnecting electric
wiring harnesses and hoses.
q Install a plug or flange in the place where a hydraulic hose or tube is disconnected.
When a plug or a flange is not available, cover with a plastic bag and fix it with a band.
50-200 2 PC200, 200LC, 220, 220LC-8M0

Removal and installation of fuel supply pump assembly SEN06143-01
Removal
1. Remove the bolts (1a) (7 pieces), and remove the fuel tank
bottom cover (1b).
Tools: Socket wrench
Bolt (1a): Width across flats 19 mm, M12
2. Remove the bolts (1c) (6 pieces), and remove the cover
(1d).
Bolt (1c): Width across flats 19 mm, M12
3. Close the fuel stop valve (1e).
4. Open the engine hood (2).
5. Disconnect the fuel filter hoses (2) and (3) from the fuel sup-
ply pump (16).
a Remove mud on the connections beforehand. (To pre-
vent the lock (L) from sticking with mud)
a Pull out while pressing the lock (L) from both sides.
a Fuel flows out when the hoses are disconnected. Cover
the hose fittings with cloths, etc. However, do not use
wooden plugs, which causes wood chips.
6. Disconnect the fuel return hoses (4) and (13).
7. Remove the bolts (5a) (2 pieces), and remove the fuel filter
and bracket assembly (5).
PC200, 200LC, 220, 220LC-8M0 50-200 3

8. Disconnect the connector CP3 (6).

9. Disconnect the fuel supply hose (7).
10. Remove the fuel spray prevention cap (8).

11. Disconnect the high-pressure pipe (9).
k When removing or installing fuel testing tools, stop
the engine and wait at least 30 seconds until the
remaining pressure is released from the fuel cir-
cuit. (Do not start the work immediately after the
engine is stopped since there is remaining pres-
sure.)
12. Disconnect the tube clamps (10) (2 pieces).
13. Disconnect the fuel return tube (11).

14. Remove the fuel spray prevention cap (15).
15. Remove the high-pressure pipe (9).
16. Remove the nuts (3 pieces) (parts A), and remove the fuel
supply pump assembly (16).
50-200 4 PC200, 200LC, 220, 220LC-8M0

a The fuel supply pump assembly (16) comes off

together with the gear.
17. Remove the gear from the fuel supply pump according to
the following procedure.
1) Fix the gear by using the tool A1 (support) and 1/2-inch
spinner handle [1], and loosen the nut (18).
a Do not remove the nut (18) from the shaft.
2) Install the puller [2] between the flange and gear (19).
3) Install puller [3] on puller [2] and the shaft.

4) Turn the center bolt [4] until the gear is disengaged
from the shaft.
5) Remove the pullers [2] and [3].
6) Remove the nut (18), lock washer (20), and gear (19)
from shaft (21).
PC200, 200LC, 220, 220LC-8M0 50-200 5

Installation
1. When the gear is removed from the fuel supply pump, install
it according to the following procedure.
a Clean dusts and foreign materials on the mating sur-
faces of the shaft (21) and gear (19), and keep the mat-
ing surfaces dry.
1) Install the gear (19) to the shaft (21).
2) Install the lock washer (20) and nut (18), and finger-
tighten lightly.
3) While fixing the gear by using tool A1 (support) and 1/

2-inch spinner handle [1], tighten the nut (18).
3 Fuel supply pump mounting nut:
105±5 Nm {10.7±0.51 kgm}
2. Install the fuel supply pump assembly (16) with the nuts (3
pieces) (parts A).
3 Fuel supply pump assembly mounting nut:
24±4 Nm {2.45±0.41 kgm}
a The gear teeth of the fuel supply pump assembly (16)

are not worked (no missing tooth) for showing the mark
for 1.TOP adjustment.
Accordingly, the pump assembly may be installed at an
arbitrary position.
a If grease is applied too much to O-ring (17), it will ooze

out. Do not apply grease too much. (Apply grease to
the O-ring groove area of part B.)
a When replacing the fuel supply pump mounting stud
bolts (SB), apply Loctite to stud bolt when inserting
them.
50-200 6 PC200, 200LC, 220, 220LC-8M0

3. Install the high-pressure pipe (9).

q Procedure for installing high-pressure pipe (9)
1) Finger-tighten the sleeve nuts. (Both sides)
2) Tighten the sleeve nut on the pump side first, then on
the common rail side.
3 Sleeve nut: 35±3.5 Nm {3.57±0.36 kgm}
3) Install tube clamps (10) (2 pieces).

3 Clamp mounting bolt: 24±4 Nm {2.45±0.41 kgm}
4) Install fuel spray prevention caps (8) and (15).

a Direct slits of fuel spray prevention caps outward
and downward.
a The fuel spray prevention caps are installed so
that fuel will not spout over the hot part of the
engine and catch fire when it leaks by any chance.
4. Connect the fuel return tube (11).
3 Fuel return tube (11) mounting bolt:
24±4 Nm {2.45±0.41 kgm}
5. Connect the fuel supply hose (7).

6. Connect the connector CP3 (6).
7. Install the fuel filter and bracket assembly (5) with the bolts
(5a) (2 pieces).
Tools: Torque wrench set (socket)
3 Bolt (5a): 98 to 123 Nm {10 to 12.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-200 7

8. Connect the fuel return hoses (4) and (13).

9. Connect the fuel filter hoses (2) and (3) to the fuel supply
pump (16).
a If a hose fitting is damaged when it is removed, replace
it with a brand-new one.
a Check that no mud or dirt is sticking to the connections.
(To prevent the lock (L) from sticking with mud)
a Connect while pressing the lock (L) from both sides.
10. Close the engine hood (2).
11. Open the fuel stop valve (1a).
12. Install the cover (1d) with the bolts (1c) (6 pieces).
3 Bolt (1c): 98 to 123 Nm {10 to 12.5 kgm}
13. Install the fuel tank bottom cover (1b) with the bolts (1a) (7
pieces).
3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
50-200 8 PC200, 200LC, 220, 220LC-8M0

Removal and installation of fuel injector assembly SEN06143-01
Removal and installation of fuel injector assembly 1
Standard tools list

6 Socket wrench (Commercially available) 9.5 mm (3/8 in) 1
7 Torque wrench set (socket) (Commercially available) 1
8 Angle tightening wrench (Commercially available) 1
Special tools list

3 Puller 795-799-6700 1
A 4 Gear 795-799-1131 1
5 Remover 795-799-8150 1
k Park the machine on a level ground, lower the work equipment to the ground so that it is stable,
k Stop the engine, and move the lock lever to LOCK position.
PC200, 200LC, 220, 220LC-8M0 50-200 9

SEN06143-01 Removal and installation of fuel injector assembly
Removal
1. Remove the bolts (1b) (13 pieces), and remove the covers
(1) and (1a).
Bolt (1b): Width across flats 19 mm, M12

3. Remove the following parts. For details, see "Removal and
installation of engine and hydraulic pump assembly", 6. to
25.
q Engine hood
q Upper cover of control valve
q Cover between hydraulic pump and engine
q Frame between control valve and engine
q Cover between control valve and engine
a The frame between the control valve and the engine
should be kept installed as a foothold.
ply pump (FSP).
a The fuel in the piping flows out. Cover the hose fittings
with cloths, etc.
5. Disconnect the fuel return hoses (4) and (4a).
7. Remove the clamp (7) and bands (7a) (2 places) of the wir-
ing harness (10).
50-200 10 PC200, 200LC, 220, 220LC-8M0

8. Remove the head cover mounting bolts (8) (5 pieces), and

remove the head cover (9).
a After loosening the head cover mounting bolts (8),
remove sludge and other foreign material sticking
around by airblow, etc. to prevent their entry while hold-
ing the cover with your hand.
a When removing the head cover (9), take care not to hit
it against the surrounding parts.
9. Remove the harness nuts (11) (12 pieces) from the fuel injec-
tors (10) (6 pieces).
10. Remove the connectors (3 places) of the engine harness
(12).
a Each connector has a fixing hook. Pull it out while
pressing the hook. At this time, hold the gasket to pre-
vent it from moving.
11. Lift the gasket assembly (13), and remove it.
a When removing it, prevent foreign material from enter-
ing the engine.
a When removing the head cover (9), visually check the
gasket assembly (13). If the gasket assembly (13) is
cracked, deteriorated, or worn, replace it with a brand-
new one when installing the head cover (9).
12. Disconnect the high-pressure pipes (15) (6 pieces) from the

cylinder head.
a Remove the boots and loosen the sleeve nuts on the
common rail side, as well.
a Remove the fuel pressure sensor (10a) only when
replacing it.
13. Remove the fuel spray prevention caps (14) of high-pres-
sure pipes (15).
14. Remove the mounting bolts, and remove the rocker arms
(16).
a When installing the rocker arm, loosen the lock nut (17)
and loosen the adjustment screw (18) 2 to 3 turns so
that an excessive force is not applied to the push rod.
PC200, 200LC, 220, 220LC-8M0 50-200 11

15. Remove the crossheads (19).

a Record the installed position and direction (shapes of
holes (a) and (b)) of each crosshead. (For reinstallation
in the same direction)
16. Remove the retainer (20), and remove the inlet connectors
(21) (6 pieces).
a Clean the surrounding area to remove mud and other
contamination in advance to prevent them from enter-
ing the connector hole.
a The tool A5 (remover) is set for removal of the inlet
connector (21).
a When replacing an injector assembly with a new one,
replace the inlet connector with a new one as well.
17. Remove the mounting bolts of the fuel injector assembly

(22).
18. Remove the fuel injector assembly (22) by using the tool A3
(puller).
a Do not pry the injector assembly head to remove it.
a Be careful not to allow dirt and foreign matter to enter
the mounting portion of the injector assembly.
50-200 12 PC200, 200LC, 220, 220LC-8M0

Installation
NOTICE
When replacing an injector assembly with a new one, replace the inlet connector with a new one as
well.
1. Fuel injector assembly
a Check that the injector mounting hole is free of
scratches and dirt.
1) Install the O-ring (24) and gasket (25) to the fuel injec-
tor (22).
a Replace the O-ring and gasket with new ones.
2) Apply engine oil (EO15W-40) to the O-ring of the fuel
injector (22) and to the mounting hole on the head side.
3) Align the concave portion (C) of holder (26) with the
convex portion (A) of fuel injector (22), and install the
holder (26).
4) Direct the fuel inlet hole of fuel injector assembly (22)
toward the air intake manifold, and install it to the cylin-
der head.
5) Tighten the bolts (23) of fuel injector (22) 3 or 4 turns.
6) Visually check the inlet connector. If the inlet connector

has any of the following faults, replace it and injector
assembly together.
1] When burrs or wear is found in the inlet connector
top-end (a) and rear-end (b) parts.
2] There is foreign material in the edge filter at rear
end (c) of the inlet connector.
3] The O-ring at the upper part (d) of inlet connector
is cracked or deteriorated.
4] There is a worn part or an uneven seat contact

mark on the seat face (e) at the front end of the
inlet connector.
a If high-pressure fuel leaks through the inlet
connector, seat surface has fine streaks or
cracks.
PC200, 200LC, 220, 220LC-8M0 50-200 13

7) Apply engine oil (EO15W-40) to the mounting hole on

the head side of inlet connector (21).
8) Apply engine oil (EO15W-40) to the O-ring (20) of the
inlet connector (21), and fully insert inlet connector
(21), while matching portion B with the groove on the
head side.
9) Lightly tighten the inlet connector (21) with the retaining
nut (20). (Push it into the injector hole.)
3 Retaining nut: 15±5 Nm {1.5±0.5 kgm}
10) Alternately tighten the mounting bolts (23) of the fuel

injector assembly (22).
3 Fuel injector mounting bolt:
8±0.8 Nm {0.8±0.08 kgm}
11) Tighten the retaining nut (20).
2. Crosshead and rocker arm

1) Install the crosshead and rocker arm (16).
a Hole shapes of the crossheads (a) and (b) are not
identical. Install the same intake valve or exhaust
valve in the same direction when reusing cross-
head.
a Check that the ball of adjustment screw (18) is fit-
ted in push rod socket, and tighten the mounting
bolt.
3 Mounting bolt: 36±5 Nm {3.7±0.5 kgm}
2) Adjust the valve clearance.

a See Testing and adjusting, "Testing and adjusting
valve clearance".
a Use the tool A4 (gear) to crank the engine.
3 Lock nut (17): 24±4 Nm {2.4±0.4 kgm}
50-200 14 PC200, 200LC, 220, 220LC-8M0

3. High-pressure pipe
k Do not bend high-pressure pipe to correct before
installing.
k Be sure to use the Komatsu genuine high-pressure
pipe clamps and observe the specified tightening
torque.
k Install each high-pressure pipe and wiring harness
at least 10 mm apart from each other.
a Before installing the high-pressure pipe, check it for the
following. If the high-pressure pipe has any defect,
replace it with a new one since fuel may leak.
q Make sure with visual check that the taper seal part of
the connection (a) part: 2 mm area from the tip-end is
free from longitudinal slits (b) or pits (c).
q Make sure that part (d) (end of taper seal: 2 mm from
the tip-end) is free from steps you can feel by your fin-
gernail. (free from fatigue.)
1) Lightly install the high-pressure pipes (15a) to (15f)
between the common rail (27) and cylinder head.
3 Sleeve nut: 0.2 to 0.8 Nm {0.02 to 0.08 kgm)
2) Tighten the high-pressure pipes (15a) to (15f) accord-
ing to the following procedure.
3 Sleeve nut: 35±3.5 Nm {3.6±0.4 kgm}
1] Head side of high-pressure pipes (15a) and (15f)
2] Common rail side of high-pressure pipes (15f) and
(15a)
3] Head side of high-pressure pipes (15b), (15c),
(15d), and (15e) in this order
4] Common rail side of high-pressure pipes (15b),
(15c), (15d), and (15e) in this order
3) Lightly tighten the sleeve nut of the high-pressure pipe
(28).
4) Tighten the high-pressure pipe (28) in the order of the
pump (FSP) side to the common rail (27) side.
3 Sleeve nut: 35±3.5 Nm {3.6±0.4 kgm}
5) Tighten the clamp (29) of the high-pressure pipe (28).

6) Tighten the common rail (27) with the bolts (4 pieces).
a Apply sealant (LG-7) to the thread parts of the
bolts (2 pieces) inside the engine.
7) Install the fuel spray prevention caps (14) (14 pieces) to
the high-pressure pipes.
k Direct slits of fuel spray prevention caps out-
ward and downward.
PC200, 200LC, 220, 220LC-8M0 50-200 15

4. Fuel pressure sensor and relief valve

1) Replace the fuel pressure sensor (28) according to the
a Remove the fuel pressure sensor (28) from the com-
mon rail (27) only when it needs replacement.
a Be sure to replace the fuel rail pressure sensor
removed from the common rail with a brand-new one.

1] Before removing the fuel pressure sensor, thor-
oughly remove mud etc. from around it, and clean
it. *
2] Remove the fuel pressure sensor.
3] Check the fuel pressure sensor connector for
crack, breakage, damage of the seal, foreign mat-
ter on the pin and corrosion, bend and breakage of
the pin.
4] Install a new fuel pressure sensor.
2 Threaded part of fuel pressure sensor:
Gear oil (#90)
3 Fuel pressure sensor:
70±5 Nm {7.1±0.5 kgm}
5] Connect the engine wiring harness. At this time, be
careful not to reverse connection of connector.
6] After completing assembly, start the engine, and
check for leakage.
a For the testing procedure, see Testing and adjust-
ing, Testing fuel circuit for leakage.
2) Replace the relief valve (29) according to the following

procedure.
1] Before removing the relief valve, thoroughly remove
mud etc. from around it, and clean it.
2] Remove the relief valve.
3] If the leakage from the relief valve exceeds the
specified value, do not reuse it.
4] Check the relief valve and high-pressure sealing
surface (A) on rail for damages.
5] Install the relief valve.
2 Threaded part of relief valve: Gear oil (#90)
3 Relief valve: 100±4 Nm {10.2±0.4 kgm}
a Excessive tightening may cause leakage.
Take care not to tighten excessively.
6] After completing assembly, start the engine, and
check for leakage.
For the testing procedure, see Testing and adjust-
ing, Testing fuel circuit for leakage.
5. Connect the connector (12).

6. Install the harness nuts (11) (12 pieces) to the fuel injectors
(10) (6 pieces).
a Check that wiring harness does not interfere with
rocker arm.
3 Fuel injector harness nut
1.5±0.25 Nm {0.15±0.025 kgm}
50-200 16 PC200, 200LC, 220, 220LC-8M0

7. If the injector wiring harness connector (IHC) is removed,

apply liquid gasket LG-7 to the O-ring (o) and flange surface
(p) of the connector when installing.
a As for O-ring, apply LG-7 f3 mm in diameter until the
O-ring groove is completely hidden.
a When the O-ring is damaged, replace the wiring har-
ness assembly, since the O-ring cannot be supplied
singly.
3 Connector flange mounting bolt:
10±2 Nm {1±0.2 kgm}
8. Install the head cover (9) with the head cover mounting
bolts (8) (5 pieces).
a When installing the head cover, prevent sludge or for-
eign material from entering it.
a When installing the head cover (9), take care not to hit
it against the surrounding parts.
a When installing the head cover (9), visually check the
new one.
3 Head cover mounting bolt: 24±4 Nm {2.4±0.4 kgm}
9. Fix the wiring (10) with the clamp (7) and bands (7a) (2
places).
(5a) (2 pieces).
3 Bolt (5a): 43±6 Nm {4.4±0.6 kgm}
11. Connect the fuel return hoses (4) and (4a).

a If a hose fitting is damaged when it is removed, replace
it with a brand-new one.
12. Install the covers and frame shown below. For details, see
"Removal and installation of engine and hydraulic pump
assembly", 47 to 66.
q Engine hood
PC200, 200LC, 220, 220LC-8M0 50-200 17

13. Open the fuel stop valve (1e).
14. Install covers (1) and (1a) with bolts (1b) (13 pieces).
Tools: Socket wrench and torque wrench
3 Bolt (1b): 98 to 123 Nm {10 to 12.5 kgm}
15. Start the engine, and check for fuel leakage.

a For the testing procedure, see Testing and adjusting,
Testing fuel circuit for leakage.
50-200 18 PC200, 200LC, 220, 220LC-8M0

Removal and installation of engine front oil seal SEN06143-01
Removal and installation of engine front oil seal 1
Standard tools list

59 to 74 Nm
98 to 132 Nm
Special tools list

1 Seal puller 795-799-6400 1
A
6 Angle tightening wrench 790-331-1120 1
PC200, 200LC, 220, 220LC-8M0 50-200 19

SEN06143-01 Removal and installation of engine front oil seal
Removal
1. Remove the radiator assembly. For details, see "Removal
and installation of radiator assembly".
2. Remove the hydraulic oil cooler assembly. For details, see
"Removal and installation of hydraulic oil cooler assembly".
3. Remove the aftercooler assembly. For details, see
"Removal and installation of aftercooler assembly".
4. Remove the bolts (1a) (4 pieces), and move the air condi-
tioner condenser (1) aside.
a The fins of the air conditioner condenser are particu-
larly soft and easily damaged. Take sufficient protection
measures for them.
5. Remove the bolts (2a) (2 pieces), and remove the bracket
(2).
6. Remove the bolts (3a) (6 pieces), and remove the cover (3).
7. Remove the wing bolts (4a) (4 pieces), and remove the fan
nets (4) and (5).
8. Remove the bolts (6a) (8 pieces), and remove the fan

guards (6), (7), and (7a).
50-200 20 PC200, 200LC, 220, 220LC-8M0

9. Remove the bolts (8a) (4 pieces), and remove the fan (8).
10. Loosen air conditioner compressor bracket adjustment bolts
(9) and (9a).

Bolt (9): Width across flats 17 mm, M10
Bolt (9a): Width across flats 22 mm
11. Move the air conditioner compressor assembly (10).
12. Remove the air conditioner compressor drive belt (11).
13. Remove the fan belt (12) according to the following proce-
dure.
q Set a wrench into part A of tensioner assembly (16)
(width across flats: T12.7 mm) and turn it in the oppo-
site direction (R) to the winding-up direction to loosen
the fan belt (12).
k Firmly set the wrench on tensioner assembly(16) at
part A before applying turning force to the wrench.
(The spring of tensioner assembly (16) is strong. If
the wrench is loosely inserted, the wrench can
accidentally come off and this is extremely danger-
ous.)
k After removing fan belt (12), return tensioner
assembly (16) to its original position slowly and
carefully.
k Be careful not to get your fingers caught between
the pulley and fan belt (12) during work.
14. Remove the mounting bolts (6 pieces), and remove vibra-

tion damper (13).
PC200, 200LC, 220, 220LC-8M0 50-200 21

15. Remove the dust seal (17).
16. Remove the engine front oil seal (14) according to the fol-
lowing procedure.
1) Install the tool A1 (seal puller) to the crankshaft.
2) Screw in tapping screw [1] of tool A1 (seal puller) to the
seal carrier part of engine front oil seal (14).
3) Turn the handle clockwise, and remove the engine
front oil seal (14).
a Be careful not to damage the crankshaft when
removing the oil seal.
50-200 22 PC200, 200LC, 220, 220LC-8M0

Installation
1. Install the front seal (14) by using tool A1 (seal puller).
a Use a brand-new front seal.
a Before installing the seal, check that the housing in the
end face corner of crank shaft and lip sliding surface
are free from flaws, burrs, sharp edges and rusts.
a When installing the seal, do not apply oil or grease to
the shaft and seal lip. Also, wipe off oil or grease thor-
oughly from the shaft.
a From cover (C) of front seal (14):

q Protrusion x: 0.38 mm or less
q Facial runout (TIR: Total indicator reading) y:
0.25 mm or less
2. Install the dust seal (17).

a Use a brand-new dust seal.
a Check the installed dimension (L).
q Installed dimension (L): 12 + 0.1/0 mm
3. Vibration damper
1) Install vibration damper (13) while aligning its dowel
hole to dowel pin "a" of the crankshaft.
2) Tightening order of the bolts (15)
1] Tighten the bolts to 55±5 Nm {5.6±0.5 kgm} in a
diagonal order.
2] Loosen the bolts by 180°.
3] Tighten the bolts to 55±5 Nm {5.6±0.5 kgm} in a
diagonal order.
4] Retighten 90°±5°.
q When angle tightening tool is not available (When not

using angle tightening tool)
Put marks on the vibration damper and bolts with a felt-
tip pen, and retighten the bolts 90°±5°.
PC200, 200LC, 220, 220LC-8M0 50-200 23

4. Install the fan belt (12) according to the following procedure.

q Set a wrench into part A of tensioner assembly (16)
the fan belt (12).
k Firmly set the wrench on tensioner assembly (16)
at part A before applying turning force to the
wrench. (The spring of tensioner assembly (16) is
strong. If the wrench is loosely inserted, the
wrench can accidentally come off and this is
k After installing fan belt (12), slowly and carefully
restore tensioner assembly (16).
k Visually check the fan belt. If it is cracked, scratched,
worn unevenly, or rolled up, replace it.
5. Set the air conditioner compressor assembly (10) on the

installing position.
6. Finger-tighten the air conditioner compressor bracket
adjustment bolts (9) and (9a).
7. Install the air conditioner compressor drive belt (11).
a See Testing and adjusting, "Testing and adjusting air
conditioner compressor belt tension".
8. Tighten the air conditioner compressor bracket adjustment

bolts (9) and (9a).
3 Bolt (9): 59 to 74 Nm {6 to 7.5 kgm}

9. Install the fan (8) with the bolts (8a) (4 pieces).
3 Bolt (8a): 59 to 74 Nm {6 to 7.5 kgm}
10. Install the fan guards (6), (7), and (7a) with the bolts (6a) (8
pieces).
3 Bolt (6a): 59 to 74 Nm {6 to 7.5 kgm}
50-200 24 PC200, 200LC, 220, 220LC-8M0

11. Install the nets (4) and (5) with the wing bolts (4a) (4
pieces).
12. Install the cover (3) with the bolts (3a) (6 pieces).
3 Bolt (3a): 98 to 123 Nm {10 to 12.5 kgm}
13. Install the bracket (2) with the bolts (2a) (2 pieces).
3 Bolt (2a): 59 to 74 Nm {6 to 7.5 kgm}
14. Install the air conditioner condenser (1) with the bolts (1a) (4
pieces).
3 Bolt (1a): 59 to 74 Nm {6 to 7.5 kgm}
15. Install the aftercooler assembly. For details, see "Removal

and installation of aftercooler assembly".
16. Install the hydraulic oil cooler assembly. For details, see
"Removal and installation of hydraulic oil cooler assembly".
17. Install the radiator assembly. For details, see "Removal and
installation of radiator assembly".
PC200, 200LC, 220, 220LC-8M0 50-200 25

SEN06143-01 Removal and installation of engine rear oil seal
Removal and installation of engine rear oil seal 1
Standard tools list

Special tools list

A 2 Seal puller 795-799-6500 1
50-200 26 PC200, 200LC, 220, 220LC-8M0

Removal and installation of engine rear oil seal SEN06143-01
Removal
1. Remove hydraulic pump assembly. For details, see
"Removal and installation of hydraulic pump assembly".
2. Sling the damper assembly (2), and hold it.
3. Remove the bolt (1), and install the guide bolt [1].
4. Remove the remaining bolts (1) (7 pieces), and remove the
damper assembly (2).
5. Remove mounting bolt (3), and insert the guide bolt [2].
Mounting bolt (3): Width across flats 18 mm
6. Sling the flywheel assembly (4), hold it, and pull out the fly-
wheel assembly (4).
a Be careful to prevent the guide bolt from coming off.
7. Sling the flywheel assembly (4), and remove it.

4 Flywheel assembly: 35 kg
8. Remove rear seal (5) according to the following procedure.

1) Install the tool A2 (seal puller) to the crankshaft.
2) Install the tapping screw [1] of the tool A2 (seal puller)
to the seal carrier of the rear seal.
3) Turn the handle clockwise, and remove the rear seal
(5).
9. Be careful not to damage the crankshaft when removing the
rear seal.
PC200, 200LC, 220, 220LC-8M0 50-200 27

Installation
1. Install the rear seal according to the following procedure.
a Do not remove the pilot [5] attached to rear seal (5)
until the crankshaft is inserted.
a Before installing the rear seal, degrease, clean and dry
the crankshaft sealing face and the seal lip face to pre-
vent oil leakage.
2. Install the pilot [5] to the crankshaft (6), and push the rear
seal (5) into the flywheel housing (7).
3. Push in the rear seal (5) further, and remove the pilot [5].
4. Install the rear seal (5) to a proper depth in the flywheel

housing (7) by using the tool A2 (seal puller)
a Do not remove the pilot [5] attached to rear seal (5)
until the crankshaft is inserted.
a Protrusion of rear seal (5) from flywheel housing (7)
X: 0.38 mm or less
50-200 28 PC200, 200LC, 220, 220LC-8M0

Removal and installation of engine rear oil seal SEN06143-01
5. Sling the flywheel (4), and set it to the installing position.

a Use guide bolt [2] used for removal.
4 Flywheel assembly: 35 kg
6. Install the flywheel assembly (4) with the mounting bolts (3)
(8 pieces).
Mounting bolt (3): Width across flats 18 mm
a Remove the guide bolt [2] after installing 2 to 3 mount-
ing bolts.
a Tighten the flywheel assembly mounting bolts (8 pieces) in

the order (1) to (8) as shown in the figure below.
3 Flywheel assembly mounting bolt:
137±7 Nm {13.97±0.71 kgm}
a Tighten the bolts while preventing rotation of the flywheel

by using plate [3].
q Measurement of radial runout
a Radial runout: 0.13 mm or less
1) Install the dial gauge [4] on the stand, and set it to fly-
wheel housing (7).
2) Set the probe of the dial gauge perpendicularly to the
spigot joint part (a) or outside perimeter of the flywheel.
3) Rotate the flywheel 1 turn, and measure the difference
between the maximum value and minimum value of the
dial gauge pointer.
a When the flywheel rotated 1 turn, check that the
pointer of dial gauge indicates the same value as it
of the starting rotation.
q Measurement of facial runout
a Facial runout: 0.20 mm or less
1) Similarly to the measurement of the radial runout, set
the probe of dial gauge perpendicularly to the end face
(b) near the outer circumference of the flywheel.
a Perform the measurement with the crankshaft
pulled to either the front or rear side of the engine
to prevent errors caused by backlash.
PC200, 200LC, 220, 220LC-8M0 50-200 29

2) Rotate the flywheel 1 turn, and measure the difference

between the maximum value and minimum value of the
dial gauge pointer.
7. Install the guide bolt [1].

8. Sling the damper assembly (2), and set it on the installing
position.
9. Finger-tighten the bolts (1) (7 pieces).
10. Remove guide bolt [1], and finger-tighten the bolt (1).
11. Tighten the bolts (1) (8 pieces) to the specified torque.
3 Bolt (1): 59 to 74 Nm {6 to 7.5 kgm}
12. Install the hydraulic pump assembly. For details, see

50-200 30 PC200, 200LC, 220, 220LC-8M0

Removal and installation of cylinder head assembly SEN06143-01
Removal and installation of cylinder head assembly 1
Standard tools list

10.8 to 11.8 Nm
27 to 34 Nm
59 to 74 Nm
98 to 123 Nm
610 to 765 Nm
10.58±0.5 Nm
10 Flat-head screwdriver (Commercially available) 2
11 Webbing sling (Commercially available) 1
Special tools list

3 Puller 795-799-6700 1
4 Gear 795-799-1131 1
A 5 Remover 795-799-8150 1
6 Angle tightening wrench 790-331-1120 1
7 Gauge 795-790-4510 1
equipment to the ground in a stable posture, and stop the engine.
k Before opening the water filler cap or draining coolant, check that the coolant temperature cools
down to the temperature safe enough for anyone not to get burn.
k When the engine and auxiliaries (turbocharger in the exhaust system, etc.) are at high tempera-
ture, wait until they cool down to a safe temperature, then start the work.
PC200, 200LC, 220, 220LC-8M0 50-200 31

SEN06143-01 Removal and installation of cylinder head assembly
Removal
(1) and (1a).
2. Drain the coolant.

6 Coolant:
20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
installation of engine and hydraulic pump assembly", 6. to 2.
q Engine hood
a The frame between the control valve and the engine
should be kept installed as a foothold.
ply pump (FSP).
6. Disconnect the fuel return hoses (4) and (4a).
50-200 32 PC200, 200LC, 220, 220LC-8M0

8. Remove the cover (6).

9. Remove the clamp (7).
10. Remove the mounting bolts, disconnect the connection por-
tions, and sling and remove the muffler assembly (8) with
the lifting tool.
4 Muffler assembly: 35 kg
11. Remove the hose clamp (10a), and remove the hose (10).
Hose clamp (10a): Width across flats 9.5 mm (3/8 in)
a Make matchmarks on the hose end and tube so that
the position hose was inserted originally are recog-
nized.
a When disconnecting at the intake connector (part C),
replace the gasket.
12. Disconnect the clamp (10b) from the fan guard (13).
Bolt of clamp (10b): Width across flats 10 mm, M8
13. Disconnect the hose (10c) from the engine.
14. Remove the hose clamp (11a), and disconnect the radiator
hose (11).
Hose clamp (11a): Width across flats 8 mm
15. Disconnect the heater hose (12).
guard (13).
17. Disconnect the ambient pressure sensor connector (14)

and boost pressure sensor connector (15).
a Move the lock to the right side (R), and pull out the
ambient pressure sensor connector (14) while pressing
the tab (T).
a Move the wiring harness to the left.
PC200, 200LC, 220, 220LC-8M0 50-200 33

18. Disconnect the coolant temperature sensor connector (17).
19. Disconnect fuel pressure sensor connector (18).

20. Remove the fuel return hose (19) from the common rail (20)
and cylinder head rear face.
a The fuel in the piping flows out. Cover the hose fittings
with cloths, etc.
21. Remove the clamps (2 places) of high-pressure pipe (21)
between the common rail and supply pump.
22. Remove the fuel spray prevention caps (22) (2 pieces), and
remove the high-pressure pipe (21).
23. Remove the fuel spray prevention caps (23) (12 pieces),
and remove the high-pressure pipes (24a) to (24f) (6
pieces).
24. Remove the common rail (20).
a Remove the fuel pressure sensor and relief valve (25)
only when replacing them.
25. Remove the clamps (21a) from the cylinder block, and dis-
connect the high-pressure pipe (21).
a FSP: Fuel supply pump
a Remove the fuel spray prevention caps from the sleeve
nuts.
26. Remove the protective cover (26).

27. Loosen the air hose clamp (27).
28. Loosen the hose clamp (28).
50-200 34 PC200, 200LC, 220, 220LC-8M0

29. Disconnect the lubrication oil inlet tube (29) and lubrication
oil outlet hose (30).
a When loosening the sleeve nut of tube (29), fix the con-
nector on the turbocharger side with a wrench, etc. so
that it does not turn together.
30. Remove the mounting bolts of the exhaust manifold (31),
leaving several of them.
a Leave 2 to 3 pieces easy to remove among the 12
mounting bolts.
31. Sling the exhaust manifold and turbocharger assembly (80),

and remove the remaining mounting bolts.
and remove it.
4 Exhaust manifold and turbocharger assembly: 25 kg
33. Remove the fan (32).

a Slowly lower the fan onto the undercover below.
34. Loosen the air conditioner compressor bracket mounting

bolts (33) and (34).
Bolts (33), (34): Width across flats 22 mm, M14
35. Remove the air conditioner compressor drive belt (35).
36. Disconnect the connector AC02 (36).
37. Remove the bolts (37a) (3 pieces), and remove the air con-
ditioner compressor assembly (37).
4 Air conditioner compressor assembly (37): 20 kg
a Do not disconnect the air conditioner hose.
a Remove the air conditioner compressor assembly
together with the bracket as a unit, and place them on
the counterweight.
PC200, 200LC, 220, 220LC-8M0 50-200 35

38. Remove the fan belt (38) according to the following proce-
dure.
q Set a wrench into part A of tensioner assembly (38a)
the fan belt (38).
k Firmly set the wrench on tensioner assembly (38a)

wrench. (The spring of tensioner assembly (38a) is
k After removing the fan belt (38), return the ten-
sioner assembly (38a) to its original position slowly
and carefully.
39. Disconnect the connectors AB (40) and E12 (41).
40. Remove the alternator (39).
41. Remove the clamp (43) and bands (44) (2 places) of the
wiring harness (42).
42. Remove the head cover mounting bolts (45) (5 pieces), and
remove the head cover (46) together with the blowby duct
(47).
a After loosening the head cover mounting bolts (45),
remove sludge and other foreign material sticking
around by airblow, etc. to prevent their entry while hold-
ing the cover with your hand.
a When removing the head cover (46), take care not to
hit it against the surrounding parts.
43. Remove the blowby duct (47) from the head cover (46).
44. Remove the fuel return tube (46a).
45. Remove the harness nuts (49) (12 pieces) from the fuel injec-
tors (48) (6 pieces).
a Installed positions of wring harnesses
Color of wiring harness Cylinder No.
White 1, 3, 5
Black 2, 4, 6
46. Remove the connectors (3 places) of the engine harness

(50).
a Each connector has a fixing hook. Pull it out while
pressing the hook. At this time, hold the gasket to pre-
vent it from moving.
50-200 36 PC200, 200LC, 220, 220LC-8M0

47. Lift the gasket assembly (51), and remove it.

a When removing it, prevent foreign material from enter-
ing the engine.
a When removing the head cover (46), visually check the
new one.
48. Remove the mounting bolts, and remove the rocker arms
(52).
a When installing the rocker arm, loosen the lock nut (53)
and loosen the adjustment screw (54) 2 to 3 turns so
that an excessive force is not applied to the push rod.
49. Remove the crossheads (55).

a Record the installed position and direction (shapes of
holes (a) and (b)) of each crosshead. (For reinstallation
in the same direction)
50. Remove the retaining nut (56), and remove inlet connector
(57).
a Clean the surrounding area to remove mud and other
contamination in advance to prevent them from enter-
ing the inlet connector hole.
a The tool A5 (remover) is set for removal of the inlet
connector.
PC200, 200LC, 220, 220LC-8M0 50-200 37

51. Remove the mounting bolts (59) of the fuel injector assem-
bly (58).
52. Remove the fuel injector assembly (60) by using the tool A3
(puller).
a Do not pry the injector assembly head to remove it.
a Be careful not to allow dirt and foreign matter to enter
the mounting portion of the injector assembly.
53. Remove the push rods (61).
54. Remove mounting bolts (62), sling cylinder head assembly

(63) and remove it.
a Install the lifting tool to the sling positions (a).
4 Cylinder head assembly: 75 kg
55. Remove the cylinder head gasket (64).
50-200 38 PC200, 200LC, 220, 220LC-8M0

Installation
1. Cylinder head assembly
1) Measure the stem length "a" of every cylinder head
mounting bolt, and check that it is within the using limit.
q Allowable limit length of bolt: 132.1 mm or less
a If a bolt is longer than the allowable limit, do not
reuse it but replace it.
2) Check that the cylinder head mounting face and inside

of the cylinders are free from dirt or foreign material,
and then set cylinder head gasket (64).
a Use a new gasket.
a Check that the holes of the gasket is fitted to those
of the cylinder head.
3) Sling the cylinder head assembly (63), set it on the cyl-
inder block, and finger-tighten the mounting bolt (62) 2
to 3 turns or more first.
4) Tighten the cylinder head mounting bolts (62) accord-
ing to the following procedures in the order of [1] to
[26].
q Method of tightening mounting bolts (62)
1] Tighten to 90±3 Nm {9.2±0.3 kgm}.
2] Check that the torque is 90±3 Nm {9.2±0.3 kgm}.
3] 90°±5° (Tighten with angle tightening tool)
2 Apply engine oil (EO15W-40) to the mounting
bolt thread part and bolt head seat surface.
q When angle tightening tool is not available (When not

using angle tightening tool)
Put marks on the cylinder head and bolts with a felt-tip
pen, and retighten the bolts 90°±5°.
2. Install push rods (61).
PC200, 200LC, 220, 220LC-8M0 50-200 39

3. Fuel injector assembly

NOTICE
When replacing an injector assembly with a new one,
replace the inlet connector with a new one as well.
a Check that the fuel injector sleeve (IS) is free of
scratches and dirt.
1) Install the O-ring (58a) and gasket (58b) to the fuel
injector (58).
a Replace the O-ring and gasket with new ones.
2) Apply engine oil (EO15W-40) to the O-ring of the fuel
injector (58) and to the mounting hole on the head side.
2 O-ring (58a) of fuel injector (58) and cylinder
head side: Engine oil (EO15W-40)
3) Align the concave portion (C) of holder (58c) with the
convex portion (A) of fuel injector (58), and install the
holder (58c).
4) Direct the fuel inlet hole of fuel injector assembly (58)

toward the air intake manifold, and install the assembly
to the cylinder head.
5) Tighten the bolts (59) of fuel injector (58) 3 or 4 turns.
6) Check the inlet connector for the following points. If it

has any abnormality, replace it together with the injec-
tor.
1] When burrs or wear is found in the inlet connector
top-end (a) and rear-end (b) parts.
2] There is foreign material in the edge filter at rear
end (c) of the inlet connector.
3] When there are cracks or deterioration on the O-
ring of the inlet connector upper (d) part.
4] There is a worn part or an uneven seat contact

mark on the seat face (e) at the front end of the
inlet connector.
a If high-pressure fuel leaks through the inlet
connector, seat surface has fine streaks or
cracks.
50-200 40 PC200, 200LC, 220, 220LC-8M0

7) Apply engine oil to the head side (part B) of the inlet

connector (57).
8) Apply engine oil to the O-ring of the inlet connector
(57), and fully insert inlet connector (57), while match-
ing portion B with the groove on the head side.
9) Lightly tighten the inlet connector (57) with the retaining

nut (56). (Push it into the injector hole.)
10) Alternately tighten the mounting bolts (59) of the fuel

injector assembly (58).
3 Bolt: 8±0.8 Nm {0.81±0.08 kgm}
11) Tighten the retaining nut (56).

3 Retaining nut (56): 50±5 Nm {5.1±0.5 kgm}
4. Rocker arm, crosshead

1) Install the crossheads (55) and rocker arms (52).
a Hole shapes of the crossheads (a) and (b) are not
identical. Install the same intake valve or exhaust
valve in the same direction when reusing cross-
head.
a Check that the ball of adjustment screw (54) is fit-
ted in push rod socket, and tighten the mounting
bolt.
2) Adjust the valve clearance.

a See Testing and adjusting, "Testing and adjusting
valve clearance".
a Use the tool A4 (gear) to crank the engine.
3 Lock nut (53): 20 to 28 Nm {2.04 to 2.86 kgm}
PC200, 200LC, 220, 220LC-8M0 50-200 41

5. Install the wiring harness (50), and install the nut (49).
a Check that wiring harness does not interfere with
rocker arm.
a Installed positions of wring harnesses
Color of wiring harness Cylinder No.
White 1, 3, 5
Black 2, 4, 6
3 Wiring harness mounting nut:

1.5±0.25 Nm {0.15±0.03 kgm}
6. Install the cylinder head cover (46) with the gasket (51)
attached.
a Use a new gasket.
3 Mounting nut: 24±4 Nm {2.4±0.4 kgm}
7. Install the blowby duct (45).

3 Blowby duct mounting bolt: 7±2 Nm {0.71±0.2 kgm}
8. Install the fuel return tube (46a).

3 Joint bolt: 24±4 Nm {2.4±0.4 kgm}
9. Install the clamp (43) and bands (44) (2 places) of the wiring
harness (42).
50-200 42 PC200, 200LC, 220, 220LC-8M0

10. Install the alternator (39).

11. Connect the connectors AB (40) and E12 (41).
12. Install the fan belt (38) according to the following procedure.
q Set a wrench into part A of tensioner assembly (38a)
site direction (R) to the winding-up direction to install
the fan belt (38).
k Firmly set the wrench on tensioner assembly (38a)
wrench. (The spring of tensioner assembly (38a) is
k After installing fan belt (38), slowly and carefully
restore tensioner assembly (38a).
13. Install the air conditioner compressor assembly (37) with

the bolts (37a) (3 pieces).
3 Bolt (37a): 59 to 74 Nm {6 to 7.5 kgm}
14. Install the air conditioner compressor drive belt (35).
15. Tighten the bolts (33) and (34).
Bolts (33), (34): Width across flats 22 mm, M14
3 Bolts (33), (34): 153 to 190 Nm {15.5 to 19.5 kgm}
16. Connect connector AC02 (36).
17. Install the fan (32).

3 Fan mounting bolt: 43±6 Nm {4.4±0.6 kgm}
PC200, 200LC, 220, 220LC-8M0 50-200 43


and set it to the installing position.
a Replace all the gaskets with new ones.
4 Exhaust manifold and turbocharger assembly: 25 kg
19. Install the exhaust manifold and turbocharger assembly (80)

with bolts (31a) (12 pieces).
a Tighten in the order shown in the figure.
3 Exhaust manifold mounting bolt:
1st time: Tighten to the following torque in the order of
[1] to [12].
24±4 Nm {2.4±0.4 kgm}
2nd time: Tighten to the following torque in the order of
[1] to [12].
53±6 Nm {5.4±0.6 kgm}
3rd time: Tighten only the bolts [1] to [4] to the following
torque in this order.
53±6 Nm {5.4±0.6 kgm}
20. Connect the lubrication oil inlet tube (29) and lubrication oil
outlet hose (30).
a When tightening the sleeve nut of tube (29), fix the con-
nector on the turbocharger side with a wrench, etc. so
that it does not turn together.
3 Lubrication oil inlet tube mounting sleeve nut:
35±5 Nm {3.5±0.5 kgm}
a If the connector is loosened, tighten it to the following
torque.
3 Connector: 9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3 Lubrication oil outlet tube mounting bolt:
10±2 Nm {1.02±0.2 kgm}
21. Connect the air hose (27a) with the hose clamp (27).
3 Hose clamp: 10.0 to 11.0 Nm {1.02 to 1.12 kgm}
22. Connect the hose (28a) with the hose clamp (28).
50-200 44 PC200, 200LC, 220, 220LC-8M0

1) Align the hose to its original position (marked position).

a Reference
Air hose insertion length:
40 mm (Turbocharger side)
2) Set bridge (BR) under the clamp fastening bolt, and
adjust overlap (b) between bridge (BR) and band (BD)
to Min. 5 mm.
Dimension b: Min. 5mm
2 Clamp fastening bolt thread part (BC):
Lubricating oil (ThreeBond PANDO18B)
a Impact wrench is not allowed to use.
q When reusing hose
Align the clamp position to the trace of clamp left on hose.
3 Clamp tightening bolt: Min. 6 Nm {0.6 kgm}
q When using new hose
Tighten it until dimension BDG becomes 7 to 10 mm.
23. Install the protective cover (26).
24. Install the high-pressure pipes (21) and (24a) to (24f), and
common rail (20) as a unit.
a Connect the high-pressure pipe according to the follow-
ing procedure.
q High-pressure pipe and common rail
k Do not bend high-pressure pipe to correct before
installing.
k Be sure to use the Komatsu genuine high-pressure
pipe clamps and observe the specified tightening
torque.
k Install each high-pressure pipe and wiring harness
at least 10 mm apart from each other.
a A high-pressure pipe must be replaced if dents such as
slits "b" or spots "c" are visually recognizable in taper
seal part ("a" part: 2 mm from the tip) of its connection,
or if level difference in part "d" (within 2 mm from taper
seal end face) due to fatigue is large enough to catch
your fingers because such high-pressure pipe can
induce fuel leakage. In this case, replace the high-pres-
sure pipe.
PC200, 200LC, 220, 220LC-8M0 50-200 45

1) Lightly install the common rail (20) and high-pressure

pipes (24a) to (24f).
3 Sleeve nut and mounting bolt:
0.2 to 0.8 Nm {0.02 to 0.08 kgm)
2) Tighten the high-pressure pipes (24a) to (24f) accord-
3 Sleeve nut: 35 to 3.5 Nm {3.6±0.4 kgm}
1] Head side of high-pressure pipes (24a) and (24f)
2] Common rail side of high-pressure pipes (24f) and
(24a)
3] Head side of high-pressure pipes (24b), (24c),
(24d), and (24e)
4] Common rail side of high-pressure pipes (24b),
(24c), (24d), and (24e)
3) Lightly tighten the sleeve nut of the high-pressure pipe
(21).
4) Tighten the high-pressure pipe (21) in the order of the
pump (FSP) side to the common rail side.
3 Sleeve nut: 35±3.5 Nm {3.6±0.4 kgm}
5) Tighten the clamp (21a) of the high-pressure pipe

(25b).
6) Tighten the common rails (20) with the bolts (4 pieces).

a Apply sealant (LG-7) to the thread parts of the
bolts (2 pieces) inside the engine.
7) Install the fuel spray prevention caps (22) (2 pieces)

and (23) (12 pieces) to the high-pressure pipes.
a Direct slits of fuel spray prevention caps outward
and downward.
a FSP: Fuel supply pump
8) If the injector wiring harness connector (IHC) is

removed, apply liquid gasket LG-7 to the O-ring (o) and
flange surface (p) of the connector when installing.
a As for O-ring, apply LG-7 f3 mm in diameter until
the O-ring groove is completely hidden.
a When the O-ring is damaged, replace the wiring
harness assembly, since the O-ring cannot be sup-
plied singly.
3 Connector flange mounting bolt:
10±2 Nm {1±0.2 kgm}
50-200 46 PC200, 200LC, 220, 220LC-8M0

Reference
q Handling of fuel pressure sensor (PS) and relief valve (RV)
1. Fuel pressure sensor
a Check the fuel pressure sensor (PS) connector for
crack, breakage, damage of the seal, foreign matter on
the pin and corrosion, bend and breakage of the pin.
a When the fuel pressure sensor (PS) is removed from
the common rail (CR), be sure to replace it with a new
one.
q When replacing fuel pressure sensor (PS) with a new
one
1) Before removing the fuel pressure sensor (PS), thor-
oughly remove and clean the mud etc. from around it.
2) Remove the fuel pressure sensor (PS).
3) Install a new fuel pressure sensor.
2 Thread part: Clean gear oil (#90)
3 Fuel pressure sensor 70±5 Nm {7.1±0.5 kgm}
4) Connect the engine wiring harness. At this time, be
careful not to reverse the connection of connector.
5) After completing assembly, start the engine, and check
for leakage.
a See "Testing and adjusting" for the testing proce-
dure.
2. Relief valve
a If the leakage from the relief valve (RV) exceeds the
specified value, do not reuse it.
q When replacing relief valve (RV) with a new one
1) Before removing the relief valve (RV), thoroughly
remove and clean the mud etc. from around it.
2) Remove the relief valve (RV).
3) Check the high-pressure sealing surfaces (A) of the
relief valve (RV) and common rail (CR) for damages.
4) Install the new relief valve (RV).
2 Thread part: Clean gear oil (#90)
3 Relief valve: 100±4 Nm {10.2±0.4 kgm}
a Excessive tightening can cause fuel leakage. Be
careful not to tighten it excessively.
25. Install the fuel return hose (19) from the common rail (20)
and cylinder head rear face.
3 Joint bolt of fuel return hose:
24±4 Nm {2.4±0.4 kgm}
26. Connect the fuel pressure sensor connector (18).
PC200, 200LC, 220, 220LC-8M0 50-200 47

27. Connect the coolant temperature sensor connector (17).
28. Connect the ambient pressure sensor connector (14) and

boost pressure sensor connector (15) according to the fol-
lowing pressure.
1) Slide red lever (a) in the direction of arrow (x) to unlock,

then insert the connector in the direction (y).
2) Slide the red lever in the direction of arrow (z) to lock.
29. Install the fan guard (13) with the bolts (13a) (7 pieces).
3 Bolt (13a): 59 to 74 Nm {6 to 7.5 kgm}
30. Connect the heater hose (12).
31. Connect the radiator hose (11) with the clamp (11a).
Clamp (11a): Width across flats 8 mm
3 Clamp (11a): 10.8 to 11.8 Nm {1.1 to 1.2 kgm}
32. Connect the hose (10c).

a When the hose is disconnected at the intake connector
(part C), replace the gasket.
50-200 48 PC200, 200LC, 220, 220LC-8M0

33. Install the clamp (10b) to the fan guard (13).

3 Bolt of clamp (10b): 6 to 7.5 Nm {59 to 74 kgm}
34. Install the hose (10) with the hose clamp (10a).
3 Hose clamp (10a): 10.8 to 11.8 Nm {1.1 to 1.2 kgm}

a Reference
Air hose insertion depth: 60 mm (Aftercooler side)
to Min. 5 mm.
Dimension b: Min. 5mm
q When reusing hose
Align the clamp position to the trace of clamp left on hose.

35. Sling the muffler assembly (8), and set it to the installing
position.
a Apply heat-hardening sealant, and install muffler
assembly (8).
2 All periphery of part (e) of exhaust pipe (8a): Heat-
hardening sealant (Holts Japan Firegum or equiva-
lent)
36. Lightly install the muffler assembly (8) and exhaust pipe
(8a).
37. Lightly install the muffler assembly in step 2 to the turbo-
charger, and position it.
38. Install the U-bolt (8c), and tighten the nuts (8d).
3 Nut (8d): 9.8 to 14.7 Nm {1.0 to 1.5 kgm}
39. Tighten the turbocharger outlet clamp (8e).
3 Turbocharger outlet clamp (8e):
6.8 to 8.8 Nm {0.7 to 0.9 kgm}
40. Tighten the seal clamp (8f).
3 Seal clamp (8f):
1st time: 39.2 to 49.9 Nm {4 to 5 kgm}
2nd time: 68.6 to 122.5 Nm {7.0 to 12.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-200 49

41. Install the clamp (7).

42. Install the cover (6).
(5a) (2 pieces).
3 Bolt (5a): 98 to 123 Nm {10 to 12.5 kgm}
44. Connect the fuel return hose (4).

a If the internal parts of the hose fitting are damaged
when the hose is disconnected, replace the hose with a
brand-new one.
45. Connect the fuel filter hoses (2) and (3) from the fuel supply
pump (FSP).
brand-new one.
46. Install the following parts. For details, see "Installation of

engine and hydraulic pump assembly", 48 to 64.
q Engine hood
47. Add coolant.
5 Coolant:
20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
48. Open the fuel stop valve (1e).
50-200 50 PC200, 200LC, 220, 220LC-8M0

49. Install covers (1) and (1a) with bolts (1b) (13 pieces).
3 Bolt (1b): 98 to 123 Nm {10 to 12.5 kgm}
50. After completing assembly, start the engine, and check for fuel leakage.
a For the testing procedure, see Testing and adjusting, Testing fuel circuit for leakage.
PC200, 200LC, 220, 220LC-8M0 50-200 51

SEN06143-01 Removal and installation of radiator assembly
Removal and installation of radiator assembly 1
Standard tools list

10.8 to 11.8 Nm
59 to 74 Nm
98 to 123 Nm
10.58±0.5 Nm
7 Eyebolt (Commercially available) M12 2
8 2-leg wire sling (Commercially available) 1 (15 kg)
9 Lever block (Commercially available) 1 (15 kg)
k If you drain the coolant when it is still hot, you may be scalded. Wait until the coolant tempera-
ture drops before starting the work.
50-200 52 PC200, 200LC, 220, 220LC-8M0

Removal and installation of radiator assembly SEN06143-01
Removal
6 Coolant:
21 l (PC200/200LC-8M0)
20.4l (PC220/220LC-8M0)
4. Disconnect the reservoir tank hose (2).

7. Disconnect the radiator hose (6a).
8. Remove the hose clamp (6b), and disconnect the radiator
hose (6).
nized.
PC200, 200LC, 220, 220LC-8M0 50-200 53

9. Remove the hose clamp (7a), and disconnect the radiator

hose (7).
nized.
a This work is for avoiding the flange.
11. Remove the bolts (10) (2 pieces), sling the radiator assem-
bly (9) by using the eyebolts (M12) and the sling, and
remove it.
Tools: Lever block, 2-leg wire sling, eyebolt, socket wrench
4 Radiator assembly: 15 kg
50-200 54 PC200, 200LC, 220, 220LC-8M0

Removal and installation of radiator assembly SEN06143-01
Installation
1. Sling the radiator assembly (9) by using the eyebolts (M12)
and sling, and set it on the installing position.
4 Radiator assembly: 15 kg
a Check that the heat insulation sealant (sponge) on the
periphery of the radiator is not damaged. If the heat
insulation sealant (sponge) is damaged, replace it.
Check from the undercover side that the protrusion (A)
of the radiator bottom is matched with the groove (B).
2. Install the radiator assembly (9) with the bolts (10) (2

pieces).
3 Bolt (10): 98 to 123 Nm {10 to 12.5 kgm}
3. Install the cover (8) with bolts (8a) (3 pieces).

3 Bolt (8a): 59 to 74 Nm {6 to 7.5 kgm}
a Align the hose to its original position (marked position).
a Align the clamp to the original position.
a Reference
Hose insertion depth
q 45 mm (Radiator side)
q 40 mm (Engine side)
PC200, 200LC, 220, 220LC-8M0 50-200 55

5. Connect the radiator hose (6) with the hose clamp (6b).
Hose clamp (6b): Width across flats 8 mm
3 Hose clamp (6b): 10.8 to 11.8 Nm {1.1 to 1.2 kgm}
a Reference
Hose insertion depth
q 45 mm (Radiator side)
q 40 mm (Engine side)
6. Connect the radiator hose (6a).
3 Bolt (5a): 59 to 74 Nm {6 to 7.5 kgm}

3 Bolt (3a): 59 to 74 Nm {6 to 7.5 kgm}
9. Connect the reservoir tank hose (2).
10. Refill with coolant.

5 Coolant:
20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
a Check for coolant leakage.
3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
50-200 56 PC200, 200LC, 220, 220LC-8M0

Removal and installation of hydraulic oil cooler assembly SEN06143-01
Removal and installation of hydraulic oil cooler assembly 1
Standard tools list

k After stopping the engine, loosen the cap of the hydraulic tank slowly to release the internal
pressure in the hydraulic tank, and set the lock lever to LOCK position.
NOTICE
PC200, 200LC, 220, 220LC-8M0 50-200 57

SEN06143-01 Removal and installation of hydraulic oil cooler assembly
Removal
2. Open the engine hood (1b).
3. Loosen the upper side (return) hose (7) of the hydraulic tank
(See the next page), and let air into the tank in order to
decrease the internal pressure.
4. Remove the drain plug (2) of the hydraulic oil cooler drain
hose, and drain the hydraulic oil.
Plug (2): Width across flats 22 mm, M14
6 Hydraulic oil refill capacity: 135 l,
Hydraulic oil cooler capacity: 7 l
5. Remove the bolts (3a) (5 pieces), and move the cover (3).
6. Open the L.H. side cover (11).
7. Remove the bolts (4a) (2 pieces), and disconnect the drain

hose (4).
a Cover the hose disconnection portions with plastic
bags, etc. in order to prevent oil from leaking.
50-200 58 PC200, 200LC, 220, 220LC-8M0

8. Disconnect reservoir tank hose (5).

10. Remove the bolts (7a) (2 pieces), and disconnect the

hydraulic tank return hose (7).
11. Remove the bolts (8) from the hydraulic oil cooler assembly
(10).
13. Sling the hydraulic oil cooler assembly (10), and remove it
by using eyebolts (M10) [1] and sling.
Tools: Lever block, 2-leg wire sling, eyebolt
4 Hydraulic oil cooler assembly: 25 kg
PC200, 200LC, 220, 220LC-8M0 50-200 59

SEN06143-01 Removal and installation of hydraulic oil cooler assembly
Installation
1. Sling the hydraulic oil cooler assembly (10) by using the
eyebolts (M10) [1] and sling, and set it on the installing posi-
tion.
4 Hydraulic oil cooler assembly: 25 kg
periphery of the hydraulic oil cooler is not damaged. If
the heat insulation sealant (sponge) is damaged,
replace it.
Check from the undercover side that the protrusion (A)
of the oil cooler bottom is matched with the groove (B).
2. Install the hydraulic oil cooler assembly (10) with the bolts
(8) (2 pieces).
3 Bolt (8): 59 to 74 Nm {6 to 7.5 kgm}
3. Connect the hydraulic tank return hose (7) with the bolts
(7a) (2 pieces).
3 Bolt (7a): 98 to 123 Nm {10 to 12.5 kgm}

3 Bolt (9a): 59 to 74 Nm {6 to 7.5 kgm}

3 Bolt (6a): 59 to 74 Nm {6 to 7.5 kgm}
6. Connect the reservoir tank hose (5).
50-200 60 PC200, 200LC, 220, 220LC-8M0

7. Connect the control valve drain hose (4) with the bolts (4a)
(2 pieces).
3 Bolt (4a): 98 to 123 Nm {10 to 12.5 kgm}
8. Close the L.H. side cover (11).

3 Bolt (3a): 59 to 74 Nm {6 to 7.5 kgm}
10. Install the plug (2) of the hydraulic oil cooler drain hose.
Plug (2): Width across flats 22mm, M14
3 Plug (2): 153 to 190 Nm {15.5 to 19.5 kgm}
11. Refill the hydraulic tank with hydraulic oil.

a Refill with oil to the specified level. Run the engine to
circulate the hydraulic oil through the piping, and check
the oil level again.
a Check for oil leakage.
5 Hydraulic oil refill capacity: 135 l,
Hydraulic oil cooler capacity: 7 l
3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
13. Close the engine hood (1b).
PC200, 200LC, 220, 220LC-8M0 50-200 61

SEN06143-01 Removal and installation of aftercooler assembly
Removal and installation of aftercooler assembly 1
Standard tools list

59 to 74 Nm
10.58±0.5 Nm
k Stop the engine and wait until the engine and auxiliaries cool down to a safe temperature, then
start the work.
50-200 62 PC200, 200LC, 220, 220LC-8M0

Removal and installation of aftercooler assembly SEN06143-01
Removal
nized.
a Air hose insertion depth
q A: 80 mm
PC200, 200LC, 220, 220LC-8M0 50-200 63

6. Remove the bolts (6a) (2 pieces), and disconnect the tube

(6).
(This work is for avoiding the flange.)
8. Remove the bolts (8a) (2 pieces), sling the aftercooler

assembly (8) by using the eyebolts (M10) and sling, and
remove it.
4 Aftercooler assembly: 15 kg
50-200 64 PC200, 200LC, 220, 220LC-8M0

Removal and installation of aftercooler assembly SEN06143-01
Installation
1. Sling the aftercooler assembly (8) by using the eyebolts
(M10) and sling, and set it on the installing position.
periphery of the aftercooler is not damaged. If the heat
insulation sealant (sponge) is damaged, replace it.
Check from the undercover side that the protrusion (A) of
the aftercooler bottom is matched with the groove (B).
2. Install the aftercooler assembly (8) with the bolts (8a).
3 Bolt (8a): 59 to 74 Nm {6 to 7.5 kgm}

3 Bolt (7a): 59 to 74 Nm {6 to 7.5 kgm}
4. Install the tube (6) with the bolts (6a) (2 pieces).
a Replace the O-ring on the mating face with a new one.
3 Bolt (6a): 59 to 74 Nm {6 to 7.5 kgm}

3 Bolt (5a): 59 to 74 Nm {6 to 7.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-200 65

6. Install the hose (4) with the hose clamp (4a).

3 Hose clamp (4a): 10.58±0.5 Nm {1.07±0.05 kgm}
a (Reference) Air hose insertion depth
q Aftercooler side: 60 mm
q Engine side: 80 mm

to Min. 5 mm.
Dimension (b) : Min. 5 mm
q When reusing hose
Align the clamp position to the trace of clamp left on
hose.

3 Bolt (3a): 59 to 74 Nm {6 to 7.5 kgm}

3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
50-200 66 PC200, 200LC, 220, 220LC-8M0

Removal and installation of fuel cooler assembly SEN06143-01
Removal and installation of fuel cooler assembly 1
Standard tools list

3 Wrench (Commercially available) 19 mm 1
27 to 34 Nm
98 to 123 Nm
6 Torque wrench set (wrench) (Commercially available) 54 to 93 Nm 1
NOTICE
PC200, 200LC, 220, 220LC-8M0 50-200 67

SEN06143-01 Removal and installation of fuel cooler assembly
Removal
1. Remove the bolts (1a) (7 pieces), and remove the fuel tank
bottom cover (1b).
2. Remove the bolts (1c) (6 pieces), and remove the cover
(1d).
3. Close fuel stop valve (1a).
4. Disconnect fuel hoses (1) and (2).

Tools: Wrench
a If the elbow (L) is not fixed with the wrench [1], the turn-
ing force is applied to the cooler unit and the weld por-
tion (M) comes off. Securely fix the elbow (L) with the
wrench [1] when disconnecting the hose.
5. Remove the bolts (3a) (4 pieces), and remove the fuel
cooler assembly (3).
50-200 68 PC200, 200LC, 220, 220LC-8M0

Removal and installation of fuel cooler assembly SEN06143-01
Installation
1. Connect the fuel cooler assembly (3) with the bolt (3a) (4
piece).
3 Bolt (3a): 27 to 34 Nm {2.8 to 3.5 kgm}
2. Connect the fuel hoses (1) and (2).
Tools: Torque wrench set (wrench)
Hoses (1) and (2): Width across flats 22 mm, #03 size
3 Hoses (1), (2): 54 to 93 Nm {5.5 to 9.5 kgm}
a If the elbow (L) is not fixed with the wrench [1], the turn-
ing force is applied to the cooler unit and the weld por-
tion (M) comes off. Securely fix the elbow (L) with the
wrench [1] when disconnecting the hose.
4. Install the cover (1d) with the bolts (1c) (6 pieces).

3 Bolt (1c): 98 to 123 Nm {10 to 12.5 kgm}
5. Install the fuel tank bottom cover (1b) with the bolts (1a) (7
pieces).
3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-200 69

SEN06143-01 Removal and installation of engine and hydraulic pump assembly
Removal and installation of engine and hydraulic pump assembly 1
Standard tools list

11 Hexagonal wrench (Commercially available) 4 mm 1
5.9 to 9.8 Nm
10.0 to 11.0 Nm
10.8 to 11.8 Nm
17.7 to 24.5 Nm
59 to 74 Nm
98 to 123 Nm
153 to 190 Nm
245 to 308.9 Nm
10.58±0.5 Nm
43±6 Nm
14 Torque wrench set (hexagonal) (Commercially available) 2.6 to 3.1 Nm 1
15 Wire (Commercially available) 1 (50 kg)
50-200 70 PC200, 200LC, 220, 220LC-8M0

Removal and installation of engine and hydraulic pump assembly SEN06143-01
Special tools list

1 Plate 796T-401-1110 1
A
2 Lifting tool 795-799-9300 1 (800 kg)
1 Oil stopper 796-460-1210 1
B
2 Adapter 796-770-1320 1
1 Plug (female) 02789-00210 #02 5 EPC source port
2 Plug (male) 07376-70210 #02 5 hose, pump pres-
sure input port
hose, front load
pressure input
C
port hose, rear
3 O-ring 02896-11008 5 load pressure
input port hose,
PPC circuit drain
hose
1 Flange 07379-01044 #10 4
Branch hose,
2 Head 07378-11000 #10 4 front pump dis-
D 3 O-ring 07000-13032 4 charge port hose,
4 Split flange 07371-31049 8 rear pump dis-
charge port hose
5 Bolt 07375-21035 16
k After stopping the engine, loosen the cap of the hydraulic tank slowly to release the internal
pressure in the hydraulic tank, and set the lock lever to LOCK position.
k Stop the engine and wait until the engine and auxiliaries cool down to a safe temperature, then
start the work.
k Release the remaining pressure in the hydraulic circuit referring to Testing and adjusting,
"Releasing remaining pressure from hydraulic system".
NOTICE
PC200, 200LC, 220, 220LC-8M0 50-200 71

Removal
1. Remove the bolts (1f) (6 pieces), and remove the cover
(1g).
2. Remove the hydraulic tank strainer, and stop the oil with
tools B1 (oil stopper) and B2 (adapter).
Bolt (1f): Width across flats 19 mm, M12
6 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
<When not using oil stopper B1 and adapter B2>

1. Remove the bolts (1h) (11 pieces), and remove the covers
(1) and (1j).
2. Remove the hydraulic oil drain plug (1k), and drain the oil
from the hydraulic tank.
Plug (1k): Width across flats 24 mm
6 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
a After draining the oil, install the plug (1k).
3. Remove the bolts (1a) (7 pieces), (1b) (6 pieces), and (1c)

(6 pieces), and remove the covers (1), (1d), and (1e).
Bolt (1a), (1b), (1c): Width across flats 19 mm, M12
6 Coolant:
20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
50-200 72 PC200, 200LC, 220, 220LC-8M0

5. Close fuel stop valve (1a).
7. Sling the engine hood (2), and hold it.

Tools: Wire
4 Engine hood: 50 kg
a When slinging the engine hood, take care not to dam-
age the rubber seal.
8. Remove pins (3) and (4), and remove the gas springs (5) (2
pieces).
9. Remove the mounting bolts (2a) (4 pieces), sling the engine

hood (2), and remove it.
10. Remove the pre-cleaner (6) and pre-cleaner stand pipe (7).
(If equipped)
11. Remove the bolts (8a) (4 pieces) and (9a) (3 pieces), and
remove the air cleaner top cover (8) and control valve top
cover (9).
Bolt (8a), (9a): Width across flats 19 mm, M12
4 Air cleaner top cover (8): 11 kg
Control valve top cover (9): 11 kg
PC200, 200LC, 220, 220LC-8M0 50-200 73

12. Disconnect the hose (10a).

13. Remove the bolts (10b) (7 pieces), and remove the cover
(10).
14. Remove the bolts (11a) (2 pieces), and remove the frame
(11).
15. Remove the bolts (12a) (4 pieces), and remove the cover
(12) between the hydraulic pump and engine.
(13).
17. Remove the bolts (14a) (3 pieces), and remove the covers
(14) and (15).
a You cannot remove the cover (15) before removing the
control valve top cover (9).
18. Remove the mounting bolts (16) (2 pieces).

19. Remove the mounting bolts (17) (3 pieces).
(18).
(19).
(20).
23. Remove the bolt (21a), and remove the cover (21).
(22) between the control valve and engine.
a You cannot remove the cover (24) before removing the
frame (22).
50-200 74 PC200, 200LC, 220, 220LC-8M0

25. Remove the bolts (23) (3 pieces), and pull the cover (24)
upward to remove it.
a The cover (24) is stuck. You do not need to remove the
underside bolts.
26. Install frame (20) again in order to secure a foothold.
a Remove the frame as soon as it is no longer used as
the foothold.
27. Remove the bolts (25a) (2 pieces), and disconnect the fuel
filter and bracket assembly (25).
a Place this assembly on the engine.
28. Cut the cable tie (25a).

nized.
a When disconnecting at the intake connector (C),
replace the gasket.
30. Remove the clamp (27a), and disconnect the radiator hose
(27) on the engine side.
Clamp (27a): Width across flats 8 mm
nized. (See the figure)
guard (29).
33. Remove the clamp (30a), and disconnect the air cleaner
tube (30).
Clamp (30a): Width across flats 9.5 mm (3/8 in)
34. Remove the hose clamps (31a) and (31b), and remove the
aftercooler hose and tube assembly (31).
Hose clamp (31a): Width across flats 11mm
nized.
PC200, 200LC, 220, 220LC-8M0 50-200 75

35. Disconnect the fuel filter hoses (32) from the fuel supply
pump (FSP).
a Fuel flows out when the hoses are disconnected. Cover
the hose fittings with cloths, etc. However, do not use
wooden plugs, which causes wood chips.
36. Remove the joint bolt (33a), and disconnect the fuel supply
hose (33).
37. Remove the joint bolt (34a), and disconnect the fuel return
hose (34).
38. Remove the bolts (35a) (4 pieces), and remove the fan (35).
39. Loosen the air conditioner compressor bracket adjustment

bolts (36) and (36a).
a One more bolt is on the rear side.
40. Move the air conditioner compressor assembly (37).
41. Remove the fan belt (38).
50-200 76 PC200, 200LC, 220, 220LC-8M0

42. Disconnect the connector AC02 (39).

43. Remove the bolts (36) and (36a), and remove the air condi-
tioner compressor assembly (37) without disconnecting the
air conditioner hoses.
a Remove the air conditioner compressor assembly
together with the bracket as a unit, and place them on
the counterweight so that they do not hinder the work.
44. Disconnect the intake air heater connector E01 (40).
45. Remove the bolts (L6) (2 pieces), and disconnect the con-
nectors CE02 (41) and CE02 (42) from the engine control-
ler.
Tools: Hexagonal wrench
Bolt (L6): Width across flats 4 mm, M6
a Remove the connector (42). Although it is installed on
the engine, it is an obstacle when you remove the
engine mounting bolts.
46. Disconnect the connector (43) from the engine controller by
pressing its lock.
47. Disconnect the connector E06 (44).
48. Remove the bolt (45a), and disconnect the engine controller
ground connector T12 (45).
49. Remove the bolt (46a), disconnect bracket (46), and
remove the spacer (47).
50. Remove the bolt (48a), and disconnect the clamp (48).
PC200, 200LC, 220, 220LC-8M0 50-200 77

51. Remove the nut (49a), and disconnect the terminal (49)
from the starting motor ST.
52. Disconnect the connector E10 (50).
a Connector on starting motor side: T13
54. Disconnect the connectors E08 (51) and P44 (52).
56. Remove the bolts (55a) (2 pieces), and remove the filter
and bracket assembly (55) and move it toward the hose
bracket (HB) so that it is not an obstacle.
57. Disconnect the hoses (56), (57), (58), (59), (60), and (61).
q (56): Rear pump load pressure input port hose
(Band color: No color)
Tools: Wrench, special tool C
Hose (56): Width across flats 19 mm, #02 size
q (57), (58): EPC source pressure port hose
Hose (57), (58): Width across flats 19 mm, #02 size
q (59): Pump pressure input port hose
(Band color: Blue)
q (60): Front pump load pressure input port hose
(Band color: Red)
q (61): Drain port hose
(62).
59. Direct the elbow (63) down.
a Prevent it from being an obstacle to removal of the
engine.
60. Remove the flanges (64a), (65a), and (66a), and disconnect
the hoses (4 pieces).
Tools: Socket wrench, special tool D
Bolts of flanges (64a), (65a), (66a): Width across flats 14
mm
q (64): Branch hose
q (65): Rear pump discharge port hose
q (66): Front pump discharge port hose
(67).
50-200 78 PC200, 200LC, 220, 220LC-8M0


Cover the hose disconnection portions with plastic bags,
etc. in order to prevent dirt entry.
62. Return the bracket (62).
(Install it to the pump)
63. Disconnect the pump wiring connectors (4 places).

q (68): V12PC-EPCR solenoid valve
Band color: Yellow
q (69): P22 hydraulic oil temperature sensor
Band color: None
q (70): V19LS-EPC solenoid valve
Band color: Red
q (71): V11PC-EPCF solenoid valve
Band color: White
a Installed on the back of bracket (69).
64. Remove the bolt (72a) (1 piece), and disconnect the bracket
(72).
65. Remove the bolt (73a), and disconnect the tube (73).

hoses (74) and (75) from the hydraulic tank.
a Prevent it from being an obstacle to removal of the
engine.
67. Remove the fan belt (76) from the alternator by using the
wrench [1].
Tools: Wrench [1]
PC200, 200LC, 220, 220LC-8M0 50-200 79

68. Disconnect the connector CN-E12 (77).

69. Remove nut (78a), and disconnect the alternator terminal B
(78).
Nut (78a): Width across flats 10 mm
70. Remove the bolts (79a) and (79b), and remove the alterna-
tor (79).
72. Remove the bolts (81a) (3 pieces), and remove the radiator
hose and flange assembly (81).
73. Remove the bolt (82a), and disconnect the engine ground
cable (82).
74. Remove the engine mounting bolts (83) (4 pieces).
a A nut is welded to the installation position of the engine
ground cable (82). Nothing other than it is welded.
Therefore, fix the nut lock tool A1 (plate) with the bolt
(b) in order to lock nut (n), and then remove the engine
mounting bolt (83).
75. Sling the engine and hydraulic pump assembly (84), and
remove it.
a Install the sling to 3 points, 2 points on the engine, and
1 point on the hydraulic pump.
CUMMINS recommends tool A2 (lifting tool).
a Check that all the wirings and pipings are discon-
nected, and remove it.
4 Engine and hydraulic pump assembly: 800 kg
50-200 80 PC200, 200LC, 220, 220LC-8M0

Installation
1. Sling the engine and hydraulic pump assembly (84), and set
it on the installing position.
a Install the sling to 3 points, 2 points on the engine, and
1 point on the hydraulic pump. CUMMINS recommends
sling A2 (lifting tool) (See the tools list).
4 Engine and hydraulic pump assembly: 800 kg
2. Install the engine mounting bolts (83) (4 pieces).

3 Bolt (83): 245 to 308.9 Nm {25 to 31.5kgm}
a A nut is welded to the installation position of the engine
ground cable (82). Nothing other than it is welded.
Therefore, fix the nut lock tool A1 (plate) with the bolt
(b) in order to lock nut (n), and then install the engine
mounting bolt (83).
a The bolt on the engine front side is shorter than the one
on the rear side.
a The engine mount rubber on the engine front side is
smaller than that on the rear side.
3. Connect the engine ground cable (82) with the bolt (82a).
3 Bolt (82a): 59 to 74 Nm {6 to 7.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-200 81

a Reference
Air hose and radiator hose insertion depth list
4. Install the radiator hose and flange assembly (81) with the
bolts (81a) (3 pieces).
Bolt (81a):
Width across flats13 mm (Inlet connector mounting
bolt)
3 Bolt (81a): 43±6 Nm {4.4±0.6 kgm}
a Reference
Radiator hose insertion depth: 40 mm
3 Radiator hose clamp:
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
6. Install the alternator (79) with the bolts (79a) and (79b).
7. Connect the alternator terminal B (78) with the nut (78a).
Nut (78a): Width across flats 10 mm
3 Nut (78a): 5.9 to 9.8 Nm {0.6 to 1 kgm}
8. Connect the connector CN-E12 (77).
9. Install the fan belt (76) to the alternator by using the wrench
[1].
Tools: Wrench [1]
a Check the fan belt. If it is worn unevenly, cracked,
chipped, or rolled up, replace it.
10. Connect the hoses (74) and (75) to the hydraulic tank with
3 Bolt (74a): 98 to 123 Nm {10 to 12.5 kgm}
50-200 82 PC200, 200LC, 220, 220LC-8M0

11. Connect the clamp (73) with the bolt (73a).

3 Bolt (73a): 59 to 74 Nm {6 to 7.5 kgm}
12. Connect the bracket (72) with the bolt (72a) (1 piece).
3 Bolt (72a): 98 to 123 Nm {10 to 12.5 kgm}
13. Connect the pump wiring connectors (4 places).
q (68): V12PC-EPCR solenoid valve
Band color: Yellow
Band color: None
q (70): V19LS-EPC solenoid valve
Band color: Red
q (71): V11PC-EPCF solenoid valve
Band color: White
14. Connect the tube (1 piece) with the bolts (67a) (4 pieces).
3 Bolt (67a): 98 to 123 Nm {10 to 12.5 kgm}
15. Connect the hoses (4 pieces) with the flanges (64a), (65a),
and (66a).
Bolts of flanges (64a), (65a), (66a): Width across flats 14
mm
3 Bolts of flanges (64a), (65a), (66a):
59 to 74 Nm {6 to 7.5 kgm}
q (64): Branch hose
16. Direct the elbow (63) up, which was directed down during
the removal work.
17. Install the bracket (62) with the bolt (62a) (2 pieces).
3 Bolt (62a): 98 to 123 Nm {10 to 12.5 kgm}
18. Connect the hoses (6 pieces).
q (56): Rear load pressure input port hose (Band color:
No color)
Tools: Torque wrench set (spanner), wrench
3 Hose (56): 34 to 63 Nm {3.5 to 6.5 kgm}
Hoses (57), (58): Width across flats 19 mm, #02 size
3 Hoses (57), (58): 34 to 63 Nm {3.5 to 6.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-200 83

q (59): Pump pressure input port hose (Band color: Blue)

3 Hose (59): 34 to 63 Nm {3.5 to 6.5 kgm}
q (60): Front load pressure input port hose (Band color:
Red)
3 Hose (60): 34 to 63 Nm {3.5 to 6.5 kgm}
q (61): Drain port hose
3 Hose (61): 34 to 63 Nm {3.5 to 6.5 kgm}
19. Install the filter and bracket assembly (55) with the bolts
(55a) (2 pieces).
3 Bolt (55a): 98 to 123 Nm {10 to 12.5 kgm}
3 Bolt (54a): 98 to 123 Nm {10 to 12.5 kgm}
21. Connect the terminal (49) to the starting motor ST with the
nut (49a).
Nut (49a): Width across flats 17 mm, M10
3 Nut (49a): 17.7 to 24.5 Nm {1.8 to 2.5 kgm}
22. Connect the connector E10 (50).

a Connector on starting motor side: T13
23. Connect the connectors E08 (51) and P44 (52).
3 Bolt (53a): 98 to 123 Nm {10 to 12.5 kgm}

3 Bolt (48a): 98 to 123 Nm {10 to 12.5 kgm}
26. Install the bracket (46) and spacer (47) with the bolt (46a).
3 Bolt (46a): 98 to 123 Nm {10 to 12.5 kgm}
27. Connect the engine controller ground connector T12 (45)
with the bolt (45a).
Tools: Torque wrench set (socket), wrench
3 Bolt (45a): 98 to 123 Nm {10 to 12.5 kgm}
50-200 84 PC200, 200LC, 220, 220LC-8M0

28. Connect the connector E06 (44).

29. Connect the connectors CE02 (41) and (42) to the engine
controller with the bolts (L6) (2 pieces).
Tools: Hexagonal wrench (4 mm), torque wrench
Bolt (L6): Width across flats 4 mm, M6
3 Bolt (L6): 2.6 to 3.1 Nm {0.27 to 0.32 kgm}
30. Connect the connector (43) to the engine controller.
31. Connect the intake air heater connector E01 (40).

32. Install the air conditioner compressor assembly (37) and
bracket as a unit with the bolts (36) and (36a).
a Finger-tighten the bolts. (2 places)
3 Bolt (36): 153 to 190 Nm {15.5 to 19.5 kgm}

3 Bolt (36a): 153 to 190 Nm {15.5 to 19.5 kgm}
33. Install the fan belt (38).

a Visually check the fan belt. If it is torn, worn unevenly,
scratched, or cracked, replace it with a brand-new one.
34. Connect the connector AC02 (39).
PC200, 200LC, 220, 220LC-8M0 50-200 85

35. Install the fan (35) with the bolts (35a) (4 pieces).
3 Bolt (35a): 43±6 Nm {4.4±0.6 kgm}
36. Connect the fuel supply hose (33) with the joint bolt (33a).
37. Connect the fuel return hose (34) with the joint bolt (34a).
38. Connect the fuel filter hose (32) to the fuel supply pump (FSP).
a Check that no mud or dirt is sticking to the connections.
brand-new one.
39. Install the aftercooler hose and tube assembly (31) with the
hose clamps (31a) and (31b).
a Reference
Air hose insertion length
q Turbocharger side: 65 mm
to Min. 5 mm.
Dimension (b): Min. 5 mm
q When reusing hose
hose.

50-200 86 PC200, 200LC, 220, 220LC-8M0

40. Connect the air cleaner tube (30) with the clamp (30a).
Clamp (30a): Width across flats 9.5 mm (3/8 in)
41. Install the fan guard (29) with the bolt (29a) (7 pieces).
3 Bolt (29a): 59 to 74 Nm {6 to 7.5 kgm}

3 Hose clamp (27a): 10.8 to 11.8 Nm {1.1 to 1.2 kgm}
a Reference
Hose insertion depth: 40 mm
44. Fix the hose with a brand-new cable tie (25a) to the place
from where it was removed.
45. Connect the hose (26) with the hose clamps (26a) and
(26b).
3 Hose clamp (26a): 10.58±0.5 Nm {1.07±0.05 kgm}
a Reference
Air hose insertion length
adjust overlap (b) between the bridge and band (BD) to
Min. 5 mm.
Dimension (b): Min. 5 mm
q When reusing hose
hose.
a When the intake connector (C) is disconnected
from the engine, replace the gasket.
PC200, 200LC, 220, 220LC-8M0 50-200 87

a Reference
Air hose and radiator hose insertion depth list
46. Install the fuel filter and bracket assembly (25) with the bolt
(25a) (2 pieces).
3 Bolt (25a): 98 to 123 Nm {10 to 12.5 kgm}
47. Insert the cover (24) between the control valve and engine,
and install it with the bolts (23) (3 pieces).
3 Bolt (23): 98 to 123 Nm {10 to 12.5 kgm}
48. Install the frame (22) between the control valve and engine
with the bolts (22a) (3 pieces).
3 Bolt (22a): 98 to 123 Nm {10 to 12.5 kgm}
3 Bolt (21a): 98 to 123 Nm {10 to 12.5 kgm}
50. Install the frame (20) with the bolts (20a) (2 pieces).
3 Bolt (20a): 98 to 123 Nm {10 to 12.5 kgm}
3 Bolt (19a): 98 to 123 Nm {10 to 12.5 kgm}
3 Bolt (18a): 98 to 123 Nm {10 to 12.5 kgm}
53. Install the mounting bolts (17) (3 pieces).
50-200 88 PC200, 200LC, 220, 220LC-8M0


3 Bolt (17): 98 to 123 Nm {10 to 12.5 kgm}
54. Install the mounting bolts (16) (2 pieces).

3 Bolt (16): 98 to 123 Nm {10 to 12.5 kgm}
55. Install the covers (14) and (15) with the bolts (14a) (3
pieces).
3 Bolt (14a): 98 to 123 Nm {10 to 12.5 kgm}
3 Bolt (13a): 98 to 123 Nm {10 to 12.5 kgm}
57. Install the cover (12) between the hydraulic pump and
engine with the bolts (12a) (4 pieces).
3 Bolt (12a): 98 to 123 Nm {10 to 12.5 kgm}
3 Bolt (11a): 98 to 123 Nm {10 to 12.5 kgm}
59. Install the cover (10) with the bolts (10b) (7 pieces).
3 Bolt (10b): 98 to 123 Nm {10 to 12.5 kgm}
60. Connect the hose (10a).
61. Install the air cleaner top cover (8) and control valve top
cover (9) with the bolts (8a) (4 pieces) and (9a) (3 pieces).
Bolts (8a), (9a): Width across flats 19 mm, M12
3 Bolts (8a), (9a): 98 to 123 Nm {10 to 12.5 kgm}
62. Install the pre-cleaner (6) and pre-cleaner stand pipe (7). (If
equipped)
63. Sling the engine hood (2), and set it on the installing posi-
tion.
Tools: Wire, shackle
4 Engine hood: 50 kg
64. Insert the gas springs (5) (2 pieces), and install them with
the pins (3) and (4).
PC200, 200LC, 220, 220LC-8M0 50-200 89

65. Install the bolts (2a) (4 pieces).

5 Coolant:
20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
69. Remove the tools B1 (oil stopper) and B2 (adapter), and

install the hydraulic tank strainer.
70. Install the cover (1g) with the bolts (1f) (6 pieces).
Bolt (1f): Width across flats 19 mm, M12
3 Bolt (1f): 98 to 123 Nm {10 to 12.5 kgm}
a When not using tools B1 (oil stopper) and B2 (adapter),
install the drain plug and add hydraulic oil.
5 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
a Check for coolant leakage, oil leakage, or fuel leakage.
50-200 90 PC200, 200LC, 220, 220LC-8M0

71. Install the covers (1), (1d), and (1e) with the bolts (1a) (7
pieces), (1b) (6 pieces), and (1c) (6 pieces).
Bolt (1a), (1b), (1c): Width across flats 19 mm, M12
3 Bolt (1a), (1b), (1c): 98 to 123 Nm {10 to 12.5 kgm}
72. Check after work

1) Visually check the outside, and wipe off sticking oil, grease, coolant, etc., if any. In addition, check
for scratches, pealing of paint, etc. made during the removal and installation work.
2) Bleed air from the fuel, hydraulic, and coolant system, then start the engine, and check that the
machine operates normally.
PC200, 200LC, 220, 220LC-8M0 50-200 91

SEN06143-01

© 2018 KOMATSU
All Rights Reserved
50-200 92
SEN06144-01
HYDRAULIC EXCAVATOR
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

300 Power train
Removal and installation of final drive assembly ............................................................................................ 2
Disassembly and assembly of final drive assembly........................................................................................ 7
Removal and installation of swing motor and swing machinery assembly ................................................... 27
Disassembly and assembly of swing motor and swing machinery assembly ............................................... 33
Removal and installation of swing circle assembly ....................................................................................... 45
PC200, 200LC, 220, 220LC-8M0 50-300 1

300 Power train
SEN06144-01 Removal and installation of final drive assembly
Removal and installation of final drive assembly 1
Standard tools list

4 Box-end combination wrench (Commercially available) 14 mm 1
59 to 74 Nm
98 to 123 Nm
245 to 309 Nm
265 to 309 Nm
34 to 54 Nm
11 Torque wrench set (wrench) (Commercially available) 1
84 to 132 Nm
(300 kg), (350
12 Webbing sling (Commercially available) Width: 25 mm 1
kg)
Special tools list

1 Plug (female) 02789-00210 #02 1
A 2 Plug (male) 07376-70210 #02 1
3 O-ring 02896-11008 1
1 Plug (female) 02789-10422 #04 1
B 2 Plug (male) 07376-70422 #04 1
3 O-ring 02896-11012 1
k Park the machine on a level ground, lower the work equipment completely to the ground in a sta-
ble posture, and set the lock lever to LOCK position.
NOTICE
50-300 2 PC200, 200LC, 220, 220LC-8M0

300 Power train
Removal and installation of final drive assembly SEN06144-01
Removal
1. Remove the sprocket. For details, see "Removal and instal-

lation of sprocket".
k Lower the work equipment to the ground and stop

the engine. Then, loosen the cap of the hydraulic
tank to release the internal pressure in the tank.
Tool: Socket wrench
3. Disconnect the hoses (3) and (4).

Tool: Wrench
4. Disconnect hoses (2) and (5).
Tool: Wrench, special tools A, B
Special tool A
Special tool B
q For PC200-8M0, PC200LC-8M0
5. Sling the final drive assembly (6), and hold it.
a PC200-8M0, PC200LC-8M0
Tools: Webbing sling
4 Final drive assembly: 300 kg
6. Remove the bolts (7) (18 pieces), sling the final drive
assembly (6), and remove it.
a PC200-8M0, PC200LC-8M0
Tools: Socket wrench, webbing sling
a Take extreme care not to damage the nipple seal of
hose mounting part.
PC200, 200LC, 220, 220LC-8M0 50-300 3

300 Power train

7. Sling the final drive assembly (8), and hold it.
a PC220-8M0, PC220LC-8M0
8. Remove the bolts (8a) (18 pieces), sling the final drive
assembly (8), and remove it.
a PC220-8M0, PC220LC-8M0
Tools: Wrench, belt sling
hose mounting part.
50-300 4 PC200, 200LC, 220, 220LC-8M0

300 Power train
Removal and installation of final drive assembly SEN06144-01
Installation

1. Sling the final drive assembly (6), and set it on the installing
position.
a PC200-8M0, PC200LC-8M0
2. Install the final drive assembly (6) with the bolts (7) (18
pieces).
a PC200-8M0, PC200LC-8M0
3 Bolt (7): 245 to 309 Nm {25 to 31.5 kgm}
hose mounting part.

3. Sling the final drive assembly (8), and set it on the installing
position.
a PC220-8M0, PC220LC-8M0
4. Install the final drive assembly (8) with the bolts (8a) (18
pieces).
a PC220-8M0, PC220LC-8M0
3 Bolt (8a): 265 to 309 Nm {27 to 31.5 kgm}
hose mounting part.
5. Connect the hoses (2) and (5).

3 Hose (2): 34 to 54 Nm {3.5 to 5.5 kgm}

3 Hose (5): 84 to 132 Nm {8.5 to 13.5 kgm}
Hoses (3), (4): Width across flats 41mm, #10 size
3 Hoses (3), (4): 177 to 245 Nm {18.0 to 25.0 kgm}
PC200, 200LC, 220, 220LC-8M0 50-300 5

300 Power train

3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
8. Install the sprocket. For details, see "Removal and installa-

tion of sprocket".
q Refilling with oil (hydraulic tank)
9. Refill the hydraulic tank with Komatsu genuine oil to the
specified level through the oil filler port. Start the engine to
circulate the oil through the piping, and check the oil level
again. (For details, see Structure and function, Table of fuel,
coolant, and lubricants.)
q Bleeding air
10. Bleed air from the travel motor. For details, see Testing and
adjusting, "Bleeding air from each part".
50-300 6 PC200, 200LC, 220, 220LC-8M0

300 Power train
Disassembly and assembly of final drive assembly SEN06144-01
Disassembly and assembly of final drive assembly 1

PC200-8M0, PC200LC-8M0
Special tools
Symbol Part number Part name Necessity Q’ty N/R Sketch
796-427-1400 Wrench assembly t 1
796-427-1410 • Wrench 1
1
796-427-1140 • Pin 3
01314-20612 • Screw 3
796T-427-1510 Push tool t 1
790-101-2510 Block t 1
790-101-3310 Block t 1
790-101-2610 Rod t 2
J
790-101-2730 Adapter t 2
2
01580-11613 Nut t 2
790-101-2570 Plate t 2
01643-31645 Washer t 2
790-101-2102 Puller (30 t) t 1
790-101-1102 Pump t 1
3 796-427-1520 Installer t 1
7 790-331-1110 Wrench t 1
PC200, 200LC, 220, 220LC-8M0 50-300 7

300 Power train
SEN06144-01 Disassembly and assembly of final drive assembly
Disassembly
1. Oil drain
Remove drain plug to drain the oil from final drive case.
6 Final drive case: 3.8 l
2. Cover
Remove 18 mounting bolts and sling cover (1) using eye-
bolts [1] to remove it.
4 Cover: 20 kg
a When ring gear (12) is lifted together, separate the ring
gear by lightly tapping it with a plastic hammer.
3. Washer
Remove washer (2).
4. No.1 planetary carrier assembly

1) Remove No.1 planetary carrier assembly (3).
2) Disassemble No.1 planetary carrier assembly in the fol-

lowing procedure.
1] Drive pin (4) into shaft (5) to remove shaft (5) from
No.1 planetary carrier (6).
a Remove pin (4) from shaft (5) after shaft (5) is
removed.
2] Remove thrust washer (7), No.1 planetary gear
(8), needle bearing (9) and thrust washer (10).
5. No.1 sun gear shaft

Remove No.1 sun gear shaft (11).
50-300 8 PC200, 200LC, 220, 220LC-8M0

300 Power train
6. Ring gear
Remove ring gear (12).
4 Ring gear: 40 kg
7. Thrust washer
Remove thrust washer (13).
8. No.2 sun gear

Remove No.2 sun gear (14).
9. Thrust washer

1) Remove No.2 planetary carrier assembly (16).
2) Disassemble No.2 planetary carrier assembly in the fol-

lowing procedure.
1] Drive pin (17) into shaft (18) to remove shaft (18)
from No.2 planetary carrier (19).
a Remove pin (17) from shaft (18) after shaft
(18) is removed.
2] Remove thrust washer (20), No.2 planetary gear
(21), needle bearing (22) and thrust washer (23).
11. Ring nut

1) Remove lock (24).
2) Use the tool J1 to remove ring nut (25).
12. Hub assembly

1) Using eyebolts [2], sling hub assembly (26) and
remove from travel motor.
4 Hub assembly: 80 kg
PC200, 200LC, 220, 220LC-8M0 50-300 9

300 Power train
2) Remove bearing (27).
3) Remove bearing outer races (29) and (30) from hub

(28).
13. Remove floating seals (32) and (33) from travel motor (31).
a The floating seals (32) and (33) may be both on the
hub assembly (26) and the travel motor (31).
14. Use the puller [3] and push tool [4] to remove bearing (34).
a Bearing may come off without using the puller.
50-300 10 PC200, 200LC, 220, 220LC-8M0

300 Power train
Assembly
a Clean the parts completely and inspect them for any foreign material or damage. Apply power train oil
(TO30) on the sliding surfaces before assembly.
1. Hub assembly
1) Use push tool to press fit bearing outer races (29) and
(30) into hub (28).
2) Use the tool J3 to install floating seal (32).

a Install floating seal with the O-ring and O-ring con-
tact surface degreased and dried completely.
a After installing the floating seal, check that the
angle of the floating seal is within 1 mm.
a After floating seal installation, apply a thin coat of
power train oil (TO30) on the sliding surfaces.
2. Install bearing (34) to travel motor (31).

a Warm the inner race of the bearing (34) to 50 to 70°C
with heater.
a Cool the bearing (34) down. Tap the bearing (34) with a
drift and listen to the sound to check that it is fully
seated.
3. Use the tool J3 to install floating seal (33) to travel motor
(31).
a Install floating seal with the O-ring and O-ring contact
surface degreased and dried completely.
a After installing the floating seal, check that the angle of
the floating seal is within 1 mm.
power train oil (TO30) on the sliding surfaces.
4. Using eyebolts [2], set hub assembly (26) to travel motor.

PC200, 200LC, 220, 220LC-8M0 50-300 11

300 Power train
5. Install bearing (27) by tapping it lightly with the push tool.
6. Ring nut
1) Install ring nut as follows.
1] Rotate the hub 2 to 3 times.
2] Use the tool J2 and the push tool [5] to press the
inner race of the bearing (27).
a Pressing force: 29.4 to 38.2 kN {3.0 to 3.9
ton}
3] Rotate the hub to the both directions at least 5
times in total with the bearing inner race pressed.
4] Release the pressing force.
5] Press the bearing again.
a Pressing force: 17.7 to 21.6 kN {1.8 to 2.2 ton}
6] Rotate the hub 2 to 3 times.
7] Measure the size (a) under the condition described

in 6] above.
a After measuring the size (a), remove the tool
J2.
8] (b) is the thickness of the ring nut (25) itself.

9] Calculate the value of (c) by subtract (b) from (a).
10] Using tool J1, tighten ring nut (25) until dimension
(d) becomes value below.
Dimension (d): c (+0.06/-0.04) mm
2) Measure the tangential force of the hub against the

motor case in the rotation direction using the push
scale [6].
a Tangential force: 490 N or less {50 kg or less}
a The tangential force denotes the maximum force at
start of the rotation.
50-300 12 PC200, 200LC, 220, 220LC-8M0

300 Power train
3) Install lock plate (24).

a Install the lock plate so that the splines (A) of the
lock plate and the motor are in full contact.
2 Mounting bolt thread: Adhesive (LT-2)
a Do no apply the adhesive (LT-2) to the tapped por-
tion of the nut.

1) Assemble No.2 planetary carrier assembly as follows.
a Replace thrust washers (20) and (23) as well as
pin (17) with new ones.
a There are traces of expansion on the end surface
of No.2 planetary carrier side hole (e) which were
originally caused when the pin was inserted. Make
such the end surfaces are smooth enough before
reassembly.
1] Assemble needle bearing (22) to No.2 planetary
gear (21), fit top and bottom thrust washers (20)
and (23) and then set the gear assembly on No.2
planetary carrier (19).
2] Align the pin holes on the shaft (18) and the car-
rier, and install the shaft (18) by tapping it lightly
with a plastic hammer.
a Install the shaft, rotating the No.2 planetary
gear (21). Take care so the thrust washer is
not damaged.
3] Insert pin (17).

a When inserting the pin, take care so that any
of the three pawls on the circumference (Por-
tion (f)) may not touch the thin-walled portion
o n t h e N o . 2 p l a n e ta r y c a r r i e r ( P o r t i o n
(g)).Take note, however, that the thin-walled
portion is likely to be on the opposite side of
the carrier, depending on actual individual
items. Pay attention so that a pin pawl will not
come to the slender side of the No.2 planetary
carrier any way. And when traces of the
groove are present, assembly must be done
avoiding such locations.
a After assembling the No.2 planetary carrier
assembly, check that No.2 planetary gear (21)
rotates smoothly.
a After the pin is inserted, stake the pin (B) on
the carrier.
PC200, 200LC, 220, 220LC-8M0 50-300 13

300 Power train
2) Install No.2 planetary carrier assembly (16).

a Align the 4 gear shaft ends of the No.2 planetary
carrier assembly (16) with the 4 dimples on the
motor case end surface to install.
8. Thrust washer
Install thrust washer (15).
9. No.2 sun gear

Install No.2 sun gear (14).
10. No.1 sun gear shaft

Install No.1 sun gear shaft (11).
11. Thrust washer

12. Ring gear

1) Install O-ring to the hub.
2) Install ring gear (12) to hub.
4 Ring gear: 40 kg
a Degrease the mating surfaces of the ring gear and the
hub, and do not apply liquid gasket on the mating sur-
faces.
a Align the holes in the ring gear and the hub.

1) Assemble No.1 planetary carrier assembly as follows.
a Replace thrust washers (7) and (10) and pin (4)
with new ones. (Refer to Pin (4): 3].)
a There are remains of caulking when the pin is
inserted at the end face of hole (h) at the side of
the No.1 planetary carrier. Remove the caulked
metal from the inside diameter of the hole before
starting to assemble.
1] Assemble bearings (8) and (9), fit top and bottom
thrust washers (7) and (10) and then set the No.1
planetary gear assembly on carrier (6).
50-300 14 PC200, 200LC, 220, 220LC-8M0

300 Power train
2] Align the pin holes on the shaft (5) and the No.1
planetary carrier, and install the shaft (5) by tap-
ping it lightly with a plastic hammer.
a Install the shaft, rotating the No.1 planetary
gear (8). Take care so the thrust washer is not
damaged.
3] Insert pin (4).
a When inserting the pin, take care so that any
of the three pawls on the circumference (Por-
tion (f)) may not touch the thin-walled portion
o n t h e N o . 1 p l a n e ta r y c a r r i e r ( P o r t i o n
(g)).Take note, however, that the thin-walled
portion is likely to be on the opposite side of
the carrier, depending on actual individual
items. Pay attention so that a pin pawl will not
come to the slender side of the carrier any
way. And when traces of the groove are pres-
ent, assembly must be done avoiding such
locations.
a After assembling the No.1 planetary carrier
assembly, check that No.1 planetary gear (8)
rotates smoothly.
a After the pin is inserted, stake the pins (C) on
the carrier at 2 locations.
2) Install No.1 planetary carrier assembly (3).
14. Washer
Install washer (2).
a After installing washer (2), measure distance (i) from
the top of No.1 planetary gear (8) to the top of ring gear
(12) and check the assembly condition.
a If dimension (i) is not within 0.54 to 0.56 mm range,
they are not assembled correctly. In this case, check
again.
PC200, 200LC, 220, 220LC-8M0 50-300 15

300 Power train
15. Cover
1) Using eyebolts [1], install cover (1).
4 Cover: 20 kg
2 Contacting face of cover and ring gear:
Liquid gasket (LG-6)
2) Using tool J7, tighten the 18 mounting bolts.

3 Mounting bolts:
First time: 98 Nm {10 kgm}
Second time: 80 to 90° (rotating angle)
16. Oil refill

Tighten drain plug and fill power train oil (TO30) from the oil
filler port.
5 Final drive case: Approx. 3.8 l
a Do a final check of the oil level at the determined posi-

tion after installing the final drive assembly to the chas-
sis.
50-300 16 PC200, 200LC, 220, 220LC-8M0

300 Power train
Disassembly and assembly of final drive assembly 1

PC220-8M0, PC220LC-8M0
Special tools
4 796-427-1400 Wrench assembly t 1
5 796-427-1520 Installer t 1
796T-427-1510 Push tool t 1
790-101-2510 Block t 1
790-101-3310 Plate t 1
790-101-2610 Leg t 2
J 790-101-2730 Adapter t 2
6
01580-11613 Nut t 2
790-101-2570 Plate t 2
01643-31645 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
7 790-331-1110 Wrench t 1
PC200, 200LC, 220, 220LC-8M0 50-300 17

300 Power train
Disassembly
1. Oil draining
Remove the drain plug to drain the oil from the final drive
case.
2. Remove 20 mounting bolts. Using eyebolts [1], sling and

remove cover (1).
4 Cover: 25 kg
a If ring gear (12) is slung together with the cover, gently
tap the ring gear off the cover by using a plastic ham-
mer.
3. Washer
Remove washer (2).
4. No. 1 planetary carrier assembly

1) Remove No. 1 planetary carrier assembly (3).
2) Disassemble No. 1 planetary carrier assembly accord-

1] Drive pin (4) into shaft (5) to remove shaft (5) from
No. 1 planetary carrier (6).
a After removing shaft (5), remove pin (4) from
shaft (5).
2] Remove thrust washer (7), No. 1 planetary gear
(8), needle bearing (9), and thrust washer (10).
5. No. 1 sun gear shaft

Remove No. 1 sun gear shaft (11).
50-300 18 PC200, 200LC, 220, 220LC-8M0

300 Power train
6. Ring gear
Remove ring gear (12).
4 Ring gear: 45 kg
7. Thrust washer
8. No. 2 sun gear

Remove No. 2 sun gear (14).
9. Thrust washer

1) Remove No. 2 planetary carrier assembly (16).
2) Disassemble the No. 2 planetary carrier assembly

1] Drive pin (17) into shaft (18) to remove shaft (18)
from No. 2 planetary carrier (19).
a After removing shaft (18), remove pin (17)
from shaft (18).
2] Remove thrust washer (20), No. 2 planetary gear
(21), needle bearing (22), and thrust washer (23).
11. Ring nut

1) Remove lock plate (24).
2) By using tool J4, remove ring nut (25).
12. Hub assembly

1) Using eyebolts [2], sling and remove hub assembly
(26) from the travel motor.
PC200, 200LC, 220, 220LC-8M0 50-300 19

300 Power train
2) Remove bearing (27).
3) Remove bearing outer races (29) and (30) from hub

(28).
13. Remove floating seals (32) and (33) from travel motor (31).
a Floating seals (32) are attached to hub assembly (26)
and travel motor.
14. Use the puller [3] and push tool [4] to remove bearing (34).
a Bearing may come off without using the puller.
50-300 20 PC200, 200LC, 220, 220LC-8M0

300 Power train
Assembly
a Clean the parts completely and inspect them for any foreign material or damage. Apply power train oil
(TO30) to the sliding surfaces before assembly.
1. Hub assembly
1) Use push tool to press fit bearing outer races (29) and
(30) into hub (28).
2) Using tool J5, install floating seal (32).

a Install the floating seal after degreasing and drying
the O-rings and O-ring contacting surfaces com-
pletely.
a After installing the floating seal, check the inclina-
tion of the seal. It must be 1 mm or less.
power train oil on the sliding surfaces.
2 Sliding surface: Power train oil (TO30)
2. Install bearing (34) to travel motor (31).

a Warm the inner race of the bearing (34) to 50 to 70°C
with heater.
a Cool bearing (34) down. Tap the bearing (34) with a
wood bar and listen to the sound to check that it is fully
seated.
3. Using tool J5, install floating seal (33) to travel motor (31).
a Install the floating seal after degreasing and drying the
O-rings and O-ring contacting surfaces completely.
a After installing the floating seal, check the inclination of
the seal. It must be 1 mm or less.
power train oil on the sliding surfaces.
2 Sliding surface: Power train oil (TO30)
4. Using eyebolts [2], place hub assembly (26) on the travel

motor.
PC200, 200LC, 220, 220LC-8M0 50-300 21

300 Power train
5. Install bearing (27) by tapping it lightly with the push tool.
6. Ring nut
1) Install the ring nut according to the following procedure.
1] Rotate the hub two to three times.
2] Use tool J6 and push tool [5] to press the inner
race of bearing (27).
3] Rotate the hub to the both directions at least five
times in total with the bearing inner race pressed.
4] Release the pressing force.
5] Press the bearing again.
6] Rotate the hub two to three times.
7] Measure dimension (a) under the condition

described in 6].
a After measuring dimension (a), remove tool
J6.
8] Measure the thickness of ring nut (25) and name it

(b) dimension.
9] Subtract (b) from (a), and name it (c).
10] By using tool J4, tighten ring nut (25) until dimen-
sion (d) is as shown.
Dimension (d): c (+0.06/-0.04) mm
2) Measure the tangential force of the hub against the

motor case in the rotation direction using the push
scale [6].
a Tangential force: Max. 490 N {50 kg}
a The tangential force denotes the maximum force at
start of the rotation.
50-300 22 PC200, 200LC, 220, 220LC-8M0

300 Power train
3) Install lock plate (24).

a Install the lock plate so that the splines (A) of the
motor and the lock plate are in full contact.
2 Mounting bolt threads: Adhesive (LT-2)
a Do not apply the adhesive (LT-2) to the thread por-
tion of the nut.

1) Assemble No. 2 planetary carrier according to the fol-
lowing procedure.
a Replace thrust washers (20) and (23) as well as
pin (17) with new ones.
a There is trace of punching on the end face of car-
rier side hole (e) which was caused when the pin
was inserted and locked. Before pin installation,
remove the protrusion in the pin hole as a result of
punching.
1] Install needle bearing (22) to No. 2 planetary gear
(21). Fit upper and lower thrust washers (20) and
(23) and set the gear assembly to No. 2 planetary
carrier (19).
2] Align the pin holes on shaft (18) and the carrier,
and install shaft (18) by tapping it lightly with a
plastic hammer.
a Install the shaft, while rotating No. 2 planetary
gear (21) with care not to damage the thrust
washer.
3] Insert pin (17).

a When inserting the pin, take care that the
three claws (parts (f)) on the periphery of the
pin will not be placed on the thin-wall parts of
No. 2 planetary carrier (parts (g)). The thin-
wall part may be on the opposite side depend-
ing on carriers. Check each carrier and avoid
setting any claw of the pin to the thin-wall part.
If there is a groove, avoid the groove.
a After assembling the No. 2 planetary carrier,
check that No. 2 planetary gear (21) rotates
smoothly.
a After the pin is inserted, punch the pin (B) on
the carrier.
PC200, 200LC, 220, 220LC-8M0 50-300 23

300 Power train
2) Install No. 2 planetary carrier assembly (16).

a Align the four gear shaft ends of No. 2 planetary
carrier assembly (16) with the four dimples on the
motor case end face to install.
8. Thrust washer
9. No. 2 sun gear

Install No. 2 sun gear (14).
10. No. 1 sun gear shaft

Install No. 1 sun gear shaft (11).
11. Thrust washer

12. Ring gear

1) Install the O-ring to the hub.
2) Install ring gear (12) on the hub.
4 Ring gear: 45 kg
a Degrease the mating faces of the ring gear and hub.
Do not apply liquid gasket on the mating faces.
a Align the bolt holes of the ring gear with those of the
hub.

1) Assemble the No. 1 planetary carrier according to the
a Replace thrust washers (7) and (10) as well as pin
(4) with new ones. (See Pin (4): 3].)
a There is a punching mark made when the pin was
inserted on the end face of carrier side hole (h)
and the inside wall of the hole is swelled at that
mark. Flatten the swelled part in advance.
1] Assemble needle bearing (9) in No. 1 planetary
gear (8), fit top and bottom thrust washers (7) and
(10), and then set the gear assembly on No. 1
planetary carrier (6).
50-300 24 PC200, 200LC, 220, 220LC-8M0

300 Power train
2] Align the pin holes in shaft (5) and the No. 1 plane-
tary carrier, and install the shaft (5) by tapping it
lightly with a plastic hammer.
a Install the shaft, while rotating No. 1 planetary
gear (8) with care not to damage the thrust
washer.
3] Insert pin (4).
a When inserting the pin, take care that the
three claws (parts (f)) on the periphery of the
pin will not be placed on the thin-wall parts of
No. 1 planetary carrier (parts (g)). The thin-
wall part may be on the opposite side depend-
ing on carriers. Check each carrier and avoid
setting any claw of the pin to the thin-wall part.
If there is a groove, avoid the groove.
a After assembling the carrier, check that No. 1
planetary gear (8) rotates smoothly.
a After the pin is inserted, punch the pins (C) on
the carrier at 2 locations.
2) Install No. 1 planetary carrier assembly (3).
14. Washer
Install washer (2).
a After installing washer (2), measure dimension (i) from
the upper end face of No. 1 planetary gear (8) to that of
ring gear (12) to check for the correct assembly condi-
tion.
a If dimension (i) does not fall within 2.11 ± 0.97 mm, the
assembly is built incorrectly. Recheck.
15. Cover
1) Using eyebolts [1], install cover (1).
4 Cover: 25 kg
2 Mating faces of cover and ring gear:
a Do not apply liquid gasket (LG-6) to tap.
PC200, 200LC, 220, 220LC-8M0 50-300 25

300 Power train
2) Using tool J7, install the 20 mounting bolts.

3 Mounting bolt
1st time: 98 Nm {10 kgm}
2nd time: 80 to 90 deg. (rotating angle)
16. Refilling of oil

Tighten drain plug and supply power train oil (TO30) from
the oil filler port.
a Do a final check of the oil level at the determined posi-
tion after installing the final drive assembly to the chas-
sis.
50-300 26 PC200, 200LC, 220, 220LC-8M0

300 Power train
Removal and installation of swing motor and swing machinery assembly SEN06144-01
Removal and installation of swing motor and swing machinery assembly1
Standard tools list

59 to 74 Nm
490 to 608 Nm
12 Wire (Commercially available) 1 (250 kg)
Special tools list

1 Plug (female) 02789-00210 #02 1
A 2 Plug (male) 07376-70210 #02 1
3 O-ring 02896-11008 1
1 Plug (female) 02789-00522 #05 2
B 2 Plug (male) 07376-70522 #05 2
3 O-ring 02896-11015 2
1 Plug (female) 02789-00628 #06 1
C 2 Plug (male) 07376-70628 #06 1
3 O-ring 02896-11018 1
1 Flange 07379-00640 #06 1
2 Head 07378-10600 #06 1
D 3 O-ring 07000-13030 1
4 Split flange 07371-30640 2
5 Bolt 07375-21035 4
k Stop the engine, and disconnect the cable from the negative (-) terminal of the battery.
NOTICE
PC200, 200LC, 220, 220LC-8M0 50-300 27

300 Power train
SEN06144-01 Removal and installation of swing motor and swing machinery assembly
Removal

4. Remove the flanges (4a) and (5a), and disconnect the

hoses (4) and (5). (if equipped)
Flange (4a) bolt: Width across flats 19 mm, M10
and hose (6) as a unit. (if equipped)

hoses (7) and (8).
q (7): Between swing motor and control valve (port MA)
q (8): Between swing motor and control valve (port MB)
Bolts of flanges (7a) and (8a): Width across flats 14 mm,
M10
7. Disconnect hoses (9) to (11) (3 pieces).
q (9): Suction hose (port S)
q (10), (11): Drain hose (port T)
Tools: Wrench, special tools B, C
Special tool C
Special tool B
Special tool B
50-300 28 PC200, 200LC, 220, 220LC-8M0

300 Power train
8. Loosen lock nut (12a), and remove nipple (12) (port T).
Tools: Wrench
Lock nut (12a): Width across flats 32 mm
Nipple (12): Width across flats 30 mm
9. Remove clamp (13).
Bolt of clamp (13): Width across flats 19 mm, M12
10. Remove clamp (14a), and move hose (14) aside so that it
does not hinder the work.
Bolt of clamp (14a): Width across flats 17 mm, M10
11. Remove the bolts (15) (2 pieces), and disconnect the drain
hose (16) from the revolving frame.
12. Pull up out drain hose (16).

13. Disconnect pilot hose (17) (port B) for releasing swing
brake.
Tools: Wrench, special tools A
14. Remove bolts (18) (12 pieces).

15. By using the lifting tool, sling the swing motor and swing
machinery assembly (19), and remove it.
Tools: Wire
a Sling and remove the swing motor and swing machin-
ery assembly gradually so that the hoses around it are
not damaged.
a When slinging, extremely pay attention to the drain
hose.
a Gradually sling and raise the assembly with extreme
care until it avoids the hose of the center swivel joint.
4 Swing motor and swing machinery assembly: 250 kg
PC200, 200LC, 220, 220LC-8M0 50-300 29

300 Power train
Installation
1. By using the lifting tool, sling the swing motor and swing
machinery assembly (19), and set it on the installing posi-
tion.
Tools: Wire
a Sling and hang the swing motor and swing machinery
assembly (19) gradually so that the hoses around it are
not damaged.
a Sling the assembly gradually while extremely paying
attention to the drain hose.
4 Swing motor and swing machinery assembly (19):
250 kg
2. Install the swing motor and swing machinery assembly (19)

with the bolts (18) (12 pieces).
4 Bolt (18): 490 to 608 Nm {50 to 62 kgm}
3. Connect pilot hose (17) (port B) for releasing swing brake.

3 Hose (17): 34 to 54 Nm {3.5 to 6.5 kgm}
4. Lower the drain hose (16) on the installing position side.
5. Fix drain hose (16) to the revolving frame with bolts (15) (2
pieces).
3 Bolt (15): 98 to 123 Nm {10 to 12.5 kgm}
50-300 30 PC200, 200LC, 220, 220LC-8M0

300 Power train
6. Fix the hose (14) with the clamp (14a).

Torque wrench set (socket)
Bolt of clamp (14a): Width across flats 17 mm, M10
3 Bolt of clamp (14a): 59 to 74 Nm {6 to 7.5 kgm}
7. Connect the clamp (13).

Clamp (13a) bolt: Width across flats 19 mm, M12
3 Bolt (13a): 98 to 123 Nm {10 to 12.5 kgm}
8. Install nipple (12) (port T), and fix it with lock nut (12a).
Tools: Wrench
Lock nut (12a): Width across flats 32 mm
Nipple (12): Width across flats 30 mm
9. Connect the hoses (9) to (11) (3 pieces).
q (9): Suction hose (port S)
q (10), (11): Drain hose (port T)
3 Hose (9): 177 to 245 Nm {18.0 to 25.0 kgm}

3 Hose (10): 128 to 186 Nm {13.0 to 19.0 kgm}

3 Hose (11): 128 to 186 Nm {13.0 to 19.0 kgm}
10. Connect the hoses (7) and (8) with the flanges (7a) and
(8a).
q (7): Between swing motor and control valve (port MA)
q (8): Between swing motor and control valve (port MB)
Bolts of flanges (7a) and (8a): Width across flats 14 mm,
M10
3 Bolts of flanges (7a) and (8a): 59 to 74 Nm {6 to 7.5
kgm}
11. Install the bracket and hose (6) together as a unit with the
bolts (6a) (6 pieces). (if equipped)
3 Bolt (6a): 98 to 123 Nm {10 to 12.5 kgm}
(5a). (if equipped)
3 Flange (4a) bolt: 59 to 74 Nm {6 to 7.5 kgm}

PC200, 200LC, 220, 220LC-8M0 50-300 31

300 Power train
3 Bolt (3a): 98 to 123 Nm {10 to 12.5 kgm}
3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}

16. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the
engine to circulate the oil through the piping, and check the oil level again. (For details, see Structure
and function, Table of fuel, coolant, and lubricants.)
q Bleeding air
17. Bleed air from the swing motor. For details, see Testing and adjusting, "Bleeding air from each part".
50-300 32 PC200, 200LC, 220, 220LC-8M0

300 Power train
Disassembly and assembly of swing motor and swing machinery assembly SEN06144-01
Disassembly and assembly of swing motor and swing machinery

assembly 1
Special tools
1 796T-426-1410 Push tool t 1 N Q
2 796-426-1120 Push tool t 1
F 796T-426-1130 Plate t 1 Q
3 790-101-5421 Grip t 1 N
01010-81240 Bolt t 1
q Sectional view
a A number shows the number in the text.
a Though the drawing is for PC200, 200LC-8M0, PC220,
220LC-8M0 also operates in a similar way basically. The
different parts are indicated in the text.
PC200, 200LC, 220, 220LC-8M0 50-300 33

300 Power train
SEN06144-01 Disassembly and assembly of swing motor and swing machinery assembly
Disassembly
1. Set the swing motor and the swing machinery assembly
onto block [1].
2. Oil drain
Loosen drain plug (39) and drain the oil inside the swing
machinery case.
6 Swing machinery case: 7.1 l
3. Remove drain hose (1).
4. Remove 6 pcs. of the mounting bolt and remove the swing

motor assembly (2).
4 Swing motor assembly: 70 kg
5. Remove No.1 sun gear (3).
6. No.1 carrier assembly

1) Remove No.1 carrier assembly (4).
2) Disassemble No.1 carrier assembly by the following

order.
1] Remove snap ring (5), thrust washer (6), gear (7),
bearing (8), thrust washer (9) in order.
2] Remove plate (10).
3] Reverse carrier (34) and remove snap ring (35).
a PC200-8M0, PC200LC-8M0
a PC220-8M0, PC220LC-8M0
50-300 34 PC200, 200LC, 220, 220LC-8M0

300 Power train
3) Using push tool [2], remove shaft (11) from carrier (34).
q Input pin press (reference):
11.2 to 25.8 kN {1,140 to 2,630 kg}
7. Remove No.2 sun gear (12).

8. Remove the mounting bolt and remove ring gear (13).
9. Remove holder mounting bolt (14).

1) Remove No.2 carrier assembly (15).
2) Disassemble No.2 carrier assembly as follows.

1] Push pin (16) and shaft (17) from carrier (18).
a After removing the shaft, remove pin (16).
2] Remove thrust washer (19), gear (20), and bearing
(21).
3] Remove plate (22).
a PC200-8M0, PC200LC-8M0
PC200, 200LC, 220, 220LC-8M0 50-300 35

300 Power train
a PC220-8M0, PC220LC-8M0
11. Shaft and case assembly

1) Reverse shaft and case assembly (23).
2) Remove cover mounting bolt (24).
3) Reverse shaft and case assembly (23) again and set to

the press.
4) Using push tool [3], remove shaft assembly (25) from
shaft and case assembly (23).
50-300 36 PC200, 200LC, 220, 220LC-8M0

300 Power train
12. Shaft assembly

1) Using push tools [4], [5], remove shaft (26).
2) Remove bearing (27) and oil seal (29) from cover (28).
13. Remove spacer (41) and O-ring (42) from shaft (26).
a PC220-8M0, PC220LC-8M0 only
14. Remove bearing (31) from case (30).

a Apply a suitable tool on the circumference of the outer
race (thick line: (Q) section), strike the tool on the cir-
cumference with the hammer lightly, equally, by turns,
and remove the bearing gradually.
a If the outer race is made incline, bearing becomes
hard, so remove it horizontally.
PC200, 200LC, 220, 220LC-8M0 50-300 37

300 Power train
Assembly
a Wash each part finely and check if there are not a garbage, a crack, etc., and apply power train oil to
the sliding portion and assemble them.
a The bearing and the oil seal, which were removed, are not re-used. New ones should be used.
1. Oil seal
Using tool F3, install oil seal (29) into cover (28).
a Be careful for the direction of the oil seal (up and
down).
2 Outside perimeter of oil seal: Gasket sealant (LG-6)
a When press-fitting, take care so that gasket sealant
(LG-6) will not stick to the lip surface of the oil seal.
a If tool F3 is not used, use the push tool which can push
outside perimeter section (A) of oil seal (29).
a Be careful not to incline oil seal (29).
2. Using push tool [9], press fit bearing (27) into case (30).
a Use the new bearing.
3. Install cover assembly (33) into case assembly (32).

2 Cover mounting face: Gasket sealant (LG-6)
a Be careful not to adhere gasket sealant (LG-6) to drain
port section (DP).
a Align the drain process section of cover into the drain
port section (DP).
50-300 38 PC200, 200LC, 220, 220LC-8M0

300 Power train
4. Shaft and case assembly

a 1) and 2): PC220-8M0, PC220LC-8M0 only
1) Install O-ring (42) to spacer (41).
2) Using push tool [16], press-fit spacer (41) to shaft (26).
a Be careful not to bite O-ring (42) to the spacer.
3) Set case assembly (32) into shaft (26).

2 Oil seal lip section: Grease (G2-LI)
a Put case assembly not to interfere the oil seal.

4) Using tool F1, push tool [10], and hammer [11], strike
inner race section of bearing (27) not to fall down the
shaft.
a Let lifting tool [12] be slacked.
5) Set into the press.

6) Using tool F1, push tools [13], [14], press fit inner race
section of bearing (27).
a Put in push tool [14] for the cases that the case
assembly is inclined a lot.
a If case assembly (32) is inclined, strike the flange
section lightly and correct it.
a Just before oil seal (29) goes into shaft (B) part,
case assembly (32) is leveled so that case assem-
bly (32) may be located at the center of shaft (26),
and be careful not to damage the oil seal lip part.
5. Bearing
Using tool F2 and push tool [15], press fit bearing (31).
a When press-fitting the bearing, press both inner and
outer races of the bearing at the same time. Avoid
pressing the inner race only.
9.4 to 35.5 kN {960 to 3,620 kg}
a After the bearing is press-fitted, check that the case will
turn freely.
PC200, 200LC, 220, 220LC-8M0 50-300 39

300 Power train

1) Assemble No.2 carrier assembly as follows.
a Since there is a mark to be caulked in the side hole (h) of carrier (18) at the time of pin inser-
tion, remove protrusion for hole inner diameter beforehand.
(Refer to 5])
1] Incorporate plate (22) into carrier (18).
2] Incorporate bearing (21) and 2 pcs. of upper and lower thrust washer (19) into gear (20).
3] Set gear assembly into carrier (18).
a PC200-8M0, PC200LC-8M0
a PC220-8M0, PC220LC-8M0
4] Strike lightly with plastic hammer, etc., align pin

hole location of shaft (17) and carrier and install
shaft (17).
a Install the shaft, rotating the planetary gear.
Take care so the thrust washer is not dam-
aged.
5] Insert pin (16),
a As inserting the pin, install not to interfere
claw section ((a) section) which is in 3 places
on circumference into carrier thin part ((b) sec-
tion).
However, actual thing may have the thin sec-
tion on the other side. So make sure to con-
firm the actual thing and assemble not to
interfere claw section of the pin into the thin
part.
a After inserting the pin, caulk 2 parts of the car-
rier (c) around the pin hole.
50-300 40 PC200, 200LC, 220, 220LC-8M0

300 Power train
2) Install No.2 carrier assembly (15) with bolt (14).

2 Mounting bolt threaded section:
Adhesive compound (LT-2)
3 Mounting bolts:157 to 196 Nm {16 to 20 kgm}
3) Install O-ring (36) into case (30).
7. No.2 sun gear

8. Ring gear
Using eyebolt (M10 x 1.5), install ring gear (13).
a Degrease mating face of ring gear (13) and case (30).

a Do not adhere gasket sealant in mating face of the ring
gear and the case.
a Align the counter mark on the ring gear (Portion (c))
and the convex portion on the case flange (Portion (d))
in the position illustrated in the following figure, and
then install it.
3 Mounting bolts:157 to 196 Nm {16 to 20 kgm}
9. Install O-ring (37).
a PC200-8M0, PC200LC-8M0
a PC220-8M0, PC220LC-8M0
PC200, 200LC, 220, 220LC-8M0 50-300 41

300 Power train

1) Assemble No.1 carrier assembly as follows.
1] Press fit shaft (11) into carrier (34) in the arrow
direction (1st) until the slot on the snap ring can be
seen.
2] After installing snap ring (35), push back (to the
2nd direction) from the opposite side until the snap
ring adheres to the carrier (P) surface. Be careful
not to push too much.
11.2 to 25.8 kN {1,140 to 2,630 kg}
3] Install plate (10) into carrier (34).

4] Install thrust washer (9), bearing (8), gear (7),
thrust washer (6), snap ring (5) in order.
a PC200-8M0, PC200LC-8M0
a PC220-8M0, PC220LC-8M0
2) Install No.1 carrier assembly (4).
11. No.1 sun gear assembly

a When installing the No.1 sun gear, be careful not to
install it upside down.
a Install the No.1 sun gear with the tooth portion (Portion
(e)) facing down.
50-300 42 PC200, 200LC, 220, 220LC-8M0

300 Power train
a PC200-8M0, PC200LC-8M0
a PC220-8M0, PC220LC-8M0
a P: Press-fit plate
12. Swing motor assembly

Put swing motor assembly (2) on ring gear (13).
4 Swing motor assembly: 70 kg
a Degrease mating face of swing motor assembly (2) and ring gear (13).
a Do not adhere gasket sealant in mating face of swing motor assembly (2) and ring gear (13).
a After aligning the position of swing motor assembly (2) and ring gear (13) as follows and install
them.
3 Mounting bolts: 59 to 74 Nm {6.0 to 7.5 kgm}
a PC200-8M0, PC200LC-8M0
q Align the relation between the positions of the filler ((f)
section) and convex portion of the case ((d) section) as
mentioned in the drawing and install them.((c), (d):
Above-mentioned)
a PC220-8M0, PC220LC-8M0
q Align the relation between the positions of the motor
port ((g) section) and convex portion of the case ((d)
section) as mentioned in the drawing and install
them.((c), (d): Above-mentioned)
PC200, 200LC, 220, 220LC-8M0 50-300 43

300 Power train
13. Confirm mounting angle of elbow for drain (38): 15° and the
tightening torque.
3 Elbow mounting nut:
128 to 186 Nm {13.0 to 19.0 kgm}
14. Install the drain hose.

a As installing the hose, be careful that the drain plug to
be downward.
3 Drain hose: 128 to 186 Nm {13.0 to 19.0 kgm}
15. Oil refill

Fill the power train oil (TO30) from oil filler port up to the
standard level by tightening the drain plug.
3 Drain plug: 19.6 to 24.5 Nm {2.0 to 2.5 kgm}
5 Swing machinery case: Approx. 7.1 l

a Check oil level by using oil level gauge.
50-300 44 PC200, 200LC, 220, 220LC-8M0

300 Power train
Removal and installation of swing circle assembly SEN06144-01
Removal and installation of swing circle assembly 1
Standard tools list

5 3-leg wire sling (Commercially available) 6 mm 1 (270 kg)
6 Eyebolt (Commercially available) M20, L = 110 mm 3
Special tools list

1 Nut 01580-12016 M20 3
k Stop the engine, and disconnect the cable from the negative (-) terminal of the battery.
PC200, 200LC, 220, 220LC-8M0 50-300 45

300 Power train
SEN06144-01 Removal and installation of swing circle assembly
Removal
1. Remove the revolving frame assembly. For details, see
"Removal of revolving frame assembly".
2. Sling the swing circle assembly (1) by using the eyebolts
and lifting tool, and hold it.
a Install the eyebolts to 3 of the revolving frame mounting
bolt holes of circle by using tools A (nut).
Tools: Eyebolt, 3-leg wire sling
4 Swing circle assembly: 270 kg
3. Remove the bolts (2) (38 pieces).
4. Sling the swing circle assembly (1), and remove it.
50-300 46 PC200, 200LC, 220, 220LC-8M0

300 Power train
Removal and installation of swing circle assembly SEN06144-01
Installation
1. Sling the swing circle assembly (1) by using the eyebolts
and lifting tool, and set it on the installing position.
a Install the eyebolts to 3 of the revolving frame mounting
bolt holes of circle by using tools A (nut).
Tools: Eyebolt, 3-leg wire sling
4 Swing circle assembly: 270 kg
a Install the swing circle assembly to the track frame with

the inner race soft zone position S mark (a) and outer
race soft zone position S mark (b) in the right side of
the machine as shown in the figure.
2 Amount of grease filled in grease bath:
Grease (G2-LI)
14.6 l (PC200/PC200LC-8M0)
15.8 l (PC220/PC220LC-8M0)
2 Threaded portion of bolt (2): Adhesive (LT-2)
2. Install the swing circle assembly (1) with the bolts (2) (38
pieces).
q Torque tightening:
3 Bolt (2):
588 to 677 Nm {60 to 69 kgm} (PC200/PC200LC-
8M0)
716 to 814 Nm {73 to 83 kgm} (PC220/PC220LC-
8M0)
q Angle tightening:
Tools: Angle tightening wrench
a Apply to PC200-8M0 and PC200LC-8M0.
3 Bolt (2):
1) Initial torque: 191.2±19.6 Nm {19.5±2 kgm}
2) Then, turn the bolt 48±5° turns
3. Install the revolving frame assembly. For details, see
"Installation of revolving frame assembly".
PC200, 200LC, 220, 220LC-8M0 50-300 47

SEN06144-01

© 2018 KOMATSU
All Rights Reserved
50-300 48
SEN06145-02
HYDRAULIC EXCAVATOR
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

Disassembly and assembly of carrier roller assembly .................................................................................... 2
Disassembly and assembly of track roller assembly ...................................................................................... 6
Removal and installation of idler and idler cushion assembly......................................................................... 9
Disassembly and assembly of idler............................................................................................................... 12
Disassembly and assembly of idler cushion ................................................................................................. 17
Removal and installation of sprocket ............................................................................................................ 20
Separation and connection of track assembly .............................................................................................. 22
Removal and installation of revolving frame assembly ................................................................................. 28
Removal and installation of counterweight assembly ................................................................................... 35
PC200, 200LC, 220, 220LC-8M0 50-400 1

SEN06145-02 Disassembly and assembly of carrier roller assembly
Disassembly and assembly of carrier roller assembly 1
Special tools
L 1 790-434-1660 Installer t 1
q Sectional view
a A number shows the number in the text.
Disassembly
1. Remove plug (9) and drain the oil from carrier roller (1).
6 Carrier roller: 75 to 85 ml
2. Using push tool [1], push the end surface of a shaft and
remove followings from carrier roller (1).
q Roller (4), ring (5) assembly, shaft (2) and cover (3).
q Press fitting force (reference): 59 kN {6,000 kg} min.
a The press fitted shaft (2) and ring (5), and also roller (4)
and cover (3) will be both disassembled.
a Cover (3) is placed under shaft (2).
3. Remove ring (5) from roller (4).

4. Remove floating seal (6) from ring (5).
a Take care not to damage the sealing surface.
50-400 2 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of carrier roller assembly SEN06145-02
5. Remove floating seal (7) from roller (4).

a Take care not to damage the sealing surface.
6. Using push tools [2] and [3], remove bushing (8) from roller
(4).
PC200, 200LC, 220, 220LC-8M0 50-400 3

SEN06145-02 Disassembly and assembly of carrier roller assembly
Assembly
1. Using push tools [3] and [4], press fit bushing (8) to roller
(4).
a Press it from the side of cover (3).
2. Floating seal
1) Using tool L1, install floating seal (7) to roller (4).
2) Using tool L1, install floating seal (6) to ring (5).
a When installing the floating seal, completely wash,
degrease and dry both O-ring and the surfaces
where the O-ring and the floating seal will contact
each other (hatched area in the sketch). And take
care that there is no dust sticking on the contact
surface of floating seal.
a When fitting the floating seal, use tool L1 and be
sure that the O-ring is pushed during the insertion.
a After inserting the floating seal, verify that the incli-
nation of the seal is less than 1 mm per its diame-
ter and that the protrusion height of the seal shown
as (a) in the illustration falls within the range of 7 to
11 mm.
3. Install roller (4) and ring (5) to shaft (2).

a On the sliding surfaces of floating seals, apply some oil
and take care not to have any dirt stuck on them.
50-400 4 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of carrier roller assembly SEN06145-02
4. To make the height gap between roller (4) and ring (5) 1.8 ±
0.2 mm, put washer [7] between push tool [6] and roller (4),
then press fit ring (5) to shaft (2).
a The thickness of washer [7] is 1.8 ± 0.2 mm.
a Use push tool [5] to support shaft (2) on it.
5. Using push tool [8], press fit cover (3) to roller (4).
a Degrease, wash and dry the surfaces where roller (4)
and cover (3) fit tight.
a Press fitting force (reference):
59 kN {6,000 kg} min.
6. Fill carrier roller assembly (1) with oil and tighten plug (9).
5 Carrier roller: 75 to 85 cc (EO30-DH)
3 Plug: 15 ± 5 Nm {1.5 ± 0.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-400 5

SEN06145-02 Disassembly and assembly of track roller assembly
Disassembly and assembly of track roller assembly 1
Special tools
L 2 796-670-1020 Installer t 1
Disassembly
1. Remove pin (1) and then collar (2).
2. Remove floating seal (3) from collar (2) and roller (4).
3. Pull out roller (4) from shaft (5) and collar (8) assembly.
a Since 195 ml of oil is filled in, drain it at this timing, or
underlay some cloth to prevent any careless smearing.
4. Pull out other side floating seal (6) from roller (4), shaft (5)
and collar (8) assembly.
5. Remove pin (7) and then collar (8) from shaft (5).
6. Remove bushings (9) and (10) from roller (4).
50-400 6 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of track roller assembly SEN06145-02
Assembly
1. Using push tool [1], press fit bushings (9) and (10) to roller
(4).
2. Fit an O-ring and install collar (8) to shaft (5), and insert pin
(7).
3. Using tool L2, install floating seal (6a) to collar (8).

a When installing the floating seal, completely wash,
degrease and dry both O-ring and the surfaces of float-
ing seal where they contact each other (shown hatched
area in the illustration). And take care that there is no
dust sticking on the contact surfaces of floating seal.
a After inserting the floating seal, verify that the inclina-
tion of the seal is less than 1 mm per its diameter and
that the protrusion height shown as (a) in the illustration
falls within the range of 7 to 11 mm.
4. Using tool L2, install floating seals (6b) and (3b) to roller (4).
a As to notes for installation of floating seals (6b) and
(3b), refer to a marked comments in the step 3.
5. Install shaft (5) to roller (4).

6. Put roller (4) and shaft (5) assembly upside down.
PC200, 200LC, 220, 220LC-8M0 50-400 7

SEN06145-02 Disassembly and assembly of track roller assembly
7. Using tool L2, install floating seal (3a) to collar (2).

a As to notes for installation of floating seal (3a), refer to
a marked comments in the step 3.
a On the sliding surfaces of the floating seals, apply
some oil and take care not to have any dust stuck on
them.
8. Fit an O-ring and install collar (2) to the shaft with pin (1).
9. Add oil and tighten the plug.

5 Amount of oil: 190 to 200 cc (EO30-DH)
3 Plug: 15 ± 5 Nm {1.5 ± 0.5 kgm}
50-400 8 PC200, 200LC, 220, 220LC-8M0

Removal and installation of idler and idler cushion assembly SEN06145-02
Removal and installation of idler and idler cushion assembly 1
Standard tools list

5 Bar (Commercially available) 1
6 Wire (Commercially available) 8 mm 1 (235 kg)
(105 kg), (130
kg)
8 Block (Commercially available) 3
PC200, 200LC, 220, 220LC-8M0 50-400 9

SEN06145-02 Removal and installation of idler and idler cushion assembly
Removal
1. Separate the track assembly. For details, see "Separation
and connection of track assembly".
2. Move idler and idler cushion assembly (1) forward to the

position where it can be slung by using bar [5].
Tool: Bar
3. While slinging idler and idle cushion assembly (1), pull it for-
ward from the track frame (2).
Tool: Wire
4 Idler and idler cushion assembly: 235 kg
4. Place blocks under the right and left of yoke and under the
spring to lock them, while slinging the idler assembly (3)
and idler cushion assembly (4).
Tools: Blocks
4 Idler cushion assembly: 130 kg
5. Sling the idler assembly (3) with the sling, and hold it.
Tool: Webbing sling
4 Idler assembly: 105 kg
6. Remove the bolts (4a) (2 pieces), and disconnect the idler

assembly (3) from the idler cushion assembly (4).
50-400 10 PC200, 200LC, 220, 220LC-8M0

Removal and installation of idler and idler cushion assembly SEN06145-02
Installation
1. Sling the idler cushion assembly (4) with a sling, and set it
on blocks.
Tools: Blocks, webbing sling
4 Idler cushion assembly: 130 kg
2. Sling the idler assembly (3) with a sling, and set it on the
idler cushion assembly (4).
4 Idler assembly: 105 kg
3. Connect the idler assembly (3) to the idler cushion (4) with
Torque wrench set (socket)
3 Bolt (4a): 230 to 289 Nm {23.5 to 29.5 kgm}
4. While slinging the idler and idle cushion assembly (1) with a
sling, push it in the track frame (2).
Tool: Wire
5. Install the track assembly. For details, see "Separation and

connection of track assembly".
PC200, 200LC, 220, 220LC-8M0 50-400 11

SEN06145-02 Disassembly and assembly of idler
Disassembly and assembly of idler 1
Special tools
L 3 791-530-1510 Installer t 1
Disassembly
q Figure of structure
1. Remove dowel pin (1) to remove support (2).

2. Remove floating seals (3) from support (2) and idler (4).
3. Remove idler (4) from the assembly of shaft (5) and support
(7).
a Since approximately 250 cc of oil is filled in, drain it at
this timing, or underlay some cloth against any careless
smearing.
4. Remove floating seals (6) on the other side from idler (4)
and the assembly of shaft (5) and support (7).
50-400 12 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of idler SEN06145-02
5. Remove dowel pin (8), and then remove support (7) from
shaft (5).
6. Remove bushings (9) and (10) from idler (4).
PC200, 200LC, 220, 220LC-8M0 50-400 13

Assembly
1. Press fit bushings (9) and (10) to idler (4).
2. Install shaft (5) with O-ring (12) to support (2), and insert
dowel pin (1).
50-400 14 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of idler SEN06145-02
3. By using tool L3, install floating seals (3) to idler (4) and the
assembly of shaft (5) and support (2).
a Completely clean, degrease, and dry the contact sur-
faces (hatched area shown in the figure) of the floating
seal and the O-ring.
a Apply oil to the sliding surface of the floating seal, and
take care not to have any dirt stuck on it.
a After inserting the floating seals, check that the inclina-
tion is less than 1 mm and the protrusion (a) is within
the range of 7 to 11 mm.
4. Install the assembly of shaft (5) and support (2) to idler (4).
5. Turn it over, and supply oil between shaft (5) and idler (4).
5 Amount of oil to be sealed (EO-30DH): 245 to 255 cc
PC200, 200LC, 220, 220LC-8M0 50-400 15

6. By using tool L3, install floating seal (6) to idler (4) and sup-
port (7).
a Completely clean, degrease, and dry the contact sur-
faces (hatched area shown in the figure) of the floating
seal and the O-ring.
a Apply oil to the sliding surface of the floating seal, and
take care not to have any dirt stuck on it.
a After inserting the floating seals, check that the inclina-
tion is less than 1 mm and the protrusion (a) is within
the range of 7 to 11 mm.
7. Install shaft (5) with O-ring (11) to support (7), and insert
dowel pin (8).
a See figure of structure.
8. Supply oil and tighten plug (13).
3 Plug (13): 157 to 255 Nm {16 to 26 kgm}
a When mounting the idler assembly on the machine,

make sure that plug (13) faces right side of the
machine.
50-400 16 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of idler cushion SEN06145-02
Disassembly and assembly of idler cushion 1
Special tools
791-600-2001 Compressor (A) t 1
or
791-685-8006 Compressor (B) t 1
790-201-2780 Spacer t 1
1 791-635-3160 Extension t 1
Cylinder
790-101-1600 t 1
(686 kN {70 ton})
790-101-1102 Pump t 1
M 791-640-2180 Guide bolt t 1
790-101-5201 Push tool kit (B) q 1
790-101-5241 • Plate 1
2
790-101-5221 • Grip 1
01010-51225 • Bolt 2
790-201-1620 • Plate 1
3
790-101-5021 • Grip 1
01010-50816 • Bolt 1
k Since the load at installed length of the spring is large and dangerous, set the spring securely to
the tool.
PC200, 200LC, 220, 220LC-8M0 50-400 17

SEN06145-02 Disassembly and assembly of idler cushion
Disassembly
1. Remove piston assembly (2) from idler cushion assembly

(1).
2. Disassembly of idler cushion assembly

1) Set idler cushion assembly (1) to tool M1.
a Load at installed length of spring:
PC200-8M0: 109.3 kN {11,150 kg}
PC200LC-8M0, PC220-8M0,
PC220LC-8M0: 126.5 kN {12,900 kg}
2) Apply hydraulic pressure gradually to compress the
spring and remove lock plate (3) and nut (4).
a Compress the spring until the nut becomes loose.
a Release the hydraulic pressure slowly to release
the compression of the spring.
a Free length of spring:
PC200-8M0: 503 mm
PC200LC-8M0, PC220-8M0,
PC220LC-8M0: 561 mm
3) Remove yoke (6) and cylinder (7) from spring (5).
4) Remove snap ring (8), dust seal (9) and bushing (10),
in turn from cylinder (7).
3. Further disassembly of piston assembly (2)
1) Remove lock plate (12) from piston (11), and then
remove valve (13).
2) Remove snap ring (14), then remove U-packing (15)
and ring (16).
50-400 18 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of idler cushion SEN06145-02
Assembly
1. Assembly of piston (2)

1) Install ring (16) and U-packing (15) to piston (11), and
secure them with snap ring (14).
2) Tighten valve (13) lightly, and secure it with lock plate
(12).
2. Assembly of idler cushion

1) Using tool M2, press fit bushing (10) into cylinder (7).
2) Using tool M3, install dust seal (9) to cylinder (7).
3) Secure them by using snap ring (8).
4) Install plate (7a), cylinder (7) and yoke (6) to spring (5).
Install the assembly to tool M1.
2 Sliding surface of cylinder: Grease (G2-LI)
5) Apply hydraulic pressure slowly to compress the

spring, and then tighten nut (4) so that the installed
length of the spring is dimension (a) and secure it with
lock plate (3).
a Installed length (a) of spring:
PC200-8M0: 389 mm
PC200LC-8M0, PC220-8M0,
PC220LC-8M0: 433 mm
6) Remove idler cushion assembly (1) from tool M1.

3. Install piston assembly (2) to idler cushion assembly (1).
2 Sliding surface of cylinder: Grease (G2-LI)
2 Wear ring: Grease (G2-LI)
a Install the piston assembly with the valve installed posi-
tion facing outward.
a Pump 300 cc of grease (G2-LI) into the cylinder and
bleed air. Check that grease comes out of the grease
hole.
PC200, 200LC, 220, 220LC-8M0 50-400 19

SEN06145-02 Removal and installation of sprocket
Removal and installation of sprocket 1
Standard tools list

3 Block (Commercially available) 5 [1], [2]
4 Webbing sling (Commercially available) Width: 25 mm 1 (40 kg)
50-400 20 PC200, 200LC, 220, 220LC-8M0

Removal and installation of sprocket SEN06145-02
Removal
1. Separate the track assembly. For details, see "Separation
2. Swing the work equipment 90  and raise the machine off

the ground by using the work equipment to set blocks [1]
between the track frame and track.
3. Remove the sprocket (2) as shown below.
1) Remove the bolts (1) (20 pieces).
a Before removing the last mounting bolt, put block
[2] under sprocket (2).
2) Put sprocket (2) on block [2] to create a gap from final
drive (FD), and put sling [3] through it.
4 Sprocket: 40 kg
Installation
1. Sling the sprocket (2) with the webbing sling [3], and place it
on the block [2].
4 Sprocket: 40 kg
2. Remove webbing sling [3], and push sprocket (2) and set it
on the installing position.
3. Remove webbing sling [3].
a Take care that sprocket (2) does not fall.
4. Coat bolts (1) (20 pieces) with adhesive, and finger-tighten
them.
2 Threaded portion of sprocket mounting bolt: Adhe-
sive (LT-2)
5. Tighten bolts (1) (20 pieces) to the specified torque.
3 Bolt (1): 441 to 490 Nm {45 to 50 kgm}
6. Raise the machine off the ground by using the work equip-
ment, and remove blocks [1] between the track frame and
track.
7. Connect the track assembly. For details, see "Separation
PC200, 200LC, 220, 220LC-8M0 50-400 21

SEN06145-02 Separation and connection of track assembly
Separation and connection of track assembly 1
Standard tools list

4 Torque wrench set (socket) (Commercially available) 49050 Nm 1
7 Bar (Commercially available) 1
8 Wire (Commercially available) 1
9 Grease pump (Commercially available) 1
10 Hammer (Commercially available) 1
Special tools list

1 Remover and installer 791-630-3000 1
A 2 Cylinder 790-101-1300 980 kN {100 ton} 1
3 Pump 790-101-1102 1
50-400 22 PC200, 200LC, 220, 220LC-8M0

Separation and connection of track assembly SEN06145-02
Separation of track assembly
1. Swing the upper structure by 90 deg.

2. Loosen lubricator (1) and slacken the track tension.
Lubricator (1): Width across flats 19 mm
k Since the internal pressure of the adjustment cylin-
der is very high, do not loosen the lubricator more
than 1 turn. If the grease does not come out suffi-
ciently, drive the machine forward and reverse.
3. Set the position of master pin (2).

Tools: Blocks
1) Raise the machine body by using the work equipment,
and float the track (3).
2) Move master pin (2) to the position where it can be
easily removed above the idler.
3) Raise the work equipment, and lower the machine and
fix it on the blocks.
4. Remove the bolts (7) (4 pieces each), and remove the

shoes (5) (2 pieces) on the right and left at the master pin
(2).
a Loosen the bolts (4 pieces) by 1 to 2 turns each and
check that they rotate lightly, and then remove them.
a If a bolt does not turn smoothly and it is unscrewed
forcibly, the threaded part of the bolt and link may be
damaged.
5. Remove the master pin (2) by using tool A (remover and

installer, etc.)
a Press out master pin (2) with the guide pin (GP).
PC200, 200LC, 220, 220LC-8M0 50-400 23

6. Move the position of guide pin (GP).

Tools: Blocks
1) Rotate the track and bring the guide pin (GP) to the
front of the idler.
2) Set block [6] at the lower part of track shoe (3) of the
front of the idler.
7. Remove guide pin (GP), and slowly reverse the machine to
separate track (3).
a Place a block, etc. between the track and track frame to
avoid damage.
8. Remove the block [6] placed in front of the idler.
50-400 24 PC200, 200LC, 220, 220LC-8M0

Connection of track assembly
1. While tensing the wire [8] with a forklift truck, work equip-
ment, etc., move the machine forward slowly to wind the
track (3).
Tools: Wire
2. Position track (3) by using bar [7], hammer [10], etc., and
insert the guide pin (GP).
a Place block [6] etc. under track (3) in front of the idler
and support the track.
Tools: Bar, hammer
3. Raise the forward end of track (3), and place block [6] under
it.
4. Align the pin holes of link (6), and drive the guide pin (GP).
PC200, 200LC, 220, 220LC-8M0 50-400 25

5. Install the dust seals to both ends of the outer link.

a Apply grease to the seal bushing contact face.
a Apply grease to the inside of bushing (contact face on
the link pin).
2 Contact surfaces of bushing (4) and dust seal
(Portion b): Grease
NIGTIGHT LYK-2
2 Between bushing (4) and master pin (2)
(hatched area): Grease
NIGTIGHT LYK-2
6. Install the master pin (2) by using tool A (remover and

installer, etc.)
a Apply grease to master pin (2).
a Press fit master pin (2), and remove guide pin (GP).
a Press fit the master pin by using tool A (remover and
installer, etc.) so that projection (a) of master pin (2) is
the following dimension.
Projection of master pin (a): 2.51 mm
7. Install the shoe.

1) Clean the mating faces of shoe (5) and link, and the
seats of bolts (7) and nuts to remove dirt, dust, and
rust.
2) Install the shoe (5) with the bolts (7) (4 pieces).
Tool: Torque wrench set (socket)
3 Bolt (7)
1] 49050 Nm {505 kgm}
a Finger tighten the bolts (7) (4 pieces) until the mat-
ing faces of the links are fitted.
a If the bolts (7) are tightened forcibly before the link
mating faces are fitted, the threaded portions of
themselves and link may be damaged.
2] 12010 deg. (Tighten with angle tightening
wrench)
50-400 26 PC200, 200LC, 220, 220LC-8M0

8. Remove the block [6].

1) Raise the machine body by using the work equipment,
and float the track (3).
2) Remove the blocks [B] under the track at the idler and
sprocket.
3) Slowly lower the machine.
9. Adjust the track shoe tension with the lubricator (1)

a For details, see Testing and adjusting, "Testing and
adjusting track tension".
10. Swing the upper structure by 90 deg.
PC200, 200LC, 220, 220LC-8M0 50-400 27

SEN06145-02 Removal and installation of revolving frame assembly
Removal and installation of revolving frame assembly 1
Standard tools list

59 to 74 Nm
716 to 814 Nm
34 to 54 Nm
177 to 245 Nm
(180 kg), (200
kg)
(5100 kg), (5500
14 Chain (Commercially available) 4
kg)
(5100 kg), (5500
15 Lever block (Commercially available) 3
kg)
50-400 28 PC200, 200LC, 220, 220LC-8M0

Removal and installation of revolving frame assembly SEN06145-02
Special tools list

1 Plug (female) 02789-00210 #02 1 Hose between
2 Plug (male) 07376-70210 #02 1 center swivel
A
joint (port E) and
3 O-ring 02896-11008 1 solenoid valve
B joint (port D) and
3 O-ring 02896-11012 1 swing motor (port
T)
joint (port B) and
control valve L.H.
travel (port A2),
hose between
center swivel
joint (port D) and
control valve
R.H. travel (port
C B5), hose
3 O-ring 02896-11018 4 between center
swivel joint (port
A) and control
valve L.H. travel
(port B2), hose
between center
swivel joint (port
C) and control
valve R.H. travel
(port A5)
k Extend the arm and bucket fully and lower the work equipment to the ground, and set the lock
lever to LOCK position.
NOTICE
PC200, 200LC, 220, 220LC-8M0 50-400 29

Removal
1. Remove the work equipment assembly. For details, see
"Removal and installation of work equipment assembly".
2. Remove the counterweight assembly. For details, see
"Removal and installation of counterweight assembly".
3. Remove the flanges (1a), (17a), (18a), and (19a), and dis-
connect the boom cylinder hoses (1) (4 pieces).
Tools: Socket wrench, special tool C
Bolts of flanges (1a), (17a), (18a), and (19a): Width
across flats 14 mm, M10
4. Sling the boom cylinder assembly (2), and hold it.

4 Boom cylinder assembly:
180 kg (PC200/200LC-8M0)
200 kg (PC220/220LC-8M0)
5. Remove the bolts (3a) (2 pieces), and remove the plate (3)
and pin (4).
6. Sling the boom cylinder assembly (2), and remove it.
a Check the positions and number of spacers.
Remove the boom cylinder on the opposite side in the same
way.
7. Remove the bolts (5a) (2 pieces), and disconnect the fuel

filter and bracket assembly (5).
a Fix the fuel filter and bracket assembly (5) to the engine
in order to prevent it from interfering with the sling when
the revolving frame assembly is removed.
a When other parts can interfere with the lifting tool in
removal of the revolving frame, such parts must be
removed beforehand.
50-400 30 PC200, 200LC, 220, 220LC-8M0

8. Remove hoses (8) to (13) (6 pieces) from the center swivel

joint assembly.
Tools: Wrench, special tools A, B, C
q (8): Center swivel joint (port D) to swing motor (port T)
Special tool B
q (9): Center swivel joint (port E) to solenoid valve
Special tool A
q (10): Center swivel joint (port B) to control valve L.H.
travel (port A2)
Special tool C
q (11): Center swivel joint (port D) to control valve R.H.
travel (port B5)
Special tool C
q (12): Center swivel joint (port A) to control valve L.H.
travel (port B2)
Special tool C
q (13): Center swivel joint (port C) to control valve R.H.
travel (port A5)
Special tool C
9. Pull out pin (14) on the center swivel joint side, and discon-
nect lock plate (15) from the center swivel joint.
10. Sling revolving frame assembly (16), and hold it.
Tools: Socket wrench, chain, lever block
4 Revolving frame assembly:
5100 kg (PC200/200LC-8M0)
5500 kg (PC220/220LC-8M0)
11. Remove the bolts (16a) (32 pieces), sling the revolving
frame assembly (16), and remove it.
a Leave 2 or 3 mounting bolts each at front and rear. Bal-
ance the revolving frame assembly (16) longitudinally
and laterally with lever blocks etc., and remove the
remaining bolts.
a When removing revolving frame assembly (16), lift it up
gradually while taking care not to hit it against the cen-
ter swivel joint.
PC200, 200LC, 220, 220LC-8M0 50-400 31

Installation
1. Sling the revolving frame assembly (16), and set it on the
Tools: Chain, lever block
4 Revolving frame assembly:
5100 kg (PC200/200LC-8M0)
5500 kg (PC220/220LC-8M0)
2 Mating surfaces of the swing circles:
a Sling revolving frame assembly (16) by using the 2
holes for the counterweight mounting bolts and the 2
holes for boom cylinder foot pins.
2. Install the revolving frame assembly (16) with the bolts

(16a) (32 pieces).
2 Threaded part of revolving frame mounting bolt:
Adhesive (LT-2)
Tools: Torque wrench set (socket), angle tightening wrench
q Torque tightening:
3 Bolt (16a): 716 to 814 Nm {73 to 83 kgm}
q Angle tightening:
3 Bolt (16a):
1) Initial torque: 294.229.4 Nm {303 kgm}
2) Then, turn the bolt 606 turns
a Install the mounting bolts (2 or 3 pieces each at front
and rear), balance the revolving frame assembly (16)
longitudinally and laterally with the lever blocks etc.,
and install the remaining bolts.
a When installing revolving frame assembly (16), lower it
gradually while taking care not to hit it against the cen-
ter swivel joint.
3. Connect the stopper plate (15) to the center swivel joint,

and insert the pin (14) on the center swivel joint side.
a Fix the pin (14) with the stopper cotter pin.
4. Connect hoses (8) to (13) (6 pieces) to the center swivel
joint assembly.
3 Hose (8): 84 to 132 Nm {8.5 to 13.5 kgm}
3 Hose (9): 34 to 54 Nm {3.5 to 5.5 kgm}
travel (port A2)
3 Hose (10): 177 to 245 Nm {18.0 to 25.0 kgm}
travel (port B5)
3 Hose (11): 177 to 245 Nm {18.0 to 25.0 kgm}
50-400 32 PC200, 200LC, 220, 220LC-8M0


travel (port B2)
3 Hose (12): 177 to 245 Nm {18.0 to 25.0 kgm}
travel (port A5)
3 Hose (13): 177 to 245 Nm {18.0 to 25.0 kgm}
(5a) (2 pieces).
3 Bolt (5a): 98 to 123 Nm {10 to 12.5 kgm}
6. Sling the boom cylinder assembly (2), and align the pin on
the bottom side with the pin hole of the revolving frame
bracket.
4 Boom cylinder assembly:
180 kg (PC200/200LC-8M0)
200 kg (PC220/220LC-8M0)
7. Install the pin (4), and fix the plate (3) with the bolts (3a) (2
pieces).
3 Bolt (3a): 98 to 123 Nm {10 to 12.5 kgm}
a Check the positions and number of spacers.
a Install the boom cylinder on the opposite side in the
same way.
8. Connect the boom cylinder hoses (1) (4 pieces) with the

flanges (1a), (17a), (18a), and (19a).
Bolts of flanges (1a), (17a), (18a), and (19a): Width
3 Bolts of flanges (1a), (17a), (18a), and (19a): 59 to
74 Nm {6 to 7.5 kgm}
9. Install the counterweight assembly. For details, see "Removal and installation of counterweight assem-
bly".
10. Install the work equipment assembly. For details, see "Removal and installation of work equipment
assembly".
PC200, 200LC, 220, 220LC-8M0 50-400 33


q Bleeding air
12. Bleed air from the work equipment and travel motor. For details, see Testing and adjusting, "Bleeding air
from each part".
50-400 34 PC200, 200LC, 220, 220LC-8M0

Removal and installation of counterweight assembly SEN06145-02
Removal and installation of counterweight assembly 1
Standard tools list

98 to 123 kg
1180 to 1470 Nm
(3750kg),
5 4-leg chain sling (Commercially available) 1 (4450kg),
(5050kg)
(3750kg),
6 Lever block (Commercially available) 1 (4450kg),
(5050kg)
PC200, 200LC, 220, 220LC-8M0 50-400 35

SEN06145-02 Removal and installation of counterweight assembly
Removal
1. Mirror specification
1) Remove the bolts (1a) (2 pieces), and remove the mir-
ror (1).
2) Install the eyebolts to the 2 slinging positions, sling the
counterweight assembly (2) with the sling, and hold it.
Tools: 4-leg chain sling, lever block, eyebolts
4 Counterweight assembly:
3750 kg (PC200/200LC-8M0)
5050 kg (PC220/220LC-8M0)

Tools: Socket wrench, impact wrench
a Check the locations of shim.
3. Sling counterweight assembly (2), and remove it.

a Take care that the counterweight will not hit the engine,
radiator, cooler assembly, etc.
a When storing the removed counterweight, take mea-
sures to prevent it from falling down by using blocks,
ropes, etc., since it is very heavy.
50-400 36 PC200, 200LC, 220, 220LC-8M0

Installation
1. Before installing the counterweight, check the following.
a Check that the recirculation prevention seats (4) to (9)
are securely installed.
a If recirculation prevention seats (4) to (9) peel off, the
high temperature air in the engine compartment flows
in the cooling side and can cause overheating. Cor-
rectly install those seats.
2. Sling counterweight assembly (2), and set it on the installing

position.
Tools: 4-leg chain sling, lever block, eyebolts
a Take care that the counterweight will not hit the engine,
radiator, cooler assembly, etc.
4 Counterweight assembly:
3750 kg (PC200/200LC-8M0)
5050 kg (PC220/220LC-8M0)
3. Adjust the counterweight to the following dimensions, and

install it.
1) Adjust the step from the exterior (top and bottom gaps)
with shims.
a Shim: 20Y-46-11410
2) Install the counterweight so that the gap between the
door and counterweight (2), and the gap (front and
back) between the revolving frame and counterweight
are even at 105 mm.
3) Horizontal step between exterior door (D) and counter-

weight (C)
a: 104 mm
Horizontal step between revolving frame (R) and coun-
terweight (C)
b: 5 mm or less
Vertical step between exterior top cover (UC) and
counterweight (C)
c: 05 mm
Install the counterweight so that the above is achieved.
a Seen from the rear of the machine. (Enlarged view
of machine right side)
4. Install the counterweight assembly (2) with the bolts (3) (4

pieces).
3 Bolt (3): 1180 to 1470 Nm {120 to 150 kgm}
2 Threaded portion of bolt (3): Adhesive (LT-2)
PC200, 200LC, 220, 220LC-8M0 50-400 37

SEN06145-02 Removal and installation of counterweight assembly
5. Mirror specification
1) Install the mirror (1) with the bolts (1a) (2 pieces).
3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
50-400 38 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 50-400 39

SEN06145-02

© 2019 KOMATSU
All Rights Reserved
50-400 40
SEN06146-01
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

500 Hydraulic system
Removal and installation of center swivel joint assembly ............................................................................... 2
Disassembly and assembly of center swivel joint assembly ........................................................................... 9
Removal and installation of hydraulic tank assembly.....................................................................................11
Removal and installation of control valve assembly ..................................................................................... 21
Disassembly and assembly of control valve ................................................................................................. 38
Removal and installation of hydraulic pump assembly ................................................................................. 44
Removal and installation of hydraulic pump input shaft oil seal.................................................................... 54
Disassembly and assembly of work equipment PPC valve assembly .......................................................... 55
Disassembly and assembly of travel PPC valve........................................................................................... 57
Disassembly and assembly of work equipment cylinder............................................................................... 59
PC200, 200LC, 220, 220LC-8M0 50-500 1

SEN06146-01 Removal and installation of center swivel joint assembly
Removal and installation of center swivel joint assembly 1
Standard tools list

6 Wrench (Commercially available) 22mm 1
58.8 to78.5Nm
10 Torque wrench set (socket) (Commercially available) 59 to74 Nm 1
98 to 123Nm
34 to 54Nm
11 Torque wrench set (wrench) (Commercially available) 84 to 132Nm 1
177 to 245Nm
12 Webbing sling (Commercially available) 1 (40kg)
Special tools list

1 Oil stopper 796-460-1210 1
A
2 Adapter 796-770-1320 1
joint (port T) and
L.H. travel motor
(port T), hose
between center
swivel joint (port
T) and R.H.
travel motor (port
T), hose between
center swivel
B
joint (port E) and
3 O-ring 02896-11008 5 L.H. travel motor
(port P), hose
between center
swivel joint (port
E) and R.H.
travel motor (port
P), hose between
center swivel
joint (port E) and
solenoid valve
C joint (port D) and
3 O-ring 02896-11012 1 swing motor (port
T)
50-500 2 PC200, 200LC, 220, 220LC-8M0

Removal and installation of center swivel joint assembly SEN06146-01

joint (port B) and
control valve L.H.
travel (port A2),
hose between
center swivel
joint (port D) and
control valve
R.H. travel (port
D
B5), hose
3 O-ring 02896-11018 4 between center
swivel joint (port
A) and control
valve L.H. travel
(port B2), center
swivel joint (port
C) and control
valve R.H. travel
(port A5)
1 Flange 07379-00640 #06 4 Hose between
2 Head 07378-10600 #06 4 center swivel
joint (port B) and
3 O-ring 07000-13030 4
L.H. travel motor
4 Split flange 07371-30640 8 (port PA), hose
between center
swivel joint (port
D) and R.H.
travel motor (port
E PB), hose
between center
swivel joint (port
5 Bolt 07375-21035 16
A) and L.H. travel
motor (port PB),
hose between
center swivel
joint (port C) and
R.H. travel motor
(port PA)
k Swing the upper structure clockwise 45 degrees, lower the work equipment to the ground, and
stop the engine.
k Loosen the cap of the hydraulic tank slowly, and release the pressure inside of the hydraulic
tank.
NOTICE
PC200, 200LC, 220, 220LC-8M0 50-500 3

Removal
1. Remove the bolts (1a) (8 pieces), and remove the revolving
frame lower cover (1b) on the right side of the machine.
tool A1 (oil stopper) and tool A2 (adapter).
6 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
a When not using tools A1 (oil stopper) and A2 (adapter),
remove the drain plug and drain the oil from the
hydraulic tank and piping.
a After draining the oil, install the plug (1c).
3. Disconnect hoses (1) and (2) (2 pieces) (under the swivel

joint) between the travel motor and center swivel joint (17).
Tools: Wrench, special tool B
q (1): Center swivel joint (port T) to L.H. travel motor (port
T)
q (2): Center swivel joint (port T) to R.H. travel motor
(port T)
4. Remove the flanges (3a), (4a), (5a), and (6a), and discon-
nect hoses (3), (4), (5), and (6) (1 piece each) (under the
swivel joint) between the travel motor and center swivel joint
(17).
q (3): Center swivel joint (port B) to L.H. travel motor
(port PA)
q (4): Center swivel joint (port D) to R.H. travel motor
(port PB)
q (5): Center swivel joint (port A) to L.H. travel motor
(port PB)
q (6): Center swivel joint (port C) to R.H. travel motor
(port PA)
Tools: Socket wrench, special tool E
Bolts of flanges (3a), (4a), (5a), (6a): Width across
flats 14 mm
50-500 4 PC200, 200LC, 220, 220LC-8M0

5. Disconnect the hoses (7) to (14) (8 pieces) (above the cen-

ter swivel joint).
Tools: Wrench, special tools B, C
q (7): Center swivel joint (port E) to L.H. travel motor (port
P)
q (8): Center swivel joint (port E) to R.H. travel motor
(port P)
Special tool A
Special tool B
Special tool A
travel (port A2)
travel (port B5)
travel (port B2)
travel (port A5)
Tools: Wrench, special tool D
Hose (11) to (14): Width across flats 36 mm, #06
size
Special tool C
6. Pull out pin (15) on the center swivel joint side and remove
the lock plate (15a) from the center swivel joint.
7. Remove the bolts (16) (4 pieces) (under the center swivel

joint (17)).
8. Sling center swivel joint assembly (17), and remove it.

4 Center swivel joint assembly (17): 40 kg
PC200, 200LC, 220, 220LC-8M0 50-500 5

Installation
1. Sling the center swivel joint assembly (17), and set it on the
4 Center swivel joint assembly (17): 40 kg
a Install the center swivel joint (17) in the direction shown in

the figure. (The figure shows the top view of the machine.)
a S: Sprocket
A to D: Port name
2. Install the center swivel joint assembly (17) with the bolts
(16) (4 pieces) (under the center swivel joint).
3 Bolt (16): 98 to 123 Nm {10 to 12.5 kgm}
3. Match the lock plate (15a) with the fixing hole of center
swivel joint (17), and insert pin (15) on the center swivel
joint (17) and fix it with the cotter pin.
a Set the lock plate with the red identification mark up.
4. Connect the hoses (7) to (14) (8 pieces) (above the center
swivel joint).
travel (port A5)
travel (port B2)
travel (port B5)
travel (port A2)
Hose (11) to (14): Width across flats 36 mm, #06
size
3 Hoses (11) to (14):
177 to 245 Nm {18.0 to 25.0 kgm}
3 Hose (10): 34 to 54 Nm {3.5 to 5.5 kgm}
50-500 6 PC200, 200LC, 220, 220LC-8M0


3 Hose (9): 84 to 132 Nm {8.5 to 13.5 kgm}
q (8): Center swivel joint (port E) to R.H. travel motor

(port P)
q (7): Center swivel joint (port E) to L.H. travel motor (port
P)
3 Hoses (7), (8): 34 to 54 Nm {3.5 to 5.5 kgm}
5. Connect the hoses (3) to (6) (4 pieces) between the travel

motor and center swivel joint with the flanges (3a), (4a),
(5a), and (6a) (under the center swivel joint).
q (3): Center swivel joint (port B) to L.H. travel motor
(port PA)
q (4): Center swivel joint (port D) to R.H. travel motor
(port PB)
q (5): Center swivel joint (port A) to L.H. travel motor
(port PB)
q (6): Center swivel joint (port C) to R.H. travel motor
(port PA)
flats 14 mm, M10
3 Bolts of flanges (3a), (4a), (5a), (6a):
59 to 74 Nm {6 to 7.5 kgm}
6. Connect hoses (1) and (2) (2 pieces) (under the swivel joint)
between the travel motor and center swivel joint.
q (1): Center swivel joint (port T) to L.H. travel motor
(port T)
q (2): Center swivel joint (port T) to R.H. travel motor
(port T)
3 Hoses (1), (2): 84 to 132 Nm {8.5 to 13.5 kgm}
7. Tighten the drain plug (1c) of the hydraulic tank to the spec-
ified torque.
Plug (1c): Width across flats 24 mm
3 Plug (1c): 58.8 to 78.5 Nm {6.0 to 8.0 kgm}
PC200, 200LC, 220, 220LC-8M0 50-500 7

8. Add oil to the hydraulic tank.

5 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
a Refill the hydraulic tank with Komatsu genuine oil to the
specified level through the oil filler port. Start the engine
to circulate the oil through the piping, and check the oil
level again. (For details, see Structure and function,
Table of fuel, coolant, and lubricants.)
a When the oil stopper is used, remove it according to
"Removal and installation of hydraulic pump assem-
bly".
9. Install the revolving frame lower cover (1b) on the right side
of the machine with the bolts (1a) (8 pieces).
Plug (1a): Width across flats 19 mm, M12
3 Plug (1a): 98 to 123 Nm {10 to 12.5 kgm}
10. Bleed air from the hydraulic circuit. For details, see Testing
and adjusting, "Air bleeding from each part".
50-500 8 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of center swivel joint assembly SEN06146-01
Disassembly and assembly of center swivel joint assembly 1
Special tools
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
T1 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2
Disassembly
1. Remove elbows (1), (2) and tee (3).
3. Remove snap ring (5) and ring (6).
4. Using tool T1, pull out swivel shaft (8) from swivel rotor (7).
5. Remove seal (9) and O-ring (10) from swivel rotor (7).
6. Remove dust seal (11) from cover (12).
PC200, 200LC, 220, 220LC-8M0 50-500 9

SEN06146-01 Disassembly and assembly of center swivel joint assembly
Assembly
1. Install seal (9) and O-ring (10) to swivel rotor (7).
2. Install dust seal (11) to cover (12).
3. Install cover (12) to swivel shaft (8).
4. Set swivel shaft (8) to block, then using push tool, tap swivel
rotor (7) with a plastic hammer to install.
2 Contact surface of rotor, shaft: Grease (G2-LI)
a When installing rotor, be extremely careful not to dam-
age the dust seal and O-ring.
5. Install ring (6) and fix with snap ring (5).
6. Fit O-ring and install cover (4).

3 Mounting bolts: 31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
7. Install elbows (1), (2) and tee (3).
3 Elbow (1):128 to 186 Nm {13 to 19 kgm}
3 Elbow (2), tee (3): 35 to 63 Nm {3.5 to 6.5 kgm}
50-500 10 PC200, 200LC, 220, 220LC-8M0

Removal and installation of hydraulic tank assembly SEN06146-01
Removal and installation of hydraulic tank assembly 1
Standard tools list

58.8 to 78.5 Nm
59 to 74 Nm
98 to 123 Nm
245 to 309 Nm
34 to 54 Nm
177 to 245 Nm
8 2-leg chain sling (Commercially available) 1 (130 kg)
Special tools list

1 Plug (female) 02789-00315 #03 1
A 2 Plug (male) 07376-70315 #03 1 Drain hose
3 O-ring 02896-11009 1
1 Plug (female) 02789-00628 #06 1
B 2 Plug (male) 07376-70628 #06 1 Drain hose
3 O-ring 02896-11018 1
1 Flange 07379-01044 #10 1
2 Head 07378-11000 #10 1
C 3 O-ring 07000-13032 1 Drain hose
4 Split flange 07371-31049 2
5 Bolt 07375-21035 4
stop the engine.
tank.
NOTICE
PC200, 200LC, 220, 220LC-8M0 50-500 11

SEN06146-01 Removal and installation of hydraulic tank assembly
Removal
(1) and (1b).
2. Remove the drain plug (1c), and drain the oil from the
hydraulic tank.
6 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)

installation of engine and hydraulic pump assembly", 5 to
20.
q Engine hood (2a)
q Air cleaner top cover (2b) and frame (2k)
q Control valve top cover (2c)
q Cover and frames (2d) to (2g) between hydraulic pump
and engine
q Cover and frames (2h) to (2q) for removal of frame (2)
between control valve and engine
50-500 12 PC200, 200LC, 220, 220LC-8M0

4. Remove the frame (2) between the control valve and

engine.
5. Open the battery case top cover, remove bolts (3a) (4

pieces), and move cover (3) forward.
a Move forward in order to remove bolt (4a).
6. Remove bolts (4a) (8 pieces), and remove covers (4) and

(5).
7. Remove the flange (6a), and disconnect the drain hose (6).
q (6): From control valve
8. Remove the bolts (7a) and (8a) (2 pieces each), and dis-
connect the drain hoses (7) and (8).
Bolts (7a) and (8a): Width across flats 19 mm, M12
q (8): From oil cooler upper side
9. Disconnect the clamp (9).
Clamp (9) bolt: Width across flats 19 mm, M12
PC200, 200LC, 220, 220LC-8M0 50-500 13

10. Remove the bolts (11a) (2 pieces), and disconnect the filter
bracket (11).
(12).
a The bolts (12a) are fixed to the inside bottom of the
machine frame (12).
12. Disconnect the drain hoses (13) to (18).

Tools: Wrench, special tools A, B
Hoses (13) to (17): Width across flats 19 mm, #03 size
Special tool A
Special tool B
13. Disconnect clamps (19) and (19b).

Bolts of clamps (19) and (19b): Width across flats 19
mm, M12
14. Remove the hose clamps (20a) (2 pieces), and disconnect

the suction hose (20).
bags, etc. in order to prevent dirt entry.
nized.
50-500 14 PC200, 200LC, 220, 220LC-8M0


16. Sling the hydraulic tank assembly (22), and remove it.
Tools: 2-leg chain sling
4 Hydraulic tank assembly: 130 kg
PC200, 200LC, 220, 220LC-8M0 50-500 15

Installation
1. Sling the hydraulic tank assembly (22), and set it on the
Tools: 2-leg chain sling
4 Hydraulic tank assembly: 130 kg
2. Install the hydraulic tank (22) with the bolts (21) (6 pieces).
3 Bolt (21): 245 to 309 Nm {25 to 31.5 kgm}
3. Connect the suction hose (20) with the hose clamps (20a)
(2 pieces).
a Use new hose clamps.
a Reference
Hose insertion length: 85 mm (Both right and left)
to Min. 5 mm.
Dimension (b): Min. 5mm
q When reusing hose
3) Align the clamp position to the trace of clamp left on
hose.
4) Tighten it until dimension BDG becomes 7 to 10 mm.
50-500 16 PC200, 200LC, 220, 220LC-8M0

4. Connect the clamps (19) and (19b).

Bolts of clamps (19) and (19b): Width across flats 19
mm, M12
3 Bolts of clamps (19) and (19b):
98 to 123 Nm {10 to 12.5 kgm}
5. Connect the drain hoses (13) to (18).

3 Hoses (13) to (17): 54 to 93 Nm {5.5 to 9.5 kgm}

3 Hose (18): 177 to 245 Nm {18.0 to 25.0 kgm}

3 Bolt (12a): 98 to 123 Nm {10 to 12.5 kgm}
7. Install the filter bracket (11) with the bolts (11a) (2 pieces).
3 Bolt (11a): 98 to 123 Nm {10 to 12.5 kgm}
8. Connect the clamps (9).

3 Bolt (9): 98 to 123 Nm {10 to 12.5 kgm}
9. Connect the drain hoses (7) and (8) with the bolts (7a) and
(8a).
Bolts (7a) and (8a): Width across flats 19 mm, M12
3 Bolts (7a) and (8a): 98 to 123 Nm {10 to 12.5 kgm}
q (8): From oil cooler upper side
10. Connect the drain hose (6) with the flange (6a).
PC200, 200LC, 220, 220LC-8M0 50-500 17

11. Install the covers (4) and (5) with the bolts (4a) (8 pieces).
3 Bolt (4a): 98 to 123 Nm {10 to 12.5 kgm}
12. Open the battery case top cover, and install cover (3) with
3 Bolt (3a): 98 to 123 Nm {10 to 12.5 kgm}
13. Install the frame (2) between the control valve and engine.
50-500 18 PC200, 200LC, 220, 220LC-8M0

14. Install the following parts. For details, see "Removal and
62.
q Engine hood (2a)
q Air cleaner top cover (2b) and frame (2k)
q Control valve top cover (2c)
q Cover and frames (2d) to (2g) between hydraulic pump
and engine
q Cover and frames (2h) to (2q) for removal of frame (2)
between control valve and engine
15. Tighten the drain plug (1c) to the specified torque.

Hydraulic tank drain plug (1c): Width across flats 24
mm
3 Hydraulic tank drain plug (1c):
58.8 to 78.5 Nm {6.0 to 8.0 kgm}
PC200, 200LC, 220, 220LC-8M0 50-500 19

16. Add oil to the hydraulic tank.

5 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
17. Install the covers (1) and (1b) with the bolts (1a) (11 pieces).
3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
50-500 20 PC200, 200LC, 220, 220LC-8M0

Removal and installation of control valve assembly SEN06146-01
Removal and installation of control valve assembly 1
Standard tools list

58.8 to 78.5 Nm
59 to 74 Nm
98 to 123 Nm
245 to 309 Nm
34 to 54 Nm
117 to 245 Nm
PC200, 200LC, 220, 220LC-8M0 50-500 21

SEN06146-01 Removal and installation of control valve assembly
Special tools list

1 Plug (female) 02789-00210 #02 29 PLS1 port hose,
2 Plug (male) 07376-70210 #02 29 PLS2 port hose,
PST port hose,
PPC hoses (12
pieces), other
control hoses (10
pieces), LS sepa-
A
ration hose,
3 O-ring 02896-11008 29 hoses (2 pieces)
between control
valve and sole-
noid valve, PPS
port hose, PR
port hose
1 Plug (female) 02789-00315 #03 9 Solenoid hoses
B 2 Plug (male) 07376-70315 #03 9 (7 pieces), PPC
3 O-ring 02896-11009 9 hoses (2 pieces)
1 Plug (female) 02789-00628 #06 4 Hoses (4 pieces)
2 Plug (male) 07376-70628 #06 4 between control
C
valve and swing
3 O-ring 02896-11018 4 motor
1 Flange 07379-00640 #06 8
2 Head 07378-10600 #06 8 Boom hoses (4
pieces), control
D 3 O-ring 07000-13025 8
valve actuator
4 Split flange 07371-30640 16 hoses (4 pieces)
5 Bolt 07375-21035 32
1 Flange 07379-01044 #10 12 Drain hoses (2
2 Head 07378-11000 #10 12 pieces), PP1 port
hose, PP2 port
E 3 O-ring 07000-13032 12
hose, control
4 Split flange 07371-31049 24 valve actuator
5 Bolt 07375-21035 48 hoses (8 pieces)
k Swing the upper structure clockwise approximately 45 degrees, park the machine on a level
ground, lower the work equipment to the ground in a stable posture, and stop the engine.
k After stopping the engine, move the lock lever to LOCK position.
NOTICE
50-500 22 PC200, 200LC, 220, 220LC-8M0

Removal
(1b).
2. Remove the drain plug (1c), and drain the oil from the
hydraulic tank.
6 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
a When using the oil stopper instead of draining the oil
from the hydraulic tank, install it according to "Removal
of hydraulic pump assembly".
3. Remove the bolts (1d) (4 pieces), and remove the cover (1).
Bolt (1d): Width across flats 19 mm, M12
4. Disconnect hoses (2) to (8).

Special tool B
Hoses (2), (4) to (8): Width across flats 19 mm, #02 size
Special tool A
a Access from underside of the machine.
Band colors
q (2): No color
q (3): Red
q (4): No color
q (5): No color
q (6): Red/Yellow
q (7): Brown
q (8): No color
5. Disconnect connectors (9) (6 places) from the clips.
(From top)
V06
V05
V04
V03
V02
V01
PC200, 200LC, 220, 220LC-8M0 50-500 23


7. Remove the bolts (10a) (2 pieces), and disconnect the sole-
noid assembly (11) from the control valve bracket (B).
a Move the solenoid assembly (11) aside so that it does
not hinder the work.

20.
q (11a) Engine hood
q (11b) Control valve top cover
q (11c) Cover between hydraulic pump and engine
q (11d) Frame between control valve and engine
q (11e) Cover between control valve and engine
9. Disconnect PLS1 port hose (12).

Tools: Wrench, special tool A
a Hose band color: None
10. Disconnect PLS2 port hose (13).
a Hose band color: Red
50-500 24 PC200, 200LC, 220, 220LC-8M0

11. Disconnect the connectors V 23 (14) and V24 (15).

a Band colors: (14) red, (15) white
12. Disconnect the connectors (14) and (15) from clip.
13. Remove the bolt (16a), and disconnect the bracket (16).

15. Disconnect the R.H. PPC hoses (18) (7 pieces).
(From top in order)
OPT (Hose band colors: yellow)
Bucket CURL (Hose band color: white)
L.H. travel forward (Hose band color: red)
Boom LOWER (Hose band color: Brown)
Right SWING (Hose band color: No color)
R.H. travel FORWARD (hose band color: green)
Arm IN (Hose band color: Blue)
Special tool A
a Only bucket CURL is #03 size (Special tool B)
16. Disconnect the hose (19). (Hose band color: Brown)
q (19): Port PST hose (Solenoid)
17. Disconnect the hoses (20) to (23) (4 pieces).
a Hose band color: None is colored
q (20): Relief valve
q (21) to (23): OPT
18. Disconnect the L.H. PPC hoses (24) to (24e) (6 pieces).
(24) Bucket DUMP (Hose band color: Black)
(From top in order)
(24a) L.H. travel REVERSE (Hose band: No color)
(24b) Boom RAISE (hose band color: Green)
(24c) Left SWING (Hose band color: Red)
(24d) R.H. travel REVERSE (Hose band color: Blue)
(24e) Arm OUT (Hose band color: Yellow)
Tools: Wrench, special tools A
Hoses (24a) to (24e): Width across flats 19 mm, #02 size
19. Disconnect the LS separation hose (25).
20. Remove the bolt (26a), and disconnect the clamps (26).
PC200, 200LC, 220, 220LC-8M0 50-500 25

21. Remove the flange (27a) bolts (4 pieces), and disconnect

the drain hose (27).
Bolt of flange (27a): Width across flats 14 mm, M10
22. Remove clamps (27b) (2 pieces), and move the hose (27)
aside so that it does not hinder the work.
23. Disconnect the connector P26 (28). (Front pump pressure

sensor)
24. Remove the bolts (29a) (1 piece each), and disconnect the
bracket (29) and junction box (29b).

Tools: Wrench, special tools A and C
q (30): Between control valve and swing motor
Special tool C
q (31): Between control valve and solenoid valve
Special tool A
26. Disconnect the rear compensation valve connector (31a).

a Reference: Rear view
hoses (32) and (35).
q (32): Port PP1 hose (rear pump)
q (35): PP2 port hose (front pump)
Bolts of flanges (32a) and (35a): Width across flats 14
mm, M10
28. Remove the bolts (36a) (2 pieces), and disconnect the hose
(36).
q (36) Drain hose (Port T) (hydraulic tank)
50-500 26 PC200, 200LC, 220, 220LC-8M0


q (33): Port PPS2 hose (front pump)
Hose band color: Blue
q (34): Port PR hose (pump)
Hose band color: Yellow
30. Disconnect the connector P25 (37).
(Rear pump pressure sensor)
31. Remove the bolts (38a) and (39a) (2 pieces each), and dis-
connect the hoses (38) and (39).
q (38): Port ATT hose (filter) (If equipped)
q (39): Port T hose (under oil cooler)
32. Remove bolts (40a) (2 pieces each), and remove boom

tube mounting clamps (40) (2 pieces).
33. Remove the flanges (41a), (48a), (49a), and (50a), and dis-
connect the boom hoses (41), (48), (49), and (50).
flats 14 mm, M10
34. Remove the bolt (42a) (2 pieces each), and disconnect the
hose (42) from the bracket.
35. Remove bolts (43a) (2 pieces each), and remove boom

tube mounting clamps (43) (2 pieces).
36. Remove the bolts (44a) (2 pieces), and disconnect the hose
(44).
PC200, 200LC, 220, 220LC-8M0 50-500 27

37. Disconnect the control valve hoses (14 pieces) and tubes (2
pieces).
q Port A port side: (From top in order)
Port A-1 hose (If equipped) (51)
Port A1 hose (Bucket head side) (52)
Port A2 hose (swivel joint port B) (53)
Port A3 tube (Boom bottom side) (54)
Port A4 hose (Swing motor port MA) (55)
Port A5 hose (Swivel joint port C) (56)
Port A6 hose (Arm head side) (57)
q Port B side: (From top in order)
Port B-1 hose (If equipped) (58)
Port B1 hose (Bucket bottom side) (59)
Port B2 hose (Swivel joint port A) (60)
Port B3 tube (Boom head side) (61)
Port BP1 hose (LS separation hose) (25)
(Opposite side is disconnected in step 19)
Port B4 hose (Swing motor port MB) (62)
Port B5 hose (Swivel joint port D) (63)
Port B6 hose (Arm bottom side) (64)
Port T1 hose (Drain hose) (27)
1) Remove flanges (51a), (52a), (53a), (55a), (56a), and
(57a), and disconnect hoses (51), (52), (53), (55), (56),
and (57).
2) Remove flanges (58a), (59a), (60a), (62a), (63a), and
(64a), and disconnect hoses (58), (59), (60), (62), (63),
and (64).
3) Remove the flange (54a), and disconnect the tube (54).
4) Remove the flange (61a), and disconnect the tube (61).
5) Remove port BP1 hose (LS separation hose) (25).
6) Remove flange (27a), and disconnect T1 port hose
(drain hose) (27).
a The necessary tools, width across flats, and sizes of
the hoses are shown below.
q Port A1 hose (Bucket head side) (52)
q Port B1 hose (Bucket bottom side) (59)
q Port A4 hose (Swing motor port MA) (55)
q Port B4 hose (Swing motor port MB) (62)
Bolts of flanges (52a), (55a), (59a), (62a): Width
q Port A-1 hose (If equipped) (51)
q Port B-1 hose (If equipped) (58)
q Port A2 hose (swivel joint port B) (53)
q Port B2 hose (Swivel joint port A) (60)
q Port A5 hose (Swivel joint port C) (56)
q Port B5 hose (Swivel joint port D) (63)
q Port A6 hose (Arm head side) (57)
q Port B6 hose (Arm bottom side) (64)
Bolts of flanges (51a), (53a), (56a), (57a), (58a),
(60a), (63a), and (64a): Width across flats 14 mm,
M10
q Port A3 tube (Boom bottom side) (54)
q Port B3 tube (Boom head side) (61)
50-500 28 PC200, 200LC, 220, 220LC-8M0

Bolts of flanges (54a) and (61a): Width across flats

14 mm, M10
q Port BP1 hose (LS separation hose) (25)
q Port T1 hose (Drain hose) (27)
a Cover the tube disconnection portions of ports A3 and
B3 with plastic bags, etc. in order to prevent oil from
leaking.
38. Remove the bolts (47a) (4 pieces), sling the control valve
assembly (47) by using the eyebolts and sling, and remove
it.
Tools: Socket wrench, 2-leg chain sling, eyebolts
4 Control valve assembly: 260 kg
PC200, 200LC, 220, 220LC-8M0 50-500 29

Installation
1. Sling the control valve assembly (47) by using the eyebolts
and sling, and set it on the installing position.
Tools: Chain, eyebolt
4 Control valve assembly: 260 kg
2. Install the control valve assembly (47) with the bolts (47a) (4
pieces).
3 Bolt (47a): 235 to 285 Nm {23.5 to 29.5 kgm}
3. Connect the control valve hoses (14 pieces) and tubes (2

pieces).
q Port A side: (From bottom in order)
Port A6 hose (Arm head side) (57)
Port A5 hose (Swivel joint port C) (56)
Port A4 hose (Swing motor port MA) (55)
Port A3 tube (Boom bottom side) (54)
Port A2 hose (swivel joint port B) (53)
Port A1 hose (Bucket head side) (52)
Port A-1 hose (If equipped) (51)
q Port B side: (From bottom in order)
Port T1 hose (Drain hose) (27)
Port B6 hose (Arm bottom side) (64)
Port B5 hose (Swivel joint port D) (63)
Port B4 hose (Swing motor port MB) (62)
Port BP1 hose (LS separation hose) (25)
Port B3 tube (Boom head side) (61)
Port B2 hose (Swivel joint port A) (60)
Port B1 hose (Bucket bottom side) (59)
Port B-1 hose (If equipped) (58)
1) Install the hose (27) with the flange (27a).
2) Install the port BP1 hose (LS separation hose) (25).
(Install the hose on the opposite side in Step 21).
3) Install the tube (61) with the flange (61a).
4) Install the tube (54) with the flange (54a).
5) Install the hoses (64), (63), (62), (60), (59), and (58)
with flanges (64a), (63a), (62a), (60a), (59a), and (58a).
6) Install the hoses (57), (56), (55), (53), (52), and (51)
with flanges (57a), (56a), (55a), (53a), (52a), and (51a).
50-500 30 PC200, 200LC, 220, 220LC-8M0

a The necessary tools, width across flats, sizes, and

tightening torques of the hoses are shown below.
q Port A6 hose (Arm head side) (57)
q Port B6 hose (Arm bottom side) (64)
q Port A5 hose (Swivel joint port C) (56)
q Port B5 hose (Swivel joint port D) (63)
q Port A2 hose (swivel joint port B) (53)
q Port B2 hose (Swivel joint port A) (60)
q Port A-1 hose (If equipped) (51)
q Port B-1 hose (If equipped) (58)
Bolts of flanges (51a), (53a), (56a), (57a), (58a),
(60a), (63a), and (64a): Width across flats 14 mm,
M10
3 Bolts of flanges (51a), (53a), (56a), (57a), (58a),
(60a), (63a), and (64a):
59 to 74 Nm {6 to 7.5 kgm}
q Port A4 hose (Swing motor port MA) (55)
q Port B4 hose (Swing motor port MB) (62)
q Port A1 hose (Bucket head side) (52)
q Port B1 hose (Bucket bottom side) (59)
Bolts of flanges (52a), (55a), (59a), (62a): Width
59 to 74 Nm {6 to 7.5 kgm}
q Port A3 tube (Boom bottom side) (54)
q Port B3 tube (Boom head side) (61)
14 mm, M10
3 Bolts of flanges (54a) and (61a):
59 to 74 Nm {6 to 7.5 kgm}
q Port BP1 hose (LS separation hose) (25)
Port BP1 hose (LS separation hose) (25):
Width across flats 19 mm, #02 size
3 Port BP1 hose (LS separation hose) (25):
34 to 54 Nm {3.5 to 5.5 kgm}
q Port T1 hose (Drain hose) (27)
3 Bolt of flange (27a): 59 to 74 Nm {6 to 7.5 kgm}
4. Connect the hose (44) with the bolts (44a) (2 pieces).
3 Bolt (44a): 59 to 74 Nm {6 to 7.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-500 31

5. Install the boom tube mounting clamp (43) with bolts (43a)
(2 pieces), and fix the boom piping tube.
3 Bolt (43a): 98 to 123 Nm {10 to 12.5 kgm}
6. Install the horns (42) to the bracket with bolts (42a) (2

pieces each).
3 Bolt (42a): 98 to 123 Nm {10 to 12.5 kgm}
7. Connect the hoses (41), (48), (49), and (50) with the flanges
(41a), (48a), (49a), and (50a).
flats 14 mm, M10
59 to 74 Nm {6 to 7.5 kgm}
8. Install the boom tube mounting clamps (40) (2 pieces) with
bolts (40a) (2 pieces each).
3 Bolt (40a): 98 to 123 Nm {10 to 12.5 kgm}
9. Connect the hoses (38) and (39) with the bolts (38a) and
(39a) (2 pieces each).
q (38): Port ATT hose (filter) (If equipped)
3 Bolt (38a): 59 to 74 Nm {6 to 7.5 kgm}
q (39): Port T hose (under oil cooler)

3 Bolt (39a): 98 to 123 Nm {10 to 12.5 kgm}
10. Connect the connector P25 (37).

(Rear pump pressure sensor)

q (33): Port PPS2 hose (front pump)
Hose band color: Blue
q (34): Port PR hose (pump)
Hose band color: Yellow
3 Hoses (33), (34): 34 to 54 Nm {3.5 to 5.5 kgm}
12. Connect the hose (36) with the bolts (36a) (2 pieces).
q (36) Drain hose (Port T) (hydraulic tank)
3 Bolt (36a): 59 to 74 Nm {6 to 7.5 kgm}
50-500 32 PC200, 200LC, 220, 220LC-8M0

(35a).
q (32): Port PP1 hose (rear pump)
q (35): Port PP2 hose (front pump)
14 mm, M10
3 Bolts of flanges (32a) and (35a):
59 to 74 Nm {6 to 7.5 kgm}

q (30): Between control valve and swing motor
q (31): Between control valve and solenoid valve
3 Hose (30): 117 to 245 Nm {18.0 to 25.0 kgm}
3 Hose (31): 34 to 54 Nm {3.5 to 5.5 kgm}
15. Connect the rear compensation valve connector (31a).

a Reference: Rear view
16. Install the junction box (29b) and bracket (29) with the bolts
(29a) (1 piece each).
3 Bolt (29a): 235 to 285 Nm {23.5 to 29.5 kgm}
17. Connect the connector P26 (28).

(Front pump pressure sensor)
18. Connect the drain hose (27) with the bolts (27a) (4 pieces).
3 Bolt (27a): 59 to 74 Nm {6 to 7.5 kgm}
19. Fix the hose (27) with the clamps (27b) (2 pieces).
Clamp (27b) bolt: Width across flats 19 mm, M12
3 Bolt (27b): 98 to 123 Nm {10 to 12.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-500 33

20. Connect the clamps (26) with the bolt (26a).

3 Bolt (26a): 98 to 123 Nm {10 to 12.5 kgm}
21. Connect port BP1 hose (LS separation hose) (25).

3 Hose (25): 34 to 54 Nm {3.5 to 5.5 kgm}
22. Connect the L.H. PPC hoses (24e) to (24) (6 pieces).

q (From bottom in order)
(24e) Arm OUT (Hose band color: Yellow)
(24d) R.H. travel REVERSE (Hose band color: Blue)
(24c) Left SWING (Hose band color: Red)
(24b) Boom RAISE (hose band color: Green)
(24a) L.H. travel REVERSE (Hose band: No color)
Hoses (24a) to (24e): Width across flats 19 mm, #02
size
3 Hoses (24a) to (24e):
34 to 54 Nm {3.5 to 5.5 kgm}
(24) Bucket DUMP (Hose band color: Black)
3 Hose (24): 54 to 93 Nm {5.5 to 9.5 kgm}

a Hose band color: None is colored
q (20): Relief valve
q (21) to (23): OPT
3 Hose (20) to (23): 34 to 54 Nm {3.5 to 5.5 kgm}
24. Connect the hose (19).
q (19): Port PST hose (Solenoid)
(Hose band: Brown)
3 Hose (12): 34 to 54 Nm {3.5 to 5.5 kgm}
25. Connect the R.H. PPC hoses (18) (7 pieces).
3 Hose (18): 34 to 54 Nm {3.5 to 5.5 kgm}
(From top in order)
OPT (Hose band colors: yellow)
Bucket CURL (Hose band color: white)
L.H. travel FORWARD (Hose band color: red)
Boom LOWER (Hose band color: Brown)
Right SWING (Hose band color: No color)
R.H. travel FORWARD (hose band color: green)
Arm IN (Hose band color: Blue)
3 Clamp (17) bolt: 98 to 123 Nm {10 to 12.5 kgm}
50-500 34 PC200, 200LC, 220, 220LC-8M0

27. Connect the bracket (16) with the bolt (16a).

3 Bolt (16a): 235 to 285 Nm {23.5 to 29.5 kgm}
28. Install the connectors (14) and (15) to the clips.

29. Connect the connectors V23 (14) and V24 (15).
a Band colors (14) red, (15) white
30. Connect the port PLS2 hose (13).

a Hose band color: Red
3 Hose (13): 34 to 54 Nm {3.5 to 5.5 kgm}
31. Connect the port PLS1 hose (12).
a Hose band color: None
3 Hose (12): 34 to 54 Nm {3.5 to 5.5 kgm}
32. Install the following parts. For details, see "Removal and
64.
q (11a) Engine hood
q (11b) Control valve top cover
q (11c) Cover between hydraulic pump and engine
q (11d) Frame between control valve and engine
q (11e) Cover between control valve and engine
PC200, 200LC, 220, 220LC-8M0 50-500 35

33. Install the solenoid assembly (11) to control valve bracket

(B) with the bolts (10a) (2 pieces).
3 Bolt (11a): 59 to 74 Nm {6 to 7.5 kgm}

50-500 36 PC200, 200LC, 220, 220LC-8M0

35. Connect the connectors (9) (6 pieces) to the clips.

(From top)
V06
V05
V04
V03
V02
V01
36. Install the hoses (2) to (8).
Band colors
q (2): No color
q (3): Red
q (4): No color
q (5): No color
q (6): Red/Yellow
q (7): Brown
q (8): No color
3 Hose (3): 54 to 93 Nm {5.5 to 9.5 kgm}
Hoses (2), (4) to (8): Width across flats 19 mm, #02 size
3 Hoses (2), (4) to (8): 34 to 54 Nm {3.5 to 5.5 kgm}
37. Tighten the oil drain plug (1c) to the specified torque.
3 Plug (1c): 58.8 to 78.5 Nm {6.0 to 8.0 kgm}
5 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
a When the oil stopper is used, remove it according to
"Removal and installation of hydraulic pump assem-
bly".
38. Install the cover (1b) with the bolts (1a) (6 pieces).
3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-500 37

SEN06146-01 Disassembly and assembly of control valve
Disassembly and assembly of control valve 1

a This section explains only the precautions for assembling the control valve assembly.
Special tools
796-946-1310 Guide f21.8 mm
t 1
(For 723-46-40100)
796-946-1610 Guide f21.4 mm
t 1
(For 723-46-41100)
796-946-1810 Guide f21.2 mm
2 t 1
(For 723-46-43100 and 723-46-43400)
796-946-1910 Guide f21.0 mm
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2210 Guide f20.6 mm
t 1
(For 723-46-45100 and 723-46-45700)
796-946-1320 Guide f21.8 mm
t 1
(For 723-46-40100)
796-946-1620 Guide f21.4 mm
t 1
(For 723-46-41100)
796-946-1820 Guide f21.2 mm
t 1
(For 723-46-43100 and 723-46-43400)
3
796-946-1920 Guide f21.0 mm
T t 1
(For 723-46-46101 and 723-46-46300)
796-946-2220 Guide f20.6 mm
t 1
(For 723-46-45100)
796-946-1420 Guide f21.6 mm
t 1
(For 723-46-42700)
796-946-1330 Sleeve
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
t 1
(For 723-46-43100 and 723-46-43400)
4
796-946-1930 Sleeve
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)
50-500 38 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of control valve SEN06146-01
Procedures for replacing pressure compensation valve seal

a Since many types of pressure compensation valves are
installed, put a mark on each and record the installed posi-
tion when removing them.
1. Remove piston (2), plug (3) and spring (4) from pressure
compensation valve (1).
2. Remove seals (5) and (6) from piston (2).
a There are many types of pistons.
3. Place tool T2 on piston (2), put seal (5) on the tool, and then
push the seal down slowly in such a way that it expands
evenly to install it in position.
a Put the seal on the tool and push it down to the flat part
of the tool. Then you may install the tool to the piston to
push in the seal further.
4. Repeat the same process to install another seal (6). Place

tool T3 on the same end of piston (2). Slowly push seal (6)
down in such a way that it expands evenly to install it in
position.
a Put the seal on the tool and push it down to the flat part
of the tool. Then you may install the tool to the piston to
push in the seal further.
5. Install settling tool T4 on piston (2) and keep it installed for

approximately one minute so that seals (5) and (6) fit in.
a Check that there is no extrusion or cut on the seal.
PC200, 200LC, 220, 220LC-8M0 50-500 39

6. Fit plug (3) and spring (4) to piston (2), then install pressure
compensation valve (1).
a After the installation, push piston (2) by hand and check
that the piston returns with the spring force alone.
50-500 40 PC200, 200LC, 220, 220LC-8M0

Assembly of control valve

a Apply engine oil to the sliding surfaces before assembling.
a When installing spool (7) to the valve chamber, set drilled

hole (H1) to the direction shown in the following figure.
a Do the same with section L-L.
q When installing spool (8) to the valve chamber, set

drilled hole (H2) to the direction shown in the following
figure.
a Do the same with H-H, K-K and M-M shown in the sectional
view.
a Assemble filter (9) installed to the bottom ports (PLS1) and

(PLS2) in the direction shown in the figure below. (Pay
attention to the position of caulked portion (10).)
PC200, 200LC, 220, 220LC-8M0 50-500 41

50-500 42 PC200, 200LC, 220, 220LC-8M0

q Upper and lower control valve covers

2 Mating face of upper and lower control valve cover
blocks (11): Loctite 222 or equivalent
a Tighten the mounting bolts of the control valve upper

and bottom cover blocks in the following order. (A → D
→ C → B)
3 Mounting bolts for control valve upper and lower
cover blocks: 156.9 to 176.5 Nm {16 to 18 kgm}
q Merge-divider valve
2 Merge-divider valve mating face (12):
Loctite 222 or Sealend 242 equivalent

a Tighten the mounting bolts of merge-divider valve in the
same order as that for the control valve cover block.
3 Merge-divider valve mounting bolt:
156.9 to 176.5 Nm {16 to 18 kgm}

q Variable back pressure valve
a Tighten the mounting bolts of the variable back pres-
sure valve in the same order as that for the control
valve cover block.
3 Variable back pressure valve mounting bolt:
58.8 to 73.6 Nm {6 to 7.5 kgm}

q Boom drift prevention valve
a Tighten the mounting bolts of the boom hydraulic drift
prevention valve in the same order as that for the con-
trol valve cover block.
3 Mounting bolt of boom hydraulic drift prevention
valve: 58.8 to 73.6 Nm {6 to 7.5 kgm}
q Arm quick return valve
a Tighten the mounting bolts of the arm quick return
valve in the same order as that for the control valve
cover block.
3 Mounting bolt of arm quick return valve:
58.8 to 73.6 Nm {6 to 7.5 kgm}

q Arm drift prevention valve
a Tighten the mounting bolts of the arm hydraulic drift
prevention valve in the same order as that for the con-
trol valve cover block.
3 Mounting bolt of arm hydraulic drift prevention valve:
58.8 to 73.6 Nm {6 to 7.5 kgm}

a After assembling, put stoppers to prevent cleaning solvent
from entering through f12 holes (13).
q Pressure compensation valve
a Install each pressure compensation valve paying atten-
tion to the matchmark that was put when removing it.
3 Pressure compensation valve:
372.7 to 411.9 Nm {38 to 42 kgm}

q Main relief valve assembly
a After installing to the control valve, check and adjust
them. For details, see Testing and adjusting, "Measur-
ing and adjusting oil pressure in work equipment,
swing, and travel circuits".
3 Main relief valve assembly:
49 to 58.8 Nm {5 to 6 kgm}
PC200, 200LC, 220, 220LC-8M0 50-500 43

SEN06146-01 Removal and installation of hydraulic pump assembly
Removal and installation of hydraulic pump assembly 1
Standard tools list

14.7 to 19.6 Nm
98 to 123 Nm
8 Webbing sling (Commercially available) 1 (220 kg)
Special tools list

1 Oil stopper 796-460-1210 1
A
2 Adapter 796-770-1320 1
1 Plug (female) 02789-00210 #02 5
B 2 Plug (male) 07376-70210 #02 5
3 O-ring 02896-11008 5
1 Flange 07379-01044 #10 4
2 Split flange 07371-31049 #10 8
C 3 Head 07378-11000 #10 4
4 O-ring 07000-13032 4
5 P-bolt 07375-21035 16
stop the engine.
tank.
NOTICE
50-500 44 PC200, 200LC, 220, 220LC-8M0

Removal and installation of hydraulic pump assembly SEN06146-01
Removal
1. Remove the bolts (1b), and remove the cover (1c).
tool A1(oil stopper) and tool A2 (adapter).
a When not using tools A1 (oil stopper) and A2 (adapter),
remove the drain plug and drain the oil from the
hydraulic tank and piping.
6 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
5. Sling the engine hood (2).

6. Remove pins (3) and (4), and remove the gas springs (5) (2
pieces).
PC200, 200LC, 220, 220LC-8M0 50-500 45

7. Remove the mounting bolts (2a) (4 pieces), sling the engine

hood (2), and remove it.
4 Engine hood assembly: 50 kg
a Cover (13) cannot be removed while cover (7) is
installed.
9. Disconnect the hose (8a).

10. Remove the bolts (8b) (7 pieces), and remove the cover (8).
11. Remove the bolts (9a) (2 pieces), and remove the frame (9).
(10).
(11).
(12) and (13).
50-500 46 PC200, 200LC, 220, 220LC-8M0


16. Remove the bolts (15a) (2 pieces), and move the filter and
bracket assembly (15) aside so that it does not hinder the
work.
a Put it on hose bracket (HB) Top.
17. Disconnect hoses (16) to (21) (6 pieces).

q (16): Rear load pressure input port hose
(Band color: Blue)
q (20): Front load pressure input port hose
(Band color: Red)
q (21) Drain port hose
Hoses (16), (17), (18), (19), (20), (21): Width across
flats 19 mm, #02 size
bracket (22).
19. Remove the flanges (23a), (24a), and (25a), and disconnect
the hoses (23), (24), and (25).
q (23): Branch hose
Bolts of flanges (23a), (24a), and (25a): Width
(26) (1 piece).
q (26): Pump suction port tube
Tools: Torque set wrench
21. Remove drain plug (26b) and drain the damper case oil.
Plug (26b): Width across flats 19 mm, M12
6 Damper case: 0.65l
a After draining the oil, finger-tighten the plug.
PC200, 200LC, 220, 220LC-8M0 50-500 47

22. Disconnect the pump wiring connectors (4 places).

q (27): V12 PC-EPC R solenoid valve
Band color: Yellow
Band color: None
q (29): V19 LS-EPC solenoid valve
Band color: Red
q (30): V11 PC-EPC F solenoid valve
Band color: White
23. Remove the bolt (31a) (1 piece), and disconnect the bracket
(31).
24. Remove the clip (32).

25. Remove the clamp (33).
26. Remove the bolts (34a) (2 pieces) and (34b) (2 pieces), and
remove the bracket (34).
27. Sling the main pump assembly (35), hold it, and remove the
Tools: Socket wrench, webbing sling
4 Hydraulic pump assembly: 220 kg
a Install the sling to the center of the pump assembly.
a Muffler drain tube (36) is tightened together.
28. Sling and remove the hydraulic pump assembly (37).
50-500 48 PC200, 200LC, 220, 220LC-8M0

Installation
1. Sling the hydraulic pump assembly (37), and set it on the
4 Hydraulic pump assembly: 220 kg
2 Hydraulic pump involute spline:

Molybdenum disulfide grease (LM-G)
2 Mating face of hydraulic pump case:
a Install the sling to the center of the pump assembly.
2. Install the hydraulic pump assembly (35) with the bolts (35a)
(10 pieces).
3 Bolt (35a): 59 to 74 Nm {6 to 7.5 kgm}
a Since flywheel housing is made of aluminum, make

sure that it is not tightened with excessive torque.
Impact wrench is not allowed to use.
3. Install the bracket (34) with the bolts (34a) (2 pieces) and
(34b) (2 pieces).
a Tighten the muffler drain tube (36) together.
3 Bolt (34a): 59 to 74 Nm {6 to 7.5 kgm}

3 Bolt (34b): 59 to 74 Nm {6 to 7.5 kgm}
4. Install the clip (32).

6. Install the bracket (31) with the bolt (31a).

3 Bolt (31a): 98 to 123 Nm {10 to 12.5 kgm}
7. Connect the pump wiring connectors (4 places).

q (27): V12 PC-EPC R solenoid valve
Band color: Yellow
Band color: None
q (29): V19 LS-EPC solenoid valve
Band color: Red
q (30): V11 PC-EPC F solenoid valve
Band color: White
PC200, 200LC, 220, 220LC-8M0 50-500 49

8. Tighten the drain plug (26b) of the damper case to the spec-
ified torque.
Plug (26b): Width across flats 19 mm, M12
3 Drain plug (26b): 14.7 to 19.6 Nm {1.5 to 2.0 kgm}
9. Install the tube (26) (1 piece) with the bolts (26a) (4 pieces).
q (26): Pump suction port tube
3 Bolt (26a): 98 to 123 Nm {10 to 12.5 kgm}
10. Install the hoses (23), (24), and (25) with the flanges (23a),
(24a), and (25a).
q (23): Branch hose
Bolts of flanges (23a), (24a), and (25a): Width
3 Bolts of flanges (23a), (24a), and (25a):
59 to 74 Nm {6 to 7.5 kgm}
3 Bolt (22a): 98 to 123 Nm {10 to 12.5 kgm}
q (16): Rear load pressure input port hose
3 Hose (16): 34 to 54 Nm {3.5 to 5.5 kgm}

3 Hoses (17), (18): 34 to 54 Nm {3.5 to 5.5 kgm}

(Band color: Blue)
3 Hoses (19), (20): 34 to 54 Nm {3.5 to 5.5 kgm}
q (20): Front load pressure input port hose

(Band color: Red)
3 Hoses (19), (20): 34 to 54 Nm {3.5 to 5.5 kgm}
q (21) Drain port hose

3 Hose (21): 34 to 54 Nm {3.5 to 5.5 kgm}
50-500 50 PC200, 200LC, 220, 220LC-8M0

13. Install the filter and bracket assembly (15) with the bolts
(15a) (2 pieces).
3 Bolt (15a): 98 to 123 Nm {10 to 12.5 kgm}
14. Connect the clamp (14).

15. Install the covers (12) and (13) with the bolts (12a) (3
pieces).
3 Bolt (12a): 98 to 123 Nm {10 to 12.5 kgm}
3 Bolt (11a): 98 to 123 Nm {10 to 12.5 kgm}
17. Install cover (10) with bolts (10a) (3 pieces).

3 Bolt (10a): 98 to 123 Nm {10 to 12.5 kgm}
3 Bolt (9a): 98 to 123 Nm {10 to 12.5 kgm}
19. Install the cover (8) with the bolts (8b) (7 pieces).
3 Bolt (8b): 98 to 123 Nm {10 to 12.5 kgm}
20. Connect the hose (8a).
3 Bolt (7a): 98 to 123 Nm {10 to 12.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-500 51

22. Sling the engine hood (2), and set it to the installing posi-
tion.
4 Engine hood assembly: 50 kg
23. Install the engine hood assembly with bolts (2a) (4 pieces).
3 Bolt (2a): 98 to 123 Nm {10 to 12.5 kgm}
24. Remove the gas springs (5) (2 pieces) with pins (3) and (4).

3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
50-500 52 PC200, 200LC, 220, 220LC-8M0

27. Remove bolts (1b), and remove cover (1c), tool A1 (oil stop-
per), and tool A2 (adapter).
3 Bolt (1b): 98 to 123 Nm {10 to 12.5 kgm}
28. Install the strainer assembly and cover (1c) with the bolts
(1b) (6 pieces).
3 Bolt (1b): 98 to 123 Nm {10 to 12.5 kgm}
29. When not using tools A1 (oil stopper) and A2 (adapter),

install the drain plug and add hydraulic oil.
3 Hydraulic tank drain plug:
58.8 to 78.5 Nm {6.0 to 8.0 kgm}
5 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
30. Supply the oil through the oil filler port of the damper case to
the specified level. (For details, see Structure and function,
5 Damper case: 0.65 l (EO30-DH)
q Bleeding air
31. See Testing and adjusting, "Bleeding air from various parts".
PC200, 200LC, 220, 220LC-8M0 50-500 53

SEN06146-01 Removal and installation of hydraulic pump input shaft oil seal
Removal and installation of hydraulic pump input shaft oil seal 1
Standard tools list

1 Snap ring pliers (Commercially available) 1
Special tools list

A Push tool 796T-467-2410 1
Removal
1. Remove the hydraulic pump assembly. For details, see
"Removal of hydraulic pump assembly".
2. Remove the snap ring (1), and remove spacer (2) by using
snap ring pliers.
Tools: Snap ring pliers
3. Remove oil seal (3) by prying it with a screwdriver.
a When removing the oil seal, take care not to damage
the shaft.
Installation
1. Press-fit oil seal (3) by using tool A (push tool).
2 Oil seal lip: Grease (G2-LI)
2 Oil seal outside surface: Grease (G2-LI)
a Apply it lightly on the oil seal outside surface and press-
fit it.
a When installing the oil seal, take care not to damage
the shaft.
2. Install the snap ring (1) by using the snap ring pliers.
3. Install the spacer (2).
4. Install the hydraulic pump assembly. For details, see
50-500 54 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of work equipment PPC valve assembly SEN06146-01
Disassembly and assembly of work equipment PPC valve assembly 1
a Only precautions for assembling the work equipment PPC valve assembly are explained below.
Disassembly
a Spring (6) and spring (7) consist of each one of two types of springs with different installed loads in four
places, so check the mounting position (oil pressure port) and mark with tags to prevent mistakes when
installing.
PC200, 200LC, 220, 220LC-8M0 50-500 55

SEN06146-01 Disassembly and assembly of work equipment PPC valve assembly
Assembly
a Before assembly, thoroughly clean the parts and check them for dirt, rust, or damage to prevent failure.
Assemble the parts with utmost care.
a Install spring (5) with its small diameter side on the shim (4) side.
Diameter of spring (Inside diameter)
Small diameter side: f4.9 mm
Large diameter side: f5.55 mm
a When installing springs (6) and (7), note that they are different and they must be installed to different
hydraulic ports.
q Installed height: 31.9 mm (Common to both springs)
q Installed load:
Spring (6) (P1, P2): 35.3 N {3.6 kg}
Spring (7) (P3, P4): 21.6 N {2.2 kg}
a When installing piston (8), apply grease (G2-LI) to its outside and the inside of the body (1) hole.
3 Bolt (11): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
a When installing joint (12) to body (1), apply LOCTITE as

shown below.
1) When installing the joint, apply 1 drop (approx. 0.02 g)
of LOCTITE (No. 262) each to 2 places of the female
screw (A) of the body. Before installing the joint, thor-
oughly degrease and dry its male screw and the female
screw of the body with DRYSOL.
2) Drop LOCTITE to the following positions.
2 Female screw (A) of body:LOCTITE No. 262
3 Joint (12): 39 to 49 Nm {4 to 5 kgm}
a Apply grease (G2-LI) to the sliding parts of joint (12) and
contact surfaces of disc (13) and piston (8).
2 Quantity of grease (G2-LI)
The sliding portions of the joint (J portion): Apply grease

(G2-LI) 7 to 10 ml to entire circumference.
The sliding portions of the joint (P portion): Apply gear oil
0.2 to 0.4 ml to the sliding portions (4 places) between
the joint and pin.
Contact surfaces of disc and piston: 0.3 to 0.8 cc/place
a When assembling disc (13), adjust it so that the end play of
the lever will be 0.5 to 3 mm at 200 mm from the center of
revolution.
a See Testing and adjusting, "Adjusting play of work
equipment and swing PPC valve".
a Tighten nut (14) to the following tightening torque.
3 Nut (14): 69 to 88 Nm {7 to 9 kgm}
50-500 56 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of travel PPC valve SEN06146-01
Disassembly and assembly of travel PPC valve 1
Special tools
Figure of structure
Disassembly
1. Remove screws (19) and remove damper assemblies (18).
2. Remove mounting bolt (17) and remove case (16), shafts (15) and levers (13) as a unit.
3. Remove mounting bolts (11) to remove plate (10).
a Note the thickness and installed position of washer (12).
a Remove pin (21) from valve body (1).
4. Remove seals (9) and collars (8).
5. Remove pistons (7), and then to remove retainers (6), springs (5) and (4), and shims (3).
a Note the installed position, quantity and thickness of shims (3) and keep them.
6. Remove valves (2) from valve body (1).
PC200, 200LC, 220, 220LC-8M0 50-500 57

SEN06146-01 Disassembly and assembly of travel PPC valve
Assembly
a Only precautions for assembly are described.
a Before assembly, thoroughly clean the parts and check them for dirt, rust, or damage to prevent failure.
Assemble the parts with utmost care.
a When installing piston (7), apply grease (G2-LI) to its periphery and the inside of the valve body hole.
a Install spring (4) with its small diameter end facing shim (3).
q Diameter of spring (inside diameter)
Small diameter end: f 4.9 mm
Large diameter end: f 5.55 mm
a Apply grease (G2-LI) to the rocking parts of shaft (15), contact surfaces on lever (13) and piston (7),
and contact surfaces on damper (18) and pin.
2 Grease (G2-LI)
Rocking parts of shaft (15): 4 to 8 cc/entire periphery
Contact surfaces on lever (13) and piston (7): 0.3 to 0.8 cc/part
Contact surfaces on damper (18) and pin: 0.3 to 0.8 cc/part
a For washer (12), install the one 1.6 mm in thickness (t) first. If the difference in the lever angle between
right and left when the lever is at full stroke position exceeds 0.7 degree, change the thickness of the
washer to make the difference 0.7 degree or smaller.
a If the thickness of the washer is reduced by 0.3 mm, the full stroke angle of the lever increases by 0.39
deg.
q Settings of thickness (t) of washer (12): 1.0, 1.3, 1.6, 1.9, 2.2 mm
a Tighten each part to the following torque.
3 Bolt (11): 27 to 34 Nm {2.8 to 3.5 kgm}
3 Bolt (17): 25 to 31 Nm {2.5 to 3.2 kgm}
3 Screw (19): 0.441 to 0.588 Nm {0.045 to 0.06 kgm}
50-500 58 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of work equipment cylinder SEN06146-01
Disassembly and assembly of work equipment cylinder 1
Special tools
790-502-1003 Cylinder repair stand q 1
1
790-101-1102 Pump q 1
790-102-4300 Wrench assembly t 1
2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
Rubber band
796-720-1670 q 1
(for boom and bucket))
07281-01279 Clamp q 1
4
Rubber band
796-720-1680 q 1
(for bucket)
07281-01589 Clamp q 1
U
790-201-1702 Push tool kit t 1
• Push tool
790-201-1841 1
5
790-201-1851 • Push tool (for arm) 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit t 1
790-201-1650 • Plate (for boom and bucket) 1
6 790-201-1660 • Plate (for arm) 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
PC200, 200LC, 220, 220LC-8M0 50-500 59

SEN06146-01 Disassembly and assembly of work equipment cylinder
Disassembly
Disconnection of cylinder assembly and piston rod assembly
1. Remove the piping from the cylinder assembly.
2. Remove 12 mounting bolts and disconnect cylinder head
assembly (1).
3. Pull out piston rod assembly (2).
a Place a container under the cylinder to collect oil from
the cylinder.
Disassembly of piston rod

1. Set piston rod assembly (2) on tool U1.
2. Using a hexagonal wrench (6 mm), remove lock screw (3)

at the end of piston assembly (4).
a Above operation is common to the boom, arm and
bucket cylinder.
q Screw size: M12 x 1.75 mm (16 mm in length)
a If screw (3) is caulked too firmly to be loosened, squeeze

the screw further once and then apply tap (T) to the
threaded portion to ease the caulking.
3. Using tool U2, remove piston assembly (4).

a When not using tool U2, use the drilled holes (H) (f10
mm, two places) to loosen the piston assembly.
50-500 60 PC200, 200LC, 220, 220LC-8M0

4. Remove plunger (5) and collar (6).

a Only for the arm and boom cylinders
5. Remove cylinder head assembly (7).
6. Remove cap (8) to remove 12 balls (9), and remove plunger

(10).
a Arm cylinder only
Disassembly of piston
1. Remove two rings (11).
2. Remove two wear rings (12).
3. Remove piston ring (13).
4. Remove the O-ring and two backup rings (14).
Disassembly of cylinder head

1. Remove the O-ring and backup ring (15).
2. Remove snap ring (16), then remove dust seal (17).
3. Remove rod packing (18) and buffer ring (19).
4. Remove snap ring (30).
5. Remove bushing (20).
Disassembly of cylinder (arm cylinder only)

1. Remove plug (21).
2. Remove spring (22) and valve (23).
PC200, 200LC, 220, 220LC-8M0 50-500 61

Assembly
a Be careful not to damage the packings, dust seals, O-rings,
etc.
a Clean each part. After assembling the cylinder, cover the
piping ports and pin holes to prevent entering of dirt.
a Before installing the backup ring, warm it in hot water of
approximately 50 to 60°C. Do not attempt to force it into
position.
Assembly of cylinder (only for arm cylinder)
1. Install valve (23) and spring (22).
2. Install plug (21) with O-ring (24).
a Clean, degrease, and dry the thread portion of the plug,
and then apply liquid gasket to the entire periphery of
the thread portion.
3 Plug (21): 83.4 to 102.9 Nm {8.5 to 10.5 kgm}
2 Plug (21): Liquid gasket (LG-5)
Assembly of cylinder head

1. Using tool U5, press fit bushing (20).
2. Install snap ring (30).
3. Install buffer ring (19) and rod packing (18).
4. Install dust seal (17) using tool U6, and install snap ring
(16).
5. Install backup ring (15) and the O-ring.
Assembly of piston
1. Set piston ring (13) on tool U3. Expand piston ring (13) by
turning the handle 8 to 10 turns.
2. Remove piston ring (13) from tool U3. Install the ring to the
piston.
3. Using tool U4, compress piston ring (13).
50-500 62 PC200, 200LC, 220, 220LC-8M0

4. Install two backup rings (14) and the O-ring.

a Install the backup rings and O-ring as shown in the fig-
ure.
5. Install wear rings (12) (2 pieces).
6. Install wear rings (11) (2 pieces).
a Be careful not to open the end gap of the ring too wide.
Assembly of piston rod

1. Set piston rod assembly (2) to tool U1.
2. Install cylinder head assembly (7).

3. Install the O-ring and the backup rings to collar (6) and
install the collar to the piston rod.
a Install the two backup rings, one each in the front and
rear of the O-ring.
a Only the boom and arm cylinders
4. Install plunger (5).
a Only the boom and arm cylinders
5. Place plunger (10) on piston rod assembly (2). Install 12

balls (9) and cap (8).
a After installing the plunger, check that there is a little
play at its end.
a Arm cylinder only
6. If both of piston rod assembly (2) and piston assembly (4)

are to be reused, assemble them according to the following
procedure. (If either or both of them are to be replaced with
new ones, see Step 7.)
1) Using tool U2, install piston assembly (4) to piston rod
assembly (2).
a Any burrs or sharp edges on threaded portions
must be removed using files before installation.
PC200, 200LC, 220, 220LC-8M0 50-500 63

a Fully tighten piston assembly (4) until it contacts

with end face (b) of the rod. Then, at around this
position, align screw holes (H) in the piston and
piston rod end face.
a For a cylinder with a head cushion, ensure that
there is a small play in plunger (5) with piston
assembly (4) installed.
q Only the boom and arm cylinders
2) Install screw (3) to lock piston assembly (4) and piston

rod assembly (2).
2 Screw (3) thread portion:
Adhesive (Loctite #262)
3 Screw (3): 58.9 to 73.6 Nm {6 to 7.5 kgm}
a After installing screw (3), caulk the screw at four
peripheral places (a).
7. When replacing either or both of piston rod assembly (2)

and piston assembly (4) with new ones, assemble the new
ones according to the following procedure.
1) Using tool U2, screw in piston assembly (4) until it
comes into contact with end face (b) of the rod.
a If the cylinder has the bottom cushion, put a mark
on the rod end face to indicate the tightening posi-
tion of the ball cap.
3 Piston assembly (4):
294 ± 29.4 Nm {30 ± 3.0 kgm}
a For a cylinder with a head cushion, ensure that
there is a little play in plunger (5) with piston
assembly (4) installed.
q Only the boom and arm cylinders
2) Drill a screw hole across the threads of piston rod

assembly (2) and piston assembly (4).
a With a drill aligned with the V groove where the
threads of piston assembly (4) and piston rod
assembly (2) are mated, drill a hole straight.
a The cylinder with the bottom cushion must not be
machined in the cushion cap machining hole posi-
tion.
q Dimensions of screw hole (mm):
Tap drill diameter 10.3
Tap drill hole depth 27
Screw hole size 12 x 1.75
Screw hole depth 20
a After tapping the screw hole, remove chips and
other dirt and thoroughly clean the area.
50-500 64 PC200, 200LC, 220, 220LC-8M0

3) Install screw (3) to lock piston assembly (4) and piston

rod assembly (2).
a After installing screw (3), caulk the screw at four
peripheral places (a).
2 Screw (3) thread portion:
Adhesive (Loctite #262)
3 Screw (3): 58.9 to 73.6 Nm {6 to 7.5 kgm}
Connection of cylinder assembly and the piston rod assembly

1. Install piston rod assembly (2) to tool U1.
2. Install the cylinder assembly to piston rod assembly (2).

a Align axial center of the cylinder tube, then insert.
a Check that the ring is not broken and has not come out,
then push in fully.
3. Tighten the mounting bolts for cylinder head assembly (1).

3 Cylinder head assembly (1) mounting bolt:
Boom cylinder: 270 ± 39 Nm {27.5 ± 4.0 kgm}
Arm cylinder: 373 ± 54 Nm {38.0 ± 5.5 kgm}
Bucket cylinder: 270 ± 39 Nm {27.5 ± 4.0 kgm}
4. Install piping.
3 Piping fixing band mounting bolt:
Boom cylinder: 27 ± 7 Nm {2.8 ± 0.7 kgm}
Arm and bucket cylinder: 89 ± 34 Nm {9.0 ± 3.5
kgm}
PC200, 200LC, 220, 220LC-8M0 50-500 65

SEN06146-01

© 2018 KOMATSU
All Rights Reserved
50-500 66
SEN06147-01
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

600 Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
PC200, 200LC, 220, 220LC-8M0 50-600 1

600 Work equipment
SEN06147-01 Removal and installation of work equipment assembly
Removal and installation of work equipment assembly 1
Standard tools list

59 to 74 Nm
235 to 285 Nm
7 Webbing sling (Commercially available) 1
(3300 kg), (3450
8 Chain (Commercially available) 20 mm 1 kg), (4100 kg),
(4450 kg)
(3300 kg), (3450
9 Wire (Commercially available) 20 mm 1 kg), (4100 kg),
(4450 kg)
(3300 kg), (3450
10 Lever block (Commercially available) 1 kg), (4100 kg),
(4450 kg)
Special tools list

- Remover 796-900-1200 1
1 qSleeve 796-900-1210 1
2 qPlate 796-900-1520 1
A 3 qScrew 796-900-1230 1
4 qAdapter 796-900-1240 1
5 qWasher 01643-33080 1
6 qNut 01803-13034 1
B Puller 790-101-4000 490 kN {50 ton}, long 1
C Hydraulic pump 790-101-1102 294 kN {30 ton} 5
1 Flange 07379-00640 #06 4
2 Head 07378-10600 #06 4
D 3 O-ring 07000-13030 4
4 Split flange 07371-30640 #06 8
5 P bolt 07375-21035 16
k Extend the arm and bucket fully and lower the work equipment to the ground, and set the lock
lever to LOCK position.
k Stop the engine, loosen the cap of the hydraulic tank slowly, and release the pressure inside of
the hydraulic tank.
k Release the remaining pressure in the hydraulic circuit referring to "Testing and adjusting",
"Releasing remaining pressure in hydraulic cylinder circuit".
NOTICE
50-600 2 PC200, 200LC, 220, 220LC-8M0

600 Work equipment
Removal and installation of work equipment assembly SEN06147-01
Removal
1. Sling either of the boom cylinder assemblies (2) by using
the lifting tool, and hold it.
2. Disconnect grease hose (1).
Tools: Wrench
Grease hose (1): Width across flats 19 mm
3. Remove lock bolt (3).
4. Remove the plate (4), and remove the cylinder (2) from the
pin (5).
a Install blocks, and lower and fix the cylinder onto them
so that the cylinder head side is higher than the bottom
side.
a Check the quantity and installing positions of installed
shims in advance.
5. Place blocks under the boom cylinder, lower the head end
of cylinder onto them, and fix it.
6. Remove the boom cylinder on the opposite side from the
head side pin in the same way.
a When slinging the work equipment, remove the work
equipment light if the lifting tool hits it.
7. Start the engine, and retract the cylinder rod fully by lower-
ing the boom.
a Operate only the boom cylinder (If any other cylinder is
operated, the remaining pressure in the circuit must be
released again).
a Both R.H. and L.H. cylinders operate simultaneously.
Work with extreme care.
8. Remove flanges (6a) and (7a), disconnect bucket cylinder

hoses (6) (2 pieces) and arm cylinder hoses (7) (2 pieces).
Flange (6a), (7a) bolt: Width across flats 14 mm, M10
Special tool D
9. Disconnect intermediate connector A13 (8) for the working
lamp.
PC200, 200LC, 220, 220LC-8M0 50-600 3

600 Work equipment
10. Install the lifting tool to the sling positions (a) and (b).
a Wind the webbing sling around pin part (a) on the boom
cylinder head side, and install the wire to bucket end
part (b).
Tools: 3-leg chain sling, lever block, wire
11. Sling the work equipment assembly, and hold it.

4 Work equipment assembly:
3450 kg (PC200/200LC-8M0)
4450 kg (PC220/220LC-8M0)
12. Remove the bolts (9a) (2 pieces), and remove the plate (9).
13. Remove the foot pin (10).
a Sling and remove the foot pin by using the lifting tool
before pulling it out of the pin hole.
shims in advance.
4 Pin (10): 45 kg
q When using tool for removal

Remove plate (9), and remove foot pin (10) by using tool A
(remover), tool B (puller), and tool C (hydraulic pump).
shims in advance.
14. Sling work equipment assembly (11), and remove it.
50-600 4 PC200, 200LC, 220, 220LC-8M0

600 Work equipment
Installation
1. Sling the work equipment assembly (11), and set it on the
Tools: 3-leg chain sling, lever block, wire
4 Work equipment assembly:
3450 kg (PC200/200LC-8M0)
4450 kg (PC220/220LC-8M0)
2. Install the foot pin (10).

a Sling and install the foot pin with the lifting tool.
a Align the boom foot pin hole with the pin hole of revolv-
ing frame bracket (14).
a If the pin cannot be inserted smoothly, hit it with a ham-
mer.
4 Pin (10): 45 kg
3. Install the plate (9) with the bolts (9a) (2 pieces).

3 Bolt (9a): 235 to 285 Nm {23.5 to 29.5 kgm}
2 Inner surface of bushing when assembling pin:
Anti-friction compound (LM-P)
2 Greasing after assembling pin: Grease (LM-G)
a Adjust clearance (c) between the foot end surface of
boom (13) and bracket (14) to 1 mm or less by using
shims.
Standard shim thickness: 2.0, 2.5, 3.0, 3.5 mm
4. Connect the intermediate connector A13 (8) for the working

lamp.
5. Connect the bucket cylinder hoses (6) (2 pieces) and arm
cylinder hoses (7) (2 pieces) with flanges (6a) and (7a).
Flange (6a), (7a) bolt: Width across flats 14 mm, M10
3 Flange (6a), (7a) bolt: 59 to 74 Nm {6 to 7.5 kgm}
6. Sling the boom cylinder, start the engine, and extend the
boom cylinder.
a Both R.H. and L.H. cylinders operate simultaneously.
Work with extreme care.
PC200, 200LC, 220, 220LC-8M0 50-600 5

600 Work equipment
7. Sling boom cylinder (2), start the engine, align the pin (5)
with the pin hole in the cylinder (2) by raising the boom, and
install the cylinder (2) to the pin (5).
a When the boom is raised, the cylinder rod on the oppo-
site side is extended as well. Take care.
8. Install the plate (4) with the lock bolt (3).
3 Bolt (3): 235 to 285 Nm {23.5 to 29.5 kgm}
2 Inner surface of bushing when assembling pin:
Molybdenum disulfide lubricant (LM-P)
2 Greasing after assembling pin: Grease (LM-G)
k When aligning the pin holes, never insert your fin-
gers into the holes.
a st1: Plastic shim (Thickness: 1.0 mm)
a Adjust clearance (b) between cylinder rod (12) and plate

(4) to 1.5 mm or less by using shims.
Standard shim thickness: 1.0, 2.0mm
9. Connect the grease hose (1).
Tools: Wrench
Grease hose (1): Width across flats 19 mm
q Bleeding air
10. Bleed air from the hydraulic circuit. For details, see Testing and adjusting, "Air bleeding from each part".

50-600 6 PC200, 200LC, 220, 220LC-8M0

600 Work equipment
PC200, 200LC, 220, 220LC-8M0 50-600 7

SEN06147-01

© 2018 KOMATSU
All Rights Reserved
50-600 8
SEN06148-02
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
50 Disassembly and assembly

700 Cab and its attachments
Removal and installation of operator's cab assembly ..................................................................................... 2
Removal and installation of operator's cab glass (adhered window glass)....................................................11
Removal and installation of front window assembly ..................................................................................... 24
Removal and installation of floor frame assembly ........................................................................................ 34
Removal and installation of air conditioner unit assembly ............................................................................ 44
PC200, 200LC, 220, 220LC-8M0 50-700 1

SEN06148-02 Removal and installation of operator's cab assembly
Removal and installation of operator's cab assembly 1
Standard tools list

11.8 to 14.7 Nm
27 to 34 Nm
59 to 74 Nm
9 Torque wrench (socket) (Commercially available) 1
98 to 123 Nm
245 to 309 Nm
320 to 395 Nm
10 Torque wrench (hexagonal) (Commercially available) 9.8 Nm 1
13 Phillips screwdriver (Commercially available) 1
50-700 2 PC200, 200LC, 220, 220LC-8M0

Removal and installation of operator's cab assembly SEN06148-02
Removal
1. Remove the front window (1). For details, see "Removal
and installation of front window assembly".
2. Remove the bolts (2a) (3 pieces), and remove the step plate
(2).
3. Remove the bolts (3a) (2 pieces), and remove the floor mat
(3).
4. Remove the monitor assembly (4). For details, see
"Removal of machine monitor assembly".
5. Remove the hexagon socket head screws (5a) (3 pieces)
and bolts (6a) (2 pieces), and remove the covers (5) and
(6).
Tools: Hexagonal wrench, socket wrench
Hexagon socket head screw (5a): Width across flats 4
mm, M6
and duct assembly (7).
7. Insert key (8), and turn it clockwise to open the fresh air fil-
ter cover (8a).
8. Remove fresh air filter (9).
9. Move the operator's seat forward, and tilt the backrest for-
ward.
PC200, 200LC, 220, 220LC-8M0 50-700 3

10. Open the cooler box cover, remove the bolts (10a) (5
pieces), and remove the cooler box (10).
a Disconnect the air hose at the bottom rear of cooler
box.
11. Remove the bolts (11a) (2 pieces) and screw (11b) (1
piece), and remove the cover (11).
Tools: Socket wrench, phillips screwdriver
(12).
(13).
14. Remove the bolts (14a) (2 pieces), and remove the duct
(14).
(15).
a Remove the connector H15 fixed on the back from the
clip, then remove the cover (15).
16. Remove the bolts (16a) (2 pieces), and remove the plate
(16).
17. Remove the bolts (17a) (4 pieces), and remove the plate
(17).
18. Remove the lock pin (18) and remove the duct (19).
50-700 4 PC200, 200LC, 220, 220LC-8M0

19. Remove the duct (20).

20. Disconnect the connector L03 (21).
remove the plates (22) and (23) from the operator's cab.
22. Disconnect antenna lines (24) and (24a) from KOMTRAX

communication modem (K) by turning their connectors.
23. Disconnect the connectors CK01 (25) and CK02 (26).
24. Disconnect connector M10 (27) from the operator's cab. (if
equipped)
25. Disconnect the operator's cab wiring intermediate connec-
tors H09 (28), H08 (29), and H16 (30).
a Cut the cable tie (T).
26. Disconnect the radio antenna (31).
27. Remove the ducts (32) and (33).

a Cut the cable tie.
28. Disconnect wiper motor connector M05 (34).
29. Disconnect the harness (35) and antenna line (36) from the
right wall of operator's cab.
a Cut the cable ties (2 places).
30. Remove upper and lower ducts (37).

31. Remove the upper and lower ducts (38).
32. Disconnect the window washer hose (39).

33. Disconnect the wiring harness clamp (40).
Wiring harness clamp (40) bolt: Width across flats 12
mm, M8
34. Haul in antenna line (36).
PC200, 200LC, 220, 220LC-8M0 50-700 5

35. Remove the clamp (41) at the right rear of operator's cab,
and disconnect the harness from the floor frame.
Wiring harness clamp (41) bolt: Width across flats 17
mm, M10
36. Remove the bolt (42) from the underside of the operator's
cab, and remove the lock plate (43).
37. Remove the bolt (44).
38. Remove the bolts (45) (5 pieces) and (45a) (1 piece), and
nuts (46) (4 pieces).
Nut (46): Width across flats 30 mm, M20
a Only bolt (45a) (1 piece) is longer than others. Write it
down.
39. Install the sling to the sling positions (a).

Tools: 3-leg chain sling, lever block
40. Sling and remove operator's cab assembly (47).

4 Operator's cab assembly: 470 kg
50-700 6 PC200, 200LC, 220, 220LC-8M0

Installation
1. Sling the operator's cab assembly (47) by slinging positions
(a), and set it on the installing position.
Tools: 3-leg chain sling, lever block
4 Operator's cab assembly: 470 kg
2. Install the bolts (45) (5 pieces) and (45a) (1 piece), and nuts
(46) (4 pieces).
a Only bolt (45a) (1 piece) is longer than others. Install it
to the correct position.
3 Bolt (45): 98 to 123 Nm {10 to 12.5 kgm}
Nut (46): Width across flats 30 mm, M20

3 Nut (46): 320 to 395 Nm {32.5 to 40.5 kgm}
3. Install the bolt (44).

3 Bolt (44): 245 to 309 Nm {25.0 to 31.5 kgm}
4. Install the lock plate (43) with the bolt (42).
3 Bolt (42): 98 to 123 Nm {10 to 12.5 kgm}
5. Fix the harness to the floor frame with the clamp (41) at the
right rear of operator's cab.
PC200, 200LC, 220, 220LC-8M0 50-700 7

6. Set the antenna cable (36) to the installing position.

7. Fix the wiring harness with the clamp (40).
3 Clamp (40) bolt: 27 to 34 Nm {2.8 to 3.5 kgm}
8. Connect the window washer hose (39).
9. Install the upper and lower ducts (37).

10. Install the upper and lower ducts (38).
11. Install the harness (35) and antenna cable (36) to the right
wall of the operator's cab.
a Bind with the cable ties at 2 places.
12. Connect the wiper motor connector M05 (34).
13. Install the ducts (32) and (33).
a Bind with the cable ties.
14. Connect the radio antenna (31).

15. Connect the operator's cab wiring intermediate connectors
H09 (28), H08 (29), and H16 (30).
a Bind with the cable tie (T).
16. Connect connector M10 (27) to the operator's cab. (if
equipped)
17. Connect the connector CK01 (25).
18. Connect the connector CK02 (26).
19. Connect antenna cables (24) and (24a) to the KOMTRAX
communication modem (K).
a The connector portion is threaded.
20. Install the plates (22) and (23) to the operator's cab with the
bolts (22a) (4 pieces) and (23a) (2 pieces).
Bolts (22a), (23a): Width across flats 12 mm, M8
3 Bolts (22a), (23a): 27 to 34 Nm {2.8 to 3.5 kgm}
21. Connect the connector L03 (21).

22. Install the duct (20).
50-700 8 PC200, 200LC, 220, 220LC-8M0

23. Install duct (19), and fix it with lock pin (18).
3 Bolt (17a): 27 to 34 Nm {2.8 to 3.5 kgm}
3 Bolt (16a): 27 to 34 Nm {2.8 to 3.5 kgm}
3 Bolt (15a): 27 to 34 Nm {2.8 to 3.5 kgm}
a Install the connector H15 fixed on the back to the clip,
then install the cover (15).
27. Install the duct (14) with the bolts (14a) (2 pieces).
3 Bolt (14a): 27 to 34 Nm {2.8 to 3.5 kgm}
3 Bolt (13a): 27 to 34 Nm {2.8 to 3.5 kgm}
3 Bolt (12a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
30. Install the cover (11) with the bolts (11a) (2 pieces) and
screw (11b) (1 piece).
Tools: Torque wrench set (socket), phillips screwdriver
3 Bolt (11a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
31. Install the cooler box (10) with the bolts (10a) (5 pieces),
and close the cooler box cover.
a Connect the air hose at the bottom rear of cooler box.
3 Bolt (10a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
32. Return the backrest of operator's seat, and return the oper-
ator's seat to the optimum position.
PC200, 200LC, 220, 220LC-8M0 50-700 9

33. Install the fresh air filter (9).

34. Insert key (8), and turn it clockwise to close the fresh air fil-
ter cover (8a).
a Close the fresh air filter cover, and turn the key counter-
clockwise to lock.
35. Install the cover and duct assembly (7) with the bolts (7a) (4
pieces).
3 Bolt (7a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
36. Install the covers (5) and (6) with the hexagon socket head
screws (5a) (3 pieces) and bolts (6a) (2 pieces).
Tools: Torque wrench set (hexagonal)
mm, M6
3 Hexagon socket head screw (5a): 9.8 Nm {1.0 kgm}
(Target value)
3 Bolt (6a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
37. Install the monitor assembly (4). For details, see "Removal
and installation of machine monitor assembly".
38. Install the floor mat (3) with the bolts (3a) (2 pieces).
3 Bolt (3a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
39. Install the step plate (2) with the bolts (2a) (3 pieces).
3 Bolt (2a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
41. Install the front window (1). For details, see "Removal and
installation of front window assembly".
NOTICE
q Check that the hoses, etc. are securely connected, and clean and wipe off the liquid that leaked
from the hose connections.
q Check that the wiring is securely connected and the electrical devices operate normally.

1) Visually check the outside, and wipe off sticking oil, grease, coolant, etc., if any. In addition, check
for scratches, pealing of paint, etc. made during the removal and installation work.
2) Bleed air from the fuel, hydraulic, and coolant system, then start the engine, and check that the
machine operates normally.
50-700 10 PC200, 200LC, 220, 220LC-8M0

Removal and installation of operator's cab glass (adhered window glass) SEN06148-02
Removal and installation of operator's cab glass (adhered window glass)1
a Among the window glasses on 4 sides of the (1) : R.H. window glass
operator's cab, 5 glasses from (1) to (4) and (2) : L.H. rear window glass
(18) in the figure are the stuck type. (3) : Lower door window glass
a In this section, the procedure for replacing the (4) : Front window glass
adhered glasses is explained. (5) : Front window assembly
a When replacing front window glass (4), (Front window glass + Front frame)
remove front window assembly (5). (6) : Dam rubber
(If the front glass is installed to the operator's (17) : Center trim seal
cab, the front window glass alone cannot be (18) : Rear window glass
replaced.)
a For replacement procedure of the front win-
dow assembly, see "Removal and installation
of front window assembly".
PC200, 200LC, 220, 220LC-8M0 50-700 11

SEN06148-02 Removal and installation of operator's cab glass (adhered window glass)
Standard tools list

See "Precau-
SUNSTAR Paint Surface
1 Primer for paint surface 1 tions for using
Primer 580 SUPER
primer"
See "Precau-
SUNSTAR Glass Primer
2 Primer for glass 1 tions for using
580 SUPER
primer"
Use of adhesive
depending on
season
• Apr - Oct
SUNSTAR pen-
guine seal 580
SUNSTAR Penguin Seal super "S"
3 Adhesive 1
580 SUPER • Oct - Apr
SUNSTAR pen-
guine seal 580
super "W"
See "Precau-
tions for using
adhesive"
4 Seal cutter (Commercially available) 1
5 Utility knife (Commercially available) 1
6 Scraper (Commercially available) 1
7 White gasoline (Commercially available) 1
8 Brush (Commercially available) 2
9 Dam rubber (Commercially available) 1
Electric type is
10 Caulking gun (Commercially available) 1
recommended
11 Rubber spatula (Commercially available) 1
12 Masking tape (Commercially available) 1
13 Styrene foam (Commercially available) 2
14 Rubber band (Commercially available) 2
15 Vinyl tape (Commercially available) 1
16 Screwdriver (Commercially available) 1
Special tools list

1 Lifter (suction cup) 793-498-1210 2
A
2 Stopper rubber 20Y-54-13180 2
k Park the machine at a place where it is free from rain and wind, and open either R.H. or L.H. door.
Do not close the door until curing after the glass replacement is finished.
(The glass may fall off due to increase in the cab internal pressure caused by opening and clos-
ing the door.)
Precautions for using primer

q Do not use primer if it has passed the expiration date which is 4 months after its production date.
q Make sure to use primer within 2 hours after opening its cap.
q Even when it is plugged again immediately after opening, be sure to use it within 24 hours after
opening.
(Dispose of primer 24 hours after opening it.)
50-700 12 PC200, 200LC, 220, 220LC-8M0

Precautions for using adhesive

q Do not use adhesive if it has passed the expiration date which is 4 months after its production
date.
q Store adhesive at 25°C or lower in a dark place.
q Do not heat adhesive any higher than 30°C.
q When reusing adhesive, remove the hardened adhesive at the nozzle tip completely.
PC200, 200LC, 220, 220LC-8M0 50-700 13

Removal
a Remove the window glass to be replaced according to the
1. Cut off the adhesive between the window glass (7) to be

replaced and operator' cab (sheet metal) (8) by using the
seal cutter [4].
Tools: Seal cutter, utility knife, screwdriver
a If the window glass is broken in small pieces, it may be
removed with utility knife [5] and a flat-head screw-
driver.
a While widening the cut with a flat-head screwdriver, cut
the adhesive and dam rubber with a utility knife [5].
a If the screwdriver is applied directly to the undamaged
window glass, it is probably broken.
2. Remove the window glass.
50-700 14 PC200, 200LC, 220, 220LC-8M0

Installation
1. Remove the remaining adhesive and dam rubber from the
sheet metal (adhesion surfaces) of the operator's cab by
using a utility knife [5] and scraper [6].
Tools: Utility knife, scraper
a Remove the adhesive and dam rubber to a degree that
they will not affect adhesion of the new adhesive. Take
care not to scratch the paint surfaces.
(If the paint surfaces are damaged, adhesion will be
lowered.)
(Figure shows the operator's cab on a wheel loader.)
2. Remove oil, dusts and stains from bonding surfaces on

operator's cab (8) and window glass (9) by using white gas-
oline [7].
Tools: White gasoline
a If the adhesion surfaces are not cleaned well, the glass
may not be stuck perfectly.
a Clean all the black part on the back of the window
glass.
a After cleaning, leave them for more than 5 minutes for
natural drying.
(Figure shows the operator's cab on a wheel loader.)
3. Apply primer ([1], [2]).

Tools: Primer for paint surface, primer for glass, brush
a Do not use primer if it has passed the expiration
date which is 4 months after its production date.
a Make sure to use primer within 2 hours after opening its
cap.
a Even when it is plugged again immediately after open-
ing, be sure to use it within 24 hours after opening.
(Dispose of primer 24 hours after opening it.)
1) Stir both paint surface primer and glass primer thor-
oughly before use.
a If the primer is stored in a refrigerator, leave it at
the room temperature for at least half a day before
stirring it. (If it is opened soon after taken out of a
refrigerator, condensation occurs. Wait until its
temperature reaches the room temperature.)
2) When reusing a brush [8] for applying a primer, clean it
with white gasoline [7] before use.
a Check again that the brush is free from stains or
fouling after cleaning.
a Prepare respective brushes for the paint surface
primer [1] and glass primer [2].
PC200, 200LC, 220, 220LC-8M0 50-700 15

3) Apply paint surface primer [1] evenly to the mounting

part of the dam rubber [9] of operator's cab (8) and the
place outside which adhesive is applied to.
2 Paint surface primer [1]:
SUNSTAR Paint Surface Primer 580 SUPER
a 2 times are the upper limit of primer application.
(Application beyond 2 times causes degradation.)
a Application position: Entire area of dimension (a).

q Primer application dimension (a): 25 mm
a In addition to the above, apply additional primer to

R.H. window glass (1) and door lower window
glass (3).
q R.H. window glass (1) additional primer application
area: (b)
q Lower door window glass (3) additional primer
application area: (c)
a After applying the primer, leave it in air for at least
5 minutes to dry.
a Install the glass within 8 hours after applying the
primer.
a Never apply wrong primer.

If glass primer, etc. is applied by mistake, wipe it
off with white gasoline [7].
50-700 16 PC200, 200LC, 220, 220LC-8M0

4) Apply the glass primer [2] to the mounting surface of

window glass (17).
Tools: Primer for glass
2 Glass primer [1]:
SUNSTAR Glass Primer 580 SUPER
q 2 times are the upper limit of primer application.
(Application beyond 2 times cause degradation.)
a Application position: Apply the primer to the entire

area of installation position (d) which is a periphery
of whole area of window glass (17) relative to dam
rubber [9] mounting part and operator's cab (8).
a Do not apply the primer to about 5 mm of the bor-
der area between the black and transparent por-
tions on the window glass.
a After applying the primer, leave it in air for at least
5 minutes to dry.
a Install the glass within 8 hours after applying the
primer.
a Never apply wrong primer.
If paint surface primer, etc. is applied by mistake,
wipe it off with white gasoline [7].
4. Attach the dam rubber (double-sided adhesion tape) [9]

along the inner edge of the window glass mounting surface.
Tools: Dam rubber
a Do not remove the tape on glass-adhering side of the
dam rubber until installation of the window glass is
started.
a When installing the dam rubber, do not touch the
cleaned surface.
a Take care that the dam rubber is not floated in each
sticking corner.
a When bonding dam rubber [9] around a window, use

care to prevent its overlapping in the joining area of the
starting and ending points. Or provide a clearance of 5
mm or so in joining area (e).
1) Attach the dam rubber [9] for R.H. window glass (1) to
the position indicated in the figure.
a Attach additional dam rubber [9a] for R.H. window

glass (1).
q Right side window glass additional dam rubber
installing position:
(f): 50 mm
(g): 90 mm
(h): 250 mm
PC200, 200LC, 220, 220LC-8M0 50-700 17

2) Attach the dam rubber [9] for L.H. rear window glass (2)
to the position indicated in the figure.
3) Attach dam rubber [9] for door lower window glass (3)
to the position indicated in the figure.
a Stick dam rubber [9b] additionally for door lower

window glass (3).
q Door lower window glass additional dam rubber
installing position:
(j): 110 mm
(k): 90 mm
(m): 200 mm
4) Attach dam rubber [9] for front window glass (4) to the
position indicated in the figure.
a Unlike dam rubber [9] other than the lower dam

rubber, install lower dam rubber [9c] of the front
window glass along the outer edge of the lower
line. (The dam rubber will be visible through the
transparent part of the glass when installed along
the inside.)
50-700 18 PC200, 200LC, 220, 220LC-8M0

5. Position the new window glass.

Tools: Tape, utility knife
1) Check clearance between a window glass and opera-
tor's cab in the right, left, top and bottom. Then adjust
the window glass position so that the clearance is even
in every direction.
2) Attach tape [15] between window glass (9) and opera-
tor' cab (8), and draw a line (n) on the tape for the posi-
tion alignment.
a Attach tapes [15] at 3 positions, right side window
glass, rear left side window glass, and door lower
window glasses, for position alignment.
3) Cut the tape [15] at a position between window glass

(9) and operator's cab (8) by using a utility knife [5],
etc., and remove the window glass.
a Do not remove the tapes [15] left on the window
glass and the operator's cab until the window glass
is installed.
a When positioning front window glass (4), set right

and left installing positions to the frame width.
And set its vertical position to make the height dif-
ference (p) between the frame top and the front
window glass (4) 3 mm.
6. Apply adhesive [3].

Tools: Adhesive
a 2 types of adhesives must be selectively used depend-
ing on the season.
2 Adhesive [3] (Apr. to Oct.):
SUNSTAR penguine seal 580 super "S"
2 Adhesive [3] (Oct. to Apr.):
SUNSTAR penguine seal 580 super "W"
a Do not use adhesive if it has passed the expiration date

which is 4 months after its production date.
a Store adhesive at 25°C or lower in a dark place.

a Do not heat the adhesive any higher than 30°C.
a When reusing the adhesive, remove the hardened
adhesive at the nozzle tip completely.
1) Break the aluminum dehumidification film (13) at the

mouth of adhesive cartridge (12), and attach the noz-
zle.
PC200, 200LC, 220, 220LC-8M0 50-700 19

2) Cut the tip of adhesive nozzle (14) to dimensions (q)

and (r) as shown in the figure.
q Dimension (q): 10 mm
q Dimension (r): 15 mm
3) Set adhesive cartridge (12) on caulking gun [10].

Tools: Caulking gun
a A better workability is obtainable from a power
caulking gun.
4) Remove the protective tape on the glass-bonding side

of dam rubber.
5) Apply adhesive [3] to outside portion of dam rubber [9]
on the operator's cab.
a Apply adhesive [3] to dam rubber [9] of operator's

cab (8) in conformity with dimensions (s) and (t)
indicated in the figure.
q Dimension (s): 10 mm
q Dimension (t): 15 mm
a Thickness of applied adhesive [3] must be higher
than that of dam rubber [9].
a Height of applied adhesive must be even.
50-700 20 PC200, 200LC, 220, 220LC-8M0

a Apply adhesive [3] additionally to additional dam

rubber [9a] of right side window glass and addi-
tional dam rubber [9b] of lower door window glass.
7. Install the window glass.

Tools: Glass primer, adhesive, rubber spatula, masking tape
1) Install the window glass (9) aligning it to the lines drawn
on the tapes in the process of step 5 above.
a Since the window glass cannot be removed and
adhered again, adhere it with utmost care.
a Adhere the glass within 5 minutes after applying
the adhesive.
2) After bonding the window glass (9), press down entire
circumference of the window glass until it firmly sticks
to dam rubber.
a Press the corners of the window glass firmly.
a Pulling window glass (9) from inside of the opera-

tor's cab by using tool A1 (suction cup) will facili-
tate your work.
a If you fail in alignment of glass bonding position,
you must clean the installed position and apply
primer again. Therefore, carefully position the win-
dow glass before bonding.
PC200, 200LC, 220, 220LC-8M0 50-700 21

a After installing front window glass (4) fill the clear-

ances between the glass and center trim seal (16)
by using caulking material in range (s) with dimen-
sions of (t) and (u). Apply the primer to glass (4)
shown in section A-A as caulking material.
q Caulking dimension (t): 2mm
q Caulking dimension (u): 5mm
a Apply adhesive [3].
a Mask the glass side, and mold the adhesive to the
shape shown in the figure by using a rubber spat-
ula [11].
a Wipe off adhesives forced out.
2 Glass primer [2]:
SUNSTAR Glass Primer 580 SUPER
2 Adhesive [3]:
SUNSTAR Penguin Seal 580 SUPER "S" or "W"
8. Fix the window glass.

Tools: Rubber band, styrene foam
1) After installing right window glass (1) to the operator's
cab, insert tool A2 (stopper rubber) to 2 places (v) at
the bottom of the glass to fix the glass.
2) Make the window glass and dam rubber stick together

by clamping them with expanded styrene foam [13] and
rubber band [14], and cure them in that state.
50-700 22 PC200, 200LC, 220, 220LC-8M0

9. After installing the window glass, remove any excess of the

primer and adhesive from the operator's cab and window
glass.
Tools: White gasoline
a Wipe off adhesives before it is dried up by using white
gasoline [7].
a When cleaning the glass, do not give an impact to it.
10. Cure the adhered window glass.

1) Keep the stopper rubbers, styrene foam blocks, and
rubber bands installed for 10 hours of curing period.
(Ambient temperature 20°C / Humidity 60%)
2) Before actual operation of the machine, let it cure for 14
hours after the stopper rubbers, styrene foam blocks,
and rubber bands are removed, and for a total of 24
hours after the adhesive is applied.
PC200, 200LC, 220, 220LC-8M0 50-700 23

SEN06148-02 Removal and installation of front window assembly
Removal and installation of front window assembly 1
Standard tools list

8 Torque wrench set (hexagonal) (Commercially available) 34.3 Nm 1
k Lower the work equipment to the ground, and stop the engine.
NOTICE
q To replace the front window glass, the front window assembly must be removed from the opera-
tor's cab. Procedure for installing and removing the front window assembly (front frame + front
glass) are described as following.
50-700 24 PC200, 200LC, 220, 220LC-8M0

Removal and installation of front window assembly SEN06148-02
Removal
1. Fix the rear locks (right and left) with the front window assembly put up to the ceiling.
2. Remove the hexagon socket head screws (2a) and (4)

(2) pieces each on right and left sides), and remove L.H.
corner block (1) and R.H. corner block (2).
mm, M8
a L.H. corner block mounting hexagon socket head

screws (2a), (4) and washers (3) are used to place the
pull-up assist cable in section 6 below.
3. Unlock the lock at the rear of the cab.

4. Carefully lower the front window assembly a little, and pull
rollers (5) and (6) at the lower left and right of the front win-
dow out of the locations (rail open spaces) where corner
blocks were removed in section 2 above and hold them.
5. Remove rollers (5) and (6) at the lower right and left of the
front window.
6. Remove lower left pin (7).

Tools: Wrench
Pin (7): Width across flats 19 mm
a When lower left pin (7) is removed, plate (8) at the tip of
pull-up assist cable (9) is removed.
a Hang plate (8) on the mounting bolt (use washer) for
the left corner block and set in place.
k A return load of 58.8 N {6 kg} is applied on the rear
side of the operator's cab of pull-up assist cable
(9). When disconnecting the cable, remove lower
left pin (7) carefully.
7. Put out the bottom of front window assembly (10) through

the rail opening portion and lower it gradually.
PC200, 200LC, 220, 220LC-8M0 50-700 25

8. Lower front window assembly (10) completely.

a Be careful not to bring the front window assembly into
contact with the machine monitor.
9. Remove upper right and lower left rollers (11) and (12) by
twisting front window assembly (10) rightward and leftward,
and remove front window assembly (10).
4 Front window assembly (10): 17 kg
50-700 26 PC200, 200LC, 220, 220LC-8M0

Installation
1. Place the R.H. and L.H. upper rollers (11) and (12) on the
rail while twisting the front window assembly (10) to the right
and left.
4 Front window assembly (10): 17 kg
a Be careful not to bring the front window assembly into
contact with the monitor.
2. Set the pull-up assist cable (9) and plate (8) as a unit on the
3. Install R.H. and L.H. plates (8) with pin (7).
Pin (7): Width across flats 19 mm
3 Pin (7): 27 to 34 Nm {2.75 to 3.47 kgm}
2 Mounting bolt: Liquid adhesive (LT-2)
k A return load of 58.8 N {6 kg} is applied on the rear
side of the operator's cab of pull-up assist cable
(9). When installing the cable, install pin (7) very
carefully.
PC200, 200LC, 220, 220LC-8M0 50-700 27

4. Install rollers (5) and (6) to the lower right and left of the
front window.
5. Push in the front window assembly along the rail, and lock
it.
k Check that the lock is securely locked.
(Adjust the opening and closing of the front window assembly)

q Adjust the opening and closing of the front window
assembly according to the following procedure.
6. Open and close the front window to check for any interfer-
ence between the front window and rail or stuck roller.
7. If there is any problem in opening and closing of the front
window, loosen the hexagon socket head screw (13a) of
roller positioning adjustment bracket (13) and make adjust-
ment, and tighten the mounting bolt again.
mm, M8
3 Hexagon socket head screw (13a):
34.3 Nm {3.5 kgm}
a Be careful not to install bracket (13) at an angle.
8. Raise the front window assembly, and fix it with the rear
locks (right and left).
a Check the lock of the operator's cab rear is securely
engaged.
50-700 28 PC200, 200LC, 220, 220LC-8M0

9. Install R.H. corner block (2) with the hexagon socket head
screws (2a) (2 pieces).
mm, M8
a Lightly tightening is appropriate since it will be tight-
ened to the specified torque after adjustment on
"CLOSE" side.
a Install right corner block (2) so that clearance (a)
between the rail and right corner block (2) becomes 0
to 2.0 mm.
a Install it so that there is no level difference on rail sur-
face (R) for the roller.
10. Install L.H. corner block (1) with the hexagon socket head
screws (4) (2 pieces).
mm, M8
a Lightly tightening is appropriate since it will be tight-
ened to the specified torque after adjustment on
"CLOSE" side.
a Install left corner block (1) so that clearance (b)
between the rail and left corner block (1) becomes 0 to
2.0 mm.
a Install it so that there is no level difference on rail sur-
face (R) for the roller. (See the figure above)
PC200, 200LC, 220, 220LC-8M0 50-700 29

11. Adjust the lock "CLOSE" side of the front window assembly
1) Tighten right and left corner blocks (1) and (2) to the
specified torque at an approximate position so that
front window glass (14) and cab side trim seal (15)
come into close contact.
2) Check the locking state of right and left locks (16) and
(17) when the front window assembly is opened and
closed.
q If right and left locks (16) and (17) do not lock well
1] Loosen lock clamping bolt (18), move lock (16) for-
ward, and tighten it again.
Lock clamping bolt (18): Width across flats 12
mm, M8
3 Lock clamping bolt (18):
27 to 34 Nm {2.8 to 3.5 kgm}
a Similarly in the right side
2] After moving the lock, check again the contact
between front window glass (14) and cab side trim
seal (15) checked in 1).
3] Repeat the work in 1] and 2]. Tighten right and left
corner block mounting bolts at a place where the
contact of the front window glass and locking of left
and right locks (16) and (17) coexist.
12. After adjustment, splash water from the front of the front
window glass and check for any water leakage in the cab.
50-700 30 PC200, 200LC, 220, 220LC-8M0

13. Adjust the lock "open" side of the front window assembly.
1) After the adjustment of the lock "close" side of the front
window assembly in 6 and 7, pull up the front window
assembly to the ceiling.
2) Check the following when right and left front window
assembly locks in the operator's cab rear are in the
"open" side.
q Locking state of right and left locks (16) and (17)
q The front window assembly must come into con-
tact with right and left rubber stoppers (18) and
push them backward by 1.5 to 3.0 mm.
q Limit switch (19) must be pushed backward by 4 to
7 mm by the front window assembly.
a Because the position of limit switch (19) cannot be
adjusted, the front window assembly "open" posi-
tion is determined in the range where this switch
functions.
a Limit switch (19) prevents the windshield wiper
from operating when the wiper switch is turned ON
in the front window assembly "open" state. If the
windshield wiper operates without glass on the
front, the windshield wiper will fall into the cab,
causing failure.
To determine if limit switch (19) is enabled, turn on
the key switch, and check that the windshield
wiper does not operate even when the wiper
switch is turned on in the front window assembly
"open" state.
q After checking the above items, if it becomes nec-
essary to do the adjustment;
3) Close front window assembly (10).
4) Loosen lock nut (20) of right and left rubber stoppers
(18), and retract left and right rubber stoppers (18)
backward so that the front window assembly in the
"open" state does not come into contact with left and
right rubber stoppers (18).
5) Loosen right and left lock nuts (22), and adjust the posi-
tions of right and left striker bolts (21) by moving them
within the range of difference between the striker bolt
outside diameter and plate (23) hole diameter.
Tools: Wrench
Lock nut (22): Width across flats 14 mm
3 Lock nut (22): 39 to 49 Nm {4.0 to 5.0 kgm}
a Striker bolt (21): Width across flats 19 mm, M10
Diameter of hole in plate (23): f14.5 mm
PC200, 200LC, 220, 220LC-8M0 50-700 31

1] Limit switch (19) must be pushed backward by 4 to

7 mm by the front window assembly (10) ("open"
state).
2] Locking state of lock (17)
6) Adjustment of right and left rubber stoppers (18)

1] Bring right and left stopper rubbers (18) into con-
tact with front window assembly (10) (lock "open").
2] Close front window assembly (10).

3] Turn right and left rubber stoppers (18) to the left
for one and a half rotation.
a Turning right and left stopper rubbers (18) counter-
clockwise 1 turn is equivalent to pressing the rub-
ber by approximately 1.5 mm.
a When the front window assembly is in the "open"
state, the front window assembly must push right
and left rubber stoppers (18) by 1.5 to 3.0 mm.
4] Tighten lock nut (20) of right and left rubber stop-

pers (18).
Tools: Wrench, ring wrench
Lock nut (20): Width across flats 17 mm
3 Lock nut (20):
39 to 49 Nm {4.0 to 5.0 kgm}
50-700 32 PC200, 200LC, 220, 220LC-8M0

14. Adjust front window assembly runout stopper (24).

1) When front window assembly (10) is opened/closed,
adjust right and left stoppers (24) so that surface "d" of
stopper part (D) of front window assembly (10) and sur-
face "c" of stopper (24) come into contact, and fix them.
15. Check the lock operating effort of the front window assem-
bly.
1) After the adjustments in sections 11 to 14 are com-
pleted, check that the latch operating efforts for right
and left locks (16) and (17) are even for left and right.
a Check both "Close" side (front of operator's cab)
and "Open" side (at rear of operator's cab).
PC200, 200LC, 220, 220LC-8M0 50-700 33

SEN06148-02 Removal and installation of floor frame assembly
Removal and installation of floor frame assembly 1
Standard tools list

8 to 12 Nm
34 to 54 Nm
8 Torque wrench (socket) (Commercially available) 1
59 to 74 Nm
98 to 123 Nm
34 to 54 Nm
9 Torque wrench set (spanner) (Commercially available) 1
54 to 93 Nm
Special tools list

1 Plug (female) 02789-00210 #02 1
Each hose of
A 2 Plug (male) 07376-70210 #02 1
PPC
3 O-ring 02896-11008 1
1 Plug (female) 02789-00315 #03 1
PPC lock sole-
B 2 Plug (male) 07376-70315 #03 1
noid outlet hose
3 O-ring 02896-11009 1
q Precautions for handling refrigerant

k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit.
k If refrigerant (air conditioner gas: R134a) gets in your eyes, you may lose your sight. Put on pro-
tective eyeglasses during collecting or filling operation.
NOTICE
q Ask a registered person for collecting, adding and filling operations of the refrigerant (air condi-
tioner gas: R134a).
q Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
50-700 34 PC200, 200LC, 220, 220LC-8M0

Removal and installation of floor frame assembly SEN06148-02
Removal
(1b).

6 Coolant:
20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
3. Remove the operator's cab assembly. For details, see

"Removal of operator's cab assembly."
4. Remove the bolts (1c) (6 pieces) and (1d) (7 pieces), and

remove the cover (1).
Bolt (1c), (1d): Width across flats 19 mm, M12
5. Remove the bolt (2a) (1 piece), and disconnect the ground

cable (2).
6. Disconnect connectors (4a) to (5b) from travel PPC valve

(3).
q Connector (4a): L.H. reverse oil pressure sensor (P10)
q Connector (4b): L.H. forward oil pressure sensor (P09)
q Connector (5a): R.H. forward oil pressure sensor (P11)
q Connector (5b): R.H. reverse oil pressure sensor (P12)
7. Disconnect hoses (6a) to (7b) from travel PPC valve (3).
a The band colors of the hoses are shown below.
q Hose (6a): Red (L.H. forward port (P2))
q Hose (6b): No band (L.H. reverse port (P1))
q Hose (7a): Blue (R.H. reverse port (P3))
q Hose (7b): Green (R.H. forward port (P4))
PC200, 200LC, 220, 220LC-8M0 50-700 35

q Items 8 to 10 are for breakers (if equipped).
8. Disconnect the PPC hoses (8) and (9) from the PPC valve.
Band colors are as follows;
q (8): Yellow
q (9): None
9. Disconnect connectors S11(10) and S10 (11).
10. Disconnect the connectors P13 (12) and V30 (13).
11. Remove the bolt (14a) (1 piece each), and disconnect the
ground cables (14) (6 pieces).
From left, T04, T05, T06, T07, T09, T10
12. Remove the bolts (15a) (1 piece), and remove the clamp
(15).
13. Disconnect connector A08 (16) from the clip.
14. Disconnect connector P17 (17) from the air conditioner
tube.
15. Remove the clamp, and remove the spacer (18).
16. Disconnect the hose (19).
a Confirm the destinations.
a The work equipment PPC hoses (P) (4 pieces on the
right and left) are disconnected in Step 33. Do not work
on them.
17. Disconnect the hose (20).
a Coolant remaining in the heater hose flows out. Cover
the hose with a cloth, etc.
19. Remove the bolt (22), and disconnect the air conditioner
tube (23).
20. Remove the clamps (24) and (25).
Bolts of clamps (24) and (25): Width across flats 17 mm,
M10
21. Disconnect clamp (26) from the floor frame. (Option:
Breaker specification)
50-700 36 PC200, 200LC, 220, 220LC-8M0

22. Disconnect connectors N10 (27) and AC01 (28).

23. Disconnect the connectors ECU10 and ECU11 (29) from
the air conditioner controller (B).
(31).
25. Disconnect connectors (32) and (33) on the back of cover
(31).
q Connector (32): R.H. console intermediate harness
(H14)
(H15)
26. Remove the grommet (34).

27. Move harness (35) to the outside of the floor frame.
a (SP) is made of sponge.
28. Disconnect clamp (35a) of wiring harness (35) from the floor
frame.
move plates (36) and (37) and harness (35) to the boom
side as a unit.
30. Open the engine hood (38a).

31. Remove the bolts (38b) (3 pieces), and remove the cover
(38).
PC200, 200LC, 220, 220LC-8M0 50-700 37

32. Disconnect clamp (39) from the revolving frame.

33. Disconnect the work equipment PPC hoses (40) (8 pieces)
from the junction block.
From top, band color:
White
Brown
None
Blue
Black
Green
Red
Yellow
34. Pull out the work equipment PPC hose assembly (41) from
the floor frame.
35. Sling floor frame assembly (42), and remove it.

Tools: Chain, lever block, eyebolts (M12)
4 Floor frame assembly: 250 kg
NOTICE
q Check that all the hoses, connectors, and clamps are
disconnected, and sling it gradually.
50-700 38 PC200, 200LC, 220, 220LC-8M0

Installation
1. Sling the floor frame assembly (42), and set it on the install-
ing position.
Tools: Chain, lever block, eyebolts (M12)
4 Floor frame assembly: 250 kg
2. Put the work equipment PPC hose assembly (41) in the

floor frame.
3. Connect the work equipment PPC hoses (40) (8 pieces).

3 Hose (40): 34 to 54 Nm {3.5 to 5.5 kgm}
From top, band color:
White
Brown
None
Blue
Black
Green
Red
Yellow
4. Fix the hose with the clamp (39).
5. Install cover (38) with bolts (38b) (3 pieces).

3 Bolt (38b): 98 to 123 Nm {10 to 12.5 kgm}
6. Close the engine hood (38a).
PC200, 200LC, 220, 220LC-8M0 50-700 39

7. Return the plates (36) and 37) and wiring harness (35) as a
unit to the floor frame, and install them with the bolts (36a)
(4 pieces) and (37a) (4 pieces).
3 Bolt (36a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}

3 Bolt (37a): 27 to 34 Nm {2.8 to 3.5 kgm}
8. Fix wiring harness (35) with clamp (35a).

3 Clamp (35a) bolt: 59 to 74 Nm {6 to 7.5 kgm}
9. Return the wiring harness (35) to the original mounting posi-
tion.
a (SP) is made of sponge.
10. Install the grommet (34).
11. Connect the connectors (32) and (33) to the back of the
cover.
(H14)
(H15)
3 Bolt (31a): 27 to 34 Nm {2.8 to 3.5 kgm}
13. Connect the connectors ECU10 and ECU11 (29) to the air
conditioner controller (B).
14. Connect the connectors N10 (27) and AC01 (28).
15. Fix the hose with the clamp (26). (Option: Breaker specifica-
tion)
3 Bolt (26a): 59 to 74 Nm {6.0 to 7.5 kgm}
16. Fix the hose with the clamps (24) and (25).
Bolts of clamps (24) and (25): Width across flats 17 mm,
M10
3 Bolts of clamps (24) and (25):
59 to 74 Nm {6 to 7.5 kgm}
a Make sure that no hoses overlap.
50-700 40 PC200, 200LC, 220, 220LC-8M0

17. Connect the air conditioner tubes (23) with the bolt (22).
3 Bolt (22): 8 to 12 Nm {0.8 to 1.2 kgm}
a When installing the hose for the air conditioner circuit,
be careful to prevent any dirt, dusts and water from
entering into the hose.
a Check that the O-ring is installed for the air conditioner
hose connection before installation.
a Check that the O-ring is not damaged or deteriorated.
a When connecting the refrigerant piping, apply com-
pressor oil (DENSO: ND-OIL8, ZEXCEL: ZXL100PG
(equivalent to PAG46)) for refrigerant (R134a) to O-
ring.
3 Hose (20): 34 to 54 Nm {3.5 to 5.5 kgm}

3 Hose (19): 54 to 93 Nm {5.5 to 9.5 kgm}
a Connect as you checked when disconnecting.
a The work equipment PPC hoses (P) (4 pieces on the
right and left) are connected already on the joint box
side.
21. Install the spacer (18) with the clamp.
22. Connect the connector P17 (17) to the air conditioner tube.
23. Connect the connector A08 (16) to the clip.
24. Connect the clamp (15) with the bolt (15a) (1 piece).
3 Bolt (15a): 59 to 74 Nm {6 to 7.5 kgm}
25. Connect the ground cables (14) (6 pieces) with the bolts
(14a) (1 piece each).
3 Bolt (14a): 59 to 74 Nm {6 to 7.5 kgm}
From left, T04, T05, T06, T07, T09, T10
q Items 25 to 27 are for the breaker (if equipped).

26. Connect the connectors P13 (12) and V30 (13).
27. Connect the connectors S11 (10) and S10 (11).
28. Connect the PPC hoses (8) and (9) to the PPC valve.
3 Hoses (8), (9): 34 to 54 Nm {3.5 to 5.5 kgm}
Band colors are

q (8): Yellow
q (9): None
PC200, 200LC, 220, 220LC-8M0 50-700 41

29. Connect the hoses (6a) to (7b) to the travel PPC valve (3).
a The band colors of the hoses are shown below.
q Hose (6a): Red (L.H. forward port (P2))
q Hose (6b): No band (L.H. reverse port (P1))
q Hose (7a): Blue (R.H. reverse port (P3))
q Hose (7b): Green (R.H. forward port (P4))
30. Connect the connectors (4a) to (5b) to the travel PPC valve
(3).
q Connector (4a): L.H. reverse oil pressure sensor (P10)
q Connector (4b): L.H. forward oil pressure sensor (P09)
q Connector (5a): R.H. forward oil pressure sensor (P11)
q Connector (5b): R.H. reverse oil pressure sensor (P12)
31. Connect the ground cable (2) with the bolt (2a) (1 piece).
3 Bolt (2a): 59 to 74 Nm {6 to 7.5 kgm}
32. Install the cover (1) with the bolts (1c) (6 pieces) and (1d) (7
pieces).
Bolt (1c), (1d): Width across flats 19 mm, M12
3 Bolt (1c), (1d): 98 to 123 Nm {10 to 12.5 kgm}
33. Install the operator's cab assembly. For details, see

"Removal and installation of operator's cab assembly."

5 Coolant
20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
a Refill it with the coolant to the specified level through
the coolant filler port. Run the engine to circulate the
coolant through system. Then check the coolant level
again.
35. Install the cover (1b) with the bolts (1a) (7 pieces).
3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
36. Refill the air conditioner circuit with refrigerant (R134a).

a Refill amount: 870±50 g
50-700 42 PC200, 200LC, 220, 220LC-8M0


1) Wipe off the removed and installed portions to remove
all oil, water, dirt, etc. Wipe off oil, grease, etc. accumu-
lating in the cover as well.
2) Start the engine, and check that the machine operates
normally.
PC200, 200LC, 220, 220LC-8M0 50-700 43

SEN06148-02 Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner unit assembly 1
Standard tools list

6 Torque wrench set (socket) (Commercially available) 8 to 12 Nm
11.8 to 14.7 Nm
1
27 to 34 Nm
98 to 123 Nm
q Precautions for handling refrigerant

k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit.
k If refrigerant (air conditioner gas: R134a) gets in your eyes, you may lose your sight. Put on pro-
tective eyeglasses during collecting or filling operation.
k If you disconnect the heater hoses when the coolant in radiator is still hot, you may be scalded.
Wait until the coolant temperature drops, then disconnect the heater hoses.
NOTICE
q Ask a registered person for collecting, adding and filling operations of the refrigerant (air condi-
tioner gas: R134a).
q Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
q Before disconnecting the wiring and hoses, write down their connector numbers and installed
positions.
50-700 44 PC200, 200LC, 220, 220LC-8M0

Removal and installation of air conditioner unit assembly SEN06148-02
Removal
a The location of each controller in the cover at the rear of

the operator's seat is shown below.
q A: Pump controller assembly
q B: Air conditioner controller assembly
q C: KOMTRAX terminal
(1a) and (1c).
Tool: Socket wrench

6 Coolant:
20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
3. Pull up the front window assembly (1) to the ceiling, and

lock it.
a Check that the lock is securely locked.
4. Remove the front window (lower) (2).
(3).
PC200, 200LC, 220, 220LC-8M0 50-700 45

ward.
7. Open the cooler box cover, remove the bolts (8a) (5 pieces),
and remove the cooler box (8).
a Disconnect the air hose at the bottom rear of the cooler
box (8).
8. Remove the bolts (9a) (2 pieces) and screw (9b) (1 piece),
and remove the cover (9).
a Be careful about the connectors (10) and (11) located
behind the cover (9). (Machines equipped with 12V
power socket)
q Connector (10): 12V power socket intermediate har-
ness (M13A)
ness (M13B)
(12).
a Be careful not to catch the connectors and harnesses
on the back.
(13).
a Disconnect connector (14) on the back of cover (13).
q Connector (14): Cigarette lighter (M04)
50-700 46 PC200, 200LC, 220, 220LC-8M0

11. Remove the bolts (15a) (2 pieces), and remove the duct
(15).
(16).
13. Disconnect the connectors (17) and (18) fixed to the back of
cover (16).
(H14)
(H15)
(41).
15. Remove the bolts (19) (4 pieces), and remove plate (19).
16. Remove the lock pin (20), and remove the duct (21).

a The mounting bolt of cover (48) is behind cover (47).
Remove cover (47) first.
a When removing the ducts (24) and (26), remove the
cover (48), then the work is easier.
19. Remove the ducts (24), (25), (26), (27), and (28).
a Cut the cable tie fixing the duct.
PC200, 200LC, 220, 220LC-8M0 50-700 47

20. Remove the cable tie (39) of the L.H. console harness.
21. Remove cable tie (40) of the floor harness.
22. Remove the bolts (29) (4 pieces), move pump controller

assembly (A) away from the operator's cab, and gather it on
the floor.
23. Disconnect the connectors AC01 (30), AC02 (31), and

AC04 (32) from the air conditioner controller assembly (B).
q Connector (30): Machine main wiring harness (AC01)
q Connector (32): Air conditioner unit harness (AC04)
24. Disconnect the connectors GPS (42), CK1 (43), CK2 (44),
and communication antenna (45).
q Connector (42): Communication antenna (GPS)
q Connector (43): Machine main wiring harness (CK01)
q Connector (45): Communication antenna
25. Remove the bolts (46) (4 pieces), and remove KOMTRAX
terminal assembly (C).
50-700 48 PC200, 200LC, 220, 220LC-8M0

26. Remove the bolts (32) (6 pieces), and remove the cover
(33).
27. Remove the bolt (34), and disconnect the air conditioner
tube (35).
28. Disconnect heater hose (36).
29. Remove the bolts (37) (7 pieces), and remove the air condi-
tioner unit assembly (38).
4 Air conditioner unit assembly (38): 10 kg
PC200, 200LC, 220, 220LC-8M0 50-700 49

Installation
1. Install the air conditioner unit assembly (38) with the bolts
(37) (7 pieces).
4 Air conditioner unit assembly (38): 10 kg
3 Bolt (37): 27 to 34 Nm {2.8 to 3.5 kgm}

a When connecting the heater hose, install it so that the
white line (mark) on the heater hose becomes a
straight line to avoid any twist of the heater hose.
3. Connect the air conditioner tubes (35) with the bolt (34).
3 Bolt (34): 8 to 12 Nm {0.8 to 1.2 kgm}
a When installing the hose for the air conditioner circuit,
be careful to prevent any dirt, dusts and water from
entering into the hose.
a Check that the O-ring is installed for the air conditioner
hose connection before installation.
a Once an O-ring is used, it is deformed and deterio-
rated. Accordingly, do not reuse it.
a When removing the O-rings, use a soft tool so that the
piping is not damaged.
a Check that the O-ring is not damaged or deteriorated.
a When connecting the refrigerant piping, apply com-
pressor oil (DENSO: ND-OIL8, ZEXCEL: ZXL100PG
(equivalent to PAG46)) for new refrigerant (R134a) to
O-ring.
4. Install the cover (33) with the bolts (32) (6 pieces).

3 Bolt (32): 98 to 123 Nm {10 to 12.5 kgm}
5. Install the KOMTRAX terminal assembly (C) with the bolts

(46) (4 pieces).
3 Bolt (46): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6. Connect the connectors GPS (42), CK1 (43), CK2 (44), and
communication antenna (45).
50-700 50 PC200, 200LC, 220, 220LC-8M0

7. Connect the connectors AC01 (30), AC02 (31), and AC04

(32) to the air conditioner controller assembly (B).
q Connector (32): Air conditioner unit harness (AC04)
8. Install the pump controller assembly (A) with the bolts (29)
(4 pieces).
3 Bolt (29): 27 to 34 Nm {2.8 to 3.5 kgm}
9. Fix the floor wiring harnesses with the cable tie (40).
10. Bind the L.H. console wiring harnesses with the cable tie
(39).
11. Install the ducts (28), (27), (26), (25), and (24).
a Bind with the cable ties.
PC200, 200LC, 220, 220LC-8M0 50-700 51


14. Install the duct (21), and fix it with the lock pin (20).
3 Bolt (19a): 27 to 34 Nm {2.8 to 3.5 kgm}
3 Bolt (41a): 27 to 34 Nm {2.8 to 3.5 kgm}
3 Bolt (41a): 27 to 34 Nm {2.8 to 3.5 kgm}
a Connect the connectors (17) and (18) on the back side
of the cover (16).
(H14)
(H15)
18. Install the duct (15) with the bolts (15a) (2 pieces).
3 Bolt (15a): 27 to 34 Nm {2.8 to 3.5 kgm}
19. Connect the connector (14) on the back of the cover (13).
50-700 52 PC200, 200LC, 220, 220LC-8M0

3 Bolt (13a): 27 to 34 Nm {2.8 to 3.5 kgm}
3 Bolt (12a): 27 to 34 Nm {2.8 to 3.5 kgm}
on the back.
22. Install the cover (9) with the bolts (9a) (2 pieces) and screw
(9b) (1 piece).
3 Bolt (9a): 27 to 34 Nm {2.8 to 3.5 kgm}
behind the cover (9). (Machines equipped with 12V
power socket)
ness (M13A)
ness (M13B)
23. Install the cooler box (8) with the bolts (8a) (5 pieces), and
close the cooler box cover.
Bolts (8a): Width across flats 10 mm, M6
3 Bolt (8a): 27 to 34 Nm {2.8 to 3.5 kgm}
a Connect the air hose at the bottom rear of the cooler
box (8).
24. Return the operator's seat and its backrest to their original
positions.
3 Bolt (3a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
26. Install the front window (lower) (2).

27. Lower the front window assembly (1) from the ceiling, and
lock it.
PC200, 200LC, 220, 220LC-8M0 50-700 53


5 Coolant
20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
a Refill it with the coolant to the specified level through the coolant filler port. Run the engine to circu-
late the coolant through system. Then check the coolant level again.
29. Refill the air conditioner circuit with refrigerant (R134a).
a Refill amount: 870±50 g
1) Wipe off the removed and installed portions to remove all water, dirt, etc. Wipe off water accumulat-
ing in the cover, as well.
2) Start the engine, and check that the machine operates normally.
3) Start the air conditioner, and check that it operates normally.
50-700 54 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 50-700 55

SEN06148-02

© 2018 KOMATSU
All Rights Reserved
50-700 56
SEN06149-02
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up

Removal and installation of machine monitor assembly ................................................................................. 2
Removal and installation of engine controller assembly ................................................................................. 9
Removal and installation of pump controller assembly ................................................................................. 13
Removal and installation of KOMTRAX terminal assembly .......................................................................... 18
PC200, 200LC, 220, 220LC-8M0 50-800 1

SEN06149-02 Removal and installation of machine monitor assembly
Removal and installation of machine monitor assembly 1
Standard tools list

11.8 to 14.7 Nm
27 to 34 Nm
k Park the machine on a level ground, lower the work equipment to the ground in a stable posture,
NOTICE
positions.
50-800 2 PC200, 200LC, 220, 220LC-8M0

Removal and installation of machine monitor assembly SEN06149-02
Removal
1. Pull up the front window assembly (1) to the ceiling, and

lock it.
2. Remove the front lower window (2).
(3).
4. Remove the hexagon socket head screws (4a) (3 pieces),

and move the cover (4).
mm, M6
a One of the three hexagon socket head screws (4a) is
covered with the cap (5).
5. Remove the connector (6), and then remove the cover (4).
q Connector (6): Sunlight sensor (P31)
6. Remove the bolt (10a), and remove the duct (10).

PC200, 200LC, 220, 220LC-8M0 50-800 3

7. Insert a flat-head screwdriver in the slit (7), and pull it up to

remove the cover (9) around the protrusion (8).
a Hooks (17) are installed to the back of the cover (9).
8. Loosen the bolt (19) of the cover and duct assembly (18).
Bolt (19): Width across flats 12 m, M8
a If the bolt (19) is loosened in advance, the bolts (11) of
the machine monitor can be removed easily.
9. Remove the bolts (11) (4 pieces), and float the machine

monitor assembly (12).
50-800 4 PC200, 200LC, 220, 220LC-8M0

10. Disconnect the connectors CM01 (13), CM02 (14), CM03

(15), and CM04 (16).
a By disconnecting connector (15) in advance, other con-
nectors can be disconnected easily.
q Connector (13): Machine monitor (CM01)
q Connector (15): Machine monitor (unused) (CM03)
q Connector (16): Machine monitor (for camera con-
nection) (CM04)
a CM02 (14) and CM03 (15) can be connected reverse.
However, do not connect them reverse. CM03 (15) is
the green connector.
PC200, 200LC, 220, 220LC-8M0 50-800 5

Installation
1. Connect the connectors CM01 (13), CM02 (14), CM03 (15),

and CM04 (16).
a CM02 (14) and CM03 (15) can be connected reverse.
However, do not connect them reverse. CM03 (15) is
the green connector.
a Connect the connector (15) last.
q Connector (15): Machine monitor (unused) (CM03)
q Connector (16): Machine monitor (for camera con-
nection) (CM04)
2. Install the monitor assembly (12) with the bolts (11) (4

pieces).
3 Bolt (19): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
3. Tighten the bolt (19) of the cover and duct assembly (18).
Bolt (19): Width across flats 12 m, M8
3 Bolt (19): 27 to 34 Nm {2.8 to 3.5 kgm}
50-800 6 PC200, 200LC, 220, 220LC-8M0

4. Install the cover (9) along the slit (7) around the protrusion
(8).
a Hooks (17) are installed to the back of the cover (9).
5. Install the duct (10) with the bolt (10a).

3 Bolt (10a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6. Connect the connector (6).

q Connector (6): Sunlight sensor (P31)
PC200, 200LC, 220, 220LC-8M0 50-800 7

7. Install the cover (4) with the hexagon socket head screws
(4a) (3 pieces).
mm, M6
a One of the three hexagon socket head screws (4a) is
covered with the cap (5).
3 Bolt (3a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
9. Install the front window (lower) (2).
10. Lower the front window assembly (1) from the ceiling, and
lock it.
50-800 8 PC200, 200LC, 220, 220LC-8M0

Removal and installation of engine controller assembly SEN06149-02
Removal and installation of engine controller assembly 1
Standard tools list

NOTICE
positions.
PC200, 200LC, 220, 220LC-8M0 50-800 9

SEN06149-02 Removal and installation of engine controller assembly
Removal
Bolt (1a): 19 mm, M12
2. Open the engine hood (1b).
3. Disconnect connectors CE02 (2) and (3) from the engine

controller.
a The connectors are locked with internal hexagonal
head bolt (L6) (4 mm).
4. Disconnect connector (4) from the engine controller by
pressing the lock.
5. Remove the clamps (7) (3 pieces), and disconnect the cable
(8) from the engine controller (5).
Clamp (7) nut: Width across flats 10 mm, M6
6. Remove the bolts (9) (5 pieces), and remove the engine
controller (5).
a The ground cable (E) is tightened together.
7. Check the controller connector interior (especially lower

side) for sand, dust, or moisture. If any, remove it com-
pletely by using air blow. (Sand, dust, and moisture may
cause defective contact or problem due to water intrusion.)
50-800 10 PC200, 200LC, 220, 220LC-8M0

Removal and installation of engine controller assembly SEN06149-02
q Replacing O-ring seal of power supply connector (4)

O-ring seal: 1010-074-0406 (Deutsch Japan Ltd.)
8. Remove the cover (6) by holding down the claws with twee-
zers [1].
9. Remove O-ring (7) by using tweezers [1].
PC200, 200LC, 220, 220LC-8M0 50-800 11

SEN06149-02 Removal and installation of engine controller assembly
Installation
1. Install the engine controller (5) with the bolts (9) (5 pieces).
a Tighten the grounding cable (E) together.
2. Connect the connectors CE02 (2) and (3) to the engine con-
troller.
a The connectors are locked with hexagon socket head
bolts (L6) (4 mm).
3. Install the cable (8) to the engine controller (5) with the
clamps (7) (3 pieces).
Clamp (7) nut: Width across flats 10 mm, M6
4. Connect the connector (4) to the engine controller by push-
ing it in.
5. Close the engine hood (1b).

Bolt (1a): 19 mm, M12
3 Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
50-800 12 PC200, 200LC, 220, 220LC-8M0

Removal and installation of pump controller assembly SEN06149-02
Removal and installation of pump controller assembly 1
Standard tools list

11.8 to 14.7 Nm
27 to 34 Nm
NOTICE
positions.
PC200, 200LC, 220, 220LC-8M0 50-800 13

SEN06149-02 Removal and installation of pump controller assembly
Removal
ward.
3. Remove relay R08 (4) from the clip.

4. Disconnect bracket (5) and move it toward the right.
5. Disconnect wiring connectors C01 (6) and C02 (7) accord-
q While pressing lock (L1), turn lock (L2) inward.
a Bar (B) comes out and the lock is released.
6. Remove the bolts (8a) (4 pieces), and remove the pump
controller assembly (8).
50-800 14 PC200, 200LC, 220, 220LC-8M0

Reference: Method for removing connector cover (1)
1. Cut and remove cable tie (2).

2. Move the lever (3) upward.
3. Lightly press part (A) from both sides of connector cover (1)
to release claw (B).
4. Remove the connector cover (1) around the claw (C) along
the arc line.
a The photo shows the connector without connector

cover (1).
Reference: Method for installing connector cover (1)
1. Push in the right and left sliders (4) to the end.
PC200, 200LC, 220, 220LC-8M0 50-800 15

SEN06149-02 Removal and installation of pump controller assembly
a Right and left sliders (4) pushed in as far as they go

(left in the figure)
2. Move the lever (3) of the connector cover (1) from above to
the left side (LOCK state) as shown in the drawing.
a (B), (C): Claws
a If the sliders and lever are not set as shown in the right
figure, the connector is not disconnected or locked
securely with the lever. Accordingly, check their posi-
tions again.
3. Set the claw (C) to the connector, and place the connector
cover (1).
a Take care not to catch the wiring harness (5).
4. Put claw (B) in to install connector cover (1).

5. Replace the cut cable ties with new ones to bind connector
cover (1) and the wiring harness together. (See "Procedure
for removing connector cover (1), Step 1.)
50-800 16 PC200, 200LC, 220, 220LC-8M0

Installation
1. Install the pump controller assembly (8) with the bolts (8a)
(4 pieces).
3 Bolt (8a): 27 to 34 Nm {2.8 to 3.5 kgm}
2. Push in wiring connectors C01(6) and C02(7), and tilt lock

(L2) outward to connect them.
3. Bring the bracket (5) to the left, and connect it.
4. Install relay R08 (4) to the clip.

3 Bolt (1a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-800 17

SEN06149-02 Removal and installation of KOMTRAX terminal assembly
Removal and installation of KOMTRAX terminal assembly 1
Standard tools list

11.8 to 14.7 Nm
27 to 34 Nm
NOTICE
positions.
50-800 18 PC200, 200LC, 220, 220LC-8M0

Removal and installation of KOMTRAX terminal assembly SEN06149-02
Removal
ward.
2. Open the cooler box cover, remove the bolts (1a) (5 pieces),
and remove the cooler box (1).
a Disconnect the air hose at the bottom rear of cooler
box.
3. Remove the bolts (2a) (2 pieces) and screw (2b) (1 piece),
and remove the cover (2).
behind the box (2). (Machines equipped with 12V
power socket)
q Connector (5): 12V power socket intermediate harness
(M13A)
(M13B)
on the back.
a Disconnect the connector (7) on the back of the cover
(4).
PC200, 200LC, 220, 220LC-8M0 50-800 19

6. Disconnect connectors GPS (8), CK1 (9), CK2 (10), and

communication antenna (11).
q Connector (9): Machine main harness (CK01)
7. Remove the bolts (12) (4 pieces), and remove KOMTRAX
terminal assembly (13).
50-800 20 PC200, 200LC, 220, 220LC-8M0

Installation
1. Install KOMTRAX terminal assembly (13) with the bolts (12)

(4 pieces).
Bolt (12): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
2. Connect connectors GPS (8), CK1 (9), CK2 (10), and com-
munication antenna (11).
3. Connect the connector (7) on the back of the cover (4).


3 Bolt (4a): 27 to 34 Nm {2.8 to 3.5 kgm}
on the back.
3 Bolt (3a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6. Install the cover (2) with bolts (2a) (2 pieces) and screw (2b)
(1 piece).
Tools: Torque wrench set (socket), phillips screwdriver
3 Bolt (2a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
behind the box (2). (Machines equipped with 12V
power socket)
(M13A)
(M13B)
PC200, 200LC, 220, 220LC-8M0 50-800 21

7. Install the cooler box (1) with the bolts (1a) (5 pieces), and
close the cooler box cover.
a Connect the air hose at the bottom rear of cooler box.
3 Bolt (1a): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
9. Start the engine, and check that KOMTRAX operates nor-
mally.
50-800 22 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 50-800 23

SEN06149-02

© 2018 KOMATSU
All Rights Reserved
50-800 24
SEN06151-00
SEN06002-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
80 Appendix
100 Air conditioner
Precautions for refrigerant .......................................................................................................................... 3

Air conditioner component .......................................................................................................................... 4
Configuration and function of refrigeration cycle......................................................................................... 6
Outline of refrigeration cycle ....................................................................................................................... 7
Air conditioner unit ...................................................................................................................................... 9
Air conditioner controller ............................................................................................................................. 15
Compressor ................................................................................................................................................ 16
Condenser and Modulator .......................................................................................................................... 17
Sensor......................................................................................................................................................... 18
Procedure for testing and troubleshooting .................................................................................................. 20
Circuit diagram and arrangement of connector pins ................................................................................... 22
System diagram .......................................................................................................................................... 24
Parts and connectors layout ....................................................................................................................... 26
Testing air leakage (duct)............................................................................................................................ 29
Testing with self-diagnosis function............................................................................................................. 31
Testing vent (mode) changeover................................................................................................................. 33
Testing FRESH/RECIRC air changeover.................................................................................................... 34
Testing sunlight sensor ............................................................................................................................... 35
Testing (dual) pressure switch for refrigerant.............................................................................................. 36
Testing relays .............................................................................................................................................. 37
PC200, 200LC, 220, 220LC-8M0 80-100 1

100 Air conditioner
SEN06151-00
Troubleshooting chart 1............................................................................................................................... 38

Troubleshooting chart 2............................................................................................................................... 40
Information in troubleshooting table ............................................................................................................ 42
Failure code list related to air conditioner ................................................................................................... 43
Failure code [879AKA] A/C Inner sensor Open Circuit ............................................................................... 44
Failure code [879AKB] A/C Inner sensor Short Circuit ............................................................................... 45
Failure code [879BKA] A/C Outer sensor Open Circuit .............................................................................. 46
Failure code [879BKB] A/C Outer sensor Short Circuit............................................................................... 48
Failure code [879CKA] Ventilating sensor Open Circuit.............................................................................. 50
Failure code [879CKB] Ventilating sensor Short Circuit.............................................................................. 51
Failure code [879DKZ] Sunlight sensor Open or Short Circuit.................................................................... 52
Failure code [879EMC] Ventilating Damper Abnormality ............................................................................ 54
Failure code [879FMC] Air Mix Damper Abnormality.................................................................................. 55
Failure code [879GKX] Refrigerant Abnormality ......................................................................................... 56
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate).... 58
Troubleshooting for compressor and refrigerant system (Air is not cooled)................................................ 60
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ................................ 63
Troubleshooting for FRESH/RECIRC air changeover................................................................................. 65
Troubleshooting with gauge pressure ......................................................................................................... 67
Connection of service tool........................................................................................................................... 69
Precautions for disconnecting and connecting air conditioner piping ......................................................... 71
Handling of compressor oil.......................................................................................................................... 73
Desiccant replacement procedure .............................................................................................................. 75
80-100 2 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Precautions for refrigerant SEN06151-00
Precautions for refrigerant
k Collect the refrigerant (Air conditioner gas:

R134a) from air conditioner circuit before
disconnecting air conditioner hose to re-
place air conditioner unit, condenser, air
conditioner compressor or receiver drier and
so on.
a Ask a qualified person for collecting, adding and
filling operations of the refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmo-
sphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches
your skin, you may suffer from frostbite. Put
on protective eyeglasses, gloves and work-
ing cloth with long sleeves while collecting
the refrigerant or filling the air conditioner
circuit with the refrigerant.
PC200, 200LC, 220, 220LC-8M0 80-100 3

100 Air conditioner
SEN06151-00 Air conditioner component
Air conditioner component
80-100 4 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Air conditioner component SEN06151-00
1. Compressor Specifications
2. Condenser Refrigerant R134a
3. Modulator * Refrigerant refilling level (g) 725 ± 50
4. Hot water piping
5. Hot water return piping A. Front vent
6. Refrigerant piping B. Rear vent
7. Dual pressure switch C. Foot vent
8. Sight glass D. Defroster air vent
9. Air conditioner controller E. Recirculation air inlet
10. Air conditioner unit F. Fresh air inlet
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
*: Receiver drier and condenser are integrated on this product. The existing receiver drier unit is called "mod-
ulator" here.
PC200, 200LC, 220, 220LC-8M0 80-100 5

100 Air conditioner
SEN06151-00 Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle

Cycle Compression Condensation Expansion Evaporation
(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator cab In operator cab
Location Engine compartment Front of radiator (Built in air conditioner (Built in air conditioner
unit) unit)
Circulates refrigerant
gas and increases its Lowers temperature and Evaporates refrigerant to
Condenses refrigerant
temperature and pres- pressure of refrigerant liq- absorb heat from air
to discharge heat
sure so that it can be uid and gas for easy evap- around evaporator, and
Function absorbed in evaporator.
liquefied easily in con- oration with throttle. cool the air.
(condensation of refrig-
denser. Controls flow rate, too. (Evaporation of refriger-
erant)
(Compression of (Throttle of refrigerant) ant)
refrigerant)
Gas o Gas Gas o Liquid
Liquid o Liquid and gas Liquid and gas o Gas
State of refriger-
ant Adiabatic compres- Cnstant pressure
Adiabatic expansion Cnstant pressure change
sion change
80-100 6 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Outline of refrigeration cycle SEN06151-00
Outline of refrigeration cycle

The refrigeration cycle is comprised of 4 cycles. The refrigerant is circulated while repeatedly vaporizing and
liquefying.
1. Compression (Compressor) The expansion valve controls the refrigerant

The compressor sucks in the refrigerant that has feed rate so that the optimum quantity of liquid
been vaporized in the evaporator and refrigerant is supplied to the evaporator.
compresses it into a state where it can be easily
liquefied at the ambient temperature. (*1) Throttle action
The gaseous refrigerant sucked into the If there is a narrow section in the passage
compressor cylinder is compressed to a temper- through which liquid is flowing at a constant rate,
ature and pressure at which it can be easily a resistance to the flow will be generated.
liquefied when cooled to the ambient tempera- The liquid expands when it passes through the
ture. narrow section and rushes into the passage
where the sectional area is larger, and conse-
2. Condensation (Condenser) quently, its pressure and temperature are
The condenser cools and liquefies the high pres- reduced.
sure and high-temperature gaseous refrigerant No heat is transferred from or to the outside
sent from the compressor. during the throttle action.
The heat released to the outside from the
condenser is called condensation heat. 4. Evaporation (Evaporator)
The amount of condensation heat is the sum The evaporator evaporates the liquid refrigerant
total of the heat absorbed by the evaporator from (superheated vapor).
the air in the cab and the quantity of the work The refrigerant evaporates, while absorbing an
applied (the value converted into a heat quantity) amount of heat necessary for evaporation (evap-
by compression of the compressor. oration heat) from the air around the cooling fins
The refrigerant liquefied in the condenser is sent (air in the cab).
to the receiver drier, where moisture is removed. After the heat has been removed, the cooled air
In the compression cycle, the gaseous refrig- is sent into the cab by the blower fan, reducing
erant and liquid refrigerant coexist. the temperature inside the cab.
The temperature (condensation temperature) The mist refrigerant that has been sent from the
and the pressure (condensation pressure) at expansion valve coexists with the evaporated
which the gaseous refrigerant is liquefied are refrigerant in the evaporator
proportional to each other. The temperature (evaporation temperature) and
the pressure (evaporation pressure) at which the
Reference: The pressure varies depending on liquid refrigerant is evaporated are proportional
the condensation temperature of the refrigerant. to each other.
The compressor sucks in the evaporated refrig-
3. Expansion (Expansion valve) erant in order to keep the pressure level in the
The expansion valve reduces the liquid refrig- evaporator as low as possible so that the liquid
erant pressure to a level where liquid refrigerant refrigerant can be evaporated at a much lower
can be easily evaporated by the throttle action temperature.
(*1).
The action of reducing the liquid refrigerant pres- Relationship between refrigerant and defective
sure to a level where it can be easily evaporated air conditioning
before it is sent to the evaporator is called q The refrigerant circulates in the refrigeration cir-
expansion. cuit while repeating the refrigeration cycle to ex-
The expansion valve, which reduces the refrig- pel the heat from inside the cab.
erant pressure, also adjusts the refrigerant flow q If there is an insufficient quantity of refrigerant,
rate simultaneously. all of it will be evaporated while it is passing
The quantity of the liquid refrigerant that can be through the evaporator. This causes evaporator
evaporated in the evaporator depends on the efficiency to deteriorate, which will result in de-
amount of heat (refrigeration load) to be fective air conditioning.
removed under the specific evaporation temper-
ature (evaporation pressure).
PC200, 200LC, 220, 220LC-8M0 80-100 7

100 Air conditioner
SEN06151-00 Outline of refrigeration cycle
q If there is excessive refrigerant, not all of it will be

evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the
compressor to compress the liquid and may
damage the components.
q If water gets into the refrigeration circuit, it will
freeze at a small hole in the expansion valve,
lower the refrigerant flow, and may result in de-
fective air conditioning.
80-100 8 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Air conditioner unit SEN06151-00

a This air conditioner unit is auto temperature control type.
PC200, 200LC, 220, 220LC-8M0 80-100 9

100 Air conditioner
SEN06151-00 Air conditioner unit
A: Refrigerant inlet (from condenser) *: See "Parts and connectors layout" for details re-
B: Refrigerant outlet (to compressor) garding the compressor clutch relay.
C: Hot water inlet
D: Hot water outlet Air flow adjustment
E: Recirculation air hole q Whenever an air flow control switch is operated
F: Fresh air hole on the machine monitor, air flow setting data is
G: Front air vents sent to the air conditioner controller. The air con-
H: Rear air vents ditioner controller controls blower motor (4) us-
J: Foot level air vents ing power transistor (13) in order to adjust the air
K: Defroster vents flow.
1. Evaporator Vent (mode) changeover

2. Heater core q Whenever a vent switch is operated on the ma-
3. Expansion valve chine monitor, mode data is sent to the air con-
4. Blower fan, blower motor ditioner controller. The air conditioner controller
5. Air mix servomotor controls mode changeover servomotor (7) to ad-
6. Air mix door just the opening angle of mode changeover
7. Vent (mode) changeover servomotor doors (8) to (10) and thus perform vent change-
8. Rear door over.
9. Foot door
10. Defroster door FRESH/RECIRC air changeover
11. FRESH/RECIRC air changeover servomotor q Whenever a FRESH/RECIRC air changeover
12. FRESH/RECIRC air changeover servomotor switch is operated on the machine monitor,
13.Power transistor FRESH/RECIRC air changeover setting data is
14. Evaporator temperature sensor sent to the air conditioner controller. The air con-
15. Inner sensor (inside air temperature sensor) ditioner controller controls FRESH/RECIRC air
changeover servomotor (11) to open and close
Outline FRESH/RECIRC air changeover door (12).
q The air conditioner unit consists of the evapora-
tor (1) and heater core (2), and is used to cool Automatic air conditioner
down or warm up the air in the cab. q Inside air temperature sensor (15) detects the in-
ternal temperature based on changes in resis-
Temperature control tance. The air conditioner controller detects the
q Whenever a temperature control switch is oper- internal temperature by converting the changes
ated on the machine monitor, temperature set- in the resistance of inside air temperature sensor
ting data is sent to the air conditioner controller, (15) into voltage changes.
which is located behind the operator seat. The The air conditioner controller checks the voltage
air conditioner controller controls the air mix ser- of inside air temperature sensor (15) and
vomotor (5) and changes the angle of the air mix controls the internal temperature so that it
door (6) in order to adjust the temperature. matches the setting made on the machine
monitor.
Over-cooling (Freezing) prevention Data from the sunlight sensor and the outside air
q Evaporator temperature sensor (14) varies its temperature sensor is also taken into consider-
electrical resistance according to temperature. ation when adjusting the internal temperature.
q The air conditioner controller detects the temper-
ature of the evaporator (1) by converting the a The door is the same as the damper.
changes in the resistance of the evaporator tem-
perature sensor (14) into voltage changes.
q The air conditioner controller performs control to
prevent freezing of the evaporator (1) by operat-
ing the compressor clutch relay (*) to stop the
compressor.
80-100 10 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Changeover pattern of the vent (mode) changeover door

Rear door (8) Foot door (9) Defroster door (10)
Opening and Opening and Opening and
Angle Angle Angle
closing door closing door closing door
Front Close 0 Close 0 Close 0
Front and rear Open 25 Close 0 Close 0
Front, rear and
Air vent Open 25 Open 35 Close 0
foot
mode
Foot Open 25 Open 53 Close 0
Foot and defroster Open 25 Open 23 Open 38
Defroster Open 25 Open 0 Open 38
Selection pattern of air mix door (6)

Set temperature Opening and closing door Angle
Max. Cool Close 0
Max. Hot Open 80
PC200, 200LC, 220, 220LC-8M0 80-100 11

100 Air conditioner
Functions of major components q When the door (damper) reaches the position
a For details of the numbers in the following sen- specified by each switch, the air conditioner con-
tence, see "Air conditioner unit". troller stops the supply of current to the servomo-
Evaporator tor, then the corresponding door stops.
q Evaporator (1) is cooled by the low-pressure, q When the potential difference fails to reach a
low-temperature refrigerant gas being sent from predefined voltage for control of the servomotor,
expansion valve (3). the air conditioner controller notifies the machine
q Air from blower motor (4) is cooled and dehumid- monitor of an abnormality. [879EMC] or
ified when passing through the fins of the evap- [879FMC] is displayed in the "Electrical System"
orator (1). (electrical systems abnormality record) screen in
service mode of the machine monitor.
Heater core a FRESH/RECIRC air changeover servo motor
q Heater core (2) is warmed by the hot water (en- does not feature a variable resistance, and
gine coolant) being sent from the engine. therefore, does not have a self-diagnosis
q Air from blower motor (4) is warmed when pass- function.
ing through the fins of the heater core (2). a When attempting to operate a servomotor during
inspecting, do not supply power directly between
Evaporator temperature sensor servomotor terminals (6) and (7).
q Evaporator temperature sensor (14) is installed
on evaporator (1) with the holder. Its resistance
changes in response to the temperature change
of the evaporator (1).
q The air conditioner controller determines the
evaporator temperature from the voltage value
of the evaporator temperature sensor (14) and
turns the compressor on/off to prevent freeze of
the evaporator (1).
Servomotors
a Servomotors are used to adjust the temperature

(air mix) and to perform vent (mode) change-
over.
q Whenever a switch on the machine monitor is
operated, the air conditioner controller delivers
power to the servomotor by raising the voltage
between terminals (6) and (7) to 24 V. (The rota-
tion direction changes based on the supply po-
larity.)
q The servomotor contains a variable resistance,
and its resistance value changes as the motor
turns.
q The air conditioner controller delivers voltage at
5 V to the variable resistance and detects motor
rotation angle based on the potential difference.
80-100 12 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Expansion valve
A: When evaporator outlet temperature is high Structure

B: When evaporator outlet temperature is low q Box-type expansion valve (1) consists of needle
C: From receiver drier (high-pressure refrigerant) valve (1a), spring (1b), etc.
D: To compressor (low-pressure refrigerant) q Refrigerant gas (2) is sealed in the diaphragm
chamber (hatched area) outside diaphragm
1. Expansion valve (1a-1) of needle valve (1a).
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas
3. Evaporator
Outline
q The expansion valve converts high-pressure
and high-temperature liquid refrigerant from the
receiver drier to low-pressure, low-temperature
misty refrigerant through the throttle action.
q It controls the flow rate of refrigerant by changing
the level of throttling depending on the tempera-
ture in the cab.
q The temperature of the air blown out of the air
vent is adjusted depending on the volume of re-
frigerant circulating in the evaporator (3).
PC200, 200LC, 220, 220LC-8M0 80-100 13

100 Air conditioner
Operation Dual pressure switch

q Thermoprobe (1a-2) senses the refrigerant tem- a The dual pressure switch is mounted on the air
perature after it passes through the evaporator conditioner hose under the floor.
(3). q The dual pressure switch turns "OFF" when the
q After the refrigerant passes through evaporator refrigerant circuit pressure becomes abnormally
(3), its temperature is transferred to the refriger- low or abnormally high.
ant gas (2) in the diaphragm chamber (hatched q When the dual pressure switch turns "OFF", the
area) through the thermoprobe (1a-2). air conditioner controller turns the compressor
q The pressure of the refrigerant gas (2) sealed in clutch relay "OFF". As a result, the compressor's
the diaphragm chamber (hatched area) changes magnet clutch is released and air conditioner
in response to the temperature change of the components are protected.
thermoprobe (1a-2), which therefore changes
the force (Fg) pushing the needle valve (1a). Function
q The opening level of the needle valve (1a) is de-
termined based on the balance between the re-
action force exerted by the spring (1b) in a
rightward direction, and the force (Fg) of the re-
frigerant gas (2) pushing the needle valve (1a)
through the diaphragm (1a-1) in a leftward direc-
tion.
q The refrigerant flow rate flowing from the receiv-
er drier to evaporator (3) is determined based on
the opening level of needle valve (1a).
When evaporator (3) outlet temperature is high:

[When not cooled yet: Condition (A) in the fig-
ure]
q The pressure of the refrigerant gas (2) in the di-
a LA or lower: Abnormally low pressure
aphragm chamber is high and the volume is in- a HA or higher: Abnormally high pressure
creased.
q The force (Fg) of the refrigerant gas (2) pushing
LA: 0.20 MPa {2 kg/cm2}
the needle valve (1a) is increased, and the nee- LB: 0.02 MPa {0.2 kg/cm2}
dle valve (1a) moves leftward. HA: 3.14 MPa {32 kg/cm2}
q As a result, the opening level of the needle valve
HB: 0.59 MPa {6 kg/cm2}
(1a) is increased and the refrigerant flow rate to
the evaporator (3) is increased to improve cool-
ing capacity.
When evaporator (3) outlet temperature is low:

[When cooled already: Condition (B) in the fig-
ure]
q The pressure of the refrigerant gas (2) in the di-
aphragm chamber is low and the volume is de-
creased.
q The force (Fg) of the refrigerant gas (2) pushing
the needle valve (1a) is reduced, and the needle
valve (1a) is moved rightward by the spring force
(1b).
q The opening level of the needle valve (1a) is re-
duced and the refrigerant flow rate to the evapo-
rator (3) is reduced to lower the cooling capacity.
80-100 14 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Air conditioner controller SEN06151-00
Air conditioner controller
a See "System Diagrams" for details regarding in-

put/output signals.
PC200, 200LC, 220, 220LC-8M0 80-100 15

100 Air conditioner
SEN06151-00 Compressor
Compressor
A: Refrigerant inlet (from air conditioner unit) Function

B: Refrigerant outlet (to condenser) q The compressor circulates the refrigerant and
compresses the gaseous refrigerant from the
1. Pulley evaporator into a misty refrigerant at high pres-
2. Magnetic clutch sure and high temperature so that it will be easily
3. Relief valve regenerated (liquefied) at the normal tempera-
ture.
q Calling into account of the evaporator tempera-
ture and refrigerant pressure, the air conditioner
controller activates magnetic clutch (2) built in
the compressor.
q When the magnetic clutch is engaged, the power
of the engine rotates the compressor shaft along
with pulley (1) to drive the compressor.
Specifications
Number of cylinder – Bore x
Stroke 10 - 32 x 20.8
(mm)
Piston capacity
157.3
(cc/rev)
Allowable maximum speed
6,000
(rpm)
Denso: ND-OIL8 (For
Compressor oil
R134a)
Compressor oil refill capacity
180
(cc)
80-100 16 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Condenser and Modulator SEN06151-00
Condenser and Modulator
A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to air conditioner unit)
1. Condenser
2. Modulator
Function Function
q Condenser (1) q Modulator (2)
It cools and liquefies the high-pressure, a This has desiccant in it. See "Desiccant replace-
high-temperature misty refrigerant from the ment procedure".
compressor. It is used to store liquefied high-pressure,
a If the fin is crushed or is clogged with dust, heat high-temperature misty refrigerant from the
exchange efficiency is reduced and complete liq- condenser. It is capable of completely liquefying
uefaction of refrigerant becomes impossible. As the refrigerant even when bubbles are contained
a result, pressure in refrigerant circulation circuit in the refrigerant due to the condenser condition
is increased, applying extra load to the engine or in heat dissipation.
reducing cooling effect. Take extreme care not It eliminates foreign substances in the circulation
to crush or damage the fins when handling them line and moisuture in the refrigerant by use of the
or checking them in daily inspection. built-in filter and desiccant.
Specification Specification
Fin pitch (mm) 4.0 Weight of desiccating 290
Height x Width x Thickness agent (g)
421 x 540 x 16
(mm)
Weight (kg) 3.2
PC200, 200LC, 220, 220LC-8M0 80-100 17

100 Air conditioner
SEN06151-00 Sensor
Sensor
Sunlight sensor Outside air temperature sensor
1. Connector 1. Connector
2. Sensor 2. Sensor
Outline Outline
q The sunlight sensor is mounted on top of the ma- q The outside (air) temperature sensor is installed
chine monitor. on the bracket in the cooling unit. (See "Parts
q It detects the strength of incident sunlight and and connectors layout".)
sends signals to the air conditioner controller. q The outside air temperature sensor has feature
q When performing automatic air conditioning, the of change in resistance by temperature change,
air conditioner controller controls the blower mo- therefore, can detect the ambient temperature.
tor and the air mix servomotor with the data of q The air conditioner controller detects the ambi-
the sunlight sensor in order to adjust the temper- ent temperature by converting the changes in
ature and air flow. the resistance of the outside air temperature
sensor into voltage changes.
Output characteristics q When performing automatic air conditioning, the
air conditioner controller controls the blower mo-
tor and the air mix servomotor with the data of
the outside (air) temperature sensor in order to
adjust the temperature and air flow.
80-100 18 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Sensor SEN06151-00
PC200, 200LC, 220, 220LC-8M0 80-100 19

100 Air conditioner
SEN06151-00 Procedure for testing and troubleshooting
Procedure for testing and troubleshooting

The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air condi-
tioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air condi-
tioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic testing and troubleshooting sequence
80-100 20 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Procedure for testing and troubleshooting SEN06151-00
*1: By error display or abnormal display on "Electrical Systems" screen on the machine monitor.
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding
with the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant
or no refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.
S: Sight glass condition

R: Receiver drier internal condition
LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for discon-
necting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
PC200, 200LC, 220, 220LC-8M0 80-100 21

100 Air conditioner
SEN06151-00 Circuit diagram and arrangement of connector pins
Circuit diagram and arrangement of connector pins
80-100 22 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Circuit diagram and arrangement of connector pins SEN06151-00
a Diffuser servomotor means vent (mode) changeover servomotor.

a SERVOMOTOR OF INSIDE/OUTSIDE AIR means FRESH/RECIRC air changeover servomotor.
a Frost sensor means evaporator temperature sensor.
PC200, 200LC, 220, 220LC-8M0 80-100 23

100 Air conditioner
SEN06151-00 System diagram
System diagram
a This air conditioner unit is auto temperature control type.
80-100 24 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
System diagram SEN06151-00
Input and output signals of the air conditioner q Operation of air conditioner controller
controller 1. Performing CAN communication with the
Controller connector: AMP 025 - 32PM machine monitor, the air conditioner controller
Wiring harness connector: ACECU (AMP025 - controls the air conditioner unit by inputting
32PF) switches associated with air conditioning.
AMP025 - 32PF 2. The air conditioner controller controls three
Input/ servomotors located inside the air conditioner
Pin Out- unit in order to adjust the temperature (airmix),
Symbol Signal name perform vent (mode) changeover, and perform
No. put
signal FRESH/RECIRC air changeover.
1 +Bback Backup power supply Input 3. The air conditioner controller controls the
2 – (*1) – ON/OFF condition of the compressor clutch
3 SS Sunlight sensor Input relay (i.e., a switch for activating the
4 THOUT Outside air temperature sensor Input compressor).
Evaporator temperature sen- 4. The air conditioner controller controls the air flow
5 THF Input
sor volume using the power transistor.
6 THI Inside air temperature sensor Input a The power transistor has an overcurrent pre-
Servomotor potentiometer vention fuse in it.
7 POT5 V Output
power supply (5 V)
5. The air conditioner controller detects the evapo-
8 BWFB Blower feedback signal Input
rator temperature using the evaporator tempera-
9 PTRB Power transistor control signal Output
Input/o
ture sensor.
10 CAN_H CAN communication signal (H) 6. In order to prevent freezing of the evaporator,
utput
Input/o the air conditioner controller controls the
11 CAN_L CAN communication signal (L) compressor by turning the compressor clutch
utput
12 – (*1) – relay ON and OFF.
Fresh/recirculated air servomo- a When the dual pressure switch detects a
13 MRFA Output
tor terminal A pressure abnormality (i.e., turns OFF), the air
Fresh/recirculated air servomo- conditioner controller turns the compressor
14 MRFB Output
tor terminal B clutch relay OFF, and therefore, the com-
15 MAMA Air mix servomotor terminal A Output pressor stops operating.
16 MAMB Air mix servomotor terminal B Output
7. When performing automatic air conditioning, the
17 +24 V 24 V power supply Input
air conditioner controller controls the inside (air)
18 – (*1) –
temperature to the set temperature and adjust
Air mix servomotor potentiom-
19 SAM Input the air flow according to the data from the
eter signal
Vent (mode) changeover ser- sunlight sensor, the outside air temperature
20 SVI Input sensor, and the inside air temperature sensor.
vomotor potentiometer signal
PRESS 8. The air conditioner controller has the self-diag-
21 Dual pressure switch Input
SW nosis function. If any abnormality is detected, the
22 – (*1) – controller notifies it to the machine monitor by
23 – (*1) – the CAN communication. Then, failure code
24 – (*1) – [879***] is displayed on the "Electrical Systems"
25 GNDS Sensor GND Input screen of the electrical system on the machine
26 GND GND Input monitor.
27 – (*1) –
28 – (*1) –
29 RLCC Compressor clutch relay Output
30 – (*1) –
Vent (mode) changeover ser-
31 MV1A Output
vomotor terminal A
Vent (mode) changeover ser-
32 MV1B Output
vomotor terminal B
*1: Never connect these pins. Malfunctions or fail-
ures may occur.
PC200, 200LC, 220, 220LC-8M0 80-100 25

100 Air conditioner
SEN06151-00 Parts and connectors layout
Parts and connectors layout
q Three fuses related to the air conditioner are in a Note the connector numbers and installed posi-
the fuse box at the right rear of the operator's tions before disconnecting wiring and hoses.
seat.
q The air conditioner unit is mounted inside the
rear cover of at the rear cover of the operator's
seat.
k Park the machine on a level surface, swing
the upper structure by 90 degrees, lower the
work equipment to the ground so that it is
stable, and stop the engine.
k Turn the battery disconnect switch to the
"OFF" position and pull out the key.
Reference
Connector No. Remarks Location
item
AC01 Intermediate connector Right rear of cab 2.
AC02 Intermediate connector Right rear of cab 2.
AC03 Air conditioner compressor Engine 7.
ACECU Engine controller Rear of cab 2.
CM01* Machine monitor Front of cab 5.
CM02 Machine monitor Front of cab 5.
F01 Fuse box Right rear of cab 1.
Dual pressure switch
P17 Under cab 6.
aSwing upper structure 90 deg.
P18 Outside air temperature sensor Cooling unit 8.
P31 Sunlight sensor Machine monitor 4.
R21 Relay Rear of cab 2.
[2] Power transistor Air conditioner unit 3.
FRESH/RECIRC air changeover
[5]* Air conditioner unit 3.
servomotor
[6]* Inside air temperature sensor Air conditioner unit 3.
Evaporator temperature sensor
[7]* Air conditioner unit 3.
(frost sensor)
*: Connectors that are not involved in the troubleshooting
80-100 26 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Parts and connectors layout SEN06151-00
1. Each fuse in fuse box F01: 2. Air conditioner controller: *1

Open the cover of the fuse box at the right rear q AC01: Intermediate connector
of the operator's cab. q AC02: Intermediate connector
q No. 11 (20 A): Fuse for the power supply of q ACECU: Air conditioner controller connector
blower (fan) and the air conditioner compres- q R21: Connector for air conditioner compres-
sor sor electromagnetic clutch relay
q No. 10 (5 A): Fuse for the primary power sup-
ply of the air conditioner unit, air conditioner
controller, and the air conditioner compres-
sor electromagnetic clutch relay
q No. 18 (5 A): Fuse for the power supply
(backup power supply) of the air conditioner
controller
3. Air conditioner unit

a Connectors [2], [5], [6], and [7] do not have
labels.
a Rear side of air conditioner unit (Only con-
nector [2] can be removed while installed on
machine)
[2]: Power transistor (*2) connector
[5]: FRESH/RECIRC air changeover servo-
motor connector
[6]: Inner sensor (inside air temperature
sensor) connector
[7]: Evaporator temperature sensor
connector
*2: Power transistor
PC200, 200LC, 220, 220LC-8M0 80-100 27

100 Air conditioner
SEN06151-00 Parts and connectors layout
4. Sunlight sensor 7. Air conditioner compressor

P31: Sunlight sensor connector a Open the engine hood.
q AC03: Air conditioner compressor connector
5. Machine monitor
q CM01 to CM04: Machine monitor connector 8. Outside air temperature sensor
a Connector CM03: (Not used) P18: Outside (air) temperature sensor connector
a Connector CM04: (For camera connection)
6. Dual pressure switch

a Rotate cab undercover 90 degrees and re-
move it.
q P17: Dual pressure switch connector
80-100 28 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Testing air leakage (duct) SEN06151-00
Testing air leakage (duct)
k Park the machine on a level surface, lower 8. Remove drink box (8) (five bolts).
the work equipment to the ground so that it is a Disconnect the hose under drink box (8).
stable, and stop the engine. 9. Remove magazine box (9) (three bolts).
k Turn the battery disconnect switch to the a Be careful about connectors (10) and (11)
"OFF" position and pull out the key. behind magazine box (9). (for machines
a Note connector numbers and installed positions equipped with 12 V power socket).
when disconnecting wiring and hoses. q Connector (10): 12 V power socket interme-
diate harness (M13A)
Testing q Connector (11): 12 V power socket interme-
1. Lift front window assembly (1) to the ceiling and diate harness (M13B)
lock it. 10. Pull up cover (12) (three bolts) to remove.
a Check that the front window is securely a The connectors and wiring harnesses at the
locked. rear must not be caught.
2. Remove front lower window (2).
3. Remove floor mat (3).
4. Remove cover (4) first, and remove cover (5).
6. Remove cap (7-1).

a Disconnect the sunlight sensor connector
from the rear of cover (7).
PC200, 200LC, 220, 220LC-8M0 80-100 29

100 Air conditioner
SEN06151-00 Testing air leakage (duct)
11. Remove cover (13) (seven bolts).

a Be careful about connector (14) behind box
(13).
12. Check whether any of the following ducts or pins

are disconnected.
q Front duct (15)
q Defroster duct (16)
q Rear duct (17)
q Fresh air inlet duct (18) and pin (19)
80-100 30 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Testing with self-diagnosis function SEN06151-00
Testing with self-diagnosis function
Testing outline How to enter air conditioner "Electrical Sys-

The air conditioner controller performs various tems" screen in service mode of the machine
self-diagnosis such as sunlight sensor, inside air monitor.
temperature sensor, outside air temperature sen-
sor, evaporator temperature sensor, temperature q Overview of machine monitor operating pro-
control system, vent (mode) changeover system, cedure
and refrigerant pressure with the pressure switch. If Normal screen
an error is detected on the temperature control sys- O While pressing number key (4), press (1), (2),
tem, vent (mode) changeover system, or refrigerant, and (3) in this order.
the machine monitor momentarily shows "L01" (2) Service menu (Mode)
and then "Air conditioner system state monitor" is O Press [F3] twice. Press [F6].
displayed continuously. 03 Abnormality record
a The machine monitor displays the system state O Press [F3] once. Press [F6].
monitor "!" when an error occurs in the commu- 02 Electrical Systems screen
nication between the machine monitor and the
air conditioner controller. q Detailed description of machine monitor op-
erating procedure
1. On the normal operation screen, while pressing
number key (4), press (1), (2), and (3) in this
order.
a Even if the cause of a detected problem is re-

stored to normal, the self-diagnosis failure condi-
tion will not automatically be reset. To reset the
failure condition, the starter switch must be set to
OFF.
a On the "Electrical System" screen in the service
mode of the machine monitor, the system per-
forms self-diagnosis for various sensors. If a
problem is detected, failure information is dis-
played.
a FRESH/RECIRC air changeover servomotor is
not checked with self-diagnosis function.
PC200, 200LC, 220, 220LC-8M0 80-100 31

100 Air conditioner
SEN06151-00 Testing with self-diagnosis function
2. On the service menu screen, press [F3] (R) a For details, see the failure code list related to air
twice, and then select "03 Abnormality Record". conditioner
Failure Failure (Displayed on
Remarks
3. Press [F6] ( ) to confirm. code screen)
A/C Inner Sensor Open
879AKA
Circuit
*
A/C Inner Sensor Short
879AKB
Circuit
A/C Outer Sensor Open
879BKA
Circuit
A/C Outer Sensor Short
879BKB
Circuit
Ventilating Sensor Open
879CKA
Circuit
*
Ventilating Sensor Short
879CKB
Circuit
Sunlight Sensor Open or
879DKZ
Short Circuit
Ventilation Dumper
879EMC *
Abnormality
4. On the Abnormality Record screen, press [F3] Air Mix Dumper Abnor-
879FMC *
(R) once, and then select "02 Electrical mality
Systems". 879GKX Refrigerant Abnormality
A/C Model Selection See Chapter
DAZ9KQ
5. Press [F6] ( ) to confirm. Abnormality 40, "Trouble-
shooting by fail-
CAN2 Discon (Aircon
DAZQKR ure code"
ECU)
**
*: Troubleshooting cannot be performed while the
controller is mounted on the machine since the con-
nector cannot be checked.
**: Troubleshooting is not performed by the air con-
ditioner unit but by the machine monitor.
a The air conditioner inner sensor means the in-

side (air) temperature sensor.
a The air conditioner outer sensor means the out-
side (air) temperature sensor.
a The ventilating sensor means the evaporator
temperature sensor (frost sensor).
a The ventilation damper means the vent (mode)
changeover damper (door).
a The air mix damper means the temperature ad-
justment (air mix) damper (door).
80-100 32 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Testing vent (mode) changeover SEN06151-00
Testing vent (mode) changeover
k Park the machine on a level surface, lower

the work equipment to the ground so that it is
a Note connector numbers and installed positions
when disconnecting wiring and hoses.
Testing
1. Remove drink box (1) (five bolts).
a Disconnect the hose under drink box (1).
2. Remove magazine box (2) (three bolts).
a Be careful about connectors (3) and (4) be-
hind magazine box (2). (for machines
equipped with 12 V power socket). 5. Remove ducts (8) and (9).
q Connector (3): 12 V power socket intermedi-
ate harness (M13A)
q Connector (4): 12 V power socket intermedi-
ate harness (M13B)
3. Remove cover (5) (three bolts).
6. Turn the battery disconnect switch to the "ON"

position.
7. Start the engine and turn the air conditioner
power "ON".
8. Operate the vent changeover switch on the
machine monitor.
9. Check the opening/closing operation of rear
door (11) and defroster door (12) of air condi-
tioner unit (10).
4. Remove cover (6) (seven bolts).

a Be careful about connector (7) behind box
(6).
10. After finishing the inspection, turn the starting

switch to the OFF position.
PC200, 200LC, 220, 220LC-8M0 80-100 33

100 Air conditioner
SEN06151-00 Testing FRESH/RECIRC air changeover
Testing FRESH/RECIRC air

changeover

q FRESH/RECIRC air is selected by changing the
door (damper) angle in the air conditioner unit
with the servo motor. Check the opening and
closing operations of the door (damper) visually.
a The system does not have self-diagnosis func-
tion for FRESH/RECIRC air changeover servo
motor.
Testing
1. Open outside air filter cover (1) and remove
outside air filter (2).
2. Start the engine and turn the air conditioner

power "ON".
3. Operate the FRESH/RECIRC air selector switch
on the machine monitor.
4. Check the opening/closing operation of
FRESH/RECIRC air changeover rear door (3)
through the fresh air inlet on the left side of the
cab.
5. After finishing the inspection, turn the starting

switch to the OFF position.
80-100 34 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Testing sunlight sensor SEN06151-00
Testing sunlight sensor

a Note connector numbers and installed positions
when disconnecting wiring and hoses.
Testing
q If [879DKZ] "Sunlight sensor disconnection or
short circuit" is displayed by the self-diagnosis
("Air-conditioning System" screen on the ma-
chine monitor), test sunlight sensor connector
P31.
q To reset the self-diagnosis system (detection of
abnormality), the starting switch must be turned
OFF.
a If the sunlight sensor is measured with the resis-
tance range of the tester, the sunlight sensor
may be destroyed, so do not measure with the
resistance range of the tester.
1. Remove the machine monitor cover. For details,

see "Testing air leakage (duct)", Steps 6 and 7.
2. Check connector P31 at the rear of the sunlight
sensor. (Check whether the connector is coming
off.)
3. Disconnect connector P31, remove the sunlight
sensor, and measure the voltage between the
terminals on the sensor side using a circuit tester
in voltage range.
q Approximate voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoors
PC200, 200LC, 220, 220LC-8M0 80-100 35

100 Air conditioner
SEN06151-00 Testing (dual) pressure switch for refrigerant
Testing (dual) pressure switch for refrigerant
k Park the machine on a level surface, lower 4. Ensure that the resistance between the
the work equipment to the ground so that it is switch-side terminals from connector P17 is
stable, and stop the engine. shorted (ON). (If not shorted (OFF), the dual
k Turn the battery disconnect switch to the pressure switch will detect a refrigerant pressure
"OFF" position and pull out the key. abnormality.)
a Note connector numbers and installed positions a When the dual pressure switch is OFF, con-
when disconnecting wiring and hoses. nect a pressure gauge to the high-pressure
side of the air conditioner compressor and
Testing check the refrigerant pressure. See "Connec-
q If [879GKX] "Refrigerant Abnormality" is dis- tion of service tool" and "Troubleshooting
played by the self-diagnosis (on "03 Electrical with gauge pressure."
System" screen of "Abnormality Record" in the a If the refrigerant pressure is normal, the dual
machine monitor), test the dual pressure switch pressure switch is defective.
connector P17.
q To reset the self-diagnosis system (detection of q (Dual) pressure switch
abnormality), the starting switch must be turned
OFF.
q The dual pressure switch is ON when the refrig-
erant pressure is normal, and OFF when it is ab-
normal.
a As the refrigerant pressure will drop when the
ambient temperature is below 0 °C, there is a
possibility that the dual pressure switch is
OFF. In such a case, the dual pressure
switch is actually normal (i.e., not defective).
1. Swing by 90 deg..
2. Remove the cab undercover.
3. Disconnect the dual pressure switch connector
P17.
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
k When replacing the dual pressure switch, re-
frigerant must be collected in advance.
a If resistance between the switch-side terminals
from connector P17 is shorted (ON), perform
"Troubleshooting for compressor and refrigerant
system".
80-100 36 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Testing relays SEN06151-00
Testing relays
a If the air conditioner compressor is normal (air is q Checking relay unit

cooled), omit this test since the relays are nor- a Since no T-adapter is available, it is impossible
mal. to check the relay while the voltage is applied to
q Compressor clutch relay R21: the coil actually.
Turns the air conditioner compressor (clutch)
ON/OFF. Compressor clutch relay (RLCC), connector (R21)
a See Step 2 on "Parts and connectors layout". 1) The coil resistance between terminals (1)
and (2) is approximately 300 to 500 z.
Testing 2) While voltage (DC 20 to 30 V) is not applied
1. Check contact R21 of connector (for disconnec- between terminals (1) (+) and (2), terminals
tion). (3) and (4) are connected.
2. Turn the starting switch ON (do not start the 3) While voltage (DC 20 to 30 V) is applied
engine), turn the main power of the air condi- between terminals (1) (+) and (2), terminals
tioner ON, and turn the air conditioner switch. If (3) and (5) are connected.
the compressor relay is normal, it is turned ON.
Check whether its clicks.
a The air conditioner controller will not turn on
the compressor clutch relay in the following
cases.
1) When the evaporator temperature is below
3 °C (depending on the input voltage from
the evaporator temperature sensor).
2) When the dual pressure switch detects
abnormality (it is turned OFF).
PC200, 200LC, 220, 220LC-8M0 80-100 37

100 Air conditioner
SEN06151-00 Troubleshooting chart 1
Troubleshooting chart 1
The numbers in the boxes are the item numbers in the troubleshooting table.
1. Cooling trouble
80-100 38 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting chart 1 SEN06151-00
2. Heating trouble
PC200, 200LC, 220, 220LC-8M0 80-100 39

100 Air conditioner
SEN06151-00 Troubleshooting chart 2
Troubleshooting chart 2
1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
Probable cause Check method Remedy
Repair broken parts
Wire breakage or defective con- Check the connector for disconnection.
and connect cor-
nection See "Parts and connectors layout".
rectly
Operate the fan switches in order and check the fan speed. See
Defective blower fan motor Replace
"Air conditioner unit".
Defective power transistor (PTR) Operate the fan switches in order and check the fan speed. Replace
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Check duct joints.
Air leakage through duct joints Repair
See "Testing air leakage (duct)".
Remove obstruc-
Obstruction at evaporator inlet Check evaporator for stain and obstruction
tion and clean
Evaporator is frozen.
Defective evaporator tempera-
Sensor fixing clip inspection, sensor contaminated
ture sensor, defective contact of
Inspect the air conditioner hose around the dual pressure Repair or replace
evaporator temperature sensor,
switch for frost.
defective expansion valve*
(when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
3. Pressure abnormality (high-pressure/low-pressure) during cooling.

Repair leaking part,
then charge with
Insufficient refrigerant
proper quantity of
Check the refrigerant volume through sight glass.
refrigerant again
Specifically, perform checking with the gauge manifold con-
Collect refrigerant,
nected.
then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2} See Troubleshoot-
Judgment by pressure at
High pressure: Approx. 1.5 - 1.7 MPa {15 – 17 kg/cm2} ing with gauge pres-
inlet/outlet of compressor
Temperature in operator's cab: 30 to 35 °C, Engine speed: sure
Approx. 1,500 rpm
80-100 40 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting chart 2 SEN06151-00
4. During cooling, the compressor will not operate smoothly, or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled part Probable cause Check method Remedy
Deflection of belt is large.
Compressor See "Testing and adjusting of Air conditioner
Slack of belt Adjust tension
belt compressor belt tension" in the "Testing and
adjusting" in Chapter 30 of the shop manual.
Trouble in compressor Slip of clutch Repair or replace
Compressor Insufficient compressor oil See "Handling com-
Heating of compressor
Seizing on compressor pressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with multimeter (10 - 20 z) Replace
Magnet clutch Check ground cable and joints.
Wire breakage or defective con-
See "Troubleshooting for compressor and Repair
nection of ground wire
refrigerant system".
Relay Defective compressor clutch relay See "Testing relays" Replace
Refrigerant Low/high pressure (Operation of See "Troubleshooting
See "Troubleshooting with gauge pressure".
pressure pressure switch) with gauge pressure".
See "Troubleshooting for compressor and
Dual pres- refrigerant system".
Defective dual pressure switch Replace
sure switch See "Testing refrigerant (dual) pressure
switch".
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Check the duct joints by referring to "Testing air leakage
Air leakage through duct joints Repair
(duct)."
Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling

Low engine coolant tempera-
Warm up engine, and then check engine coolant temperature Find out cause
ture
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of engine Check engine coolant piping for clogging.
Bleed air and correct
coolant (Hose, pipe and core)
The connection of IN and OUT
Check the destination of heater hoses Correct
heater hoses is in reverse.
7. Fan speed abnormalities during cooling

See "Testing and adjusting of fan belt and alternator belt ten-
Fan speed is low sion" in "Testing and adjusting" in Chapter 30 of the shop man- Correct
ual.
8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be con-
Select manual mode and change temperature setting.
trolled
Vent (mode) changeover is not Common to cooling and
See "Testing vent (mode) changeover".
possible. heating
FRESH/RECIRC air cannot be
See "Testing FRESH/RECIRC air changeover".
changed over
Excessive compressor oil See "Handling of compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole
PC200, 200LC, 220, 220LC-8M0 80-100 41

100 Air conditioner

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.
Failure Problem on machine
Related information Information related to detected failure or troubleshooting

<Information described>
q Procedure
1 q Measuring location
Probable causes of
failure a "Between A and B" means "Measure voltage or resistance and so on between A and B".
(Perform trouble- q Standard value in normal condition to judge probable causes
shooting according q Remarks required for judgement
to these.)
2 <Notes on troubleshooting>
(1) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) tester leads as shown below unless
otherwise specified.
q Connect the plus (+) lead to a pin or harness indicated in the front.
q Connect the minus (–) lead to a pin or harness indicated in the rear.
3 - defective (2) Example of troubleshooting by inspection of multiple items
a Normal in 1 but abnormal in 2
At this time “- defective” shown at left is applied
a If a wiring harness is burnt, replace it.

<Defective wiring harness>
q Open circuit
Connection of connector is defective or wiring harness is broken.
q Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
q Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit
accidentally.
q Short circuit
An independent wire in the harness abnormally comes into contact with one of another wire. (Defective
insulation in connector or others)

This is the excerpted circuit diagram related to failure
q Indicates connector No., and pin No.
q See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for connector location
q The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb:
Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
q N.C.: Normally closed (Normally ON)
q [1], [2],··· are numbers of unlabeled connectors.
q Arrow (↔): Roughly indicates their mounting place on the machine.
80-100 42 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code list related to air conditioner SEN06151-00
Failure code list related to air conditioner

Compo-
Failure (Displayed on Category
Failure code nent in Action level Remarks
screen) of record
charge
A/C Inner Sensor Open Electrical Troubleshooting cannot be
879AKA MON –
Circuit system performed while the controller
is mounted on the machine
A/C Inner Sensor Short Electrical
879AKB MON – since the connector cannot be
Circuit system
checked.
A/C Outer Sensor Open Electrical
879BKA MON –
Circuit system
A/C Outer Sensor Short Electrical
879BKB MON –
Circuit system
Ventilating Sensor Open Electrical Troubleshooting cannot be
879CKA MON –
Circuit system performed while the controller
Ventilating Sensor Short Electrical
879CKB MON – since the connector cannot be
Circuit system
checked.
Sunlight Sensor Open or Electrical
879DKZ MON –
Short Circuit system
Ventilation Dumper Abnor- Electrical Troubleshooting cannot be
879EMC MON L01
mality system performed while the controller
Air Mix Dumper Abnormal- Electrical
879FMC MON L01 since the connector cannot be
ity system
checked.
Electrical
879GKX Refrigerant Abnormality MON L01
system
A/C Model Selection Electrical
DAZ9KQ MON –
Abnormality system See Chapter 40, "Trouble-
CAN2 Discon (Aircon Electrical shooting by failure code"
DAZQKR MON L01
ECU) system
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The ventilation damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes

q Troubleshooting for power supply system (Air conditioner does not operate)
q Troubleshooting for compressor and refrigerant system (Air is not cooled)
q Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
q Troubleshooting for FRESH/RECIRC air changeover
PC200, 200LC, 220, 220LC-8M0 80-100 43

100 Air conditioner
SEN06151-00 Failure code [879AKA] A/C Inner sensor Open Circuit
Failure code [879AKA] A/C Inner sensor Open Circuit
Action
Failure code Open circuit in air conditioner inside air temperature sensor
level Failure
(Machine monitor system)
– 879AKA
Detail of failure q Air conditioner controller detected open circuit in inside (air) temperature sensor.
q The air conditioner controller sends information about the inside (air) temperature sensor open cir-
Action of con-
cuit to the machine monitor via CAN communication.
troller
q Stops the air conditioner if it is in automatic mode.
q The air conditioner does not operate in automatic mode because of an open circuit in the air con-
Problem on
ditioner inside air temperature sensor.
machine
(The air conditioner can be operated in manual mode)
q Method of reproducing failure code: Turn starting switch to ON position.
q Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnor-
Related infor-
mality record) screen in the service mode of the machine monitor.
mation
q Troubleshooting cannot be performed since the connector portion of the air conditioner inside (air)
temperature sensor cannot be checked while the controller is installed on the machine.

If no failures are found by the above checks, the air conditioner controller may
1 Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be per-
formed.)
If no failures are found by the above checks, the air conditioner unit may be
2 Defective air conditioner unit defective. (Since this is an internal defect, troubleshooting cannot be per-
formed.)
80-100 44 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879AKB] A/C Inner sensor Short Circuit SEN06151-00
Failure code [879AKB] A/C Inner sensor Short Circuit
Action
Failure code Short circuit in air conditioner inside air temperature sensor
level Failure
– 879AKB
Detail of failure q Air conditioner controller detected short circuit in inside (air) temperature sensor.
q The air conditioner controller sends information about the inside (air) temperature sensor short cir-
Action of con-
cuit to the machine monitor via CAN communication.
troller
q Stops the air conditioner if it is in automatic mode.
q The air conditioner does not operate in automatic mode because of a short circuit in the air condi-
Problem on
tioner inside air temperature sensor.
machine
(The air conditioner can be operated in manual mode)
Related infor-
mation
q Troubleshooting cannot be performed since the connector portion of the air conditioner inside (air)
temperature sensor cannot be checked while the controller is installed on the machine.

formed.)
formed.)
PC200, 200LC, 220, 220LC-8M0 80-100 45

100 Air conditioner
SEN06151-00 Failure code [879BKA] A/C Outer sensor Open Circuit
Failure code [879BKA] A/C Outer sensor Open Circuit

Action
Failure code Open circuit in air conditioner outside air temperature sensor
level Failure
– 879BKA
Detail of failure q An open circuit is detected in the air conditioner controller outside air temperature sensor
q The air conditioner controller sends information about the outside air temperature sensor open cir-
Action of con- cuit to the machine monitor via CAN communication.
troller q Continues control of air conditioner in automatic mode, ignoring data of outside air temperature
sensor.
q Since there is an open circuit in the air conditioner outside temperature sensor, outside tempera-
Problem on
ture is not counted in automatic mode.
machine
(does not have any effect to the air conditioner in manual mode)
q For connectors etc., see "Parts and connectors layout".
Related infor-
q Since connector ACECU of the air conditioner controller has small pins and does not have a
mation
T-adapter, perform troubleshooting by using the intermediate connector (Although the intermediate
connector does not have a T-adapter either, it does have large pins).
q To replace the air conditioner harness between air conditioner controller connector ACECU and
intermediate controller, the air conditioner unit must be replaced.

1. Turn starting switch to OFF position.
Defective outside air temperature 2. Disconnect connector P18.
1
sensor Approx.
Resistance Between P18 (male) (1) and (2) 25 °C
1.7 kz
2. Disconnect connector AC01.
Open or short circuit in wiring har-
2 a Same as above, if resistance is normal.
ness
Approx.
Resistance Between AC01 (female) (7) and (8) 25 °C
1.7 kz
a If no failure is found by check for cause 2, this check is not required.
Open circuit in wiring harness
2. Disconnect connectors P18 and AC01.
3 (wire breakage or defective con-
tact of connector) Between AC01 (female) (7) and P18 (female) (1) Max. 1 z
Resistance
Between AC01 (female) (8) and P18 (female) (2) Max. 1 z
formed.)
5 Defective air conditioner unit If no failure is found by above checks, air conditioner unit may be defective.
80-100 46 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879BKA] A/C Outer sensor Open Circuit SEN06151-00
Circuit diagram related to air conditioner outside air temperature sensor
PC200, 200LC, 220, 220LC-8M0 80-100 47

100 Air conditioner
SEN06151-00 Failure code [879BKB] A/C Outer sensor Short Circuit
Failure code [879BKB] A/C Outer sensor Short Circuit

Action
Failure code Short circuit in air conditioner outside air temperature sensor
level Failure
– 879BKB
Detail of failure q Air conditioner controller detected short circuit in outside air temperature sensor.
q The air conditioner controller sends information about the outside air temperature sensor short cir-
Action of con- cuit to the machine monitor via CAN communication.
troller q Continues control of air conditioner in automatic mode, ignoring data of outside air temperature
sensor.
q Since there is a short circuit in the air conditioner outside air temperature sensor, outside temper-
Problem on
ature is not counted in automatic mode.
machine
(does not have any effect to the air conditioner in manual mode)
Related infor-
mation

Defective outside air temperature 2. Disconnect connector P18.
1
sensor Approx.
Resistance Between P18 (male) (1) and (2) 25 °C
1.7 kz
Open or short circuit in wiring har-
2 a Same as above, if resistance is normal.
ness
Approx.
Resistance Between AC01 (female) (7) and (8) 25 °C
1.7 kz
a If no failure is found by check for cause 2, this check is not required.
3 Short circuit in wiring harness 2. Disconnect connectors P18 and AC01.
Between AC01 (female) (7) and (8), or between
Resistance Min. 1 Mz
P18 (female) (1) and (2)
Ground fault in wiring harness 2. Disconnect connectors P18 and AC01.
4
(contact with ground circuit) Between ground and AC01 (female) (8) or P18
(female) (1)
formed.)
80-100 48 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879BKB] A/C Outer sensor Short Circuit SEN06151-00
Circuit diagram related to air conditioner outside air temperature sensor
PC200, 200LC, 220, 220LC-8M0 80-100 49

100 Air conditioner
SEN06151-00 Failure code [879CKA] Ventilating sensor Open Circuit
Failure code [879CKA] Ventilating sensor Open Circuit
Action
Failure code Open circuit in temperature (frost) sensor
level Failure
– 879CKA
Detail of failure q Air conditioner controller detected open circuit in evaporator temperature (frost) sensor.
q The air conditioner controller sends information about the evaporator temperature (frost) sensor
Action of con-
open circuit to the machine monitor via CAN communication.
troller
q Stops the air conditioner.
Problem on q The air conditioner does not operate due to an open circuit in the evaporator temperature (frost)
machine sensor.
Related infor-
mation
q Troubleshooting cannot be performed since the connector portion of the evaporator temperature
(frost) sensor cannot be checked while the air conditioner unit is installed on the machine.

formed.)
formed.)
80-100 50 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879CKB] Ventilating sensor Short Circuit SEN06151-00
Failure code [879CKB] Ventilating sensor Short Circuit
Action
Failure code Evaporator temperature (frost) sensor short circuit
level Failure
– 879CKB
Detail of failure q Air conditioner controller detected short circuit in evaporator temperature (frost) sensor.
q The air conditioner controller sends information about the evaporator temperature (frost) sensor
Action of con-
short circuit to the machine monitor via CAN communication.
troller
q Stops the air conditioner.
Problem on q The air conditioner does not operate due to a short circuit in the evaporator temperature (frost) sen-
machine sor.
Related infor-
mation
q Troubleshooting cannot be performed since the connector portion of the evaporator temperature
(frost) sensor cannot be checked while the air conditioner unit is installed on the machine.

formed.)
formed.)
PC200, 200LC, 220, 220LC-8M0 80-100 51

100 Air conditioner
SEN06151-00 Failure code [879DKZ] Sunlight sensor Open or Short Circuit
Failure code [879DKZ] Sunlight sensor Open or Short Circuit

Action
Failure code Sunlight sensor open or short circuit
level Failure
– 879DKZ
Detail of failure q Air conditioner controller detected open or short circuit in sunlight sensor.
q The air conditioner controller sends information about the sunlight sensor open or short circuit to
Action of con-
the machine monitor via CAN communication.
troller
q Continues control of air conditioner in automatic mode, ignoring data of sunlight sensor.
Problem on q Since there is an open or short circuit in the air conditioner sunlight sensor, sunlight strength is not
machine counted in automatic mode. (does not have any effect to the air conditioner in manual mode).
Related infor-
mation

1. See "Testing sunlight sensor".
Direct sun- Approx.
Between sunlight sensor terminals
light 0.55 V
1 Defective sunlight sensor Approx.
Voltage Between sunlight sensor terminals Cloudy
0.45 V
Approx. 0.4
Between sunlight sensor terminals Indoors
V
a See "Testing sunlight sensor".
2 (wire breakage or defective con-
tact of connector) Between P31 (female) (1) and AC01 (female) (10) Max. 1 z
Resistance
Between P31 (female) (2) and AC01 (female) (9) Max. 1 z
formed.)
80-100 52 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879DKZ] Sunlight sensor Open or Short Circuit SEN06151-00
Circuit diagram related to sunlight sensor
PC200, 200LC, 220, 220LC-8M0 80-100 53

100 Air conditioner
SEN06151-00 Failure code [879EMC] Ventilating Damper Abnormality
Failure code [879EMC] Ventilating Damper Abnormality
Action
Failure code Abnormality in vent (mode) changeover damper servomotor
level Failure
L01 879EMC
q Air conditioner controller judged from potentiometer voltage of servomotor that vent (mode)
Detail of failure
changeover damper servomotor is not operating.
Action of con- q The air conditioner controller sends information about the abnormality in vent (mode) changeover
troller damper to the machine monitor via CAN communication.
Problem on
q Vent (mode) cannot be changed but air conditioner can be operated.
machine
Related infor-
mation
q Troubleshooting cannot be performed since the connector portion of vent (mode) changeover
damper servomotor cannot be checked while the air conditioner unit is installed on the machine.

formed.)
formed.)
80-100 54 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879FMC] Air Mix Damper Abnormality SEN06151-00
Failure code [879FMC] Air Mix Damper Abnormality
Action Abnormality in air mix (temperature regulation) damper servomo-

Failure code
level Failure tor
L01 879FMC (Machine monitor system)
q The air conditioner controller judged from the potentiometer voltage of the servomotor that the air
Detail of failure
mix (temperature regulation) damper servomotor is not operating.
Action of con- q The air conditioner controller sends information about the air mix damper abnormality to the ma-
troller chine monitor via CAN communication.
Problem on
q The air conditioner does not operate since temperature cannot be regulated.
machine
Related infor-
mation
q Troubleshooting cannot be performed since the connector portion of the air mix damper servomo-
tor cannot be checked while the air conditioner unit is installed on the machine.

formed.)
formed.)
PC200, 200LC, 220, 220LC-8M0 80-100 55

100 Air conditioner
SEN06151-00 Failure code [879GKX] Refrigerant Abnormality
Failure code [879GKX] Refrigerant Abnormality

Action
Failure code Refrigerant (dual) pressure switch abnormality
level Failure
L01 879GKX
Detail of failure q Air conditioner controller detected that dual pressure switch was OFF (abnormal).
q The air conditioner controller sends information about the refrigerant pressure abnormality to the
machine monitor via CAN communication.
Action of con-
q The air conditioner controller turns OFF compressor clutch relay, since refrigerant pressure is ab-
troller
normal.
(air conditioner compressor stops)
Problem on
q Air conditioner (cooling) does not work
machine
Related infor-
mation

1. See "Testing (dual) pressure switch for refrigerant".
k
Defective refrigerant (dual) pres-
1 When replacing the dual pressure switch, be sure to collect refriger-
sure switch
ant in advance. See "Caution for refrigerant"
2. Disconnect connectors AC01 and AC05.
2 (wire breakage or defective con- Between P17 (female) (1) and AC01 (female) (6) Max. 1 z
tact of connector) Resistance Between P17 (female) (2) and ground
Max. 1 z
a Looseness and rust of T06
formed.)
80-100 56 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879GKX] Refrigerant Abnormality SEN06151-00
Circuit diagram related to refrigerant (dual) pressure switch
PC200, 200LC, 220, 220LC-8M0 80-100 57

100 Air conditioner
SEN06151-00 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Troubleshooting for power supply and CAN communication system (Air

conditioner does not operate)
Failure Air conditioner does not operate due to power supply system failure.
Problem on q[DAZQKR] is displayed on the operation screen of machine monitor.
machine qNo air blows out (Blower motor does not rotate).
q If failure code [DAZQKR] is displayed on machine monitor, perform this troubleshooting first.
a The machine monitor, engine controller, pump controller, and air conditioner controller are connect-
ed via CAN communication.
q "DAZQKR" is displayed on operation screen of machine monitor in the following cases. In this sec-
tion, 1) and 2) of the following are explained.
1) The air conditioner controller is receiving no power.
2) The air conditioner controller is malfunctioning.
3) No communication is possible between the air conditioner controller and the machine monitor.
a For 3), see failure code [DAZQKR].
q Turn starting switch to ON position and check whether failure code [DAZQKR] is displayed on ma-
chine monitor and whether CAN communication condition is abnormal. This type of abnormal sta-
Related infor- tus indicates that CAN communication cannot be performed between the air conditioner controller
mation above the air conditioner unit and the machine monitor.
q Referring to "Parts and connectors layout", check fuse No. 10 (5 A) in fuse box F01 for breakage.
q Ground cable of air conditioner is connected in machine wiring harness together with electrical
equipment of machine.
q For each connector, see "Parts and connectors layout".
q In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for compres-
sor and refrigerant system."
q To replace the air conditioner harness between air conditioner controller connector ACECU and in-
termediate controller, the air conditioner unit must be replaced.

2. Turn battery disconnect switch to OFF position.
1 Defective wiring harness (ground) 3. Disconnect connector AC02.
Between (1) (black) on harness side of connector
Resistance Max. 1 z
AC02 and chassis ground
2 Blown fuse 2. Referring to "Parts and connectors layout", check fuse No. 10 (5 A) in fuse
box F01 for breakage.
a If fuse described in related information is blown, replace it.
3 Defective wiring harness
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between connector AC02 (female) (4) (red) and (1)
Voltage 20 to 30 V
(black)
a If the fuse is blown again during the above test, carry out the following pro-
cedure.
Ground fault in wiring harness 2. Turn battery disconnect switch to OFF position.
4 3. Disconnect connector AC02.
(contact with ground circuit)
4. Remove fuse No. 10 of fuse box F01.
Between ground and connector AC02 (female) (4)
(red) or F01-10
80-100 58 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) SEN06151-00

5 Open circuit in wiring harness
4. Remove fuse No. 10 of fuse box F01.
Between connector AC02 (female) (4) (red) and
F01-10
6 Defective air conditioner controller Replace air conditioner controller.
8 Defective machine monitor If no failure is found by above checks, machine monitor is defective.
Circuit diagram related to power supply
PC200, 200LC, 220, 220LC-8M0 80-100 59

100 Air conditioner
SEN06151-00 Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for compressor and refrigerant system (Air is not

cooled)
Failure Air is not cooled due to compressor or refrigerant system failure.
qWhen engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air is
Problem on
not cooled as displayed on screen.
machine
q Air conditioner compressor does not operate.
q Referring to "Testing with self-diagnosis function", display "Electrical Systems" screen on the machine
monitor and check to see if the refrigerant pressure is abnormal by checking whether failure code
[879GKX] is displayed. If the refrigerant pressure is abnormal, the compressor will not be turned ON
and air will not subsequently not be cooled.
a Abnormal refrigerant pressure indicates that "Signal ((21) of connector ACECU) from the dual pres-
sure switch is not grounded".
q In certain cases, the air conditioner will not turn on at 3 °C or lower (normal).
Related infor-
q If no air comes out, see "Troubleshooting for blower motor system".
mation
q For each connector and fuse, see "Parts and connectors layout".
a A T-adapter is provided only for the connector AC03.
q Since connector ACECU of the air conditioner controller has small pins and does not have a T-adapt-
er, perform troubleshooting by using the intermediate connector (Although the intermediate connector
does not have a T-adapter either, it does have large pins).
q To replace the air conditioner harness between air conditioner controller connector ACECU and inter-
mediate controller, the air conditioner unit must be replaced.

a Perform this check when failure code [879GKX] is displayed on "Electrical Sys-
tems" screen of machine monitor.
See failure code [879GKX].
Defective dual pressure a In certain cases, the dual pressure switch may be operating normally and set to
1
switch system OFF, therefore, if abnormality is indicated (i.e., switch OFF), attach a pressure
gauge to the air conditioner compressor and check the refrigerant pressure. (See
"Troubleshooting with gauge pressure.")
k Before replacing pressure switch, collect refrigerant.
2. Disconnect the connector AC03 from the air conditioner compressor and connect a
Defective air conditioner a Ensure connection of air conditioner compressor ground cable (E).
2
compressor (See "Parts and connectors layout".)
Between connector AC03 (male) (1) and the chassis
Resistance Approx. 15 z
ground (i.e., air conditioner compressor coil resistance)
q Referring to "Testing relays", check sound when compressor clutch relay is turned
ON.
Click is heard -----------------------------------------A
a When A above is abnormal and B below is abnormal and C is normal (if the relay is
normal), go to cause 4.
2. Disconnect connector R21.
Defective compressor 3. Use a wire to short-circuit (3) (white) and (5) (red on yellow) of connector R21
3 clutch relay (does not turn (wiring harness side) . (This forces the compressor to operate without using the
ON) relay.)
Air is cooled -----------------------------------------B
2. Disconnect connector R21 and troubleshoot in that condition.
Between (1) and (2) of connector R21 300 –
Resistance C
(male) (i.e., coil resistance) 500 z
80-100 60 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting for compressor and refrigerant system (Air is not cooled) SEN06151-00

2. Disconnect connector R21 and carryout troubleshooting without turning starting
switch ON.
a Ensure that test result for cause 2 (air conditioner compressor is normal) is normal.
Between connector R21 (female) (5) and F01-11
Open circuit in wiring har- Max. 1 z
4 (Dual pressure switch is turned ON)
ness
Between connector R21 (female) (3) and chassis
Resistance ground Approx. 15 z
(Air conditioner compressor coil resistance)
Between F01-10 and AC01 (female) (4)
300 – 500 z
a Relay coil resistance
a If the fuse is not blown, skip troubleshooting.
Ground fault in wiring har- 1. Turn starting switch to OFF position.
5 ness 2. Disconnect connectors AC03 and R21, and connect a T-adapter to the female side
(contact with ground circuit) of AC03.
Resistance Between AC03 (female) (1) and chassis ground Min. 1 Mz
2. Disconnect connectors AC01, AC02, and R21.
Short circuit in wiring har- a Ensure that test result for cause 2 is normal.
6
ness
Between wiring harness side (2) of connector R21 and
AC02 (female) (2), (3), and (4)
2. Disconnect connector R21.
Defective air conditioner 3. Turn starting switch to ON position.
7 4. Display the air conditioner operation screen on the machine monitor and press the
controller
A/C switch.
Voltage Between connector R21 (female) (2) and ground Max. 1 V
Defective machine monitor 2. Display the air conditioner operation screen on the machine monitor.
8
(defective switch)
Press A/C switch. "A/C ON" is displayed
Defective air conditioner
9 If no failure is found by above checks, air conditioner unit may be defective.
unit
PC200, 200LC, 220, 220LC-8M0 80-100 61

100 Air conditioner
SEN06151-00 Troubleshooting for compressor and refrigerant system (Air is not cooled)
Circuit diagram related to compressor and refrigerant system
80-100 62 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) SEN06151-00
Troubleshooting for blower motor system (No air comes out or air flow
is abnormal)
Failure No air comes out or air flow is abnormal due to blower motor system failure.
q LCD of machine monitor on air conditioner operation screen lights up normally but air does not come
Problem on
out.
machine
q Air flow does not match fan switch setting on air conditioner operation screen.
q This failure is not checked with self-diagnosis function.
q In cases where the blown-air volume begins to behave in an unpredictable manner after a certain
while during cooling, freezing of the evaporator is a likely cause.
This may be due to the followings.
1) Defective compressor clutch relay (i.e., stuck in ON position) (see item 3-A from "Trouble-
shooting for compressor and refrigerant system")
2) Detachment of the evaporator temperature sensor's mounting holder (Replace the air condi-
tioner unit)
3) Incorrect adjustment of expansion valve (Replace air conditioner unit)
Related infor- q If air comes out, fuse and motor are normal, and also wiring harness is normal.
mation q For each connector and power transistor, see "Parts and connectors layout".
a The power transistor is on the rear side of the air conditioner unit.
q If air comes out but its flow is abnormal in heating mode, replace power transistor. (When no air
comes out, the power transistor may also be defective.)
a The blower motor cannot be replaced unless the air conditioner unit is removed once.
q To replace the air conditioner harness between air conditioner controller connector ACECU and in-
termediate controller, the air conditioner unit must be replaced.
Defective fuse No. 11 in
1 If fuse is blown, circuit probably has ground fault.
fuse box F01
2. Replace power transistor.
2 Defective power transistor
a If air comes out and air flow can be adjusted, the original power transistor is de-
fective.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness 2. Disconnect connector AC02.
3 3. Remove fuse No. 11 of fuse box F01.
(wire breakage or defective
contact of connector) Resistance Between AC02 (female) (2) and F01-11 Max. 1 z
Ground fault in wiring har- 2. Disconnect connectors AC02 and R21.
4 ness 3. Remove fuse No. 11 of F01.
Resistance Between AC02 (female) (2) or F01-11 and ground Max. 1 z
Defective air conditioner If no failures are found by the above checks, the air conditioner controller may be
5
controller defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Defective air conditioner
6 If no failure is found by above checks, air conditioner unit may be defective.
unit
PC200, 200LC, 220, 220LC-8M0 80-100 63

100 Air conditioner
SEN06151-00 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Circuit diagram related to blower motor system
80-100 64 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting for FRESH/RECIRC air changeover SEN06151-00
Troubleshooting for FRESH/RECIRC air changeover

Failure FRESH/RECIRC air cannot be changed over
qWhen FRESH/RECIRC air selector switch of machine monitor is operated, recirculated or fresh air
Problem on
does not change over.
machine
(FRESH/RECIRC air changeover door (damper) does not rotate)
q FRESH/RECIRC air changeover is not checked with self-diagnosis function.
q Referring to "Testing FRESH/RECIRC air changeover", operate the FRESH/RECIRC air selector
switch and check operation of FRESH/RECIRC air changeover door (damper).
q For each connector, see "Parts and connectors layout".
a The T-adapter is not prepared for the connector.
Related infor-
mation
q Troubleshooting cannot be performed since the connector portion of the servomotor cannot be
checked while it is installed on machine.

Defective fuse No. 18 in fuse box
1 If fuse is blown, circuit probably has ground fault.
F01
a Connector [5] installed on machine cannot be disconnected since it is on
the rear side of the air conditioner unit.
Open circuit in wiring harness 1. Turn starting switch to OFF position.
2 (wire breakage or defective con- 2. Disconnect connector AC02.
tact of connector) 3. Remove fuse No. 18 of F01.
Resistance Between F01-18 and AC02 (female) (3) Max. 1 z
Ground fault in wiring harness
3 3. Remove fuse No. 18 of F01.
Between F01-18 and ground, or between AC02
Resistance Max. 1 z
(female) (3) and ground
formed.)
formed.)
Defective machine monitor 2. Display the air conditioner operation screen on the machine monitor.
6
(defective switch) Display of Recirc/Fresh
Press FRESH/RECIRC air selector switch.
changes.
PC200, 200LC, 220, 220LC-8M0 80-100 65

100 Air conditioner
SEN06151-00 Troubleshooting for FRESH/RECIRC air changeover
Circuit diagram related to FRESH/RECIRC air changeover
80-100 66 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting with gauge pressure SEN06151-00
Troubleshooting with gauge pressure

Perform troubleshooting according to the high and <Measurement condition for pressure>
low gauge pressures of the cooling cycle. For de- Item Condition value
tails, see "Connection of service tool". Ambient temperature 25 to 50 °C
a The gauge pressure varies largely with the Engine speed 1,500 rpm
weather condition and operating condition of the Air conditioner switch ON
Fan switch HI
machine. Check the gauge pressure under the
Set temperature Full cool
pressure measurement conditions.
q High-pressure line pressure is too high: Above q Dual pressure switch
approx. 2.5 MPa {25 kg/cm2} a The swiths is normally "ON", and becomes
q High-pressure line pressure is too low: Below
"OFF" when it detects abnormal pressure for
compressor operation.
approx. 1 MPa {10 kg/cm2}
q Low-pressure line pressure is too high: Above
approx. 0.3 MPa {3 kg/cm2}

q Low-pressure line pressure is too low: Below ap-
prox. 0.05 MPa {0.5 kg/cm2}

a Dual pressure switch turns "OFF" to protect the
air conditioner circuit if the pressure of the
high-pressure or low-pressure line is abnormal.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
PC200, 200LC, 220, 220LC-8M0 80-100 67

100 Air conditioner
SEN06151-00 Troubleshooting with gauge pressure
Indicated gauge
Cause Check method Remedy
pressure
Air conditioner cycle is operating normally.
If there is any trouble (cooling trouble), there is another cause.
Pressure is normal –
High-pressure: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2}
2
Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm }
Collect refrigerant, then
Bubble can be seen through sight glass. *1, fill up with proper quan-
Insufficient refrigerant
*3 tity of refrigerant again
*2
There is a temperature difference between
Replace
Clogging of receiver drier inlet and outlet pipes of receiver drier.
*2
Tank is frosty
Clean or replace
<Both high-pres- Clogging of expansion valve Expansion valve is frosted
*2
sure and low-pres-
Gas leakage at thermoprobe of expan- Replace
sure are too low> Low-pressure gauge reads vacuum
sion valve *2
Repair or replace
Low-pressure gauge Evaporator is frozen
Replace receiver drier
reads vacuum Defective evaporator temperature sensor Flow rate of refrigerant is reduced due to
or defective contact of sensor (coming off freezing.
fill up with proper quan-
of mounting clip) (At Cool Max. and HI speed of fan, later it
tity of refrigerant again
becomes not to cold.)
*2
Piping between receiver drier and com-
pressor is clogged or crushed. Clean or replace
Clogged or crushed piping
If clogged completely, low-pressure gauge *2
reads vacuum
fill up with proper quan-
Filling too much with refrigerant Connect gauge manifold
tity of refrigerant again
*2
Clean, repair fins, or
Dirty condenser, clogging or crushing of repair or replace con-
<Both high-pres- Defective cooling of condenser
fins, or defective rotation of cooling fan denser
sure and low-pres-
*2
sure are too high>
Improper adjustment of expansion valve Replace
Bubble can be seen through sight glass. *3
(Valve is opened too wide) *2
Evacuate and then fill up
with proper quantity of
Air in cycle parts Bubble can be seen through sight glass. *3
refrigerant again
*2
<High-pressure is Clean inside of cycle or
Clogged or crushed piping between com- There is a remarkable temperature differ-
too high and low- replace
pressor and condenser ence across clogged part
pressure is too low> *2
<High-pressure is Both high-pressure and low-pressure are
too low and Defective compressor (Compression balanced while compressor is in operation. Replace
low-pressure is too trouble of compressor) Compressor has seized and is extremely *2
high> hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2:
k When replacing a cooling cycle part, see “Caution about refrigerant” and collect refrigerant. After
replacing it, fill up the air conditioner system with refrigerant again.
*3: Sight glass is on the air conditioner hose near condenser.
80-100 68 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Connection of service tool SEN06151-00
Connection of service tool

Sym- Connect the gauge manifold, hoses and other ser-
Part number Part name
bol vice tools according to the following procedure.
X 799-703-1200 Service tool kit 1. Close high-pressure valve (6) and low-pressure
valve (7) of gauge manifold (1).
a Use the service tool kit for R134a. 2. Connect the red charging hose (2) to the HI side
Service tool kit X of the gauge manifold and the blue charging
(1): Gauge manifold hose (3) to the LO side.
(2): Red high-pressure charging hose (red) 3. Connect quick joints (4) and (5) to each hose.
(3): Blue low pressure charging hose (blue) 4. Connect quick joints (4) and (5) to service valves
(4): Quick joint for HI side (large diameter) (8) and (9) of high- and low-pressure piping
(5): Quick joint for LO side (small diameter) respectively.
(a): As the thread is coarse, care should be taken

with regard to loosening.
PC200, 200LC, 220, 220LC-8M0 80-100 69

100 Air conditioner
SEN06151-00 Connection of service tool
A: From Cab
B: To Condenser
80-100 70 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Precautions for disconnecting and connecting air conditioner piping SEN06151-00
Precautions for disconnecting and connecting air conditioner piping
Precautions for disconnecting Precautions for connecting

k Collect the refrigerant (Air conditioner gas: q Once an O-ring is used, it is deformed and dete-
R134a) from air conditioner circuit before riorated. Accordingly, do not reuse it. When re-
disconnecting air conditioner hose to removing it, use a soft tool (such as a toothpick) so
place air conditioner unit, condenser air con- that the piping will not be damaged.
ditioner compressor or receiver drier and so q When connecting piping check that there is no
on. damage and deterioration.
a Ask a qualified person for collecting, adding and q Apply compressor oil (ND-OIL8) for R134a to its
filling operation of refrigerant (R134a). O-rings. (See item 4 of "Handling compressor
a Never release the refrigerant (R134a) to the at- oil")
mosphere. a Do not apply oil to the threads of a bolt, nut or
k If refrigerant gas (R134a) gets in your eyes, union, however.
you may lose your sight. And if it touches q Push in each pipe to the stopper and tighten the
your skin, you may suffer from frostbite. Put bolt or nut fully with your fingers.
on protective eyeglasses, gloves and work- q Be sure to use two wrenches to tighten each nut.
ing cloth with long sleeves while collecting Use one wrench to fix and tighten the nut with
the refrigerant or filling the air conditioner the other wrench to the specified torque (Use a
circuit with the refrigerant. torque wrench for tightening).
q When loosening the air conditioner hose nuts af- a Example of O-ring installation
ter collecting the refrigerant, be sure to use 2 q There are O-rings at all the connections of the air
wrenches. Use one wrench to fix and use the conditioner piping.
other one to loosen the nuts.
q Cover the air conditioner piping connections not
to enter dust, water or moisture.
PC200, 200LC, 220, 220LC-8M0 80-100 71

100 Air conditioner
SEN06151-00 Precautions for disconnecting and connecting air conditioner piping
Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque Nm {kgm}
M6 x 1.0 8 – 12 {0.8 – 1.2}
1. Engine
2. Compressor
3. Condenser
4. Modulator
5. Air conditioner unit
80-100 72 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Handling of compressor oil SEN06151-00
Handling of compressor oil
1. Compressor oil management (DENSO: Quantity to

ND-OIL8 for R134a) Air conditioner part be added
(cc)
Although compressor oil differs from engine oil in Air conditioner unit, evaporator Approx. 40
that it does not need regular checking or filling, the Condenser (including modulator) Approx. 60
following types of problem can occur if the amount
Modulator (desiccant) only Approx. 20
in the system is too high or too low.
Condition Content Hose (between compressor and cab) Approx. 35
Insufficiency of Lubrication trouble and seizure of com- Hose (between compressor and con-
Approx. 30
oil pressor denser)
Cooling trouble Hose
Approx. 10
Excess of oil (Excessive oil stick to parts and lower (between condenser and cab)
heat exchange performance)
Accordingly, compressor oil must be filled to the
specified level, similarly to refrigerant.
2. Filling compressor oil
k Refrigerant is potentially hazardous to health

and to the environment. Before disconnect-
ing air conditioner hoses, therefore, refriger-
ant should be collected in accordance with
"Precautions for connecting air conditioner
piping."
a If oil for CFC-12 (R-12) is used, lubrication trou-
ble will occur and the compressor may be broken
or seized.
Be sure to use an oil suitable for R134a
(DENSO: ND-OIL8).
a Oil for use with R134a is extremely hygroscopic,
and therefore, the cap must be immediately
closed after use to limit contact with air.
Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow oil for use with R134a to come into
contact with acrylic plastic or polystyrene
surfaces (except a baked finish) as it may
dissolve these plastics.
Check compressor oil in the following cases, and
then add new oil if necessary.
q When much refrigerant is discharged because of
leakage.
q When the compressor is troubled and replaced.
(See 3 below)
q When a cycle parts such as condenser, receiver
drier, evaporator unit, etc. is replaced.
q Quantity of oil to be added when cycle part is re-
placed
PC200, 200LC, 220, 220LC-8M0 80-100 73

100 Air conditioner
SEN06151-00 Handling of compressor oil
3. Replacement of compressor 4. Applying compressor oil to O-rings
q In case of compressor seizure or breakage. Whenever connecting piping or hoses, the com-
Metal chips will circulate through the air condi- pressor oil (ND-OIL8) must be applied to O-rings in
tioner circuit and contaminate the compressor oil order to prevent the leakage of refrigerant.
extremely.
In this case, flush the air conditioner circuit and
replace the compressor and receiver drier.
The compressor oil is removed from the air
conditioner circuit by flushing. Accordingly,
install a new compressor with the oil of the spec-
ified quantity (180 cc) filled in it.
q Other cases
a New compressor contains compressor oil of 180
cc in it.
1) Prepare an oil container and drain oil from
the old compressor.
2) Measure the quantity of the drained oil with a
measuring cylinder, and note the quantity or
mark the level.
3) Drain below-mentioned quantity of oil from

the new compressor.
Quantity to be drained = 180 cc - "Noted
quantity"
Example: If 30 cc was drained from the
removed compressor, the quantity to be
drained from the new compressor would be
150 cc (i.e., 180 - 30 cc).
80-100 74 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Desiccant replacement procedure SEN06151-00
Desiccant replacement procedure

a Prepare desiccant replacement kit Taking out desiccant (D)
(20Y-810-1250). 1. Remove snap ring (SR) from receiver drier (2).
2. Remove cap (C) from receiver drier (2).
Hold boss (B) of cap (C) with pliers etc. to
remove.
a Cap (C) may be hard to remove. When re-
moving it, take care not to damage or deform
the seal or receiver drier (2).
3. Remove filter (F) from receiver drier (2)
4. Take desiccant (D) out of receiver drier (2).
a Removed snap ring (SR), cap (C), filter (F),
desiccant (D) will be replaced with the parts
of the drier (desiccant replacement kit) and
will not be necessary any more.
k When replacing the desiccant, be sure to col-

lect the refrigerant from the air conditioning
cycle. If the desiccant is replaced without
collecting the refrigerant, the refrigerant may
blind you or cap (C) may fly out and injure
you because of the refrigerant pressure in
the cycle.
1. Condenser
2. Receiver drier
a The desiccant is in receiver drier (2).
PC200, 200LC, 220, 220LC-8M0 80-100 75

100 Air conditioner
SEN06151-00 Desiccant replacement procedure
Installing new desiccant (D)

1. Apply ND-OIL 8 to the periphery of O-ring (OR)
of cap (C).
2. Install filter (F) to cap (C).
3. Insert desiccant (D) in receiver drier (2).

4. Install cap (C) with filter (F) to receiver drier (2).
5. Install snap ring (SR) to receiver drier (2).
a Install snap ring (SR) to the groove in receiv-
er drier (2) securely. If it is not installed se-
curely, cap (C) may come off.
80-100 76 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Desiccant replacement procedure SEN06151-00
PC200, 200LC, 220, 220LC-8M0 80-100 77

SEN06151-00
© 2012 KOMATSU
All Rights Reserved
80-100 78
SEN06153-01
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
90 Diagrams and drawings 1

100 Hydraulic diagrams and drawings
Symbols in hydraulic circuit diagram............................................................................................................... 2
Hydraulic circuit diagram................................................................................................................................. 5
PC200, 200LC, 220, 220LC-8M0 90-100 1

SEN06153-01 Symbols in hydraulic circuit diagram
Symbols in hydraulic circuit diagram 1
90-100 2 PC200, 200LC, 220, 220LC-8M0

Symbols in hydraulic circuit diagram SEN06153-01
PC200, 200LC, 220, 220LC-8M0 90-100 3

SEN06153-01 Symbols in hydraulic circuit diagram
90-100 4 PC200, 200LC, 220, 220LC-8M0

Hydraulic circuit diagram
Hydraulic circuit diagram PC200, 200LC, 220, 220LC-8M0
1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN06153-01
PC200, 200LC, 220, 220LC-8M0 5
Hydraulic circuit diagram (Boom RAISE)
Hydraulic circuit diagram (Boom RAISE) PC200, 200LC, 220, 220LC-8M0
1
*
SEN06153-01
PC200, 200LC, 220, 220LC-8M0 7
Hydraulic circuit diagram (Swing Left)
Hydraulic circuit diagram (Swing Left) PC200, 200LC, 220, 220LC-8M0
1
*
SEN06153-01
PC200, 200LC, 220, 220LC-8M0 9
Hydraulic circuit diagram (Boom RAISE+Swing LEFT)
Hydraulic circuit diagram (Boom RAISE+Swing LEFT) PC200, 200LC, 220, 220LC-8M0
1
*
SEN06153-01
PC200, 200LC, 220, 220LC-8M0 11
Symbols in hydraulic circuit diagram SEN06153-01
PC200, 200LC, 220, 220LC-8M0 90-100 13

SEN06153-01
© 2018 KOMATSU
All Rights Reserved
90-100 14
SEN06154-02
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
90 Diagrams and drawings 1

200 Electrical diagrams and drawings
Symbols in electric circuit diagram.................................................................................................................. 2
Electrical circuit diagram ................................................................................................................................. 5
Wiring harness diagram ................................................................................................................................ 15
PC200, 200LC, 220, 220LC-8M0 90-200 1

SEN06154-02 Symbols in electric circuit diagram
Symbols in electric circuit diagram 1
90-200 2 PC200, 200LC, 220, 220LC-8M0

Symbols in electric circuit diagram SEN06154-02
PC200, 200LC, 220, 220LC-8M0 90-200 3

SEN06154-02 Symbols in electric circuit diagram
90-200 4 PC200, 200LC, 220, 220LC-8M0

Electrical circuit diagram (1/5) Electrical circuit diagram
PC200, 200LC, 220, 220LC-8M0
PC200-8M0,PC200LC-8M0, PC220-8M0, PC220LC-8M0
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN06154-02
PC200, 200LC, 220, 220LC-8M0 5
PC200, 200LC, 220, 220LC-8M0
SEN06154-02
PC200, 200LC, 220, 220LC-8M0 7
PC200, 200LC, 220, 220LC-8M0
SEN06154-02
PC200, 200LC, 220, 220LC-8M0 9
PC200, 200LC, 220, 220LC-8M0
SEN06154-02
PC200, 200LC, 220, 220LC-8M0 11
PC200, 200LC, 220, 220LC-8M0
SEN06154-02
PC200, 200LC, 220, 220LC-8M0 13
Wiring harness diagram (1/10) Wiring harness diagram
PC200, 200LC, 220, 220LC-8M0
★ Wiring harness diagram may differ from some sales vehicles.
DB F01-11D F01-1A K01-2 S25-7 S25-1

A DA 5RY
.
3R
.
3R
.
FS 0.85GR
.
0.85GR
.
0.85GR
.
F04-2 DA F01-6B J04-8 N08-9 N08-12

DB 8RY
.
5RY
.
3R
.
FT 0.85B 0.5B 0.85B
. . .
OFF
K01-1 S25-13 H15-6 F01-1 . V23-1 . V05-1 V02-1 J01-1 M14-1 .
FH D03-7 C02-115
FD 0.85W
.
0.85W
.
0.5LR
.
0.85W
. GR 1.25B 0.85B 1.25B 121 FN 120 FL 119 M05-3 113 GRO
.
0.85LR
1V23
GRO
.
0.85BrR
.
0.85GL
.
0.85R
.
0.85RL
.
GRO
.
106
. . . 1.25RY 1.25B 0.85YL
B . . .
. S25-9 . . D01-7 . . .
1 2 3 4 5 6 7 8 9 10
FJ S25-12 S25-6 105 GRO 0.85G GRO GRO 0.85LW GRO GRO GRO 98 11 12 13 14 15 16 17 18 19 20
ON
. 9S25 . . . . . .
FF 1.25B 0.85L 0.85L D03-2 J01-8 D03-1
118 FN 117 FH
. 12S25 6S25 HB 0.5G
.
0.5GL
.
0.5G
.
1.25RY 1.25B
. . V30-1 S25-3 . . . . . .
97 0.85G
1V30
0.85G
3S25
GRO
.
GRO
.
GRO
.
GRO
.
GRO
.
GRO
.
90
FH
FL FJ GR C02-117 R24-1 R23-1 D11-1 D10-1 116 FN 115 GR 114 M05-1
1.25B
.
3B
.
1.25B
.
1.25B
.
HC 0.85Br 0.85Br 0.85Br 0.85Br 1.25RY 1.25B 0.85L V24-1 V19-1 V04-1 V06-1 V25-1 . . .
. . . . . . . 89 0.85RL
1V24
0.85G
1V19
0.85GR
.
0.85BrG
.
0.85RW
.
GRO
.
GRO
.
GRO
.
82
C FG FF FH R24-3 R23-3 F01-19
FJ 1.25B
.
1.25B
.
3B
. HE 2R 2R 3RW CONTROLLER
. . .
CH700䝁䞁䝖䝻䞊䝷 CN-F01
C02-121 F01-2 C02-116 C02-118
FN 1.25RY 3RY 1.25RY 1.25RY
LD
H16-6
0.85W
R07-1
0.5L
F01-3
0.85W
CN-C02(AMP) FUSE BOX VIEWED FROM BACK SIDE
. . . .
. . .
(FUSE) (⿬㠃䛛䜙ぢ䜛)
J04-4 S25-15 S25-10 S25-4
D FP 0.85B
.
0.5B
.
0.85B
.
0.85B
. RELAY FOR CM850(1) RELAY FOR CM850(2)
CM850⏝䝸䝺䞊(1) CM850⏝䝸䝺䞊(2) GD . R12-3 M09-1 J03-11 BJ BW AC02-3 HE CE02-39
20
11 2RL . 1.25LR 0.85G 0.85LR 0.85GR 2RY 0.5RL 3RW *0.85LW
CN-R23 CN-R24 . . . . . . . . . .
2 2
30A
20A
10A
10A
10A
20A
10A
10A
5A
5A
HF HF
0.85B 0.85B
.
5 6 .
5 6 DA . . . . F05-2 . . . J03-6
⿬㠃䛛䜙ぢ䜛 3R .
.
. . . 3RW . . . 0.85LW
HD . HD . . . . . . . . . .
E 2LR . 2LR . VIEWED FROM BACK SIDE
11D 15D 16E 19E 20F
. . . .
HC HE
HC HE
0.85Br 2R 䝠䝳䞊䝈䝪䝑䜽䝇㒊ヲ⣽ 1A 5A 6B 9B 10C
0.85Br 2R
. . . .
DETAIL OF FUSE BOX
DA . . . . DB . . . J03-5
3R . . . . 3R . . . 0.85LW
1 3 1 3 . . . . . . . . . .
10A
30A
10A
10A
10A
10A
10A
20A
10A
5A
1 10
F FD FN LD J03-13 GE R18-3 J03-20 FW BA GC
0.85W 3RY 0.85W 0.85WL 1.25GW 0.85Br 0.85GL 2LR 0.85GY 0.85R
. . . . . . . . . .
HE
RELAY FOR
AUTO PREHEATER
䜸䞊䝖䝥䝸䝠䞊䝍⏝䝸䝺䞊 EMERGENCY OPERATION
CN-R18 SWITCH CONNECTOR
RESISTOR PUMP(PC) 㠀ᖖ᫬సື䝇䜲䝑䝏䝁䝛䜽䝍
H RESISTOR FOR DUMMY
OF HORN RELAY
F01-6 䝺䝆䝇䝍.䝫䞁䝥(PC) CN-S25
3 0.85Br
䝩䞊䞁䝸䝺䞊䝎䝭䞊᢬ᢠ
.
CN-K01(M) (S090)
J02-9
CN-K04(DT) 5 0.85RY
. FD
0.85W 1 FS V11-1 C02-96 FP
BY BS
CE02-40 .
.
CE02-42 . 1 0.85GR 0.85G 0.85G 0.85B 4
*0.85Y *0.85YB . 2S25 3S25 .
1 0.85B 0.85GW 2 . . . FS
. . 0.85GR 2 V11-2 FF FS V12-1 C02-104 FP
I 1 2 . 5 0.85L
5S25
0.85L
6S25
0.85GR
.
0.85G
8S25
0.85G
9S25
0.85B
.
10
V12-2 FF FD J02-2 FP C01-38
11 0.85L 0.85L 0.85W 0.85WR 0.5B 0.5LB 16
11S25 12S25 . . . .
FS
FN
GR HB FP DB FF DA
(TO 6/10)
J WHITE TAPE
FJ ⓑ䝔䞊䝥
FH FD
HC
(TO 2/10)
K
FT
L
LD
HG CE02-49
0.85RB
.
2 *0.85RY
.
2
HC HC
0.85Br 1 0.85Br 1
M . .
2 1 2 1
J05-15 C02-101 J02-11 H15-2 . J04-15 . J05-14 . GR H15-21 HA
. . . CM01-6 R06-3 LD J04-9 . H16-8 J06-8 J03-9 ZG . . J06-14
. . . . J06-13 . . XH XG . 8 0.85BW
.
0.85LW
.
0.85L
.
0.85RB
.
5 8 .
0.85GY
. .
0.85BW
.
5 8 .
0.85B
.
0.5GR
.
0.5GL
.
5 0.5BR 0.5BW 0.5L 0.5BW . 0.5GL 1 0.85RY 0.85YG 0.5W GRO GRO 0.5GW 6
18 .
.
.
.
.
.
.
.
0.5GW
.
.
.
.
.
0.5L
11CK01
0.5W
10CK01
.
.
9 . . . . . . . . . . . .
DIODE DIODE J02-18
0.85LgR
J02-3 J01-4 HG .
.
J03-16 .
.
J02-8 .
.
GS HB HB
. J01-13 FT . ZH FT . .
. . . . . . . . 4 0.85WR 0.85RB 0.85RB 1 4 0.85WL 0.85RY 1 4 0.85YL 0.5G 0.5G 1 5 .
5 0.85RW 0.85B GRO 0.5L 0.5B GRO GRO
7
8 .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
1 䝎䜲䜸䞊䝗䝎䜲䜸䞊䝗 . . . . . . . . . . . .
. . 12 . . . . . .
CN-D10 CN-D11 3
R17-1
3
R07-4
N DIODE DIODE DIODE
0.85RW
.
0.5BW
.
KOMTRAX (M) (M)
䝎䜲䜸䞊䝗䝎䜲䜸䞊䝗䝎䜲䜸䞊䝗
CN-CK01 RELAY FOR STARTER CUT RELAY FOR STARTER CUT
CN-D01 CN-D02 CN-D03 CONNECTOR FOR
(070) (PERSONAL CODE) (PPC LOCK) SERVICE
(SWP) (SWP) (SWP)
䝇䝍䞊䝍䜹䝑䝖䝸䝺䞊䝇䝍䞊䝍䜹䝑䝖䝸䝺䞊䝃䞊䝡䝇䝁䝛䜽䝍
(䝟䞊䝋䝘䝹䝁䞊䝗) (PPC䝻䝑䜽) CN-N08(DT)
O . XE . . . J06-6 J06-5
CN-R07 CN-R06
12 .
.
0.5RW
.
.
.
.
.
.
.
1.25R
.
1.25R
.
6
. XF J03-4 XJ XJ
5 .
.
0.5L
.
0.5LR
.
1.25B
.
1.25B
.
1
KOMTRAX
P CN-CK02
(070)
200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222
SEN06154-02
PC200, 200LC, 220, 220LC-8M0 15
PC200, 200LC, 220, 220LC-8M0
RELAY FOR REAR LIGHT RELAY FOR REAR LIGHT

䝩䞊䞁䝸䝺䞊 ᚋ᪉䝷䜲䝖䝸䝺䞊
A ZG ZH
CN-R08 CN-R10
ZE ZF FG H16-4 H16-2 F01-9 T04 J04-3 J04-5 R12-2 R08-2 J05-9 DG CK02-4 J02-12
ZG ZH GE FW 1 BA 0.85GY
.
0.85GY
.
0.85GY
.
DM 3B
.
1.25BW
.
1.25B
.
GF 0.85B
.
0.85B
.
0.85B
.
XF 1.25L
.
0.5L
.
1.25L
.
3 1.25GW
.
3 1.25LR
. J01-5
0.5GL H09-3 R12-5 H09-1 V19-2 FJ V30-2 R24-5 R23-5 CE03-3 ZG CK01-10 C01-45
CAB LIGHT BB FG HD XG
BZ A15-1 . 5 3 1.25RL 1.25R 1.25R 0.85L 1.25B 0.85B 2LR 2LR *3RW 0.5W 0.5W 0.5W
BF 䜻䝱䝤䝷䜲䝖 5 1.25GW 5 1.25R RELAY FOR CAB LIGHT . . . 2V19 . 2V30 . . . GG 10CK01 45C01
. . . BB F01-13
B CN-L03 J01-6 . J05-6

.
.
1.25R
.
1.25LR
.
䜻䝱䝤䝷䜲䝖䝸䝺䞊 XQ V23-2 BK FH C02-120 V24-2 XQ R24-2 R23-2 CE02-33 ZH CK01-11 C01-64
FG
BS .
.
GF
0.5GL . 0.85B BF 0.85B 0.85B 0.85B FL 1.25B 1.25B 0.85B 0.85B HF 0.85B 0.85B *0.85B XH 0.5L 0.5L 0.5L
(M)
0.85GW
. .
0.85B
. . . . GF CN-R12 . 2V23 . . . 2V24 . . . . HH 11CK01 64C01
0.85B
. H16-1 F01-16 L03-2 C01-79 J03-8 C01-24 C01-43 D10-2 J01-2 D01-1 J04-20 CK02-1 CK02-2
BF 1 2 1 2 BJ 0.85GR 0.85GR 0.85LW FM 0.5LW 0.5LW 0.5LW 0.5LW HG 0.85RB 0.85RB 0.85RB XJ 1.25B 1.25B 1.25B
FL MF . . . . . . . . . . . . .
0.85B 1 2
ⓑ䝔䞊䝥 . H09-2 HH T01 R05-3 R10-3 F01-8 H16-3 H15-22 BP AC01-2 ZA ZG
WHITE TAPE DM BJ
BP 3B
.
0.85B
.
3B
.
FW 1.25LR
.
1.25LR
.
2LR
.
HH 0.85B
.
0.5B
.
0.85B
.
ZE 0.5W
2AC01
*0.5W
AE
0.5W
.
0.85LW 2
.
C BS
R08-1
0.85GW
K04-2
0.85GW
H15-20
0.85GW GC
R21-1
0.5R
F01-10
0.85R
AC02-4
0.5R KA
AC02-1
2B
BY
5B
DK
2B ZF
AC01-1
0.5L
ZB
*0.5L
ZH
0.5L
. . . . . . . . . 1AC01 BF .
1
F01-17 J06-9 H15-1 R21-5 F01-11 AC02-2 DL J04-2 J04-18 N08-3 ZE ZZ XG
J01-7 BW 2RY
.
2RY
.
0.85RB
.
GD 2RY
.
2RL
.
2RY
.
KB 2B
.
1.25B
.
1.25BR
.
ZG 0.5W
.
0.5W
.
0.5W
GZ2
0.5W
GG
0.5GL
. 5 3 RELAY FOR LIGHT
KA J05-1 J05-13 R08-3 F01-5 H15-19 J01-12 CK02-11 C01-60 N08-10 ZF CM02-9 XH
. FX FW
. 1.25R 1.25LR 䝷䜲䝖䝸䝺䞊 DK 2B
.
1.25B
.
1.25B
.
GE 1.25GW
.
1.25GW
.
0.85GW
.
XE 0.5RW
.
0.5RW
.
0.5RW
.
ZH 0.5L
.
0.5L
.
0.5L
9CM02C
0.5L
HH
. . .
D J05-5
CN-R05
0.85B
CONTROLLER
.
CH700䝁䞁䝖䝻䞊䝷
GE XG XH FM 2 CN-C01(AMP)
FW GF
(TO 3/10) 1 J06-1
1.25RY
2 J05-7
1.25B
81
.
GRO
.
.
GRO
.
FM
0.5LW
.
.
GRO
.
S30-3
0.5YB
.
P13-1
0.85LgY
.
M05-4
0.5LW
.
.
GRO
.
P01-2
0.85LgB
.
P07-2
0.85YL
.
.
GRO
.
.
GRO
.
.
GRO
.
P26-2
0.85YB
.
.
GRO
.
.
GRO
.
.
GRO
.
XH
0.5L
64C01
.
GRO
.
63
. .
J06-11 . XE . S30-4 H09-5 M05-6 P11-2 P09-2 P06-2 . . . P25-2 . . P22-1 XG .
E 62 0.5GW GRO 0.5RW GRO 0.5GW 0.5YR 0.5LR 0.85WR 0.85LgY 0.85BrY GRO GRO GRO 0.85GR GRO GRO 0.5B 0.5W GRO 44
3 J04-13 . . . . . . . . . . . . . . . . . 45C01 .
0.85GY
.
FM . H16-5 S30-1 S30-7 S25-16 . P12-2 P10-2 P05-2 . . . . P22-2 . . . .
ⓑ䝔䞊䝥 43 0.5LW
.
GRO
.
0.85GW
.
0.5R
.
0.5RY
.
0.5LB
.
GRO
.
0.85WL
.
0.85Lg
.
0.85LgW
.
GRO
.
GRO
.
GRO
.
GRO
.
0.85YR
.
GRO
.
GRO
.
GRO
.
GRO
.
25
4 J06-2 5 J04-10
WHITE TAPE 1.25RY 1.25B
KA GC . .
FM . . S30-2 . J02-16 XN P04-2 P03-2 P08-2 P02-2 . . . . J06-19 XB . .
6
BS 24 0.5LW
.
GRO
.
GRO
.
0.5YG
.
GRO
.
0.5RW
.
0.85B
.
0.85LgR
.
0.85GL
.
0.85BrW
.
0.85BrR
.
GRO
.
GRO
.
GRO
.
GRO
.
0.5WB
.
0.85WB
.
GRO
.
GRO
.
F
JUNCTION CONNECTOR(GREEN)
䝆䝱䞁䜽䝅䝵䞁䝁䝛䜽䝍(⥳) GD
CN-J03(J)
GC F01-18 . . C01-39 J05-8
AC01-4 . GC
2 0.5Lg . 0.5R 1 4 0.5R 0.5RL 3 5 . . 0.5RY 0.5B 8
. . . . . .
. . .
G GD
2
GD
2RY
KA
2B 1 1
C01-40
0.5R
C01-21
0.5YG
C01-77
0.5YB
C01-58
0.5GW 4
. M10-1 . CK02-3 F01-10C F01-20F H15-5 FM N08-2 CM01-10 2RY 5 . . . . . .
1 .
.
0.85LR
.
.
.
0.5LR
.
0.85LW
.
0.85LW
.
0.85LW
.
0.5LW
.
0.85YG
.
0.5LW
.
10 .
AC03
F01-15 . F01-4 M04-1 M06-2 D02-3 . . H15-17 F01-7
XF
*1.25W
.
3 A/C UNIT MODEL SELECTION
. . .
11 0.85LR 0.85WL 0.85WL 0.85WL 0.85WL 0.85GL 0.85GL 20
. . . . . . . . . .
A/C䝴䝙䝑䝖 ᶵ✀㑅ᢥ
COMPRESSOR RELAY CN-AC02 CN-S30
H 䝁䞁䝥䝺䝑䝃䝸䝺䞊 (S)
CN-R21
JUNCTION CONNECTOR(BLACK) JUNCTION CONNECTOR(GREEN) JUNCTION CONNECTOR(PINK) JUNCTION CONNECTOR(PINK)
JUNCTION CONNECTOR(BLACK)
䝆䝱䞁䜽䝅䝵䞁䝁䝛䜽䝍(㯮) 䝆䝱䞁䜽䝅䝵䞁䝁䝛䜽䝍(⥳) 䝆䝱䞁䜽䝅䝵䞁䝁䝛䜽䝍(᱈) 䝆䝱䞁䜽䝅䝵䞁䝁䝛䜽䝍(᱈)
䝆䝱䞁䜽䝅䝵䞁䝁䝛䜽䝍(㯮)
CN-J01(J) CN-J04(J) CN-J05(J) CN-J06(J)
CN-J02(J)
I
C02-108 HG R02 D01-2 R12-1 R10-1 R05-1 HB . . LC KB DM FP DM M09-2 J05-3 FT R06-2 C01-5 DK CM01-14 J04-7 H15-10 R05-2 R10-2 C01-2 S30-8 GF . C01-1 C01-4 CM01-1 CM01-2 CK02-6 CK02-7 . N08-1 BW .
H15-11 S25-14 D01-3 . H15-3 R15 CM01-12 D02-1 R18-5 . 1 0.85R 0.85RB 1.25R 0.85RB 0.5GL 0.5GL 0.5GL 0.5GL . .
10 1 1.25B 1.25B 1.25BW 0.85B 1.25B 0.85BW 1.25B 0.85B 0.5BW 1.25B 10 1 1.25B 0.5B 1.25B 0.85B 0.85B 0.85B 1.25B 0.5B 0.85B .
10 1 1.25RY 1.25RY 1.25R 1.25R 1.25R 1.25R . 0.85RY 2RY .
10
1 0.85WR
.
0.85WR
.
0.85WR
.
.
.
0.85RY
.
0.85RY
.
0.5RY
.
0.85RY
.
0.85RY
.
.
.
10 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H15-4 XE R06-5 CM01-11 . . . . . . H09-6 P17-2 C01-3 M06-1 D02-7 . M10-2 KB MF XJ . . DK D02-5 D01-8 . H09-4 H15-18 . . C01-62 CM01-5 CK01-14 N08-6 . . XM . C01-9 .
. . . . . . . . . . . . . . . .
D01-6 XF CM01-16 .
.
H15-9 C01-19 CM02-5 D01-4 V01-1 H16-7 11 0.85RW 0.5RW 0.85RW 0.5RW 20 11 0.5B 0.5B 0.85GY 0.85GY 0.85GY
.
0.85BR
.
1.25BR
.
0.85BR
.
1.25B
.
20 11 1.25B 0.85BW 0.85BW 0.85Y 0.85Y
.
20 11 0.5GW 0.5GW 0.5GW 0.5GW 0.85WB 0.5WB 20
11 0.85L
.
1.25L
.
0.5L
. .
0.5RW
.
0.5RW
.
0.5RW
.
0.85LgR
.
0.85LgR
.
0.85LgR
.
20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KB DK BW XJ HG
K FLOOR GND
䝣䝻䜰䝝䞊䝛䝇
CN-T01
H16-11 BP
1.25B
.
3B
.
HF HD
L 5 12
C01-41 . BJ
(FROM 1/10)
0.85GW .
. .
BA T01
0.85GY 1.25B
. .
6 10
HH .
. P17-1 P31-1
HH
0.85B
M . . 0.5GB 0.5RB OPT POWER SUPPLY(2) OPT POWER SUPPLY(1)
TO L.H. CONSOLE HARNESS . .
. OPT㟁※(2) OPT㟁※(1)
ᕥ䝁䞁䝋䞊䝹䝝䞊䝛䝇䜈 . . P31-2
(TO 7/10) CN-H16

. .
.
0.5YW
. CN-M10 CN-M09 ⓑ䝔䞊䝥
WHITE TAPE
R06-1
0.5GL R21-2
A/C UNIT
(M) (M)
(S) . 0.5Lg
.
䜶䜰䝁䞁䝴䝙䝑䝖
N
BA
0.85GY
.
J02-20
0.85LgR
.
.
.
.
CN-AC01 (TO 9/10)
BJ LD J03-2 F01-14
0.85GR 0.85W ZE P18-2 0.85LR
.
1 0.85G
.
1
. . 0.5W 0.85RW
2AC01 .
J04-17 J04-6
1 6 ZF P18-1 0.85BR 2 0.85BW 2
0.5L 0.85BrR . .
1AC01 .
4 8 1 7
J05-17 . BB BA BP
O 0.85Y .
. .
CAB HARNESS BB .
1.25RL .
䜻䝱䝤䝝䞊䝛䝇
(TO 7/10) CN-H09 BP
3B
. .
J04-11
0.5B
(M) . .
BB C01-57
1.25R 0.5YR
P . .
1 5
223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245
SEN06154-02
PC200, 200LC, 220, 220LC-8M0 17
PC200, 200LC, 220, 220LC-8M0
8 18 SUNSHINE SENSOR
A . . ᪥ᑕ䝉䞁䝃
. .
. . CN-P31 WIPER MOTOR
.
.
.
.
(050) 䝽䜲䝟䝰䞊䝍 (FROM 2/10)
. . CN-M05
R07-2
0.5BR
J02-13
0.5L 1
AC01-10
0.5RB
AC01-9
0.5YW 2
(M)
. . . .
BU BT T09 R05-5 L02-1 A13-1 DL MB M05-5 M14-2 FL BF
B MONITOR P21 #BG 3B 2B 5B #FX 1.25R 1.25R 1.25R MC 2B 2B 1.25B XQ 0.85YB 0.85B 0.85B
C02-119 . C02-114 . . . . . .
. . . . . .
䝰䝙䝍 0.85Y
.
3 0.85YL
.
.
.
0.85L
.
1
M07-1 M08-1 BG A13-2 XS P10-1 XA
CN-CM01 J05-2
0.5B
C01-56 MC C01-75 #BT 1.25B 1.25B 2B 1.25B GS
V03-1
0.85YL
H15-12
0.85YL
D03-3
0.85YL MF
J04-19
0.85BR
M04-2
0.85B
L03-1
0.85B #XR 0.85B 0.85B 0.85B
6 0.5LR 1.25B 0.5LW 4 . . . . . . . . . . . . .
(070) . . . .
J06-12 . BH V06-2 BG XR P09-1 XN P12-1 P11-1 XR
D03-5 H15-7 CM01-9
0.5GW . #BU 2B
.
0.85B
.
3B
. HA 0.5GL 0.5GL 0.5G #XA 0.85B 0.85B 0.85B #XS 0.85B 0.85B 0.85B
. . . . . . . . . . .
MB J02-7 T07 KA K04-1

C 1.25B
.
0.5RY
. #BY 5B 5B 0.85B
HN
A41-1
0.5R
A40-1
0.5R
CM04-1
0.85R #XB
XT
0.85WB
P09-3
0.85WB
C01-8
0.85WB #XT
XU
0.85WB
P10-3
0.85WB
XB
0.85WB
. . . 1A41 1A40 . . . . . . .
MB J01-14
1.25B 0.5RW R08-5 M07-2 M08-2 A41-4 A40-4 CM04-5 . A40-3 CM04-8 P12-3 P11-3 XT
. . #BZ 1.25GW 1.25GW 1.25GW JB 0.5B 0.5B 0.85B XD BRAID BRAID 1.25B #XU 0.85WB 0.85WB 0.85WB
5 12 MB ZZ HA MC XQ
. . . 4A41 4A40 . 0A41 0A40 . . . .
J06-4 J03-10
J02-17 . 1.25R 0.5LW R17-2 E08 XF T06 P13-2 J04-1 XL XA C01-18 ZG CM02-7 CM02-8
0.5RW
.
.
.
. .
#DG 1.25L
.
*1.25L
.
1.25L
. #LC 1.25B 0.85B 1.25B #XN 0.85B 0.85B 0.85B
ZZ 0.5W 0.5W 0.5W
J06-3 HA . . . . . . GZ2 . 8CM02C
D P23-1
0.85LR
.
.
1.25R
.
0.5G
.
DL T05 MC KB
MC CM01-3 CM01-4
. . DL 3B
.
2B
.
2B
. MB 2B 1.25B 1.25B
.
1 9 . . .
.
MONITOR .
䝰䝙䝍 ZH
0.5L
CN-CM02 9CM02C XD
(070) P24-1
0.85GL
ZZ
0.5W
JB
E . 8CM02C
HN
P44-1 ZZ
*0.85Y 0.5W
. . 2
CIGER LIGHTER
. . MF
.
.
.
.
䝅䜺䝷䜲䝍 0.85B
.
CN-M04
1 6 J03-14 7
F 0.85WL
.
11 1
MF J02-1 BW
0.85WR 0.85RB ⓑ䝔䞊䝥
1 . . WHITE TAPE
XD . A41-3 JB . MONITOR CAMERA 1 CAMERA 2
8 1.25B . 0.5G 0.85B . 4 GS D01-5
. . 3A41 . . 䝰䝙䝍䜹䝯䝷1 䜹䝯䝷2 0.85YL
.
0.85RB
.
3
A41-2
0.5W
A40-2
0.5W
HN
0.85R 1 CN-CM04 CN-A40 CN-A41 . J02-5
2A41 2A40 . .
(070) (DT) (DT) .
0.85RY
.
G GS
CE02-22 J01-11
(GRO) (GRO) *0.85WB 0.85RW
. .
CE02-9 J03-7
CM04-2 XD CM04-3 CM04-6 *0.85L 0.85LW 2 A/C HI䞉LO PRESSURE
(TO 10/10) 2 0.5W
2A40
BRAID
0A40
3
(TO 10/10) 2 0.5W
2A41
0.5G
3A41
3 15H15
CE02-23
.
J04-12
0.5B
SWITCH
HN JB HN JB *0.85B . 䜶䜰䝁䞁㧗పᅽ
WORK EQUIPMENT HARNESS 1 0.5R 0.5B 4 1 0.5R 0.5B 4 16H15
H
1A40 4A40 1A41 4A41 AC01-6 䝥䝺䝑䝅䝱䝇䜲䝑䝏
సᴗᶵ䝝䞊䝛䝇 J03-19
0.85GL
0.5GB
HARNESS FOR .
.
CN-P17
CN-A13 RIGHT UPPER CONSOLE J05-18 FD 1 (S090)
(DT) ྑ䝁䞁䝋䞊䝹
0.85Y
.
0.5LR
.
䜰䝑䝟䞊䝝䞊䝛䝇 GE HA
TRAVEL RF PRESSURE TRAVEL LR PRESSURE
2
BT
1.25B
.
FX
1.25R
.
1 (TO 8/10) XD
BRAID
0A41 CN-H15
0.85GW
.
0.5GL
. SENSOR SENSOR
SENSOR
TRAVEL LF PRESSURE
I NO_PLOT
(S090)
BS
0.85GW
.
. TRAVEL RR PRESSURE ྑ㉮⾜๓ᅽຊ䝉䞁䝃 ᕥ㉮⾜ᚋᅽຊ䝉䞁䝃
. . SENSOR
CN-P11 CN-P10 ᕥ㉮⾜๓ᅽຊ䝉䞁䝃
D03-6 J02-15
ྑ㉮⾜ᚋᅽຊ䝉䞁䝃 (AMP) (AMP) CN-P09
(TO 6/10) 0.5GR
.
HH
0.5RW
.
J05-4
CN-P12 (AMP)
0.5B
.
0.85B
.
(AMP) XS C01-55 XU XR C01-35 XT
1 0.85B 0.85WR 0.85WB 3 1 0.85B 0.85Lg 0.85WB 3 XA C01-54 XB
WHITE TAPE . . . . . .
22 10 1 0.85B 0.85LgY 0.85WB 3
ⓑ䝔䞊䝥 XS C01-36 XU . . .
J 1 0.85B 0.85WL 0.85WB 3
. . .
#DG #BU #BG
#FX #BT
#XN #BY
28 28 28 28 28
ATT EPC
CN-V30
#BZ (DT) #XS
L #XU
(GRO)
7
C02-97 FG
1 0.85G
1V30
0.85B
2V30
2
#XA
M #XB
#LC #XR
GB BG BY LC DL DM
5B 5B 5B 1.25B 3B 3B
. . . . . . #XT
CN-T10 CN-T09 CN-T07 CN-T06 CN- T05 CN- T04
N 2
BZ
1.25GW
BT
1.25B 1 2
BZ
1.25GW
BT
1.25B 1
. . . .
HORN HIGH TORN HORN LOW TORN

䝩䞊䞁㧗㡢䝩䞊䞁ప㡢
CN-M07 CN-M08 LC C01-76
2 0.85B 0.85LgY 1
O . .
(TO 8/10)
(TO 4/10) (GRO)
SERVICE PRESSURE
SWITCH
䝃䞊䝡䝇ᅽຊ⏝䝇䜲䝑䝏
P
CN-P13
(X)
246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268
SEN06154-02
PC200, 200LC, 220, 220LC-8M0 19
PC200, 200LC, 220, 220LC-8M0
A
2
CN-V23 BF
(DT) 0.85B
2V23
#DE #DD #NF #NA
ྜὶᘚ㟁☢ᘚ(䝯䜲䞁) C02-112 10
SOLENOID VALVE 0.85LR
1V23
7 13 7
CONFLUENCE VALVE (MAIN)
1
B FUSIBLE LINK
䝠䝳䞊䝆䝤䝹䝸䞁䜽㉥䝞䞁䝗 #NB
15
RED BAND
CN-F04 CN-F05 2
CN-V24 FL #XL
(L) (M) 0.85B
(DT) 2V24
#XM
C ྜὶᘚ㟁☢ᘚ(LS) C02-89
0.85RL 3
XM
0.85WB
C01-15
0.85BrW
XL
0.85B 1 3
NE
0.85WB
C01-16
0.85GL
NJ
0.85B 1 3
ND
0.85WB
C01-53
0.85BrY
NI
0.85B 1 3
NC
0.85WB
C01-34
0.85LgW
NH
0.85B 1 3
NB
0.85WB
C01-17
0.85LgR
NG
0.85B 1 3
NA
0.85WB
C01-72
0.85YL
NF
0.85B 1 3
XM
0.85WB
C01-14
0.85BrR
XL
0.85B 1 3
NA
0.85WB
C01-73
0.85LgB
NF
0.85B 1
SOLENOID VALVE 1V24 #NG . . . . . . . . . . . . . . . . . . . . . . . .
CONFLUENCE VALVE
1
R03 R04
ⓑ䝞䞁䝗 DD C01-49 DE #NC CN-P08 CN-P03 CN-P06 CN-P05 CN-P04 CN-P07 CN-P02 CN-P01
8R
.
1 3R
.
1 3 0.85WB 0.85GR 0.85B 1
WHITE BAND . . .
DB F01-16E #NH (AMP) (AMP) (AMP) (AMP) (AMP) (AMP) (AMP) (AMP)
8RY
.
2 3RW
.
2 T08 CN-R01 䜰䞊䝮䝎䞁䝥 ᪕ᅇ(ᕥ) 䝤䞊䝮ୖ䛢䝞䜿䝑䝖䝎䞁䝥䜰䞊䝮᥀๐ ᪕ᅇ(ྑ)ᅽຊ䝉䞁䝃䝤䞊䝮ୗ䛢䝞䜿䝑䝖᥀๐
5B
䝞䝑䝔䝸䝸䝺䞊 E CN-P25 #ND SWING (RIGHT)
D
. ᅽຊ䝉䞁䝃 ᅽຊ䝉䞁䝃 ᅽຊ䝉䞁䝃 ᅽຊ䝉䞁䝃 ᅽຊ䝉䞁䝃 ᅽຊ䝉䞁䝃 ᅽຊ䝉䞁䝃
BATTERY RELAY (AMP) #NI ARM DUMP SWING (LEFT) BOOM UP BUCKET DUMP ARM DIGGING PRESSURE SENSOR BOOM DOWN BUCKET DIGGING
F䝫䞁䝥ᅽຊ䝉䞁䝃 PRESSURE SENSOR PRESSURE SENSOR PRESSURE SENSOR PRESSURE SENSOR PRESSURE SENSOR PRESSURE SENSOR PRESSURE SENSOR
F PUMP PRESSURE SENSOR #NE
J01-3
CN-R02
1.25R
䝞䝑䝔䝸䝸䝺䞊 BR DD C01-68 DE
#NJ
.
BATTERY RELAY 3 0.85WB
.
0.85YB
.
0.85B
.
1
E PRESSURE SENSOR 1
CN-P26 AC01-7 CN-P18
0.85BrR
(AMP) 10 7 7 .
䜶䜰䝁䞁እẼ䝉䞁䝃
10
R䝫䞁䝥ᅽຊ䝉䞁䝃 AC01-8
0.85RW
A/C AMBIENT
R PUMP PRESSURE SENSOR . AIR TEMP SENSOR
1
FX
RIGHT FRONT LAMP 2
7
F 1.25R
. ྑ๓↷ⅉ
7 GB CN-L02
15
1.25B
. (DT)
TRAVEL ALARM
2
㉮⾜䜰䝷䞊䝮 J03-15 J04-14
FUEL LEVEL SENSOR CN-M14 2 0.85WL
.
0.85GY
.
1 GY CM02-3
⇞ᩱ䝺䝧䝹䝉䞁䝃 2 0.85B 0.85GL 1

G (DT) BH CM02-4 . .
CN-R04
15
CN-P21 2 0.85B 0.85LR 1 CN-M06
F05-1 1 . .
(X)
3R
. 䝞䝑䝔䝸䝸䝺䞊 B C02-107 䜴䜷䝑䝅䝱䝰䞊䝍 CN-P24
BATTERY RELAY 0.85RL
. CN-P23 WASHER MOTOR (X)
1
CM01-15 XQ (DT) 䝷䝆䜶䝍Ỉ఩䝉䞁䝃 V04-2 BD V02-2
0.85Y 0.85YB
RADIATOR WATER LEVEL SENSOR #BC 0.85B 0.85B 0.85B
. .
䜶䜰䜽䝸䞊䝘┠ワ䜎䜚䝉䞁䝃 . . .
H F04-1
CN-R03 2 AIR CLEANER CLOGGED SENSOR BE V03-2 BC
8R
䝞䝑䝔䝸䝸䝺䞊 M #BD 0.85B
.
0.85B
.
0.85B
.
.
BATTERY RELAY
BK V05-2 BD
#BE 0.85B
.
0.85B
.
0.85B
.
P23-2 V01-2 BU
#BH 0.85B 0.85B 2B
15
. . .
19
V25-2 BE BF
1 #BK 0.85B 0.85B 0.85B
. . .
R07-3 STARTER SAFETY RELAY
0.85RW BH J02-19 BD GS BC C02-87 BE C02-110
. 䝇䝍䞊䝍䝉䞊䝣䝔䜱䝸䝺䞊 2 0.85B
.
0.85LgR
.
1 2 0.85B
.
0.85YL
.
1 2 0.85B
.
0.85GR
.
1 2 0.85B
.
0.85BrR
.
1
#DD
P26-3
0.85WB
NA
0.85WB
P25-3
0.85WB
NB
0.85WB
BC C02-109
DG
1.25L
CN-R17 #BH 2 0.85B 0.85GL 1
. . . .
. .
.
(X) CN-V01 CN-V03 CN-V04 CN-V05 #DE
P26-1
0.85B
NF
0.85B
P25-1
0.85B
NG
0.85B
CN-T08 2 #BC . . . .
(DT) CN-V03 (DT) (DT) (DT)
J
R01 #BD PPCඖᅽ䢗䡫䡴㟁☢ᘚ (DT) ᪕ᅇ㥔㌴䝤䝺䞊䜻㉮⾜HI-LO㟁☢ᘚ ㉮⾜㐃㏻㟁☢ᘚ #GB
GY
2B
L02-2
1.25B
T10
5B
SOLENOID VALVE . . .
5B
.
PPC SOLENOID VALVE ᪕ᅇ㥔㌴䝤䝺䞊䜻㟁☢ᘚ SOLENOID VALVE
#GB #GY #BK LOCKING TRAVEL SPEED TRAVEL JUNCTION
#BE 㟁☢ᘚ SOLENOID VALVE
#GY
P24-2
0.85B
A15-2
1.25B
GB
2B
PRIMARYPRESSURE SWING PARKING BRAKE VALVE . . .
SOLENOID VALVE
SWING PARKING BRAKE DD P01-3 P07-3
#NA 0.85WB
.
0.85WB
.
0.85WB
.
K
CN-R15
J02-6
(FROM 3/10) 28 28 28 25 (TO 5/10) #NB
DD
0.85WB
.
P04-3
0.85WB
.
NC
0.85WB
.
䝸䝪䞁䝠䞊䝍䝸䝺䞊 0.85RY
. NB P05-3 ND
RIBBON HEATER RELAY
#NC 0.85WB
.
0.85WB
.
0.85WB
.
NC P06-3 NE
#ND 0.85WB
.
0.85WB
.
0.85WB
.
L
ND P03-3 XM
#NE 0.85WB
.
0.85WB
.
0.85WB
.
DE P01-1 P07-1
#NF 0.85B
.
0.85B
.
0.85B
.
19 19 19
BU C02-86
2 0.85B 0.85BrG 1 DE P04-1 NH
. . #NG 0.85B 0.85B 0.85B
M BK C02-85 . . .
2 0.85B
.
0.85RW
.
1
NG P05-1 NI
(GRO)
#NH 0.85B
.
0.85B
.
0.85B
.
CN-V06 CN-V25 NH P06-1 NJ
(DT) #NI 0.85B 0.85B 0.85B

(DT) . . .
ATT䝸䝍䞊䞁ษ᥮㟁☢ᘚ ྍኚ⫼ᅽᘚ NI P03-1 XL
N ATT RETURN CHANGE CHANGEABLE BACK #NJ 0.85B

.
0.85B
.
0.85B
.
SOLENOID VALVE PURESSURE VALVE
NJ P02-1 P08-1 XN
#XL 0.85B
.
0.85B
.
0.85B
.
0.85B
.
NE P02-3 P08-3 J06-17

#XM 0.85WB
.
0.85WB
.
0.85WB
.
0.85WB
.
O
CN-R16A CN-R28
䝸䝪䞁䝠䞊䝍䝸䝺䞊䝇䝍䞊䝍䝉䞊䝣䝔䜱䝸䝺䞊(C)
RIBBON HEATER RELAY STARTER SAFETY RELAY(C)
E01 E10
*15R *8R
. .
P
269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291
SEN06154-02
PC200, 200LC, 220, 220LC-8M0 21
PC200, 200LC, 220, 220LC-8M0
EPC VALVE HYD.OIL REAR EPC VALVE

FOR LS TEMP. SENSOR FOR PC
A LS⏝EPCᘚ సືἜ 䝉䞁䝃 PC⏝EPCᘚ(ᚋ)
CN-V19 CN-P22 CN-V12
(DT) (DT) (DT)
C02-88 FG C01-46 C01-29 S25-8 S25-11

1 0.85G
1V19
0.85L
2V19
2 1 0.5B
.
0.85YR
.
2 1 0.85G
8S25
0.85L
11S25
2
B ㉥䝞䞁䝗㯤䝞䞁䝗
RED BAND YELLOW BAND
WIF SENSOR
⇞ᩱỈ䝉䞁䝃
CN-P47
(DT)
C E06-2 E06-1
2 *0.85B
.
*0.85G
.
1
15
7
E FRONT EPC VALVE FOR PC
PC⏝EPCᘚ(๓)
CN-V11
7
(DT) ENGINE CONTROLLER (GND)
1 䜶䞁䝆䞁䝁䞁䜰䞊䝇
CONTROLLER
S25-2 CN-T12
F 0.85G
2S25 CE03-1 CM850䝁䞁䝖䝻䞊䝷 COMPRESSOR FOR A/C
*3B
S25-5 . CN-CE03 A/C 䝁䞁䝥䝺䝑䝃
0.85L
5S25 (DTP) CN-AC03
2 (X)
ⓑ䝞䞁䝗 Z 1
T12
*3B
.
.
GRO
.
4
R21-3
WHITE BAND . HD *1.25W
G 2 GRO
.
*3RW
.
3 .
15
CE03 Z ⓑ䝔䞊䝥
WHITE TAPE
ᔐྜ㠃䛛䜙ぢ䜛
SEE FROM CONNECTING SURFACE
10
I
(FROM 4/10) 19 19 15
22
22
19
#ZA #ZB
J
2
REAR WORKING LAMP GY
ᚋ᪉సᴗⅉ(OPT) 1.25B
(TO 10/10) CN-A15

(GRO)
.
R10-5
1.25R
K (DT) .
CN-E06
15
P47-1 P47-2
1 (DT) 1 *0.85G *0.85B 2
. .
䜶䞁䝆䞁䝝䞊䝛䝇䜈 R16A
*15R
TO ENGINE HARNESS .
CE02
CN-E01
TO ENGINE HARNESS 䝸䝪䞁䝠䞊䝍
L 䜶䞁䝆䞁䝝䞊䝛䝇䜈 RIBBON HEATER
CN-E08 A
C
(X)
DG
(TO 8/10) Y
1 *1.25L
.
(TO 10/10) B
A
ZA
M .
*0.5W
AK02
GRO
. ZB
*0.5L
BK02
. R18-2 . . . ZA ZB . D11-2 .
2 C B 41 GRO
.
*0.85YB
.
GRO
.
GRO
.
GRO
.
*0.5W
46CE02
*0.5L
47CE02
GRO
.
*0.85RY
.
GRO
. 50
ENGINE OIL LEVEL SENSOR RESISTER
. . . HF . . . . . F01-20 R18-1
䜶䞁䝆䞁Ἔ㔞䝉䞁䝃 GRO
. CAN⤊➃᢬ᢠ 31
GRO
.
GRO
.
*0.85B
.
GRO
.
GRO
.
GRO
.
GRO
.
GRO
.
*0.85LW
.
*0.85Y
. 40
N CN-P44 CM02-2
CN-K02 . H15-14 H15-16 . . . . . . .
*0.85Y GRO *0.85WB *0.85B GRO GRO GRO GRO GRO GRO GRO
(DT-T) . 21 . . 16H15 . . . . . . 30
(DT) .
. . . . . .
1 11
.
GRO GRO
.
GRO
.
GRO GRO GRO GRO GRO GRO
.
GRO
04
. . . . . . . . . . 20
. . . . . . . . H15-15 .
STARTER 1 GRO GRO GRO GRO GRO GRO GRO GRO *0.85L GRO
10
1 . . . . . . . . 15H15 .
O 䝇䝍䞊䝍 R28
*8R
15
CN-E10 .
CN-CE02
(DT) (DRC26-50S04)
K02-A CE02-46 ZE
#ZA *0.5W *0.5W *0.5W
CM850 䝁䞁䝖䝻䞊䝷
(TO 8/10) AK02
K02-B
46CE02
CE02-47
AE
ZF
CONTOROLLER
#ZB *0.5L *0.5L *0.5L
P
BK02 47CE02 BF
Y
ᔐྜ㠃䛛䜙ぢ䜛
SEE FROM CONNECTING SURFACE
292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314
SEN06154-02
PC200, 200LC, 220, 220LC-8M0 23
PC200, 200LC, 220, 220LC-8M0
B
CN-SSW
䝇䝍䞊䝍䝇䜲䝑䝏
STARTER SWITCH
CN-P20 H15-2 H15-5

CN-S02 (M) 0.85R 0.5LW
C CN-S07 CN-S04 H15-3 . .
(SWP) (SWP) (SWP) ⇞ᩱ䝎䜲䝲䝹 0.85RY
.
FUEL DIAL
ᅇ㌿ⅉ ᪕ᅇ䝻䝑䜽䝇䜲䝑䝏䝷䜲䝖䝇䜲䝑䝏
BEACON SWING LOCK SWITCH LAMP SWITCH H15-4 BR
1 11 H15-14 0.85RW ACC
1 0.5WB .
SSW-B S04-3 .
R1
0.85RB 0.5WR . . . . . H15-11 (A) H15-22 (B)
. . 1 . . . 3 1 . . 0.5WR 3 1 0.5GL 0.5B 0.5GR 3 H15-15 H15-16
. . . . . . . . . 0.5L 0.5B
SSW-BR S04-4 2 3
D 0.85R 0.5YL . H15-17 H15-18 H15-12 H15-9 H15-10 (B) H15-6 (A) 15H15 16H15 C B
. . 4 . 0.85GL 0.85Y 6 4 0.5YL 0.5RW 0.5B 6 4 0.5GR 0.5LR 0.5GL 6 H15-1
. . . . . . . . . 0.85RB
SSW-R1 . .
0.85RY .
. .
SSW-C P20-1
0.85RW 0.5WB
. .
SSW-ACC P20-2 ⓑ䝔䞊䝥
0.5LW 0.5L WHITE TAPE
E . 15H15 2
CN-H15 P20-3 H15-20
CN-S10
(S090)
0.5B 䠌䠊䠔䠑䠣䠳 (Y090)
16H15 .
(FROM 3/10) 䝣䝻䜰䝝䞊䝛䝇 S07-5
0.85GL
H15-19
䠌䠊䠔䠑䠣䠵
ྑ䝜䝤䝇䜲䝑䝏
RIGHT KNOB
䠢䠨䠫䠫䠮䚷䠤䠝䠮䠪䠡䠯䠯 . .
S02-5 S07-6 B A SWITCH
0.5LR 0.85Y
1
. .
F (A) S10-1
0.5GL 0.85GY
. .
. S10-2
. 0.85GW
. .
S04-5 (B)
0.5RW 0.5GR
. .
G S04-6 S02-2
0.5B 0.5B
H15-7 S02-1 S02-6
. .
A 0.5GL 0.5GL 0.5GL
. . .
H15-21 S02-3 S02-4
10 22
B 0.5GR 0.5GR 0.5GR
. . .
DIRECTION OF LEVER DIRECTION OF LEVER

䝺䝞䞊᪉ྥ 䝺䝞䞊᪉ྥ
ୖഃ ୗഃ(㏻ᖖ) ୗഃ(㏻ᖖ) ୖഃ
UPPER SIDE DOWN SIDE(NORMAL) DOWN SIDE(NORMAL) UPPER SIDE
J
CN-S21
㠀ᖖ᫬䝫䞁䝥㥑ື䝇䜲䝑䝏
EMERGENCY PUMP DRIVE SWITCH CN-S22
K ᪕ᅇ㥔㌴䝤䝺-䜻ゎᨺ䝇䜲䝑䝏
EMEGERNCY SWING PARKING
BRAKE RELEASE SWITCH
(9) (6)
L (12) (3) (1) (4)
(11) (2) (2) (5)
(10) (1) (3) (6)

(7) (4)
(8) (5)
M S21-11 S21-12 S22-2 S22-3 S22-5 S22-6

11 0.85Br 0.85BrR 0.85WR 0.85W 0.85LB 0.85L 16
. . . . . .
S21-5 S21-6 S21-7 S21-8 S21-9 S21-10
5 0.85B 0.85BR 0.85GR 0.85Y 0.85YB 0.85BrW 10
. . . . . .
S21-1 S21-2 S21-3 S21-4
1 0.85GR 0.85G 0.85GB 0.85BW 4
. . . .
N
CN-S25
(090)
(FROM 1/10)
O
315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337
SEN06154-02
PC200, 200LC, 220, 220LC-8M0 25
PC200, 200LC, 220, 220LC-8M0
A LEFT KNOB SWITCH

ᕥ䝜䝤䝇䜲䝑䝏䝷䝆䜸
CN-S11 RADIO
(Y090) CN-M01 CN-T03
(PA) CN-T03A
T03A (M)
B 2
H16-5 H16-4
0.85GW 0.85GY
. .
1
H08-1 H08-3 H16-2 .
0.5B
. (FROM 7/10)
1 0.85RB 0.85R 0.85GY . 4
. . . .
T03
H08-2 H08-4 H16-3 H16-1 . 0.5B
5 0.85RL 0.85RW 0.85B 0.85GR . 9 .
. . . . .
(TO 7/10)
C
RADIO GND
䝷䝆䜸䜰䞊䝇
CN-T03(M)
RING A
H16-11
1.25B 䝸䞁䜾㻭
.
D
RING B 3 1
䝸䞁䜾㻮 M01-2 M01-1 CAB HARNESS
0.85R 0.85RB
. . 䜻䝱䝤䝝䞊䝛䝇
M01-6
0.85RW
M01-5
0.85RL CN-H08 (TO 7/10)
. .
(M)
E ⓑ䝔䞊䝥 4 2
WHITE TAPE
F
12 5

Shop Pc200 8m0

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SEN06109-08

HYDRAULIC PC200 -8M0

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

PC200, 200LC, 220, 220LC-8M0 00-100 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN06109-08

00 Index and foreword SEN06110-08

10 Structure, function and maintenance standard SEN06115-03

20 Standard value table SEN06124-01

30 Testing and adjusting SEN06126-01

00-100 2 PC200, 200LC, 220, 220LC-8M0

50 Disassembly and assembly SEN06141-04

90 Diagrams and drawings SEN06152-02

PC200, 200LC, 220, 220LC-8M0 00-100 3

10 Structure, function and maintenance standard

00-100 4 PC200, 200LC, 220, 220LC-8M0

Center swivel joint ................................................................................................................... 10

20 Standard value table

30 Testing and adjusting

PC200, 200LC, 220, 220LC-8M0 00-100 5

Adjusting play of work equipment and swing PPC valves ....................................................... 51

00-100 6 PC200, 200LC, 220, 220LC-8M0

Failure code [CA122]............................................................................................................... 22

PC200, 200LC, 220, 220LC-8M0 00-100 7

Failure code [DA29KQ]............................................................................................................ 21

00-100 8 PC200, 200LC, 220, 220LC-8M0

Failure code [DY20KA] ............................................................................................................ 42

PC200, 200LC, 220, 220LC-8M0 00-100 9

H-9 Work equipment does not move in single operation ......................................................... 27

50 Disassembly and assembly

00-100 10 PC200, 200LC, 220, 220LC-8M0

Removal and installation of engine and hydraulic pump assembly ......................................... 70

PC200, 200LC, 220, 220LC-8M0 00-100 11

Testing air leakage (duct)......................................................................................................... 29

90 Diagrams and drawings

00-100 12 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 00-100 13

PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

PC200, 200LC, 220, 220LC-8M0 00-200 1

Foreword, safety and general information 1

General precautions q If welding repairs is required, always have a

00-200 2 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 00-200 3

Precautions for slinging work and making sig-

00-200 4 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 00-200 5

q When loosening the nuts fixing air conditioner

q When tightening nuts of the air conditioner

00-200 6 PC200, 200LC, 220, 220LC-8M0

Fire prevention q When performing grinding or welding work

PC200, 200LC, 220, 220LC-8M0 00-200 7

q Fire caused by piping Dispose of waste materials

00-200 8 PC200, 200LC, 220, 220LC-8M0

How to read the shop manual 1

Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table