A4 SEBM024301 (T&A Troubleshooting) PDF
Uploaded by
Joko SukarionoA4 SEBM024301 (T&A Troubleshooting) PDF
Uploaded by
Joko SukarionoSEBM024301
MACHINE MODEL
SERIAL No.
PC200-7
PC200LC-7
PC220-7
PC220LC-7
200001 and up
200001 and up
60001 and up
60001 and up
This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
PC200, 200LC, PC220, 220LC-7 mount the SAA6D102E-2 engine.
For details of the engine, see the 102 Series Engine Shop Manual.
2001
All Rights Reserved
Printed in Japan 10-01
00-1
GENERAL
CONTENTS
No. of page
01 GENERAL ............................................................................................................................
01-1
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD............................................
10-1
20 TESTING AND ADJUSTING ........................................................................
20-1
30 DISASSEMBLY AND ASSEMBLY
.................. Will Be Issued 12-15-2001
90 OTHERS ................................................................................................................................
00-2
90-1
PC200/220(LC)-7
LIST OF REVISED PAGES
The affected pages are indicated by the use of the
following marks. It is requested that necessary
actions be taken to these pages according to the
table below.
Mark
Indication
Action required
Page to be newly added
Add
Page to be replaced
Replace
Page to be deleted
Discard
Pages having no marks are those previously revised
or made additions.
LIST OF REVISED PAGES
Mark
Page
Time of
revision
Mark
Page
Time of
revision
Mark
Page
Time of
revision
Mark
Page
Time of
revision
Mark
Time of
revision
Page
00-1
01-1
10-14
10-43
10-74
00-2
01-2
10-15
10-44
10-75
00-2-1
01-3
10-16
10-45
10-76
00-2-2
01-4
10-17
10-46
10-77
00-2-3
01-5
10-18
10-47
10-78
00-2-4
01-6
10-19
10-48
10-79
00-3
01-7
10-20
10-50
10-80
00-4
01-8
10-21
10-51
10-81
00-5
01-9
10-22
10-52
10-82
00-6
01-10
10-23
10-53
10-83
00-7
01-11
10-24
10-54
10-84
00-8
01-12
10-25
10-55
10-85
00-9
01-13
10-26
10-56
10-86
00-10
01-14
10-28
10-57
10-87
00-11
10-29
10-58
10-88
00-12
10-30
10-60
10-89
00-13
10-1
10-31
10-61
10-90
00-14
10-2
10-32
10-62
10-91
00-15
10-3
10-33
10-63
10-92
00-16
10-4
10-34
10-64
10-93
00-17
10-6
10-35
10-65
10-94
00-18
10-7
10-36
10-66
10-95
00-19
10-8
10-37
10-67
10-96
00-20
10-9
10-38
10-68
10-97
00-21
10-10
10-39
10-69
10-98
00-22
10-11
10-40
10-70
10-99
10-12
10-41
10-71
10-100
10-13
10-42
10-72
10-101
PC200/220(LC)-7
00-2-1
LIST OF REVISED PAGES
Mark
Page
Time of
revision
Mark
Page
Time of
revision
Mark
Page
Time of
revision
Mark
Page
Time of
revision
Mark
Page
10-102
10-143
10-186
20-13
20-134
10-103
10-144
10-187
20-14
20-135
10-104
10-145
10-188
20-15
20-136
10-105
10-146
10-189
20-16
20-137
10-106
10-147
10-190
20-17
20-138
10-107
10-148
10-191
20-18
20-139
10-108
10-149
10-192
10-109
10-150
10-193
20-101
20-141
10-110
10-152
10-194
20-102
20-142
10-111
10-153
10-195
20-103
20-143
10-112
10-155
10-196
20-104
20-144
10-113
10-156
10-197
20-105
20-145
10-114
10-157
10-198
20-106
20-146
10-115
10-158
10-199
20-107
20-147
10-116
10-159
10-200
20-108
20-148
10-117
10-160
10-201
20-109
20-149
10-118
10-161
10-202
20-110
20-150
10-119
10-162
10-203
20-111
20-151
10-120
10-163
10-204
20-112
20-152
10-121
10-164
10-205
20-113
20-153
10-122
10-165
10-206
20-114
20-154
10-123
10-166
10-207
20-115
20-155
10-124
10-167
10-208
20-116
20-156
10-125
10-168
10-209
20-117
20-157
10-126
10-169
10-210
20-118
20-158
10-127
10-170
10-211
20-119
20-159
10-128
10-171
20-120
20-160
10-129
10-172
20-121
20-161
10-130
10-173
20-1
20-122
20-162
10-131
10-174
20-2
20-123
20-163
10-132
10-175
20-3
20-124
20-164
10-133
10-176
20-4
20-125
20-165
10-134
10-177
20-5
20-126
20-166
10-135
10-178
20-6
20-127
20-167
10-136
10-180
20-7
20-128
20-168
10-137
10-181
20-8
20-129
20-169
10-138
10-182
20-9
20-130
20-170
10-139
10-183
20-10
20-131
20-171
10-140
10-184
20-11
20-132
20-172
10-142
10-185
20-12
20-133
20-173
00-2-2
Time of
revision
20-140
PC200/220(LC)-7
LIST OF REVISED PAGES
Mark
Page
Time of
revision
Mark
Page
Time of
revision
Mark
Page
Time of
revision
Mark
Page
Time of
revision
Mark
Time of
revision
Page
20-174
20-230
20-314
20-354
20-510
20-175
20-231
20-315
20-355
20-511
20-176
20-232
20-316
20-356
20-512
20-177
20-233
20-317
20-357
20-513
20-178
20-234
20-318
20-358
20-514
20-179
20-235
20-319
20-359
20-515
20-180
20-236
20-320
20-360
20-516
20-181
20-237
20-321
20-361
20-517
20-182
20-238
20-322
20-362
20-518
20-183
20-239
20-323
20-364
20-519
20-184
20-240
20-324
20-365
20-520
20-185
20-241
20-325
20-366
20-521
20-242
20-326
20-367
20-522
20-201
20-243
20-327
20-368
20-523
20-202
20-244
20-328
20-369
20-524
20-203
20-245
20-329
20-370
20-526
20-204
20-246
20-330
20-372
20-527
20-205
20-247
20-331
20-373
20-528
20-206
20-248
20-332
20-374
20-530
20-207
20-249
20-333
20-375
20-531
20-208
20-250
20-334
20-376
20-532
20-209
20-251
20-335
20-377
20-533
20-210
20-252
20-336
20-378
20-534
20-211
20-253
20-337
20-379
20-535
20-212
20-254
20-338
20-380
20-536
20-213
20-255
20-339
20-381
20-537
20-214
20-256
20-340
20-382
20-538
20-215
20-257
20-341
20-383
20-540
20-216
20-301
20-342
20-384
20-541
20-218
20-302
20-343
20-385
20-542
20-219
20-304
20-344
20-386
20-543
20-220
20-305
20-345
20-221
20-306
20-346
20-501
20-545
20-222
20-307
20-347
20-502
20-546
20-223
20-308
20-348
20-503
20-547
20-224
20-309
20-349
20-504
20-548
20-225
20-310
20-350
20-505
20-549
20-226
20-311
20-351
20-506
20-550
20-227
20-312
20-352
20-508
20-228
20-313
20-353
20-509
PC200/220(LC)-7
20-544
20-601
00-2-3
LIST OF REVISED PAGES
Mark
Page
Time of
revision
Mark
Page
Time of
revision
Mark
Page
Time of
revision
Mark
Page
Time of
revision
Mark
Page
Time of
revision
20-602
20-603
20-604
20-605
20-606
20-607
20-608
20-609
20-610
20-611
20-612
20-613
20-614
20-615
20-616
20-617
20-618
20-619
20-620
20-621
20-622
20-623
20-624
90-1
90-3
90-5
90-7
90-9
90-11
90-13
90-15
90-17
90-17-2
90-17-4
90-19
00-2-4
PC200/220(LC)-7
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS ................................................................. 20- 2
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS................................................................. 20- 4
TESTING AND ADJUSTING ...................................................................................................................... 20-101
TROUBLESHOOTING ................................................................................................................................ 20-201
Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k
k
k
k
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt or other rotating parts.
PC200/220(LC)-7
20-1
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Item
Applicable model
PC200, 200LC-7
Engine
SAA6D102E-2
Measurement condition
Unit
High idling
Engine speed
Low idling
rpm
Rated speed
Exhaust gas color
Valve clearance
(Normal temperature)
At sudden acceleration
At high idling
Intake valve
Exhaust valve
Bosch
index
mm
Standard value
for new machine
Service limit
value
2,15070
2,15070
1,03050
1,03050
1,950
1,950
Max. 1.0
Max. 2.0
Max. 0.5
Max. 1.5
0.25
0.51
Compression pressure
Oil temperature: 4060C
Engine speed: 250rpm
MPa
{kg/cm2}
Min. 2.4
{Min. 24.6}
Difference
between cyinders
Min. 1.0
{Min. 10.3}
Blow-by pressure
(Water temperature: operating range)
At rated output
kPa
{mmH2O}
Max. 1.2
{Max. 123}
5.1
{520}
0.390.64
{4.06.5}
Min. 0.15
{Min. 1.5}
0.25
{2.6}
0.09
{0.9}
80110
120
(degree)
111
111
mm
Min. 6, Max. 10
mm
58
58
Oil pressure
(SAE15W-40)
(Water temperature: operating range)
At high idling
At low idling
Oil temperature
Whole speed range (inside oil pan)
Fuel injection timing
Before Top Dead Center
Fan belt tension
Air conditioner
compressor belt tension
20-2
Deflection when pressed with finger
force of approx. 58.8 N{6 kg}
MPa
{kg/cm2}
PC200/220(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
PC220, 220LC-7
SAA6D102E-2
Standard value
for new machine
Service limit
value
2,20070
2,20070
1,03050
1,03050
2,000
2,000
Max. 1.0
Max. 2.0
Max. 0.5
Max. 1.5
0.25
0.51
Min. 2.4
{Min. 24.6}
Difference
between cyinders
Min. 1.0
{Min. 10.3}
Max. 1.2
{Max. 123}
5.1
{520}
0.390.64
{4.06.5}
Min. 0.15
{Min. 1.5}
0.25
{2.6}
0.09
{0.9}
80110
120
111
111
Min. 6, Max. 10
58
58
PC200/220(LC)-7
20-3
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model
Operating force
of control levers
Travel of control
levers
Spool stroke
Engine speed
Category
Item
Measurement Condition
2 pumps at relief
Engine water temperature:
Within operation range
Hydraulic oil temperature: Within
operation range
Engine at high idling
Arm in relief condition
At 2-pump relief + one
touch power up
Engine water temperature:
Within operation range
Hydraulic oil temperature: Within
operation range
Engine at high idling
Arm relief + One-touch power
max. switch in ON condition
Speed when autodeceleration is operated
Engine at high idling
Auto-deceleration switch in ON
condition
All control levers in NEUTRAL
condition
Unit
rpm
Standard value
Permissible value
2,000100
2,000100
1,900100
1,900100
1,400100
1,400100
9.50.5
9.50.5
Boom control valve
Arm control valve
Bucket control valve
mm
Swing control valve
Travel control valve
Boom control lever
Engine stopped
At center of control lever grip
Max. reading up to stroke end
(excepting lever play in NEUTRAL position)
Arm control lever
Bucket control lever
Swing control lever
Travel control lever
mm
8510
8510
8510
8510
8510
8510
8510
8510
11512
11512
Play of control lever
Max. 10
Max. 15
Boom control lever
15.73.9
{1.60.4}
Max. 24.5
{Max. 2.5}
Arm control lever
15.73.9
{1.60.4}
Max. 24.5
{Max. 2.5}
12.72.9
{1.30.3}
Max. 21.6
{Max. 2.2}
12.72.9
{1.30.3}
Max. 21.6
{Max. 2.2}
24.55.9
{2.50.6}
Max. 39.2
{Max. 4.0}
74.518.6
{7.61.9}
Max. 107.6
{Max. 11}
Bucket control lever
Swing control lever
Lever
Travel control lever
Papel
20-4
PC200, 200LC-7
Hydraulic oil temperature: Within
operation range
Engine at high idling
At center of control lever grip
At tip in case of pedal
Max. reading up to stroke end
N{kg}
PC200/220(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC220, 220LC-7
Standard value
Permissible value
2,050100
2,050100
1,950100
1,950100
1,400100
1,400100
9.50.5
9.50.5
8510
8510
8510
8510
8510
8510
8510
8510
11512
11512
Max. 10
Max. 15
15.73.9
{1.60.4}
Max. 24.5
{Max. 2.5}
15.73.9
{1.60.4}
Max. 24.5
{Max. 2.5}
12.72.9
{1.30.3}
Max. 21.6
{Max. 2.2}
12.72.9
{1.30.3}
Max. 21.6
{Max. 2.2}
24.55.9
{2.50.6}
Max. 39.2
{Max. 4.0}
74.518.6
{7.61.9}
Max. 107.6
{Max. 11}
PC200/220(LC)-7
20-5
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model
Category
Item
Unload pressure
Boom
Arm
Hydraulic pressure
Bucket
Swing
Travel
Control circuit
source pressure
Measurement Condition
Unit
Standard value
Permissible value
3.91.0
{4010}
3.91.0
{4010}
34.81.0
{33510}
33.336.8
{340375}
Hydraulic oil temperature: Within operation range
Engine at high idling
Working mode: A mode
Hydraulic pump output pressure with all
control levers in NEUTRAL position
Hydraulic oil temperature: Within operation range
Engine at high idling
Working mode: A mode
Hydraulic pump output pressure with all
measurement circuits relieved
Values inside parenthesis: Hydraulic oil
pressure with one-touch power max.
switch in ON mode (reference only)
37.31.0
{38010}
36.339.2
{370400}
30.91.5
{31515}
28.932.9
{295335}
38.21.0
{39010}
37.340.2
{380410}
3.230.2
{332}
2.843.43
{2935}
When all control levers in
NEUTRAL
position
3.91.0
{4010}
3.91.0
{4010}
When
traveling at
half stroke
(without load)
2.20.1
{221}
2.20.1
{221}
Max. 100
()
Max. 130
()
3.10.3
Max. 3.7
4.40.4
Max. 5.5
Hydraulic oil temperature: Within operation range
Engine running at high idling
Self-reducing pressure valve output pressure with all control levers in NEUTRAL
position
Hydraulic oil temperature: Within operation
range
Self-reducing pres- Engine at high idling
sure valve
Working mode: A mode
Traveling speed: Hi
Hydraulic oil pump pressure - LS pressure
Hydraulic oil temperature: Within operation
range
Engine running at high idling
Working mode: A mode
Swing circle misalignment amount when
stopping after one turn
MPa
{kg/cm2}
deg.
(mm)
Swing
Swing brake angle
PC200, 200LC-7
90
Time taken to start
swing
20-6
Hydraulic oil temperature:
Within operation range
Engine running at high
idling
Working mode: A mode
Time required for passing
points 90 and 180
degrees from starting
point
sec.
180
PC200/220(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC220, 220LC-7
Standard value
Permissible value
3.91.0
{4010}
3.91.0
{4010}
34.81.0
{33510}
33.336.8
{340375}
37.31.0
{38010}
36.339.2
{370400}
30.91.5
{31515}
28.932.9
{295335}
38.71.0
{39510}
37.340.2
{380410}
3.230.2
{332}
2.843.43
{2935}
3.91.0
{4010}
3.91.0
{4010}
2.20.1
{221}
2.20.1
{221}
Max. 165
()
Max. 200
()
2.90.3
Max. 3.5
4.30.4
Max. 5.4
PC200/220(LC)-7
20-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model
Category
Item
Time taken to
swing
PC200, 200LC-7
Measurement Condition
Unit
Standard value
Permissible value
Hydraulic oil temperature: Within operation
range
Engine running at high idling
Working mode: A mode
Time required for 5 more turns after making
initial one turn
sec.
24.22.5
Max. 30
mm
/min
Max. 5
Max. 10
Lo
PC200: 51.35.1
PC200LC: 55.95.6
PC200: 46.260.4
PC200LC:
50.365.5
( Mi)
PC200: 37.53.8
PC200LC: 40.84.1
PC200: 33.745.3
PC200LC:
36.748.9
Hi
PC200: 28.01.4
PC200LC: 30.51.5
PC200: 26.631.4
PC200LC:
29.034.0
Lo
242.5
21.527.5
( Mi)
172.5
14.520.5
Hi
131.0
12.015.0
Swing
15
BKP00103
Hydraulic drift of
swing
Leakage from
swing motor
Travel
Travel speed (1)
Hydraulic oil temperature: Within operation
range
Engine stopped
Keeping upper structure transverse on
slope of 15 degrees
Notching a mating mark on inner and outer
races of swing circle
Mating mark misalignment amount during 5
minutes
Hydraulic oil temperature: Within operation
range
Engine running at high idling
Swing lock switch: ON
Leakage amount for one minute during
swing relief
BKP00104
Hydraulic oil temperature: Within
operation range
Engine running at high idling
Working mode: A mode
Time required for track shoes to
make 5 turns after making one initial idle turn
sec.
45
BKP00105
Travel speed (2)
Hydraulic oil temperature: Within
operation range
Engine running at high idling
Working mode: A mode
Flat ground
Time required for traveling 20 m
after 10 m trial run
: The Mi mode is on the multi-monitor specification machine only.
20-8
PC200/220(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC220, 220LC-7
Standard value
Permissible value
25.7 +2.8
2.4
Max. 31
Max. 5
Max. 10
PC220: 53.6 +6.0
4.9
PC220LC:
PC220: 48.763.6
PC220LC:
52.868.6
58.1 +6.5
5.3
PC220: 39.2 +4.4
3.6
PC220LC:
42.5 +4.7
3.9
+1.5
PC220: 28.0 1.3
PC220LC:
+1.6
30.3 1.4
PC220: 35.647.6
PC220LC:
38.651.2
PC220: 26.731.5
PC220LC:
28.933.9
242.5
21.527.5
172.0
15.020.0
131.0
12.015.0
PC200/220(LC)-7
20-9
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model
Category
Item
PC200, 200LC-7
Measurement Condition
Unit
Standard value
Permissible value
mm
Max. 150
Max. 250
mm
/min
13.6
27.2
Max. 600
Max. 900
Max. 18
Max. 27
Max. 160
Max. 240
Max. 40
Max. 58
45
BKP00105
Travel deviation
Hydraulic oil temperature: Within
operation range
Engine at high idling
Working mode: A mode
Travel speed: Lo
Solid and flat ground
Swerving amount while traveling
20 m (X) after initial 10 m trial run
20m
Travel
10m
BKP00107
12
BKP00108
Hydraulic drift of travel
Hydraulic drift of work equipment
Work equipment
Leakage of travel motor
20-10
Hydraulic oil temperature: Within
operation range
Engine stopped
Parking machine on slope of 12
degrees with sprocket facing
upslope
Sliding distance for 5 minutes
Hydraulic oil temperature: Within
operation range
Engine at high idling
Traveling with sprocket locked
Oil leakage amount for one
minute with traveling in relief condition
Whole work equipment (tooth tip fall
amount)
Boom cylinder (cylinder retraction amount)
Arm cylinder (cylinder
extension amount)
Bucket cylinder (cylinder retraction amount)
BKP00110
Hydraulic oil temperature: Within
operation range
Flat and level ground
Work equipment in measurement
posture as illustrated above
Engine stopped
Work equipment control lever in
NEUTRAL position
Fall amount for 15 minutes as
measured every 5 minutes starting immediately after initial setting
mm
PC200/220(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC220, 220LC-7
Standard value
Permissible value
Max. 150
Max. 250
13.6
27.2
Max. 600
Max. 900
Max. 18
Max. 27
Max. 160
Max. 240
Max. 40
Max. 58
PC200/220(LC)-7
20-11
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
RAISE
3.30.4
Max. 4.7
LOWER
2.40.3
Max. 3.7
IN
Measurement Condition
Hydraulic oil temperature: Within
operation range
Engine running at high idling
Working mode: A mode
Time required from raise stroke
end till bucket touches ground
Permissible value
3.50.3
Max. 4.5
OUT
Work equipment speed
Work equipment
Boom
Standard value
2.70.3
Max. 3.5
CURL
Item
PC200, 200LC-7
2.60.3
Max. 3.3
DUMP
Applicable model
Category
Unit
1.90.2
Max. 2.7
Max. 1.0
Max. 1.2
Arm
Hydraulic oil temperature: Within
operation range
Engine running at high idling
Working mode: A mode
Time required from dumping stroke
end to digging stroke end
sec.
Bucket
Time lag
Hydraulic oil temperature: Within
operation range
Engine running at high idling
Working mode: A mode
Time required from dumping stroke
end to digging stroke end
20-12
Boom
BKP00114
Hydraulic oil temperature: Within operation
range
Engine running at low idling
Working mode: A mode
Time required from raise stroke end till
bucket touches ground and pushes up
machine front
sec.
PC200/220(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC220, 220LC-7
Standard value
+0.5
Permissible value
3.4 0.3
Max. 4.9
2.70.3
Max. 4.4
3.80.4
Max. 4.5
+0.4
2.9 0.2
Max. 3.5
2.90.3
Max. 3.3
2.20.3
Max. 2.7
Max. 1.0
Max. 1.2
PC200/220(LC)-7
20-13
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model
Category
PC200, 200LC-7
Item
Measurement Condition
Arm
Hydraulic oil temperature: Within operation
range
Engine running at low idling
Working mode: A mode
Time required from dumping stroke end till
bucket stops momentarily after control
lever is tilted to digging and starts to move
again
Unit
Standard value
Permissible value
Max. 2.0
Max. 2.8
Max. 1.0
Max. 3.6
4.5
20
10
50
Max. 200
Max. 220
Work equipment
Time lag
BKP00115
sec.
BKP00116
Hydraulic oil temperature: Within operation
range
Engine running at low idling
Working mode: A mode
Time required from dumping stroke end till
bucket stops momentarily after control
lever is tilted to digging and starts to move
again
Hydraulic oil temperature: Within operation
Cylinders
range
Engine running at high idling
cc/min
Leakage amount for one minute with cylinCenter
der or travel to be measured in relief condiswivel joint
tion
Performance of
hydraulic pump
Performance in compound operation
Internal
leackage
Bucket
Swerving amount
in simultaneous
operation of work
equipment and
travel
Hydraulic oil temperature: Within operation
range
Engine at high idling
Working mode: A mode
Traveling speed: Lo
Flat and level ground
Swerving amount (X) when traveling 20 m
after initial trial run of 10 m
10m
Hydraulic pump
delivery
20-14
mm
20m
See next page
BKP00107
/min
See next page
PC200/220(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC220, 220LC-7
Standard value
Permissible value
Max. 2.0
Max. 2.8
Max. 1.0
Max. 3.6
4.5
20
10
50
Max. 200
Max. 220
See next page
PC200/220(LC)-7
20-15
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model
Category
Item
PC200, 200LC-7
Measurement Condition
Unit
Standard value
Permissible value
Standard value
for discharge
amount Q
(/min)
Judgement
standard lower
limit Q
(/min)
See graph
See graph
Performance of hydraulic pump
Discharge amount of hydraulic pump (A mode)
Pump speed: At 1,950 rpm, PC current 310 mA
Check point
As desired
Test pump
discharge
pressure
(MPa {kg/cm2})
Discharge
pressure of
other pump
(MPa {kg/cm2})
P1
P2
Average
pressure
(MPa {kg/cm2})
P1+P2
2
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
20-16
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
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.
PC200/220(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model
Category
Item
PC220, 220LC-7
Measurement Condition
Unit
Standard value
Permissible value
Performance of hydraulic pump
Discharge amount of hydraulic pump (A mode)
Pump speed: At 2,050 rpm, PC current 310 mA
Check point
As desired
Test pump
discharge
pressure
(MPa {kg/cm2})
Discharge
pressure of
other pump
(MPa {kg/cm2})
P1
P2
Average
pressure
(MPa {kg/cm2})
P1+P2
2
Standard value
for discharge
amount Q
(/min)
Judgement
standard lower
limit Q
(/min)
See graph
See graph
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
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.
PC200/220(LC)-7
20-17
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Flow control characteristic of PC valve (STD)
The values in this table are used as reference values when carrying out troubleshooting.
Applicable model
Category
Item
Measurement Condition
Time required for turnCharacteristics of
ing from 0 to 90
Hydraulic oil temperature: Within operation
PC flow control
degrees with boom
range
valve
raised
Engine at high idling
Working mode: A mode
Rated load applied to bucket
Solid and flat ground
Time required till passing spot of 90 degrees
starting from illustrated posture and with boom
raised
PC200, 200LC-7
Unit
Reference Value
sec.
4.20.4
Applicable model
Category
Item
Measurement Condition
Time required for turnCharacteristics of
ing from 0 to 90
Hydraulic oil temperature: Within operation
PC flow control
degrees with boom
range
valve
raised
Engine at high idling
Working mode: A mode
Rated load applied to bucket
Solid and flat ground
Time required till passing spot of 90 degrees
starting from illustrated posture and with boom
raised
20-18
PC220, 220LC-7
Unit
Reference Value
sec.
4.30.4
PC200/220(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF ENGINE RPM............................................................................... 20-102
MEASUREMENT OF EXHAUST GAS COLOR.......................................................................................... 20-104
ADJUSTMENT OF VALVE CLEARANCE................................................................................................... 20-105
MEASUREMENT OF COMPRESSION PRESSURE ................................................................................. 20-107
MEASUREMENT OF BLOW-BY PRESSURE............................................................................................ 20-108
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING........................................................... 20-109
MEASUREMENT OF ENGINE OIL PRESSURE........................................................................................ 20- 111
ADJUSTMENT OF ENGINE SPEED SENSOR.......................................................................................... 20- 112
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION.......................................... 20- 112
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM............................................... 20- 113
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS........................................................ 20- 114
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION ............................................................. 20- 115
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE
IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL .................................... 20- 116
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE......................................... 20-120
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE ....................... 20-121
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE........................ 20-124
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE .............................................................. 20-128
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE ......................................................................... 20-131
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE ......................................................... 20-132
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT................................... 20-133
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT ......................................................... 20-134
MEASUREMENT OF OIL LEAKAGE AMOUNT ......................................................................................... 20-135
AIR BLEEDING OF VARIOUS PARTS ....................................................................................................... 20-137
INSPECTION PROCEDURES FOR DIODE............................................................................................... 20-139
SPECIAL FUNCTION OF MULTI-MONITOR PANEL ................................................................................. 20-140
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT MONITOR PANEL ........................... 20-164
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM.................................................... 20-177
PC200/220(LC)-7
20-101
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF ENGINE RPM
INSPECTION AND ADJUSTMENT OF ENGINE RPM
Engine inspection and maintenance tools
Mark
1
A
2
Part No.
799-203-8001
795-790-2500
Part Name
Multi-tachometer
Adapter
Engine RPM may be detected using a monitoring
function in the monitor panel (special function
furnished to the monitor panel).
k Be careful not to touch the strongly heated portion of the engine by accident while installing a
measurement equipment.
Inspection
1. Open up the engine hood and take off cover (1).
Use a filter wrench to take off the cover.
2. Fit adapter A2, and connect pickup set
meter of multi-tachometer A1.
20-102
and
3. Measure the engine RPM after setting each
measurement condition.
1) RPM at low idling:
i) Set the fuel dial at low idling (MIN).
ii) Move all the control levers of work
equipment, swing and travel to the
NEUTRAL position.
2) RPM at high idling:
i) Turn the auto-decelerator OFF.
ii) Set the fuel dial at high idling (MAX).
iii) Move all the control levers of work
equipment, swing and travel to the
NEUTRAL position.
3) RPM at fuel pump relief
i) Set the fuel dial at high idling (MAX)
ii) Put the arm in the digging relief position.
4) RPM when 2 pump relief and one-touch
power max. switch are set (near rated RPM)
i) Set the fuel dial at high idling (MAX).
ii) Put the arm in digging relief position and
keep the one-touch max. power switch
depressed.
The one-touch power max. function is
automatically released in 8.5 seconds,
even if the knob switch is kept depressed. Take measurement during the
period.
5) RPM when auto-decelerator is set
i) Turn the auto-decelerator ON.
ii) Set the fuel dial at high idling (MAX).
iii) Move all the control levers of work
equipment, swing and travel to the
NEUTRAL position.
Approx. 5 seconds after all the control levers are moved to the NEUTRAL position, the rpm falls automatically. That is
when the rpm with the auto-decelerator
in motion should be measured.
PC200/220(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF ENGINE RPM
4. Detach all the measurement tools after the
inspection, and make sure that the machine is
back to normal condition.
Adjustment
1. Adjustment of RPM at low idling
If the rpm at low idling deviates from the
standard value, make adjustment using the
adjustment function provided in the monitor
panel.
For the adjustment procedures, refer to the
section, "Special Function of Monitor Panel"
2. Adjustment of Governor Spring
If the rpm at high idling deviates from the
standard value, or it is unsteady (hunting),
adjust the governor spring securing dimensions, using the adjustment function in the
monitor panel.
For the adjustment procedures, refer to the
section, "Special Function of Monitor Panel"
PC200/220(LC)-7
20-103
TESTING AND ADJUSTING
MEASUREMENT OF EXHAUST GAS COLOR
MEASUREMENT OF EXHAUST GAS COLOR
Exhaust gas color measurement tool
Mark
Part No.
Part Name
1
799-201-9000
Handy Smoke Checker
B
2 Commercial product
Smoke Meter
k
Be careful not to touch the highly heated parts,
while fitting and detaching a measurement tool.
If no compressed air or power is not available in
the field, use Handy Smoke Checker B1. For recording official data, use Smoke Meter B2.
1. Measurement with Handy Smoke Checker B1
1) Fit a filtering paper to Handy Smoke Checker
B1.
2) Insert the exhaust gas intake pipe into the
exhaust pipe.
3) Start the engine and keep it running until the
engine cooling water temperature comes
within the operating range.
4) Let the exhaust gas stay on the filtering
paper by operating a handle of Handy
Smoke Checker B1, when the engine speed
is suddenly accelerated or kept at high
idling.
5) Take out the filtering paper and compare it
with the attached scale for judgement.
6) Detach the measurement tool after the
measurement, and make sure the machine
is back to normal condition.
2. Measurement with Smoke Meter B2
1) Insert probe
of the Smoke Meter B2 into
the exhaust gas pipe outlet, and fasten it to
the outlet with a clip.
20-104
2) Connect the probe hose, accelerator switch
outlet and air hose to the Smoke Meter B2.
Keep the pressure of the supplied compressed air below 1.5 MPa {15 kg/cm2}.
3) Connect the power cable to an outlet of
AC100V.
Confirm that the Smoke Meter power
switch is in the OFF position, before connecting the power cable to an outlet.
4) Fit a filtering paper by loosening the suction
pump cap nut.
Fit the filtering paper securely so that air
may not leak.
5) Move the Smoke Meter B2 power switch to
the ON position.
6) Start the engine and keep it running until the
engine water temperature rises to the operating range.
7) Let the exhaust gas stay on the filtering
paper by depressing the accelerator pedal
of Smoke Meter B2, when the engine speed
is suddenly accelerated or kept at high
idling.
8) Put the polluted filtering paper on non-polluted filtering paper (more than 10 sheets) in
the filtering paper holder, and read the indicated value.
9) Detach the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
PC200/220(LC)-7
TESTING AND ADJUSTING
ADJUSTMENT OF VALVE CLEARANCE
ADJUSTMENT OF VALVE CLEARANCE
Valve clearance adjustment tools
Mark
Part No.
1
795-799-1131
C
2 Commercial product
Part Name
Gear
Filler Gauge
1. Open up the engine hood, and remove the fan
guard on the counterweight side.
2. Remove all cylinder head covers (1).
5. When No. 1 cylinder is at the top dead center,
adjust valve clearances indicated with a black
bullet mark (!) in the chart below in the following manner.
3. Take off cap (2) and fit gear C1.
4. Turn the crankshaft clockwise with gear C1,
then match 1.6 TOP notch "a" of the crank pulley with pointer (3), and bring up No.1 cylinder to
the top dead center.
When No. 1 cylinder is at the top dead center, its rocker arm can be manually moved as
much as the valve clearance. If it cannot be
moved, that means that No. 1 cylinder is not
yet at the top dead center. In that case, rotate it by one more turn.
PC200/220(LC)-7
1) Insert filler gauge C2 in between rocker arm
(4) and valve stem (5), and adjust the valve
clearance with adjusting screw (6).
For the adjustment, turn the adjusting
screw with filler gauge C2 inserted to the
extent that filler gauge C2 can be lightly
moved.
2) Fix adjusting screw (6) and then tighten lock
nut (7).
3 Lock nut: 244 Nm{2.450.41kgm}
Check the valve clearance again after
tightening lock nut (7).
Proceed to the next step once all the adjustments of valve clearance indicated with a
black bullet mark (!) have been completed.
20-105
TESTING AND ADJUSTING
ADJUSTMENT OF VALVE CLEARANCE
6. Turn the crankshaft clockwise with gear C1,
then match 1.6 TOP notch "a" of the crank pulley with pointer (3), and bring up No. 6 cylinder
to the top dead center.
7. When No. 6 cylinder is at the top dead center,
adjust valve clearances indicated with a white
bullet mark (") in the chart.
The adjustment procedures are the same as
introduced in Item 5 above.
8. After the adjustment, make sure that the
machine is back to normal condition.
3 Cylinder head cover securing bolt:
244 Nm{2.450.41 kgm}
20-106
PC200/220(LC)-7
TESTING AND ADJUSTING
MEASUREMENT OF COMPRESSION PRESSURE
MEASUREMENT OF COMPRESSION PRESSURE
Compression pressure measurement tools
Mark
1
D
2
k
Part No.
795-502-1205
795-502-1700
Part Name
Compression Gauge
Adapter
Be careful not to get burnt by touching the exhaust manifold or muffler, or get caught with a
rotating parts, while taking measurement of
compression pressure.
1. Adjust the valve clearances.
For the adjustment, refer to the section, "Adjustment of Valve Clearance".
2. Make preparations for measuring the engine
rpm.
For the preparations, refer to the section, "Inspection and adjustment of Engine RPM".
6. Take off governor spring (2).
7. Fasten governor lever (3) of the fuel injection
pump, as it is in contact with the stopper on the
STOP side.
3. Warm up the engine until the engine oil temperature rises up to 40 60C.
4. Detach nozzle holder (1) of a cylinder to be
measured.
5. Fit Adapter D2 to the nozzle holder mounting,
and connect with gauge ass'y of compression
gauge D1.
3 Adapter: 609 Nm{6.120.92 kgm}
PC200/220(LC)-7
8. Crank up the engine with the engine starting
motor, and measure the compression pressure.
Read off the value, when the needle of the
compression gauge steadies itself.
When taking measurement of the compression pressure, be sure to measure the engine rpm, too, so that it stays within the range
of designated measurement conditions.
9. Detach the measurement tools after the measurement, and make sure that the machine is
back to normal condition.
2 Nozzle holder:
Seizure preventive (Molycoat 1000)
3 Nozzle holder:
609 Nm{6.120.92 kgm}
20-107
TESTING AND ADJUSTING
MEASUREMENT OF BLOW-BY PRESSURE
MEASUREMENT OF BLOW-BY PRESSURE
Blow-by pressure measurement tools
Mark
1
E
2
Part No.
799-201-1504
795-790-1950
Part Name
Blow-by Kit
Tool (Nozzle)
Read off the blow-by pressure value, when
the needle of the gauge steadies itself.
1. Fit tool E2 to blow-by hose and connect it with
gauge of blow-by kit E1.
5. Detach the measurement tools after the measurement, and make sure that the machine is
back to normal condition.
2. Start the engine, and lock the travel.
k Insert pin
in between the sprocket and
the track frame to make sure to block the
travel.
3. Start the engine and keep it running until the
engine cooling water temperature rises to the
operating range.
4. Measure the blow-by pressure at high idling and
under the following conditions.
Working mode: A mode
Work equipment, swing and travel:
Travel relief
20-108
PC200/220(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
Fuel injection timing inspection and adjustment
tools
Mark
1
F 2
3
Part No.
795-799-1131
795-799-1900
795-799-1950
Part Name
Gear
Pin Ass'y
Lock Pin
Inspection
1. Open up the engine hood, and then detach the
fan guard on the counterweight side.
2. Take off cover (1) and fit gear F1.
3. Turn the crankshaft clockwise with gear F1, then
match 1.6 TOP notch "a" of the crank pulley with
pointer (2), and bring up No.1 cylinder to the top
dead center.
Take off the cylinder head cover for No.1 cylinder, and confirm that its rocker arm can be
manually moved as much as the valve clearance. If it cannot be moved, that means that
No.1 cylinder is not yet at the top dead center. In that case, rotate it by one more turn.
PC200/220(LC)-7
4. Fix the fuel injection pump drive gear to match
injection timing by pushing drive gear timing pin
(3) in the direction of the front cover.
Injection timing requires adjustment of high
precision. Be sure to fix the drive gear with
timing pin (3) so as to match injection timing.
Push-in depth: 8 mm
If timing pin (3) cannot be pushed in, turn the
crankshaft a bit fore or aft with gear F1.
If it is found difficult to confirm the push-in
depth with timing pin (3) as installed in the
engine, metallic pin ass'y F2 may well be
used instead.
5. Disconnect plug (4) of the fuel injection pump.
6. Reverse and push in timing pin (5) of the fuel
injection pump, and confirm its cut-out portion
matches with protruding portion b inside the
pump.
If timing pin (5) can be pushed in smoothly,
then injection timing is correct.
If timing pin (5) cannot be pushed in smoothly, injection timing is incorrect and requires
adjustment.
If it is found difficult to confirm the push-in
depth with timing pin (5) as installed in the
engine, metallic pin ass'y F3 may well be
used instead.
20-109
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
7. Detach the measurement tools after the measurement, and make sure that the machine is
back to normal condition.
3 Cylinder head cover securing bolt:
244 Nm{2.450.45 kgm}
k Do not forget to bring driving gear timing pin
(3) and injection pump timing pin (5) back to
the pre-inspection condition.
In case the adjustment follows, leave gear
F1 and timing pin (3) as they are.
Adjustment
If fuel injection timing is found incorrect, adjust it
in the following manner.
1. Confirm that drive gear injection timing is fixed
with driving gear timing pin (3).
If timing pin (3) was pulled back after the inspection had been completed, push it in
again following the foregoing inspection procedures.
3. Reverse and push in timing pin (5) of the fuel
injection pump, then match the pin cut-out portion and protruding portion "b" inside the fuel
injection pump by turning the shaft.
After fuel timing has been set, fix it by fitting
plug (4).
4. Mount the fuel injection pump.
For mounting the pump, refer to the same
section mentioned in Item 2 above.
5. Detach the measurement tools after the adjustment, and make sure that the machine is back
to normal condition.
k Before starting the engine again, check that
driving gear timing pin (3) and fuel injection
pump timing pin (5) have been brought back
to the pre-adjustment condition.
2. Dismantle the fuel injection pump.
For dismantling the fuel injection pump, refer
to the section, "FUEL INJECTION PUMP
ASSEMBLY" in the chapter of "DISASSEMBLY AND ASSEMBLY".
20-110
PC200/220(LC)-7
TESTING AND ADJUSTING
MEASUREMENT OF ENGINE OIL PRESSURE
MEASUREMENT OF ENGINE OIL PRESSURE
Engine oil pressure measurement tools
Mark
1
G
2
Part No.
799-101-5002
790-261-1203
799-401-2320
Part Name
Hydraulic Tester
Digital type
hydraulic tester
Hydraulic Tester
(1.0MPa{10 kg/cm2})
4. Measure engine oil pressure at low idling as well
as at high idling.
1. Take off engine oil pressure measurement plug
(1) on top of the engine filter.
5. Detach the measurement tools after the measurement, and make sure that the machine is
back to normal condition.
2. Install fitting
of the hydraulic tester G1, and
connect it to hydraulic tester G2.
3. Start the engine and keep it running until the
engine cooling water temperature rises to the
operating range.
PC200/220(LC)-7
20-111
TESTING AND ADJUSTING
ADJUSTMENT OF ENGINE SPEED SENSOR
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION
ADJUSTMENT OF ENGINE
SPEED SENSOR
Detach engine speed sensor (1) before the adjustment, then check that there is no metal dust
stuck or damage at the tip and fit it again.
1. Screw in sensor (1) until its tip comes to contact
with the tip of flywheel ring gear teeth (2).
3 Threaded portion:
Gasket sealant (LG-6)
2. Screw back sensor (1) from that position by the
prescribed angle.
Screw-back angle: 11/6 turn
Adjust clearance "a" between the sensor tip
and gear tooth tip to be 1.251.75 mm.
3. Fasten sensor (1) with nut (3).
3 Nut: 49.068.6 Nm{57 kgm}
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR
BELT TENSION
Inspection
Check belt deflection amount a when depressing the
mid point between the fan pulley and the compressor with a thumb.
Belt depressing force: Equivalent to 58.8 N{6 kg}
Adjustment
If the belt deflection amount is not proper, adjust
it in the following manner.
1. Loosen two compressor bracket securing bolts
(1) (upper and lower).
2. Loosen lock nut (2), and adjust the belt tension
by shifting the position of compressor bracket
(1).
3. Tighten lock nut (2).
4. Tighten two compressor bracket (1) securing
bolts.
Check the belt tension again after the adjustment.
4. After the adjustment, confirm that correct engine
speed is displayed in the monitor panel, using
the special monitoring function.
For monitoring engine speed, refer to the
section, "Special Function of Monitor Panel".
20-112
PC200/220(LC)-7
TESTING AND ADJUSTING
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL
SYSTEM
If a failure occurs on any of the engine control devices like fuel dial, governor pump controller or
governor motor potentiometer, and the engine
gets out of control, first fix the engine rpm and
take the following steps to avoid the immediate
danger.
The suggested steps are provisional ones. Identify the cause for the failure and carry out repairs
promptly thereafter.
3. Remove bolt (4), connect governor spring (3)
and fix it at the original position.
Tilt the governor motor lever to the fuel injection pump side, but stop short of the governor spring.
The governor lever of the fuel injection pump
is fixed at a near-idling position.
1. Disconnect E11 connector (1) of the governor
motor from E10 connector (2) of the governor
potentiometer.
k If the governor motor connector is left connected, the governor motor will be suddenly
activated while the engine is running, causing a mechanical damage. Be sure to disconnect it.
4. Start the engine again and travel the machine to
a safe place.
2. Detach governor spring (3) on the governor
motor side.
PC200/220(LC)-7
5. Disconnect governor spring (3) and stop the
engine.
k Operation of stopping the engine is to be
carried out while the engine is running at
high speed. Be careful not to touch the parts
of high temperature or get caught in rotating
parts.
If the governor spring is tilted all the way to
the fuel injection pump, the pump stops with
no more injection.
Hold the governor spring until the engine
comes to a complete stop. Otherwise the
fuel injection pump automatically returns to
the low idling position, and the engine does
not stop.
20-113
TESTING AND ADJUSTING
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS
Swing circle bearing clearance measurement
tools
Mark
Part No.
H
Commercial Product
Part Name
Dial Gauge
Follow the steps explained below, when measuring clearance in the swing circle bearing in the
actual machine.
k Be careful not to put a hand or foot under the undercarriage, while taking measurement.
4. Hold the arm nearly perpendicular to the
ground, and lower the boom until the track
shoes will be lifted at the machine front.
The upper structure is raised at the front and
lowered at the rear at that time.
5. Read off the value in dial gauge H in this condition.
The value indicated in dial gauge H expresses clearance in the bearings.
1. Fasten dial gauge H to swing circle outer race
(1) or inner race (2), and contact the probe with
the end surface of inner race (2) or outer race
(1) on the opposite side.
Set dial gauge H at the machine front or rear.
6. Return the machine to the posture in Item 2
above, and confirm reading of dial gauge H is
zero.
If zero value is not indicated, repeat the
steps in Items 3 through 5.
2. Keep the work equipment in the max. reach posture and keep the height of the bucket teeth tip
level with the lower height of the revolving
frame.
The upper structure is lowered at the front
and raised at the rear at that time.
3. Set dial gauge H at zero point.
20-114
PC200/220(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION
Inspection
1. Travel the machine forward by the length of
track on ground, keeping the engine at low
idling, and stop the machine slowly.
2. Place straight bar
on the track shoe between
the idler and the 1st carrier roller.
L beam is recommended for bar , because
of its deflection-free nature.
3. Measure max. clearance a between bar
and
the track shoe.
Max. standard clearance a: 1030 mm
PC200/220(LC)-7
Adjustment
If the track shoe tension is not proper, adjust it in
the following manner.
1. When the tension is too strong
Discharge grease by loosening valve (1).
k Do not loosen valve (1) by more than one
turn, because grease will spurt out due to its
internal high pressure.
2. When the tension is too weak
Add grease through grease fitting (2).
If the normal track shoe tension is not restored even after greasing, move the machine slowly back and forth.
20-115
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING
AND TRAVEL
Inspection and adjustment tools for hydraulic oil
pressure in hydraulic circuit for work equipment,
swing and travel
Mark
1
Part No.
799-101-5002
790-261-1203
J
2
799-101-5220
07002-11023
Part Name
Hydraulic Tester
Digital Type
Hydraulic Tester
Grease Fitting
(10 x 1.25 mm)
O-ring
2) Fit fitting J2 and connect it to oil pressure
gauge of hydraulic tester J1.
Use an oil pressure gauge with the capacity of 58 MPa{600 kg/cm2}.
Hydraulic oil pressure in the hydraulic circuit for
work equipment, swing and travel (hydraulic
pump output pressure) may be also confirmed
with a monitoring function in the monitor panel
(special function of monitor panel).
Measurement
1. Pre-measurement work
k Lower the work equipment to the ground,
then release the remaining pressure in the
piping by operating the control lever several
times after stopping the engine, and release
the pressure inside the hydraulic tank by
gradually loosening the oil filler cap.
1) Remove hydraulic oil pressure measuring
plugs (1) and (2).
Plug (1): For the circuit of front hydraulic
pump
Plug (2): For the circuit of rear hydraulic
pump
3) Start the engine and keep it running until the
hydraulic oil temperature rises to the operating range.
2. Combination of pump, actuator and valve
You will know that when oil flow from the
pumps is divided, the front and rear pumps
work independently of each other for each
actuator, as well as that different relief valves
are activated then.
Oil flow from the pumps is merged in the single pressure relief when the work equipment
swings, while it is divided in the single pressure relief when the machine travels.
20-116
PC200/220(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
The actuators in the table below are arranged in the order that the control valves
are viewed from the machine front.
Pump
Rear
pump
Actuator
(Unload)
Service
Bucket
Travel, left
Boom
Front
pump
Swing
Travel, right
Arm
(Unload)
Relieve valve activated
R unload valve
Safety valve
R main relief valve
R main relief valve
RAISE: R main relief valve
LOWER: Safety valve
Swing motor safety valve
F main relief valve
F main relief valve
F unload valve
3. Measurement of Unload Pressure
1) Start the engine.
2) Measure hydraulic oil pressure, when the
engine is running at high idling and all the
control levers are moved to the NEUTRAL
position.
Hydraulic oil pressure when the unload valve
unloads is displayed.
4. Measurement of work equipment relief pressure
1) Start the engine and move the cylinder to be
measured to its stroke end.
2) Measure hydraulic oil pressure, when the
engine is running at high idling and the cylinder is in relief condition.
Hydraulic oil pressure when the main relief
valve is in relief condition is displayed.
If one-touch power max. switch is depressed, the oil pressure is turned to high relief pressure, and if released, it is turned to
low relief pressure.
Keep the swing lock switch in the ON position
during the inspection. If it is moved to the OFF
position, hydraulic oil pressure is turned to
high relief pressure, as the constant 2-stage
relief valve is moved to the ON position.
5. Measurement of swing relief pressure
1) Start the engine and move the swing lock
switch to the ON position.
2) Measure hydraulic oil pressure when the
engine is running at high idling and the
swing circuit is relieved.
PC200/220(LC)-7
Hydraulic oil pressure when the swing motor
safety valve is relieved is displayed.
The swing motor relief pressure is lower than
the main relief pressure.
6. Measurement of travel circuit relief pressure
1) Start the engine and lock travel.
k Put pin
in between the sprocket and the
track frame to make sure locking travel.
2) Measure hydraulic oil pressure when the
engine is running at high idling and the
travel circuit is relieved.
Hydraulic oil pressure with the main relief
valve in relief condition is displayed. In the
travel circuit relief, the pressure is high pressure relief all the time.
Adjustment
The unload valve and the safety valve for boom
LOWER cannot be adjusted.
1. Adjustment of main relief pressure
(high pressure setting side)
If relief pressure of the high pressure in the
work equipment and travel circuits is not normal, adjust the high pressure setting side of
main relief valves (3) and (4) in the following
manner.
Main relief valve (3): For the front hydraulic pump circuit
Main relief valve (4): For the rear hydraulic pump circuit
The relief pressure at high pressure indicates that when the 2- stage relief valve is
ON and pilot pressure is applied to the
switching port.
20-117
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
1) Disconnect the pilot hose.
2) Loosen lock nut (5) and adjust the pressure
by turning holder (6).
If the holder is turned to the right, the
pressure rises.
If the holder is turned to the left, the pressure falls.
Adjustment amount per turn of holder:
Approx. 12.5 MPa{approx. 128 kg/cm2}
3 Lock nut:
53.54.9 Nm{5.50.5 kgm}
3) Check the pressure again after the adjustment, following the aforementioned steps
for measurement.
When measuring the pressure, connect
the pilot hose.
If high pressure setting side is adjusted,
low pressure setting side is also affected, so adjust it, too.
20-118
2. Adjustment of main relief pressure (low
pressure setting side)
When low pressure relief pressure of the
work equipment is not normal, or when adjustment is made of the high pressure setting
side, adjust the low pressure side of the main
relief valve, too.
The relief pressure at high pressure indicates that when the 2-stage relief valve is
OFF and pilot pressure is not applied to the
switching port.
1) Disconnect pilot hose.
2) Loosen lock nut (7) and adjust the pressure
by turning holder (8).
If the holder is turned to the right, the
pressure rises.
If the holder is turned to the left, the pressure falls.
Adjustment amount per turn of holder:
Approx. 12.5 MPa{approx. 128 kg/cm2}
3 Lock nut:
53.54.9 Nm{5.50.5 kgm}
3) Check the pressure again after the adjustment, following the aforementioned steps
for measurement.
When measuring the pressure, connect
the pilot hose.
PC200/220(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
3. Adjustment of swing relief pressure
If the swing relief pressure is not normal, adjust it with swing motor safety valve (9) in the
following manner.
1) Loosen lock nut (10) and adjust the pressure by turning adjusting screw (11).
If the holder is turned to the right, the
pressure rises.
If the holder is turned to the left, the pressure falls.
Adjustment amount per turn of adjusting
screw:
Approx. 6.71 MPa{approx. 68.4 kg/cm2}
3 Lock nut:
78103 Nm{8.010.5 kgm}
2) Check the pressure again after the adjustment, following the aforementioned steps
for measurement.
PC200/220(LC)-7
20-119
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL
PRESSURE
Control circuit oil pressure inspection and adjustment tools
Mark
1
Part No.
799-101-5002
790-261-1203
J
2
799-101-5220
07002-11023
Part Name
Hydraulic Tester
Digital Type
Hydraulic Tester
Grease Fitting
(10 x 1.25 mm)
O-ring
3. Start the engine and keep it running until the
hydraulic oil temperature rises to the operating
range.
4. Measure oil pressure with the engine running at
high idling and all the control levers in the NEUTRAL position.
Measurement
k Lower the work equipment to the ground and
stop the engine. After the engine stops, operate
the control lever several times to release the remaining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hydraulic tank.
1. Remove oil pressure measurement plug (1).
5. Detach all the measurement tools after the measurement, and make sure that the machine is
back to normal condition.
Do not attempt to adjust the control circuit oil
pressure relief valve.
2. Fit fitting J2 and connect it to oil pressure gauge
of hydraulic tester J1.
Use an oil pressure gauge with the capacity
of 5.9 MPa{60 kg/cm2}.
20-120
PC200/220(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL
PRESSURE
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL
CIRCUIT OIL PRESSURE
Pump PC control circuit oil pressure inspection
and adjustment tools
Mark
1
Part No.
799-101-5002
790-261-1203
J
2
799-101-5220
07002-11023
Part Name
Hydraulic Tester
Digital Type
Hydraulic Tester
Grease Fitting
(10 x 1.25 mm)
O-ring
Measurement
Implement measuring the pump PC control circuit oil pressure after confirming that the work
equipment, swing and travel circuit oil pressure
as well as the control circuit original oil pressure
are normal.
k Lower the work equipment to the ground and
stop the engine. After the engine stops, operate
the control lever several times to release the remaining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hydraulic tank.
2) Fit fitting J2 and connect to oil pressure
gauge
of hydraulic tester J1.
Use an oil pressure gauge with the capacity of 58.8 MPa{600 kg/cm2}.
1. Measurement of PC valve output pressure
(servo piston inlet pressure)
Measure PC valve output pressure (servo
piston inlet pressure) and pump delivery
pressure together, and compare the two
pressures.
1) Remove oil pressure measurement plugs
(1), (2), (3) and (4).
Plug (1): For measuring the front pump
delivery pressure
Plug (2): For measuring the rear pump
delivery pressure
Plug (3): For measuring the front pump
PC valve delivery pressure
Plug (4): For measuring the rear pump
PC valve delivery pressure
PC200/220(LC)-7
20-121
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL
PRESSURE
3) Start the engine and keep it running until the
hydraulic oil temperature rises to the operating range.
4) Measure the pump delivery pressure and
PC valve output pressure (servo piston inlet
pressure) together with the engine running
at high idling, after setting the machine at
the following conditions.
Working mode: A mode
Swing lock switch: ON (switched to high
pressure relief with 2-stage relief turned
ON)
Work equipment, swing and travel circuit: Arm digging relief
Judgement method:
When the ratio between the pump delivery pressure and PC valve output pressure (servo piston output pressure)
reaches the following values, both pressures are judged normal.
Pressure to be
measured
Pump delivery
pressure
PC valve outlet
pressure
Pressure ratio
2. Measurement of PC-EPC output pressure
1) Remove oil pressure measurement plug (5).
2) Fit fitting J2 and connect it to oil pressure
gauge
of hydraulic tester J1.
Use an oil pressure gauge with the capacity of 5.9 MPa{60 kg/cm2}.
3) Start the engine and keep it running until the
hydraulic oil pressure rises to the operating
range.
1
Approx. 3/5
If there is any abnormality with PC valve
or servo piston, the PC valve output
pressure (servo piston output pressure)
equals to the pump delivery pressure, or
approximates to 0 pressure.
20-122
PC200/220(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL
PRESSURE
4) Measure the hydraulic oil pressure with all
the control levers kept in the NEUTRAL
position and the engine running at high
idling and at low idling.
If PC-EPC valve output pressure changes to the following values, it is judged
normal.
Engine
speed
Low idling
High idling
Control
lever
Neutral
Hydraulic oil
pressure
2.9 MPa
{30 kg/cm2}
0{0}
1. Loosen lock nut (8) and make adjustment, turning adjusting screw (9).
If the holder is turned to the right, the pump
absorption torque rises.
If the holder is turned to the left, the pump
absorption torque falls.
The adjustable range with the adjusting
screw is as shown below.
Left turn: Less than 1 turn
Right turn: Less than 1/2 turn (less than
180 degrees)
3 Lock nut:
27.5034.3Nm{2.83.5kgm}
Adjustment
If any of the phenomena mentioned below occurs and PC valve malfunctioning is suspected,
adjust PC valves (6) and (7) in the following manner.
As workload increases, the engine rpm
sharply drops.
While the engine rpm is normal, the work
equipment moves slowly.
2. Confirm that the PC valve output pressure
(servo piston inlet pressure) is normal after the
adjustment, following the measurement steps
explained earlier.
PC200/220(LC)-7
20-123
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL
PRESSURE
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL
CIRCUIT OIL PRESSURE
Pump LS control circuit oil pressure inspection
and adjustment tools
Mark
1
K
Part No.
799-101-5002
790-261-1203
799-101-5220
07002-11023
799-401-1340
Part Name
Hydraulic Tester
Digital Type
Hydraulic Tester
Grease Fitting
(10 x 1.25 mm)
O-ring
Differential Pressure
Gauge
Measurement
Measure pump LS control circuit oil pressure after confirming that the work equipment, swing
and travel circuit oil pressure as well as control
circuit original pressure are normal.
k Lower the work equipment to the ground and
stop the engine. After the engine stops, operate
the control lever several times to release the remaining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hydraulic tank.
2) Fit fitting K2 and connect it to oil pressure
gauge
of hydraulic tester K1.
Use an oil pressure gauge with the capacity of 58.5 MPa{600 kg/cm2}.
1. Measurement of LS valve output pressure
(servo piston inlet pressure)
Measure LS valve output pressure (servo
piston inlet pressure) and pump delivery
pressure together, and compare both pressures thereafter.
1) Remove oil pressure measurement plugs
(1), (2), (3) and (4).
Plug (1): For measuring the front pump
delivery pressure
Plug (2): For measuring the rear pump
delivery pressure
Plug (3): For measuring the front pump
LS valve delivery pressure
Plug (4): For measuring the rear pump
LS valve delivery pressure
3) Start the engine and raise the track shoe to
be measured with the work equipment.
For measuring oil pressure in front circuit: Right track shoe
For measuring oil pressure in rear circuit: Left track shoe
k Provide a working area of sufficient space,
as the raised track shoe will be idly rotated.
20-124
PC200/220(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL
PRESSURE
4) Wait until the hydraulic oil temperature rises
to the operating range.
1) Remove oil pressure measurement
(1), (2), (3) and (4).
Plug (1): For measuring the front
delivery pressure
Plug (2): For measuring the rear
delivery pressure
Plug (3): For measuring the front
LS pressure
Plug (4): For measuring the rear
LS pressure
plugs
pump
pump
pump
pump
5) Measure pump delivery pressure and PC
valve output pressure (servo piston inlet
pressure) together with the machine set at
the following conditions and the engine running at high idling.
Working mode: A mode
All the control levers of the work equipment, swing and travel are kept in the
NEUTRAL position and the travel control
lever is kept at half stroke (one side of
the track shoes idly rotates).
Let the raised track shoe idly rotate, paying enough attention to the surroundings
for safety.
Judgement method:
When the ratio between the pump delivery pressure and LS valve output pressure (servo piston output pressure)
reaches the following values, both pressures are judged normal.
Oil pressure ratio
Oil pressure to be
All control levers Travel at half
measured
in NEUTRAL
stroke
Pump delivery
1
pressure
Nearly equal
pressure
LS valve delivery
Approx. 3/5
pressure
6) Detach all the measurement tools after the
measurement and make sure that the
machine is back to normal condition.
2. Measurement of LS differential pressure
LS differential pressure can be obtained by
measuring pump delivery pressure and LS
pressure (actuator loaded pressure) at the
same time and computing the difference of
both pressures.
PC200/220(LC)-7
2) Fit fitting K2 and connect it to oil pressure
gauge
of hydraulic tester K1 or differential pressure gauge K3.
When using a differential pressure
gauge:
Connect pump delivery pressure to the
high pressure side and LS pressure to
the low pressure side.
A differential pressure gauge requires
DC 12V power. Connect it with one battery.
When using an oil pressure gauge:
Use an oil pressure gauge with the capacity of 58.5 MPa{600 kg/cm2}.
The max. differential pressure is no
more than approx. 40 MPa{3.9 kg/cm2}.
The same gauge may be used throughout the measurement.
20-125
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL
PRESSURE
5) Measure pump delivery pressure and LS
p r e s s u r e ( a c tu a t o r l o a d e d p r e s s u r e )
together with the machine set at the following conditions and the engine running at
high idling.
Working mode: A mode
Traveling speed: Hi
All the control levers of the work equipment, swing and travel are kept in the
NEUTRAL position and the travel control
lever is kept at half stroke (one side of
the track shoes idly rotates).
Let the raised track shoe idly rotate, paying enough attention to the surroundings
for safety.
Calculation of LS differential pressure:
LS differential pressure = Pump delivery
pressure LS pressure
If LS differential pressure is in the following conditions, it is judged normal.
Control lever position
LS differential pressure
All levers in
Unload pressure
NEUTRAL
(see standard value table)
Travel lever at
Max. LS differential pressure
half stroke
(see standard value table)
3) Start the engine and raise the track shoe to
be measured with the work equipment.
For measuring oil pressure in front circuit: Right track shoe
For measuring oil pressure in rear circuit: Left track shoe
k Provide a working area of sufficient
space, as the raised track shoe will be
idly rotated.
4) Wait until the hydraulic oil temperature rises
to the operating range.
20-126
6) Detach all the measurement tools after the
measurement, and make sure that the
machine is back to normal condition.
3. Measurement of LS-EPC valve output pressure
1) Remove oil pressure measurement plug (5).
PC200/220(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL
PRESSURE
2) Fit fitting K2 and connect it with oil pressure
gauge
of hydraulic tester K1.
Use an oil pressure gauge with the capacity of 5.9 MPa{60 kg/cm2}.
3) Start the engine and keep it running until the
hydraulic oil temperature rises to the operating range.
4) Measure the oil pressure when the engine is
running at high idling and the travel speed
switch and travel lever are operated.
If LS-EPC valve output pressure changes to the following values, the pressure
is normal.
Travel
Speed
Lo
Hi
Travel Control
Lever
Hydraulic
Pressure
Approx. 2.9 MPa
Neutral
{approx. 30 kg/cm2}
Fine control (Note)
0{0}
Adjustment
When LS differential pressure is not normal, adjust it with LS valves (6) and (7).
1. Loosen lock nut (8) and adjust the pressure by
tuning adjusting screw (9).
If the adjusting screw is turned to the right,
the differential pressure rises.
If the adjusting screw is turned to the left, the
differential pressure falls.
Adjustment amount (LS differential pressure) per turn of adjusting screw:
1.3 MPa{13.3 kg/cm2}
3 Lock nut: 4964 Nm{57 kgm}
2. After the adjustment, confirm that LS differential
pressure is normal, following the steps for measurement explained earlier.
Note: Operate the travel control lever
slightly to the extent that the PPC
hydraulic oil pressure is turned ON.
(Stop the operation short of starting
the machine)
5) Detach all the measurement tools after the
measurement, and make sure that the
machine is back to normal condition.
PC200/220(LC)-7
20-127
TESTING AND ADJUSTING
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
Solenoid valve output pressure measurement
tools
Mark
1
Part No.
799-101-5002
790-261-1203
L
799-401-2910
07002-*1423
Part Name
Hydraulic Tester
Digital Type
Hydraulic Tester
Grease Fitting
(Size 02)
O-ring
Measure solenoid valve output pressure after
confirming that control circuit original pressure is
normal.
k Lower the work equipment to the ground and
stop the engine. After the engine stops, operate
the control lever several times to release the remaining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hydraulic tank.
2. Fit fitting L2 and connect hoses (1) through (6)
again.
3. Fit fitting
of hydraulic tester L1 and connect it
to oil pressure gauge .
Use an oil pressure gauge with the capacity
of 5.9 MPa{60 kg/cm2}.
1. Disconnect the hoses of solenoid valve to be
measured at the outlet side.
No.
1
2
3
4
5
6
Solenoid valve to be measured
PPC lock solenoid valve
Travel interconnection solenoid valve
Merge/divide solenoid valve
Travel speed shifting solenoid valve
Swing and parking brake solenoid valve
2-stage relief solenoid valve
Hose (1) is installed at the rear of operator's
cab, and hoses (2) through (6) are installed
at the center of revolving frame.
20-128
4. Start the engine and keep it running until the
hydraulic oil temperature rises to the operating
range.
PC200/220(LC)-7
TESTING AND ADJUSTING
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
5. Run the engine at full throttle, then turn each
solenoid valve ON or OFF by operating the control lever switch, and measure the pressure.
For conditions for turning each solenoid
valve ON or OFF, refer to the ensuing "Table
for Functioning Conditions" for each solenoid valve.
How each solenoid valve functions can be
confirmed with monitoring function in the
monitor panel. (Special Function of Machine
Monitor)
When each output pressure shows the following values, it is judged normal.
Solenoid Valve
OFF (Demagnetization)
ON (Excitation)
Output Pressure
0{0}
3MPa{30kg/cm2}
6. Detach all the measurement tools after the measurement, and make sure that the machine is
back to normal condition.
Table for Functioning Conditions - PPC lock
solenoid valve
Functioning Condition
Locked
Safety lock lever
Released
Table for Functioning Conditions - Swing and
parking brake solenoid
Functioning
OFF
ON
Functioning Condition
Functioning
When all of them
OFF
Work equipment,
is OFF
swing, travel,
When any of them
signaling
ON
is ON
Table for Functioning Conditions - Travel interconnection solenoid valve
Functioning Condition
When the travel steering signal is ON
When the travel steering signal is OFF
If front or rear pump pressure
is over 24.5MPa{250kg/cm2}
In conditions other than above
Traveling operation only
Functioning
ON
ON
OFF
Table for Functioning Conditions - Travel speed shifting solenoid valve
Functioning Condition
When overheat setting of the 2nd stage is ON
When the fuel dial indicates less than 1500 rpm
When the travel speed switch is at Lo (or Mi)
The travel signal is OFF
If front or rear pump pressure is
24.5 MPa{250 kg/cm2}
When the travel speed switch is at Hi The travel
signal is ON
If front or rear pump pressure is
15.3 MPa{150 kg/cm2}
In conditions other than above
Functioning
OFF
ON
: The "Mi" mode is on the multi-monitor specification machine only.
PC200/220(LC)-7
20-129
TESTING AND ADJUSTING
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
Table for Functioning Conditions - 2-stage relief solenoid valve
Functioning Condition
Functioning
When overheat setting of the 1st stage is ON
When overheat setting of the 2nd stage is ON
OFF
When all the signals for work equipment, swing and travel are OFF
When swing lock switch is ON
When travel signal is ON
When working mode is L mode
ON
When boom LOWER signal is ON
When working mode is A or E When left knob If signals other than swing operation only is ON
mode
switch is ON
If swing operation only is ON
OFF
In conditions other than above
Table for Functioning Conditions - Merge/divide solenoid valve
When working mode is B mode
When working mode is L mode
When travel signal only is ON
When compound travel marks
are ON
When travel signal is OFF
Functioning Condition
When service signal is ON
When boom RAISE and swing signals are ON
Functioning
ON
When steering sig- If front or rear pump pressure is over 19.6
nal is OFF
MPa (200 kg/cm2)
When swing lock switch is ON
When working mode is A mode
When swing signal is ON
When service and If front or rear pump
When swing signal
pressure is over
arm dumping
is OFF
signal are ON
19.6 MPa{200 kg/cm2}
In conditions other than above
OFF
ON
OFF
: The "L" mode is on the multi-monitor specification machine only.
20-130
PC200/220(LC)-7
TESTING AND ADJUSTING
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
PPC valve output pressure measurement tools
Mark
M
Part No.
799-101-5002
Part Name
Hydraulic Tester
Digital Type
Hydraulic Tester
790-261-1203
2. Fit fitting
of hydraulic tester M and connect oil
pressure gauge .
Use an oil pressure gauge with the capacity
of 5.9 MPa{60 kg/cm2}.
Measure PPC valve output pressure after confirming that control circuit original pressure is
normal.
1. Remove PPC oil pressure switches (1) through
(12) in the hydraulic circuits to be measured.
No.
1
2
3
4
5
6
Circuit to be
measured
Boom, RAISE
Boom, LOWER
Arm, DIGGING
Arm, DUMPING
Bucket, DIGGING
Bucket, DUMPING
Circuit to be
measured
7 Swing, left
8 Swing, right
9 Travel (black)
10 Steering (red)
No.
3. Start the engine and keep it running until the
hydraulic oil temperature rises to the operating
range.
Oil pressure switches (1) through (8) are installed in the PPC relay block, and (9) and (10)
are installed at the rear of operator's cab.
4. Measure the pressure when the engine is running at high idling and the control lever of the circuit to be measured is kept in the NEUTRAL
position and at the full stroke.
If PPC valve output pressure is at the level
shown below, it is judged normal.
Lever Control
In NEUTRAL
At full stroke
Hydraulic Pressure
0{0}
Nearly equal to control
original pressure
(see standard value table)
5. Detach all the measurement tools, and make
sure that the machine is back to normal condition.
PC200/220(LC)-7
20-131
TESTING AND ADJUSTING
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE
If there is excessive play in the work equipment
or swing lever, adjust it in the following manner.
1. Remove work equipment and swing PPC valve
ass'y.
2. Take off boot (1).
3. Loosen lock nut (2) and screw in disc (3) until it
contacts the heads of four pistons (4).
Do not move the piston while doing this work.
4. Keep disc (3) in place and tighten lock nut (2) to
the specified tightening torque.
3 Lock nut: 9812 7Nm{1013 kgm}
5. Install boot (1).
6. Install work equipment and swing PPC valve
ass'y.
20-132
PC200/220(LC)-7
TESTING AND ADJUSTING INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK
EQUIPMENT
If there is any hydraulic drift in the work equipment (cylinders), check in the following manner
to determine if the cause is in the cylinder packing or in the control valve.
2. Inspection of arm cylinder
1) Operate the arm cylinder to move the arm to
the position 100 mm before the digging
stroke end, and stop the engine.
1. Inspection of boom and bucket cylinders
1) Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
Fill the bucket with earth or apply the rated load to the bucket.
2) Operate the control lever to the RAISE position or the bucket control lever to the CURL
position.
If the lowering speed increases, the cylinder packing is defective.
If there is no change, the control valve is
defective.
Operate the control lever with the engine
starting switch in the ON position.
If pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator
again.
PC200/220(LC)-7
2) Operate the arm control lever to move the
arm to the digging side.
If the lowering speed increases, the cylinder packing is defective.
If there is no change, the control valve is
defective.
Operate the control lever with the engine
starting switch in the ON position.
If pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator again.
[Reference]If the cause of the hydraulic drift is in the
defective packing, and the above operation is carried out, downward movement
is accelerated for the following reasons.
1) If the work equipment is set to the above posture (holding pressure applied to the bottom
end), the oil at the bottom end leaks to the head
end. However, the volume at the head end is
small than the volume at the bottom end by the
volume of the rod end, so the internal pressure
at the head end increases because of the oil
flowing in from the bottom end.
2) When the internal pressure at the head end
increases, the pressure at the bottom end also
rises in proportion to this. The balance is maintained at a certain pressure (this differs according to the amount of leakage) by repeating this
procedure.
3) When the pressure is balanced, the downward
movement becomes slower. If the lever is then
operated according to the procedure given
above, the circuit at the head end is opened to
the drain circuit (the bottom end is closed by the
check valve), so the oil at the head end flows to
the drain circuit and the downward movement
becomes faster.
20-133
TESTING AND ADJUSTING
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASE OF REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
3. Inspection of boom lock valve
1) Set the work equipment at the maximum
reach and the boom top horizontal. Then
stop the engine.
k Lock the work equipment control levers and
release the pressure inside the hydraulic
tank.
k Do not allow anyone to come under the
work equipment during the work.
2) Disconnect drain hose (1) of the control
valve, and install a blind plug in the hose.
Part No. for the blind hose: 07376-70210
Leave the control valve end open.
If any oil leaks out from the port that is
left open, following hydraulic drift of the
work equipment, the boom lock valve is
defective (loose contact).
If the piping between the hydraulic cylinders or
the hydraulic motor and control valves is to be
disconnected, release the remaining pressure in
the following manner.
There is no pressure remaining in the swing motor circuit and travel motor circuit, but the internal
pressure in the hydraulic tank affects them. So
open the oil filler cap of the hydraulic tank.
1. Stop the engine, and loosen the oil filler cap
gradually to release the pressure inside the
tank.
2. Turn the engine starting switch to the ON position and operate the control levers several
times.
There must be power supply to the PPC lock
valve. Be sure to operate the control levers
with the engine starting switch in the ON position.
When the levers are operated 2-3 times, the
pressure stored in the accumulator is removed.
3. Start the engine, run at low idling for approx. 10
seconds to accumulate pressure in the accumulator, then stop the engine.
4. Repeat the steps in Item 2 to 3 above several
times.
4. Inspection of PPC valve
Measure the amount of hydraulic drift of the
work equipment when the accumulator is
charged with pressure and the safety lock lever
is put to the LOCK and FREE positions.
Operate the control lever with the engine
starting switch in the ON position.
If pressure in the accumulator has dropped,
run the engine for approx. 10 seconds to
charge the accumulator again.
If there is any difference in the hydraulic drift
between LOCK and FREE positions, the
PPC valve is defective (some internal failure).
20-134
PC200/220(LC)-7
TESTING AND ADJUSTING
MEASUREMENT OF OIL LEAKAGE AMOUNT
MEASUREMENT OF OIL LEAKAGE AMOUNT
1. Measurement of oil leakage amount from
boom cylinder
1) Start the engine and keep it running until the
hydraulic oil temperature rises to the operating range. Then extend the boom cylinder to
the stroke end.
k Release the pressure remaining in the piping, referring to the foregoing section of
"Release of Remaining Pressure in Hydraulic Circuit".
2) Disconnect hose (1) at the cylinder head
end and block the hose end with a plate.
k Be careful not to disconnect the hose at the
cylinder bottom end.
3) Start the engine and apply the relief pressure to the bottom end of the cylinder with
the engine running at high idling.
4) Continue this condition for 30 seconds, then
measure the oil leakage amount for one
minute.
5) After the measurement, make sure that the
machine is back to normal condition.
2. Measurement of oil leakage amount from
arm cylinder
1) Start the engine and keep it running until the
hydraulic oil temperature rises to the operating range. Then extend the arm cylinder to
the digging stroke end.
k Release the pressure remaining in the piping, referring to the foregoing section of
"Release of Remaining Pressure in Hydraulic Circuit".
2) Disconnect hose (2) on the cylinder head
end and block the hose end with a plate.
k Be careful not to disconnect the hose at the
cylinder bottom end.
3) Start the engine and apply the relief pressure to the bottom end of the cylinder with
the engine running at high idling.
PC200/220(LC)-7
4) Continue this condition for 30 seconds, then
measure the oil leakage amount for one
minute.
5) After the measurement, make sure that the
machine is back to normal condition.
3. Measurement of oil leakage amount from
bucket cylinder
1) Start the engine and keep it running until the
hydraulic oil temperature rises to the operating range. Then extend the bucket cylinder
to the digging stroke end.
k Release the pressure remaining in the piping, referring to the foregoing section of
"Release of Remaining Pressure in Hydraulic Circuit".
2) Disconnect hose (3) at the cylinder head
end block the hose end with a plate.
k Be careful not to disconnect the hose at the
cylinder bottom end.
3) Start the engine and apply the relief pressure to the bottom end of the cylinder with
the engine running at high idling.
4) Continue this condition for 30 seconds, then
measure the oil leakage amount for one
minute.
5) After the measurement, make sure that the
machine is back to normal condition.
20-135
TESTING AND ADJUSTING
MEASUREMENT OF OIL LEAKAGE AMOUNT
4. Measurement of oil leakage amount from
swing motor
1) Disconnect drain hoses (4) and (5) and fit a
blind plug in the hoses.
2) Turn the swing lock switch to the ON position.
3) Start the engine. Apply the swing relief pressure with the engine running at high idling
and measure an oil leakage amount under
such conditions.
After keeping the conditions in 3) above
for 30 seconds, measure the oil leakage
amount for one minute.
After the first measurement, turn the upper structure by 180 degrees and take
measurement again in the same way.
3) Disconnect drain hose (6) of the travel
motor and fit a blind plug in the hose end.
4) Start the engine and apply the travel relief
pressure with the engine running at high
idling, then measure an oil leakage amount
under such conditions.
k In this measurement, an erroneous operation of the control lever will likely lead
to a serious accident. Make sure that all
the signals and confirmations are followed without fail.
After keeping the conditions in 4) above
for 30 seconds, measure the oil leakage
amount for one minute.
Repeat the measurement several times,
slightly rotating the motor, i.e. shifting
the position of valve plate and cylinder,
and the position of cylinder and piston,
and take measurement several times.
4) After the measurement, make sure that the
machine is back to normal condition.
5. Measurement of oil leakage amount from
travel motor
1) Take off the travel motor cover.
2) Start the engine and lock the travel.
k Put pin
in between the sprocket and the
track frame to block the travel.
20-136
5) After the measurement, make sure that the
machine is back to normal condition.
PC200/220(LC)-7
TESTING AND ADJUSTING
AIR BLEEDING OF VARIOUS PARTS
AIR BLEEDING OF VARIOUS PARTS
Air bleeding item
Contents of Work
Change of hydraulic oil
Cleaning of strainer
Steps for air bleeding
1
Hydraulic
pump air
bleeding
Engine
start
Cylinder
air
bleeding
Swing
motor air
bleeding
"
"
"
"
Travel
Operation
motor air
start
bleeding
(Note)
"
(Note)
"
Replacement of return filter element
Repair or replacement of
hydraulic pump
Removing suction pipe
"
"
"
"
"
"
Repair or replacement of control valve
"
"
"
Replacement of cylinder
Removing cylinder piping
"
"
"
Replacement of swing motor
Removing swing motor piping
"
Replacement of travel motor swivel
Removing travel motor swivel piping
"
"
"
"
"
Note: Bleed air from the swing motor and travel motor only when oil in the casing is drained.
1. Air bleeding from hydraulic pump
1) Loosen air bleeding plug (1) and confirm
that oil seeps out from the plug.
2) If the oil seepage is confirmed, tighten air
bleeding plug (1).
3 Air bleeding plug:
7.89.8 Nm{0.81.0 kgm}
Precautions for starting engine
When starting the engine after the air bleeding work explained above, run the engine at
low idling for 10 minutes.
If the engine cooling water temperature is
low and an automatic engine warming-up
function is relied on, use the fuel dial, when it
becomes necessary to cancel it.
PC200/220(LC)-7
2. Air bleeding from hydraulic cylinder
1) Start the engine and kept it running at low
idling for 5 minutes.
2) Raise and lower the boom 4 to 5 times with
the engine running at low idling.
Be careful not to apply the relief pressure, stopping the piston rod approx.
100 mm before its stroke end.
3) Repeat the steps in Item 2) above, but this
time with the engine running at high idling.
4) Apply the relief pressure by extending the
piston rod to its stroke end and with the
engine running at low idling.
5) For bleeding air from the arm cylinder and
bucket cylinder, follow the same steps
explained in Item 2) through 4) above.
In case a cylinder is replaced with new one,
it is advised to bleed air from the new one before mounting the work equipment. It is especially so with the boom cylinder, because
its rod does not extend to the stroke end of
LOWER side, after the work equipment is
mounted.
20-137
TESTING AND ADJUSTING
AIR BLEEDING OF VARIOUS PARTS
3. Air bleeding from swing motor
1) Start the engine and run it at low idling.
2) Bleed air from the motor by swinging the
upper structure slowly.
4. Air bleeding from travel motor
1) Start the engine and run it at low idling.
2) Loosen air bleeding plug (2) and confirm
that oil seeps out from the plug.
3) If the oil seepage is confirmed, tighten air
bleeding plug (2).
3 Air bleeding plug:
27.535.3 Nm{2.83.6 kgm}
20-138
PC200/220(LC)-7
TESTING AND ADJUSTING
INSPECTION PROCEDURES FOR DIODE
INSPECTION PROCEDURES FOR DIODE
Check an assembled-type diode (8 pins) and single diode (2 pins) in the following manner.
The continuity direction of an assembled-type diode is as shown in the diagram below.
The continuity direction of a single diode is
shown on the diode surface.
1. When using digital type circuit tester
1) Switch the testing mode to diode range and
confirm the indicated value.
Voltage of the battery inside is displayed
with conventional circuit testers.
2) Put the red probe (+) of the test lead to the
anode (P) and the black probe () to the
cathode (N) of diode, and confirm the displayed value.
PC200/220(LC)-7
3) Determine if a specific diode is good or no
good with the indicated value.
No change in the indicated value: No
continuity (defective).
Change in the indicated value: Continuity established (normal) (Note)
Note: A silicon diode shows a value between
400 and 600.
2. When using analog type circuit tester
1) Switch the testing mode to resistance range.
2) Check the needle swing in case of the following connections.
i) Put the red probe (+) of the test lead to
the anode (P) and the black probe () to
the cathode (N) of diode.
ii) Put the red probe (+) of the test lead to
the cathode (N) and the black probe ()
to the anode of diode.
3) Determine if a specific diode is good or no
good by the way the needle swings.
If the needle does not swing in Case i),
but swings in Case ii): Normal (but the
breadth of swing (i.e. resistance value)
will differ depending on a circuit tester
type or a selected measurement range)
If the needle swings in either case of i)
and ii): Defective (short-circuited internally)
If the needle does not swing in any case
of i) and ii): Defective (short-circuited internally)
20-139
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
[1] Figure input switch 1
[6] Figure input switch 6
] Return switch
[2] Figure input switch 2
[7] Figure input switch 7
] Upward move switch
[3] Figure input switch 3
[8] Figure input switch 8
] Downward move switch
[4] Figure input switch 4
[9] Figure input switch 9
] Input confirmation switch
[5] Figure input switch 5
[0] Figure input switch 0
20-140
PC200/220(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Monitor panel functions - conventional and special
The monitor panel is provided with conventional and special functions, and various kind of information are
shown in the multi-display. Display items consists of automatic display items that are preset in the monitor panel
and others that are shown by switch operations.
1. Conventional function: Operator's Menu
This is a function by which an operator can set or show displays by switch operations. The display contents
are those which are normally shown.
2. Special function: Service Menu
This is a function by which a service mechanic can set or show displays by special switch operations. The
display contents are those which are not normally shown. It is mainly used for inspection, adjustment, trouble-shooting or special setting of machines.
Operator's Menu
1
Function for inputting and setting password
Function for showing Komatsu's logo
Function for machine inspection before starting day's work
Function for showing machine maintenance
Function for showing precaution items
Function for confirming working mode and
travel speed
Function for display of ordinary items
Function for adjusting display luminance and
contrast
Function for adjusting breaker and attachment flow rate
10
Function for confirming maintenance information
11
Function for showing service meter reading
12
Function for checking display LCD
13
Function for showing occurrence of caution
item
14
Function for showing users' code No.
15
Function for showing service code No. and
failure code No.
PC200/220(LC)-7
Service Menu
16
Function for monitoring [01]
17
Function for fail- Electrical system
ure history [02] Mechanical system
18
Function for maintenance history [03]
19
Function for maintenance mode change [04]
20
Function for recording phone No. [05]
21
Function for initial value setting and default
[06]
Mode with key on
Language
Unit
Attachment installed/No
attachment installed
Adjustment of governor
lever stroke
22
Function for
adjustment [07]
Fuel pump absorbin torque
RPM at low idling
Adjustment of oil flow to
attachment
20-141
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Operation of Operator's Menu and
Display (Outline)
This section introduces only the outline of the operator's menu. For details on the contents and
operation steps of each menu, refer to the operation and maintenance manual or the chapter of
"STRUCTURE AND FUNCTION" in this shop
manual.
1. Function for inputting and setting password
When the engine starting switch is turned ON,
the password inputting display is shown.
This display is shown only when a password
is registered.
2. Function for showing KOMATSU logo
When a password is inputted, or when the
engine starting switch is turned ON, KOMATSU
logo is shown for two seconds.
3. Function for machine inspection before
starting day's work
Following the KOMATSU logo, the display of
machine inspection before starting day's work is
shown for 2 seconds.
4. Function for machine maintenance
Following the display of machine inspection
before starting day's work, the maintenance
mark appears for 30 seconds, if there is an oil filter whose maintenance time is approaching or
has just passed.
This display appears only when the maintenance function is set.
20-142
PC200/220(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
5. Function for showing precaution items
If there is any item of machine inspection before
starting day's work that indicates some abnormality, a corresponding symbol mark is shown
after the display of machine inspection before
starting day's work.
6. Function for confirming working mode and
travel speed
After the display of machine inspection before
day's work, amplified symbol marks for working
mode and travel speed are shown for two seconds to urge an operator to confirm the setting.
7. Function for display of ordinary items
The display of confirming working mode and
travel speed is switched to this display of ordinary items.
If the working mode setting or travel speed
setting is changed, or auto-deceleration or
windshield wiper setting is activated while
this is in display, an amplified corresponding
symbol mark is shown for two seconds.
In this display, a symbol mark for preheat
monitor is shown only when preheating is
carried out.
8. Function for adjusting display luminance
and contrast
Luminance as well as contrast of the display can
be adjusted by operating the display adjusting
switch.
PC200/220(LC)-7
20-143
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
9. Function for adjusting breaker and attachment flow rate (For machines equipped with
breaker attachment)
When a breaker or other attachments are used,
hydraulic pump flow rate can be adjusted by
operating the select switch.
Note that the symbol mark and contents of
display partially differ between the breaker
and the other attachments.
10. Function for confirming maintenance information
Detailed information on maintenance items (set
time and elapse of time) can be confirmed and
resetting after the confirmation is feasible by
operating the maintenance switch.
Use service Menu for setting or releasing
maintenance items and setting maintenance
time.
11. Function for showing service meter reading
Only the service meter reading can be shown by
the following switching operation, when the
engine starting switch is turned OFF.
Switching operation: [ ] + [ ] (synchronized switching operation)
12. Function for checking display LCD
Display of the Display LCD can be confirmed by
the following switching operation in the display
of inputting and setting password as well as in
the display of ordinary items
Switching operation: [ ] + [A] (synchronized switching operation)
All the LCD light up, turning the entire screen
white. If there is no showing in black, the display is normal.
This display returns to the immediately preceding one, if making any other switching
operation.
20-144
PC200/220(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
13. Function for showing occurrence of caution
item
If any of the caution items occurs, the magnified
corresponding symbol mark is shown for two
seconds and thereafter stays on the display as a
small symbol mark until it is dissolved.
14. Function for showing users' code No.
When a trouble occurs on the machine, the
user's code is automatically displayed depending on the magnitude of the trouble to call attention of the operator for a proper action.
This display turns to the display of service
code and failure code, if operating the switch
(Refer to Item No. 15)
Relation between User Code and Action Directed to Operator
User
Code
Failed System
Action Directed to Operator
E02
PC-EPC Valve
Ordinary work may be resumed by turning the emergency pump drive switch ON,
but call for the inspection service immediately.
E03
Swing Brake
Release the brake after turning emergency swing and parking brake switch ON.
When applying the swing brake, operate the swing lock switch manually. The
swing brake may not be released depending on the nature of the trouble. In either
case, call for the inspection service immediately.
E05
Governor
The governor control has become inoperable. Operate the governor control lever
manually. For fixing the lever at full throttle position, use a fixing bolt provided at
the bracket. In this case, call for the inspection service immediately.
PC200/220(LC)-7
20-145
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
15. Function for showing service code No. and
failure code No.
If the following switching operation is made
while the users' code No. is shown, a phone
symbol (if registered), phone numbers (if registered), service code No. and failure code No.
are shown in turn.
Switching operation: [ ] (keep the switch
depressed)
The following display is repeated in turn,
while the switch is depressed.
Telephone symbol mark
#
Telephone No.
#
Service code No. and failure code No.
The telephone symbol mark and telephone
No. are shown only when they are registered
in the monitor panel.
For registration, correction and deletion of
telephone No., use Service Menu.
For details on the displayed service code No.
and failure code No., refer to the Table for
Service and Failure Code Nos.
20-146
PC200/220(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Code
No.
Content
E101 Abnormal data in error history
Short circuit in wiper motor drive, normal rotation system
Short circuit in wiper motor drive, reverse rotation system
Short circuit in windshield washer drive
Abnormality of windshield wiper in motion
Abnormality of windshield wiper in retraction
Failure Code
Code No.
Location
DAF0KT Failure history
Windshield wiper motor (normal rotation)
Windshield wiper motor
E113
DY2EKB
(reverse rotation)
E114
DY2CKB Windshield washer motor
E115
DY20KA Windshield wiper motor
E116
DY20MA Windshield wiper motor
Travel interlocking solenoid
E201 Short circuit in travel interconnection solenoid DW91KB
valve
E03 E203 Short circuit in swing holding brake solenoid
DW45KB Swing holding solenoid valve
E204 Short circuit in merge/divide solenoid
DWJ0KB Merge solenoid valve
E205 Short circuit in 2-stage relief solenoid
DWK0KB 2-stage relief solenoid valve
Travel Hi-Lo shifting solenoid
E206 Short circuit in travel speed shifting solenoid
DW43KB
valve
Travel interlocking solenoid
E211 Disconnection in travel interlocking solenoid
DW91KA
valve
E03 E213 Disconnection in swing holding brake solenoid DW45KA Swing holding solenoid valve
E214 Disconnection in merge/divide solenoid
DWJ0KA Merge solenoid valve
E215 Disconnection in 2-stage relief solenoid
DWK0KA 2-stage relief solenoid valve
Travel Hi-Lo shifting solenoid
E216 Disconnection in travel speed shifting solenoid DW43KA
valve
E112
DY2DKB
E217 Abnormality in model code input
DA2SKQ S_NET
DA2SKA S_NET
DXE0KB LS-EPC solenoid valve
DXE0KA LS-EPC solenoid valve
DHPAMA F pump pressure sensor
DHPBMA R pump pressure sensor
E218 Disconnection in S_NET signal
E222 Short circuit in LS-EPC solenoid
E223 Disconnection in LS-EPC solenoid
E224 Abnormality in F pump pressure sensor
E225 Abnormality in R pump pressure sensor
E226 Abnormality in pressure sensor power source
E227 Abnormality in engine revolution sensor
E228 Short circuit in ATT return switching relay
E02 E232 Short circuit in PC-EPC solenoid
E02 E233 Disconnection in PC-EPC solenoid
E238 Disconnection in ATT return switching relay
E245 Short circuit in ATT flow rate adjusting EPC
E246 Disconnection in ATT flow rate adjusting EPC
E256 Incorrect nonvolatile memory data
E306 Abnormality in governor potentiometer
E05 E308 Abnormality in fuel dial
E315 Short circuit in battery relay output
E316 Abnormality in governor motor step-out
PC200/220(LC)-7
DA25KP Governor pump controller
DLE2MA
D196KB
DXA0KB
DXA0KA
D196KA
Phenomenon
Failure
Classification
Service Code
Abnormality
in data
Short circuit
Short circuit
Short circuit
Disconnection
Malfunctioning
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Disconnection
Disconnection
Disconnection
Disconnection
Disconnection
Nonconformance in model
selecting signal
Disconnection
Short circuit
Disconnection
Malfunctioning
Malfunctioning
Lowering in output voltage
Malfunctioning
Short circuit
Short circuit
Disconnection
Disconnection
Electrical system
User Code
No.
Table for Service and Failure Code Nos.
Engine revolution sensor
ATT switching relay
TVC solenoid valve
TVC solenoid valve
ATT switching relay
ATT flow rate throttling EPC
DXE4KB
Short circuit
valve
ATT flow rate throttling EPC
DXE4KA
Disconnection
valve
Abnormality in
DA20KT Nonvolatile memory
data
Governor motor feedback
DK54KZ
Malfunctioning
potentiometer
DK10KZ Throttle potentiometer
Malfunctioning
D110KB Battery relay
Short circuit
DY10K4 Governor motor
Out of control
20-147
Code
No.
Content
Failure Code
Code No.
Location
E05 E317 Disconnection in both governor motors A and B DY10KA Governor motor
E05 E318 Short circuit in both governor motors A and B
DY10KB Governor motor
E50 E501 No setting in model selection
DA2AKM Governor pump controller
E50 E502 Malfunction in model selecting signal
DA20KT Governor pump controller
Abnormality in boom angle sensor (short circuit
DKA0KB Boom angle sensor
in power source)
None Engine high idling out of rate
A000N1 Engine
E50 E511
Phenomenon
Disconnection
Short circuit
Error in operation
or setting
Abnormality in
data
Short circuit
Overrunning
Low idling out of
rate
Clogging
Insufficient
charging
Oil pressure lowered
Oil level lowered
Overheating
Cooling water
level lowered
Overheating
None Engine low idling out of rate
A000N2 Engine
None Air cleaner clogged
AA10NX Air cleaner element
None Charging voltage abnormally low
AB00KE Alternator
None Engine oil pressure abnormally low
B@BAZG Engine oil
None Engine oil level abnormally low
None Engine cooling water overheated
B@BAZK Engine oil
B@BCNS Engine cooling water
None Radiator water level abnormally low
B@BCZK Engine cooling water
None Hydraulic oil overheated
B@HANS Hydraulic oil
Auto-lubrication system conDA80MA
Malfunction
troller
None Auto-lubrication system abnormal
Electrical system
Service Code
Failure
Classification
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Mechanical system
User Code
No.
TESTING AND ADJUSTING
This table is arranged in the sequence of Service Code No.
In case there is no number assigned in the column of User Code No., or in case "none" is described in the
column of Code No. of Service Code, the corresponding service code or failure code is not shown in the display of ordinary items, even if some abnormality occurs. It is recorded only in the failure history (either in electrical system or mechanical system) of Service Menu.
History Classification indicates that a specific failure is classified as belonging to either electrical system or
mechanical system, when it is recorded in Service Menu.
"E" at the head of Code No. of Service Code means the following status of a specific failure.
With "E":
The failure is yet to be dissolved and continues.
Without "E": The failure has already been dissolved.
20-148
PC200/220(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Operation and Display of Service Menu
Way of switching to Service Menu
When using Service Menu, change the display to
Service Menu display through the following special operation.
1) Confirmation of display
Confirm that the display of ordinary items is
shown.
Changing to Service Menu cannot be made
from displays other than this.
2) Switch operation
Operate the switch as instructed below.
Switch operation: [ ] + [1] [2] [3]
(Enter a figure, depressing [
])
3) Showing Service Menu display
The display is changed to the initial display of
Service Menu program. Select an appropriate
item from among the menu.
No.
Service Menu
00
Return (Termination of Service Menu)
01
Monitoring
02
Abnormality Record
03
Maintenance Record
04
Maintenance Mode Change
05
Phone Number Entry
06
/ Default
07
Adjustment
08
4) Termination of Service Menu function
When terminating the initial display or any subsequent display of Service Menu, do that
through any one of the following methods.
Depress [ ] switch. (This method may be
used for terminating any display)
If "Return" switch is shown, depress it.
If "Return" menu is shown, call that menu
and depress [ ] switch.
PC200/220(LC)-7
20-149
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
16. Function of monitoring [01]
The monitor panel monitors signals from an
assortment of switches, sensors and actuators
installed in various parts of the machine. Monitored information can be put in display or confirmed on a real time basis through the following
operations.
1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.
2) Setting of monitoring item
Select or register an item to be monitored
through the following switch operation.
[ ] switch: Selection
[ ] switch: Selection
[ ] switch: Registration
A monitoring item can be set in any number
between the min. one to the max. four. (Depending upon the selected item, the max.
number is less than four)
In case of monitoring 1 to 3 items, move to
the monitored information display through
any of the following switch operations, after
the registration work has been completed.
Keep [ ] switch depressed. (For about
3 seconds)
Select Menu 999 and depress [ ]
switch.
The display automatically moves to the display of monitored information, when all of the
registrable items have been duly registered.
Monitored information are transmitted via
communication circuits. Thus the number of
selected items can impact the communication speed. If truly real time monitoring is required, reduce the selected items to the
minimum.
For details on the monitoring items, display
unit, etc., refer to the Table for Monitoring
Items.
20-150
PC200/220(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
3) Monitoring operation
Call the monitoring information display and
confirm the monitored information, while
operating the machine.
4) Monitored information holding function
If [ ] switch is depressed while monitoring,
all the monitored information are put on
hold. If [ ] switch is depressed in this condition, information holding is released.
5) Machine setting mode switching function
If it becomes necessary to change settings
of working mode, select mode, travel speed
and auto-decel while monitoring, depress
the corresponding switch, then the mode
confirmation display is shown.
An illustration at right shows the display in A
mode and E mode. Symbol marks are partially different in B mode.
When a specific setting is confirmed, depress [ ] switch, then the display returns to
that of monitoring.
In case a specific setting has been changed
while monitoring, the new setting is still
maintained when returning from Service
Menu to Operator's Menu after the monitoring is finished.
PC200/220(LC)-7
20-151
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Table for Monitoring Items
Code
No.
Item to be monitored
000
Return
999
To Display Screen
002
003
010
011
Controller Model Select
Controller Model Select
Engine Speed
F Pump Pressure
012
013
015
016
017
R Pump Pressure
PC-EPC Sol. Curr.
LS-EPC Sol. Curr.
2nd Eng. Speed Command
Service Sol. Curr.
Swing
Travel
Boom Lower
Pressure
Switch 1
Boom Raise
Arm Curl
Arm Dump
Bucket Curl
Bucket Dump
Pressure
Offset
Switch 2
Service
Travel Steering
Lever Sw.
Switch Input 1
Swing Release Sw.
Swing Brake Sw.
Travel Junction
Swing Brake
Solenoid valve 1 Merge-divider
2-stage Relief
Travel Speed
Solenoid valve 2 Service Return
Model Select 1
Model Select 2
Model Select 3
Switch Input 2
Model Select 4
Model Select 5
Fuel Dial Vol.
Gov. Motor Potentio Vol.
Battery Voltage
Gov. Motor Phase A Curr.
Gov. Motor Phase B Curr.
Battery Relay O/P Vol.
Switch Input 3
Key Switch
Controller Output Batt. Relay Dr.
Engine Water Temperature
Fuel Lever Sensor Vol.
019
021
022
023
024
027
030
031
032
033
034
035
036
037
041
042
20-152
Unit (Default: ISO)
ISO
Meter
Inch
(Not displayed)
(Not displayed)
r/min
MPa
MPa
mA
mA
r/min
mA
V
V
V
mA
mA
V
C
V
Figure
Figure
rpm
2
kg/cm
kg/cm2
mA
mA
rpm
mA
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
V
V
V
mA
mA
V
ON/OFF
ON/OFF
C
V
Remark
Termination menu
Execute
Command menu
rpm
psi
psi
mA
mA
rpm
mA
(Not used)
V
V
V
mA
mA
V
F
V
PC200/220(LC)-7
TESTING AND ADJUSTING
Code
No.
043
044
045
046
049
200
201
Item to be monitored
Battery Charge Vol.
Hydr. Oil Temperature
Key Switch
Start
Monitor Input 1
Preheat
Light
Rad. level
Aircleaner
Eng. Oil Press.
Eng. Oil Level.
Monitor Input 2
Spare
Battery Charge
Swing Brake Sw.
Buzzer cancel Sw.
Monitor Input 3
Window Limit Sw.
W Limit Sw.
P Limit Sw.
Monitor Prog. Version
Controller Prog. Version
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Unit (Default: ISO)
ISO
Meter
Inch
V
V
V
C
C
F
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ABNNOR
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
Figure
Figure
Remark
Select the most favorite display unit from among the prepared three kinds, i.e. ISO, meter and inch. When
changing one display unit for another, refer to "Unit" in the initial value setting of Service Menu.
Abbreviations, ABN and NOR, stand for the following conditions.
ABN: Abnormal, NOR: Normal
PC200/220(LC)-7
20-153
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
17. Function for Abnormality Record [02]
The monitor panel records failures that occurred
on the machines in the past after classifying
them into failures in the electric system and
those in the mechanical system. Information on
them can be displayed through the following
operation.
1) Selection of menu
Select 02 Abnormality Record in the initial
display of Service Menu and depress [ ]
switch.
2) Selection of Submenu
Select an appropriate item from Submenu in
the Abnormality Record display and depress
[ ] switch.
No.
00
01
02
Abnormality Record Submenu
Return
(termination of Abnormality Record)
Electrical System
Mechanical Systems
3) Information shown in display of Abnormality
Record in the electrical system
: The numerator expresses sequence of
failure occurrence, counting from the
latest one. The denominator expresses
the total number of a specific failure
recorded.
: Service Code
: Abnormality Code No. (system in 4 digits and phenomenon in 2 digits)
: Time elapsed since the occurrence of
the first failure
: Contents of failure
Refer to "Table for Service Code and Abnormality Code" in Operator's Menu.
4) Information shown in display of Failure History in the mechanical systems
: Record No.
: Contents of Abnormality
: Abnormality Code No. (system in 4 digits and phenomenon in 2 digits)
: Total number of occurrence
: Service meter reading at the initial
occurrence
Refer to "Table for Service Code and Abnormality Code" in Operator's Menu.
20-154
PC200/220(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
5) Resetting Electrical Systems
Resetting Electrical Systems (deletion)
is possible only with the electrical system. The failure history in the mechanical system cannot be reset.
For resetting any specific or all information in the Electrical Systems, follow the
operation explained below.
i) Through the following switch operation,
call the resetting display in the display of
Electrical Systems.
Switch operation: [ ] +[1] [2] [3]
This is the same switch operation in
changing the display to Service Menu.
ii) Operate the switch, following the instructions shown in the resetting display.
When resetting specific information
only, call the display of that specific
information and reset it with either
[ ] switch or [ ] switch.
When resetting all the information, a
display of any information will do.
PC200/220(LC)-7
20-155
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
18. Function for Maintenance Record [03]
The monitor panel records information on the
maintenance of filters and oils. The stored information can be displayed through the following
switch operation.
1) Selection of menu
Select 03 Maintenance Record in Service
Menu and depress [ ] switch.
2) Information to be displayed
: Name of oils and filters
: Times of replacement to date
: Service meter reading at the latest
replacement
20-156
PC200/220(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
19. Function for Maintenance Mode Change [04]
Conditions set for controlling maintenance display function can be changed in the following
manner.
Turn the function effectual or ineffectual.
Change the set interval for replacement.
1) Selection of menu
Select 04 Maintenance Mode Change in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of item to be changed
Select an item to be changed in the display
of Maintenance Mode Change Selecting
Menu.
No.
00
01
02
03
04
05
06
07
08
09
10
11
12
Maintenance mode change item
Return
Maintenance Mode On/Off
Engine Oil Exch. Int.
Engine Oil Filter Exch. Int.
Fuel Filter Exch. Int.
Hydr. Oil Filter Exch. Int.
H/Tank Breather Exch. Int.
Corro. Resis. Exch. Int.
PTO Oil Service Int.
Final Drive Oil Exch. Int.
S/Machinery Oil Exch. Int.
Hydraulic Oil Exch. Int.
Use Default Values
01 and 12 menus are provided for setting the
whole maintenance mode, while those from
02 through 11 are for setting individual items.
3) Contents of Maintenance Mode On/Off
Use: The maintenance display function
of all oil and filter-related items are
turned effectual. (Irrespective of whether
"On" or "Off" set for individual items, this
setting prevails)
Do not use: The maintenance display
function of all oil and filter-related items
are turned ineffectual. (Irrespective of
whether "On" or "Off" set for individual
items, this setting prevails)
PC200/220(LC)-7
20-157
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
4) Set contents of individual items
: Default: The maintenance time set in
the monitor (recommended by the manufacturer and cannot be changed).
: Set: Maintenance time that can be
freely set. The maintenance mode program functions based on this maintenance time. (The maintenance time can
be increased or decreased by 50 hours
with [ ] or [ ] switch)
: On: Maintenance display function with
this instruction becomes effectual.
: Off: Maintenance display with this
instruction becomes ineffectual.
The lowest maintenance time is 50 h.
5) Set contents of "Use Default Values"
When selecting this menu and depressing
the switch [ ], all individual time settings
are reduced to the initial settings.
20-158
PC200/220(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
20. Function for Phone Number Entry [05]
In the display of User Code, a telephone number
and Service Code are shown alternately. Phone
number can be inputted or modified in the following manner.
If there is no Phone number registered, the
display for Phone numbers does not appear.
1) Selection of menu
Select 05 Phone Number Entry menu in the
display of Service Menu, and depress [ ]
switch.
2) Changing the display
Select Entry next to change the display to
the Phone Number Entry display.
Even if a Phone number is already inputted, it is deleted, upon switching to the
Phone Number Entry display.
3) Entry and setting Phone number
Following the method explained below,
Entry a Phone number in the Phone
Number Entry display. (Entry automatically
begins with a cursor at the left end)
i) Enter a number into a cursor at the left
end with a ten-key.
ii) Depress [ ] switch when all the numbers have been entered.
Numbers can be entered up to the max.
12 digits, but omit unnecessary digits.
When entering a wrong number, depress [B] switch, then the cursor goes
back by one digit.
When input is finished, the display
changes to Entry display shown above.
If the inputted Phone number is shown in
this display, the input is normal.
PC200/220(LC)-7
20-159
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
21. Function for /Default
[06]
It is possible to change the following settings for
the monitor panel as well as the machine. Make
a change as is required.
Working mode when the engine starting
switch is in the ON position.
Display language in Service Menu
Display unit in the monitoring function
With/Without Service Cir.
1) Selection of menu
Select 06 "/Default menu" in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of submenu
Select an item to change from the submenu,
and depress [ ] switch.
No.
00
01
02
03
04
/Default submenu
Return (termination of /Default)
Key-on Mode
/Language
Unit
With/Without Service Cir.
3) Function for Key-on Mode
When the engine starting switch is turned
ON, a working mode can be set that is
shown in the monitor panel.
A, E, L and B Modes: If any of them is
set, the machine always ramps up with
that working mode, when turning the engine starting switch ON.
Mode at Previous Key-off: If this mode is
set, the machine ramps up with the
working mode that was last used in the
previous machine operation.
Default Value: If this mode is set, the
machine ramps up with the default mode
(A mode) that was originally set at the
time of delivery from the factory.
Irrespective of this setting mode, a machine "With attachment" always ramps
up with B mode, when the engine starting switch is turned ON at the subsequent operation, if that was the working
mode used in the last machine work.
20-160
PC200/220(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
4) Function for /Language
In Service Menu, the language in use can
be changed between Japanese and English.
English is used as the language for default setting in the monitor panel.
If the monitor panel for spare parts is to
be used in a Japanese-speaking region
or organization, change the language
from English to Japanese, using this
function.
5) Function for unit selection
As the unit to be used in the monitoring
function display of Service Menu, three
kinds of unit are provided.
Unit used for default setting in the monitor panel is SI, i.e. International System
of Units.
6) Function for selecting distinction of With/
Without Service Cir.
It is possible in this function to set a distinction between with or without attachment.
With Service Circuit: When an attachment is installed.
Without Service Circuit: When no attachment is installed.
If "With Service Circuit" setting is not
made in this display, while it is actually
installed on a specific machine, SELECT
function in Operator's Mode (attachment
oil flow rate adjustment) cannot be utilized.
PC200/220(LC)-7
20-161
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
22. Function for Adjustment [07]
The monitor panel has a function of making various adjustments of the machine.
1) Selection of menu
Select 07 adjustment in the initial display of
Service Menu, and depress [ ] switch.
2) Selection of submenu
Select an item to change from the submenu
and depress [ ] switch.
No.
00
01
02
03
04
Adjustment submenu
Return (termination of adjustment)
Governor Motor Adjustment
Pump Absorption Torque
Low Idle Speed
Service Current Adjust.
3) Function for Governor Motor Adjustment
When adjusting the securing position of
governor actuator, fuel injection pump
and governor spring, call this display and
carry out the work in the following manner.
i) Set the fuel dial at MAX.
In this condition, the governor actuator lever shifts to the full throttle. Hold
this display while in adjustment.
ii) Loosen nuts (2) and (3) of governor
spring (1).
Nut (2) is of inverse thread (left).
iii) Turn rod (5) so that governor lever (4) of
the fuel injection pump contacts the full
stopper.
iv) Screw in rod (5) by 2 turns from this
position to reduce distance a between
the pin of governor spring (1).
Distance a between the pins is reduced by 5 mm.
v) Tighten nuts (2) and (3).
3 Nut:
11.819.6 Nm{1.22.0 kgm}
vi) Confirm that governor spring stretches
by 4.0 mm, when the fuel dial is returned
to the MIN position and operated to the
MAX side again.
20-162
PC200/220(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
4) Function for Pump Absorption Torque
adjustment
The pump absorption torque can be
adjusted within the range shown in the table
below.
Adjustment value Torque adjustment value
220
+4.0 kgm
221
+3.0 kgm
222
+2.0 kgm
223
+1.0 kgm
224
0.0 kgm
225
1.0 kgm
226
2.0 kgm
227
3.0 kgm
228
4.0 kgm
5) Function for Low Idle Speed adjustment
The engine rotation at low idling can be
adjusted within the range shown in the table
below.
Adjustment value
320
321
322
323
Low idling rotation
1,000 rpm
1,100 rpm
1,200 rpm
1,300 rpm
6) Function for Service Current Adjust.
When a machine is used for a compound
operation, distribution of hydraulic pump oil
flow can be adjusted within the range shown
in the table below.
Adjustment value
320
321
322
323
PC200/220(LC)-7
Distribution of oil flow
to attachment
0.5 Time
0.7 Time
1.0 Time
0.4 Time
20-163
TESTING AND ADJUSTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
1. Troubleshooting function of lamps, gauges, buzzer
When the starting switch is turned on, all the lamps and gauges light up for approx. 3 seconds, and the
buzzer sounds for approx. 1 second. During this time, the monitor itself carries out self-diagnosis, and after
it has finished, it gives the normal display (if any lamp does not light up during the visual check, the lamp
bulb is blown).
2. User code display function
All the abnormality data for the engine controller and pump controller are transmitted to the monitor panel.
Of the abnormality data, items with a high emergency level are displayed as a user code automatically on
digital meter display (1) of the monitor panel to advise the operator of the action to take.
On digital meter display (1) and service meter display (2), only the places marked [x] in the illustration
below light up. All the other places are OFF.
1) User code display
(1) Digital meter display
(2) Service meter display
(3) Working mode selector (UP) switch
(4) Working mode selector (DOWN) switch
(5) Setting switch
(6) Travel speed switch
(7) Auto-deceleration switch
(8) Buzzer cancel switch
Example: When user code [E02] is displayed
2) Table of user codes
User code
20-164
Abnormal system
E02
PC-EPC system
E03
Swing holding brake system
E05
Governor motor system
E06
Boom RAISE stroke end throttle EPC system
PC200/220(LC)-7
TESTING AND ADJUSTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
3. User code display function
All the abnormality data for the engine controller and pump controller are transmitted to the monitor panel.
These abnormality data, regardless of whether they are necessary to display as a user code or not, are all
stored inside the monitor panel as service codes.
When the following operations are carried out, the service codes are displayed on the monitor panel digital
display; the existing problems are marked with "E" and are displayed together with the elapsed time data
(time on the service meter) on the service meter display panel.
1) Method of displaying and deleting service
codes
i) To switch to the service code display
mode, do as follows:
Keep [Buzzer cancel switch (8)] +
[Auto-deceleration switch (7)]
pressed for at least 2.5 seconds.
Press [Buzzer cancel switch (8)] +
[Working mode selector (UP) switch
(3)] (or [Working mode selector
(DOWN) switch (4)] and set so that
[01] is displayed in the 2nd and 3rd
digits from the left on service meter
display (2).
Press [setting switch (5)].
(1) Digital meter display
(2) Service meter display
(3) Working mode selector (UP) switch
(4) Working mode selector (DOWN) switch
(5) Setting switch
(6) Travel speed switch
(7) Auto-deceleration
switch
(8) Buzzer cancel switch
Example 1:When [01] is displayed on service meter display (2)
Example 2:When [E213] occurred 6 hours
before
If the problem still exists, "E" is displayed at the 2nd digit from the left on
service meter display (2); if the situation has returned to normal, "E" is not
displayed.
The 3 digits on the right from service
meter display (2) show the elapsed
time.
PC200/220(LC)-7
20-165
TESTING AND ADJUSTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
Example 3:When no service code is
recorded, all digits on digital
meter display (1) and service
meter display (2) show [-].
ii) To go on to the next service code display, press [Buzzer cancel switch (8)] +
[Working mode selector (UP) switch
(3)].
iii) To go back to the previous service code
display, press [Buzzer cancel switch (8)]
+ [Working mode selector (DOWN)
switch (4)].
iv) To finish using the service code display
mode, press [Buzzer cancel switch (8)]
+ [Auto-deceleration switch (7)].
v) To delete the service codes from memory, keep [Buzzer cancel switch (8)]
pressed and turn the starting switch
OFF. Then turn the starting switch ON
again and keep [Buzzer cancel switch
(8)] pressed for 5 seconds.
If the number of service codes in
memory exceeds 20, the oldest service codes are deleted in turn.
2) Table of service codes
Service code
Abnormal system
User code
E101
Abnormality in data
E104
Abnormality in air cleaner clogging sensor detected
E108
Engine water temperature over 105C detected
E112
Short circuit in wiper drive normal rotation system
E113
Short circuit in wiper drive reverse rotation system
E114
Short circuit in window washer drive system
E115
Wipe failure continues for 10 seconds
E116
Stow failure continues for 10 seconds
E201
Short circuit in travel junction solenoid system
E203
Short circuit in swing holding brake solenoid system
E03
E204
Short circuit in pump merge/divider solenoid system
E205
Short circuit in 2-stage relief solenoid system
E206
Short circuit in travel speed Hi/Lo selector solenoid system
E211
Disconnection in travel junction solenoid system
E213
Disconnection in swing holding brake solenoid system
E03
E214
Disconnection in pump merge/divider solenoid system
E215
Disconnection in 2-stage relief solenoid system
E216
Disconnection in travel speed Hi/Lo selector solenoid system
E217
Error in machine model selection input
E218
Abnormality in S-NET communication
E222
Short circuit in LS-EPC solenoid system
E02
E223
Disconnection in LS-EPC solenoid system
E02
E224
Abnormality in F pump pressure sensor system
20-166
PC200/220(LC)-7
TESTING AND ADJUSTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
Service code
Abnormal system
User code
E225
Abnormality in R pump pressure sensor system
E226
Abnormality in pressure sensor system power source
E227
Abnormality in engine speed sensor system
E228( )
Short circuit in ATT return switching relay
E232
Short circuit in PC-EPC solenoid system
E02
E233
Disconnection in PC-EPC solenoid system
E02
E234
Short circuit in boom RAISE stroke end throttle EPC system
E06
E235
Disconnection in boom RAISE stroke end throttle EPC system
E06
E238( )
Disconnection in ATT return switching relay
E241
Abnormality in boom angle potentiometer system (outside input value range)
E255
Abnormality in boom angle potentiometer compensation value
(outside compensation range)
E256
Check sum abnormality
E306
Abnormality in feedback potentiometer system
E308
Abnormality in fuel control dial input value
E313
Error in automatic greasing controller system
E315
Short circuit in battery relay output
E316
Step-out in governor motor
E317
Disconnection in governor motor system
E05
E318
Short circuit in governor motor system
E05
E05
: If there is any abnormality when a display of "With Attachment" is selected in the monitor panel, a service
code is memorized for the abnormality.
PC200/220(LC)-7
20-167
TESTING AND ADJUSTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
4. Monitoring code display function
The input signals from the sensors to each component and the output signals to drive the solenoid can be
checked in real time with the monitoring code.
When the following operations are carried out, the monitoring code Nos. are displayed on the 3rd to 5th digits from the left on service meter display (2) and the monitoring data are displayed on digital meter display
(1).
1) Method of displaying monitoring codes
i) To switch to the monitoring code, do as
follows.
Keep [Buzzer cancel switch (8)] +
[Auto-deceleration switch (7)]
pressed for at least 2.5 seconds.
Press [Buzzer cancel switch (8)] +
[Working mode selector (UP) switch
(3)] (or [Working mode selector
(DOWN) switch (4)]) and set so that
[02] is displayed in the 2nd and 3rd
digits from the left on service meter
display (2).
Press [Setting switch (5)].
(1) Digital meter display
(2) Service meter display
(3) Working mode selector (UP) switch
(4) Working mode selector (DOWN) switch
(5) Setting switch
(6) Travel speed switch
(7) Auto-deceleration
switch
(8) Buzzer cancel switch
Example 1:When a numeric display monitoring code (engine speed: 2050
rpm) is displayed
Example 2:When bit pattern display monitoring code No. 20 (switch input
condition (1)) is displayed
ii)
To go on to the next monitoring code
display, press [Buzzer cancel switch (8)]
+ [Working mode selector (UP) switch
(3)].
iii) To go back to the previous service code
display, press [Buzzer cancel switch (8)]
+ [Working mode selector (DOWN)
switch (4)].
iv) To finish using the monitoring code display mode, keep [Buzzer cancel switch
(8)] + [Auto-deceleration switch (7)]
pressed for at least 2.5 seconds.
20-168
PC200/220(LC)-7
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
TESTING AND ADJUSTING
2) Table of monitoring codes
For details of the code displayed as (6 bit) in the Unit column, see the bit pattern chart.
Code No.
Item
002
Engine throttle, pump controller model code
010
Engine speed
011
Pump discharge pressure (F) input
012
Unit
Name of component
Engine throttle, pump controller
10 rpm
Engine throttle, pump controller
Engine throttle, pump controller
Pump discharge pressure (R) input
kg/cm
Engine throttle, pump controller
013
PC-EPC output current
10 mA
Engine throttle, pump controller
015
LS-EPC current output
10 mA
Engine throttle, pump controller
016
No.2 throttle command value
10 rpm
Engine throttle, pump controller
018
Boom RAISE stroke end throttle EPC current
10 mA
Engine throttle, pump controller
019
ATT PPC throttle EPC current
10 mA
Engine throttle, pump controller
020
Engine throttle, pump controller switch input condition (1)
(6 bit)
Engine throttle, pump controller
021
Engine throttle, pump controller switch input condition (2)
(6 bit)
Engine throttle, pump controller
022
Engine throttle, pump controller switch input condition signal (3)
(6 bit)
Engine throttle, pump controller
023
Engine throttle, pump controller solenoid drive
condition
(6 bit)
Engine throttle, pump controller
024
Engine throttle, pump controller solenoid drive
condition (1)
(6 bit)
Engine throttle, pump controller
027
Engine throttle, pump controller switch input condition signal (4)
(6 bit)
Engine throttle, pump controller
030
Fuel control dial input value
10 mV
Engine throttle, pump controller
031
Governor potentiometer feedback voltage
10 mV
Engine throttle, pump controller
032
Battery voltage (VBB voltage)
100 mV
Engine throttle, pump controller
033
Governor motor phase A current
10 mA
Engine throttle, pump controller
034
Governor motor phase B current
10 mA
Engine throttle, pump controller
035
Battery relay output voltage
100 mV
Engine throttle, pump controller
036
Engine throttle, pump input condition
(6 bit)
Engine throttle, pump controller
037
Engine throttle, pump output condition
(6 bit)
Engine throttle, pump controller
041
Coolant temperature sensor input voltage
10 mV
Engine throttle, pump controller
042
Fuel level sensor input voltage
10 mV
Engine throttle, pump controller
043
Alternator (charge) input voltage
100 mV
Engine throttle, pump controller
044
Hydraulic oil temperature sensor voltage
10 mV
Engine throttle, pump controller
045
Sensor input condition (1)
(6 bit)
Engine throttle, pump controller
046
Sensor input condition (2)
(6 bit)
Engine throttle, pump controller
049
(Spare)
(6 bit)
Engine throttle, pump controller
060
Boom angle
10 mV
Engine throttle, pump controller
200
Program version (monitor)
201
Program version (controller)
PC200/220(LC)-7
kg/cm
20-169
TESTING AND ADJUSTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
3) Bit pattern display (bit for applicable No.
lights up)
(1) to (6) of digital display (1) indicate the
bit Nos.
The 2nd to 4th digits from the left on
service meter display (2) indicate the
monitoring code Nos.
Code
Content
020
Input condition of engine throttle and
pump controller PPC pressure
switches
021
Input condition of engine throttle and
pump controller PPC pressure
switches and other switches
022
Input condition of engine throttle and
pump controller for switches
023
Solenoid drive condition (0) of engine
throttle and pump controller
024
Solenoid drive condition (1) on engine
throttle and pump controller
027
Input condition (2) of engine throttle
and pump controller for switches
20-170
Bit
Details (condition when bit is lighted up)
Swing PPC pressure switch
Travel PPC pressure switch
Boom LOWER PPC pressure switch
Boom RAISE PPC pressure switch
Arm IN PPC pressure switch
Arm OUT PPC pressure switch
Bucket CURL PPC pressure switch
Bucket DUMP PPC pressure switch
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
Service PPC pressure switch
Travel steering pressure switch
(ON)
(ON)
Knob switch
Swing holding brake cancel switch
Swing lock switch
Travel junction solenoid
Swing holding brake solenoid
Pump merge/divider solenoid
2-stage relief solenoid
Travel speed Hi/Lo selector solenoid
Model selection 1
Model selection 2
Model selection 3
Model selection 4
Model selection 5
Kerosene mode input
(24 V connected)
(GND connected)
(GND connected)
(ON)
(ON)
(ON)
(ON)
(ON)
(GND connected)
(GND connected)
(GND connected)
(GND connected)
(GND connected)
(GND connected)
PC200/220(LC)-7
TESTING AND ADJUSTING
Code
036
037
045
046
047
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
Content
Input/output condition of engine throttle and pump controller
Input condition of engine throttle and
pump controller
Sensor input condition
Sensor input condition
(Spare)
048
( )
049
Bit
Details (condition when bit is lighted up)
Starting switch
Battery relay
Starting switch [ON]
Starting switch [START]
Preheating switch
Light switch
(Always OFF)
(Always OFF)
(Always OFF)
(Always OFF)
(Always OFF)
(Always ON)
Alarm buzzer
Washer on
Wiper drive 1
Wiper drive 2
Wiper drive 3
Wiper drive 4
Swing lock switch
Buzzer cancel switch
Window washer switch
W contact
P contact
(ON)
(when actuated)
(ON)
[START](ON)
(ON)
(ON)
(Actuated)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
(ON)
: Code No. [048]: When wiper is stopped, bit Nos. and light up
When wiper is actuated, bit Nos. and or and light up
PC200/220(LC)-7
20-171
TESTING AND ADJUSTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
5. Function for setting working mode default
The working mode on the monitor panel is set so that the A mode normally lights up when the starting
switch in turned ON.
If the function for setting the default is used as follows, it is possible to change the setting so that the system
starts with the working mode desired by the operator.
1) Method of setting default
i) To switch to the default setting mode, do
as follows.
Keep [Buzzer cancel switch (8)] +
[Auto-deceleration switch (7)]
pressed for at least 2.5 seconds.
Press [Buzzer cancel switch (8)] +
[Working mode selector (UP) switch
(3)] (or [Working mode selector
(DOWN) switch (4)] and set so that
[05] is displayed in the 2nd and 3rd
digits from the left on service meter
display (2).
Press [Setting switch (5)].
""d[]SET"" is displayed in service meter display (2) and indicator (10) for
the mode set as default flashes.
ii)
To change the default set mode, do as
follows.
Press [Working mode selector (UP)
switch (3)] or [Working mode selector (DOWN) switch (4)].
Press [Setting switch (5)].
(1) Digital meter display
(2) Service meter display
(3) Working mode selector (UP) switch
(4) Working mode selector (DOWN) switch
(5) Setting switch
(6) Travel speed switch
(7) Auto-deceleration
switch
(8) Buzzer cancel switch
iii) To finish using the default setting mode
(default setting mode complete), keep
[Buzzer cancel switch (8)] + [Autodeceleration switch (7)] pressed for at
least 2.5 seconds.
If the starting switch is turned OFF
when the normal mode LED is flashing (default setting mode), the content of the working mode default is
not changed.
iv) Method of checking after setting working mode default
Check that the LED has changed to
continuous lighting up.
Turn the starting switch OFF, then
turn the starting switch ON again.
Check that the default for the working mode has changed to the new
setting.
20-172
PC200/220(LC)-7
TESTING AND ADJUSTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
6. Governor motor adjustment mode
This is used when adjusting the linkage between the governor motor and the injection pump.
For details of the procedure, see TESTING AND ADJUSTING, Testing and adjusting governor motor lever stroke.
1) Method of displaying governor motor adjustment mode
i) To switch to the governor motor adjustment mode, do as follows.
Keep [Buzzer cancel switch (8)] +
[Auto-deceleration switch (7)]
pressed for at least 2.5 seconds.
Press [Buzzer cancel switch (8)] +
[Working mode selector (UP) switch
(3)] (or [Working mode selector
(DOWN) switch (4)]) and set so that
[03] is displayed in the 2nd and 3rd
digits from the left on service meter
display (2).
Press [Setting switch (5)].
""GOV"" is displayed on digital meter
display (1) and ""GSET"" is displayed
on service meter display (2).
ii)
To finish using the governor motor
adjustment mode, keep [Buzzer cancel
switch (8)] + [Auto-deceleration switch
(7)] pressed for at least 2.5 seconds.
7. "With or without Attachment" Setting mode
1) Follow the steps explained below for switching to ATT setting mode.
i) To switch to the boom angle potentiometer compensation mode, do as follows.
Keep [Buzzer cancel switch (8)] +
[Auto-deceleration switch (7)]
pressed for at least 2.5 seconds.
Press [Buzzer cancel switch (8)] +
[Working mode selector (UP) switch
(3)] (or [Working mode selector
(DOWN) switch (4)]) and set so that
[16] is displayed in the 2nd and 3rd
digits from the left on service meter
display (2).
Press [Setting switch (5)].
Check that ""1[]SET"" is displayed on
service meter display (2) (the center 3
segments on digital display (1) flash).
PC200/220(LC)-7
(1) Digital meter display
(2) Service meter display
(3) Working mode selector (UP) switch
(4) Working mode selector (DOWN) switch
(5) Setting switch
(6) Travel speed switch
(7) Auto-deceleration
switch
(8) Buzzer cancel switch
(1) Digital meter display
(2) Service meter display
(3) Working mode selector (UP) switch
(4) Working mode selector (DOWN) switch
(5) Setting switch
(6) Travel speed switch
(7) Auto-deceleration
switch
(8) Buzzer cancel switch
20-173
TESTING AND ADJUSTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
If the compensation is carried out
correctly (if the boom angle is within
the theoretical value, ""ooo"" will be
displayed for 5 seconds on digital
meter display (1)), and the system
will return to Step (1) (boom angle
potentiometer compensation mode).
If compensation could not be carried
out, ""---"" will flash on digital display
(2), the buzzer will sound 5 times,
and the system will return to Step (1).
If compensation is impossible, the
mounting of the boom angle potentiometer is probably defective, so check it.
8. Adjusting service meter
1) Adjusting service meter
i) To switch to the service meter adjustment mode, keep [Buzzer cancel switch
(8)] pressed and press each switch on
the monitor panel in the following order
to .
Travel speed switch (6)
Setting switch (5)
Auto-deceleration switch (7)
Working mode selector (UP) switch (3)
ii) To select the digit to be corrected, press
[Swing lock switch (1)] + [Buzzer cancel
switch (8)] + [Auto-deceleration switch
(7)] + [Setting switch (5)] and move one
digit at a time to the left (the movement is
only to the left; from the last digit on the
left, it moves to the first digit on the right).
iii) To set or change the number, press
[Swing lock switch (1)] + [Buzzer cancel
switch (8)] + [Auto-deceleration switch
(7)] + [Working mode selector (UP)
switch (3)].
iv) To finish using the service meter adjustment mode, repeat the procedure in
Step i).
(It is impossible to set (return) to a lower
value than the value presently saved in
the service meter).
20-174
(1) Digital meter display
(2) Service meter display
(3) Working mode selector (UP) switch
(4) Working mode selector (DOWN) switch
(5) Setting switch
(6) Travel speed switch
(7) Auto-deceleration
switch
(8) Buzzer cancel switch
PC200/220(LC)-7
TESTING AND ADJUSTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
9. Displaying and setting oil maintenance function
On machines equipped with the oil maintenance function, the LED of [Oil maintenance lamp (9)] on the
monitor lights up from a point 10 hours before the time set for the oil change and stays lighted up until the
system is reset. The elapsed time is displayed on service meter display (2). (It is displayed for 20 seconds
after the starting switch is turned ON; after that, the display returns to the service meter time display.)
No display is given (does not light up) on digital meter display (1).
With the oil maintenance function, it is possible to set, change, or cancel the display.
1) Oil maintenance function display
i) As explained above, the oil maintenance display mode automatically gives
a display when the remaining time is
less than 10 hours from the set time.
ii) To finish the oil maintenance function
(within 20 seconds after the starting
switch is turned ON), press [Setting
switch (5)] quickly and return to the normal display mode.
Example: When the display shows the following:
Oil change interval setting: 250 h
Time elapsed since last oil change:
245 h
2) Setting interval and resetting elapsed time
i) Setting interval
Keep [Buzzer cancel switch (8)] +
[Auto-deceleration switch (7)]
pressed for at least 2.5 seconds.
Press [Setting switch (5)] (the display switches each time the switch is
pressed) and select the interval.
Example: When selecting interval:
250 h (no display is given on digital
meter display (1))
Interval display (displayed repeatedly
in turn)
0:
Default mode (oil maintenance
function not set)
125h: Interval is set for every 125 hours
250h: Interval is set for every 250 hours
500h: Interval is set for every 500 hours
d:
Demo mode is set
(See Step iv) for details.)
Set the interval according to the Operation and Maintenance Manual.
Keep [Buzzer cancel switch (8)] +
[Auto-deceleration switch (7)]
pressed for at least 2.5 seconds to
complete the setting of the interval.
PC200/220(LC)-7
(1) Digital meter display
(2) Service meter display
(3) Working mode selector (UP) switch
(4) Working mode selector (DOWN) switch
(5) Setting switch
(6) Travel speed switch
(7) Auto-deceleration
switch
(8) Buzzer cancel switch
20-175
TESTING AND ADJUSTING
ii)
iii)
iv)
20-176
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT
MONITOR PANEL
Checking elapsed time
Nothing is displayed until the elapsed
time enters the period of 10 hours before the change interval. (If you want
to see the elapsed time when there is
no display, keep [Setting switch (5)]
pressed and turn the starting switch
ON. Continue to press [Setting switch
(5)].)
Resetting elapsed time after changing oil
Press [Setting switch (5)] and keep it
depressed for 3 seconds while the
elapsed time and telephone number are
being displayed (within 20 seconds) on
the monitor panel. The elapsed time will
be reset and the display will show
""Elapsed time: 0h"" for one second.
Demo mode
If the demo mode is used, a demonstration of the oil maintenance function can
be carried out when the machine is
delivered.
The same display is given as for the oil
maintenance function. For the purpose
of demonstration, the elapsed time is
fixed at 240h.
After setting to the demo mode, turn the
starting switch ON again to start the
demonstration.
Note: If the starting switch is turned OFF
ON four times, the demo mode is
canceled (the demo mode can be used
3 times) and the system automatically
switches to the default mode. (If you
want to continue the demonstration, it is
necessary to set to the demo mode
again.)
PC200/220(LC)-7
TESTING AND ADJUSTING
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL
SYSTEM
When diagnosing electric circuits related to the
monitor panel and governor pump controller, first
open up the connector portions in the following
manner.
1. Monitor panel
1) Take off cover (1).
The cover is fixed with two upper and
lower clips. Pull it up for the removal.
If a sunlight sensor is equipped for an air
conditioner, detach P15 connector at the
cover rear side.
2) Remove three securing screws and take
monitor panel (2) off the mount.
Be careful not to let fall the securing
screws inside the console.
3) Insert or connect a T-adaptor for diagnosis
with P01, P02 and P70 (multi-monitor only)
connectors.
PC200/220(LC)-7
2. Governor pump controller
The governor pump controller is installed under a cover behind the operator's seat.
1) Remove three caps (1) and then three
securing bolts.
When removing the caps, use of a thin
flat-head screw driver is recommended.
2) Take off cover (2).
3) Insert or connect a T-adapter for diagnosis
with C01, C02 and C03 connectors of governor pump controller (3).
The connectors are fixed with screws.
Loosen the screws and detach the connectors.
When putting the connectors back into
position, tighten them to the specified
torque.
3 Screw: 2.82 Nm{0.288 kgm}
20-177
20-178
PC200/220(LC)-7
PC200/220(LC)-7
20-179
Engine (PC200, 200LC)
Hydraulic system (PC200, 200LC)
20-180
PC200/220(LC)-7
Full
Low
Full
Fuel dial
ON
OFF
OFF
ON
OFF
Condition setting
Working
Auto
One-touch pomode decelerator wer max. switch
Full
Fuel dial
E
( L)
Boom and arm held level
Boom held level
Bucket DIGGING
Arm DIGGING
Fully extended
Swing (5 turns)
No.
Engine stop
Fuel dial
Boom and arm held
level, Bucket loaded
Hydraulic drift amount at
bucket tooth tip (15 min.)
Hydraulic oil temperature (45 55oC)
Condition setting
Measurement item
Working
mode Work equipment posture
3. Work equipment hydraulic drift amount (PC200, 200LC-7)
Right
Left
Right
Lo
Left
A
Right
Track
shoe
raised
Travel
( Mi)
8
at one side
Left
(5 turns)
Right
Hi
Left
: The "Mi" and "L" modes are on the multi-monitor specification machine only.
1
2
3
4
5
6
No.
Hydraulic oil temperature (45 55 C)
Condition setting
Working Work equipment posture Measurement item
mode
No load, fully extended
Boom RAISE
Arm DUMPING
A
mm
Unit
Sec.
Unit
All control levers in NEUTRAL
Arm (extended) relief
All control levers in NEUTRAL
Operating travel control lever
(Do not travel machine)
26.6 31.4
26.6 29.4
600
Max. 900
600
New model
29.0 32.0
36.7 44.9
50.3 61.5
21.7 26.7
2.9 3.7
2.4 3.0
3.2 3.8
3.3 3.9
5.8 7.0
2.3 2.9
New model
0.25{2.6}
0.09{2.9}
5.1{520}
Failure judgement
Max. 900
PC200LC-7
Failure judgement
29.0 34.0
36.7 48.9
50.3 65.5
Max. 30
Max. 4.7
Max. 3.5
Max. 4.5
Max. 4.6
Max. 7.4
Max. 3.3
PC200LC-7
Failure judgement
2,080 2,220
0.39 0.64{4.0 6.5}
980 1,080
Min. 0.15{Min. 1.5}
1,800 2,000
Max. 1.2{Max. 123}
1,300 1,500
Standard value
Failure judgement
33.7 45.3
33.7 41.3
New model
46.2 60.4
46.2 56.4
PC200-7
Max. 30
Max. 4.7
Max. 3.5
Max. 4.5
Max. 4.6
Max. 7.4
Max. 3.3
2.9 3.7
2.4 3.0
3.2 3.8
3.3 3.9
5.8 7.0
2.3 2.9
21.7 26.7
Failure judgement
New model
Implemented on:
Standard value
New machine
Standard value
rpm
MPa{kg/cm2}
rpm
MPa{kg/cm2}
rpm
kPa{mmH2O}
rpm
Engine rotation
Engine oil pressure
Engine rotation
Engine oil pressure
Engine rotation
Blow-by pressure
Engine rotation
PC200-7
Unit
Client user's name
Measurement item
Service meter reading
Work equipment operation
Serial No.
2. Work equipment speed (PC200, 200LC-7)
1
2
3
4
5
6
7
No.
1. Engine (PC200, 200LC-7)
Model
Measured value
Measured value
Measured value
Good / No good
Judgement
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Judgement
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Judgement
Inspected by:
PC200/220(LC)-7
20-181
Part to be checked
Servo
Part to be checked
PC-EPC valve
No.
No.
Full
Full
Low
Fuel dial
Full
Fuel dial
Full
Fuel dial
L)
L)
Working
mode
Working
mode
Working
mode
: The "L" mode is on the multi-monitor specification machine only
LS-EPC valve
Main relief valve,
Travel safety valve,
Travel interlocking valve
Swing safety valve
Self-decompression valve
Main relief valve
(When power increased)
Part to be checked
LS valve
(LS differential
pressure valve)
No.
Condition setting
OFF
Condition setting
OFF
OFF
OFF
OFF
OFF
AutoOne-touch podecelerator wer max. switch
OFF
One-touch poAutodecelerator wer max. switch
OFF
ON
OFF
Auto-dece- One-touch polerator wer max. switch
Condition setting
4. Inspection of hydraulic circuit (PC200, 200LC-7)
Left reverse
Left forward
Right reverse
Right forward
Left relief
Right
i relief
Left
Right
Arm dumping relief
Neutral
Arm dumping relief
Work equipment operation
Arm dumping relief
Work equipment operation
Track shoe
locked
Swing lock
switch ON
Travel without load,
engine at Hi idling and
control lever at half stroke
Neutral
Arm dumping relief
Work equipment operation
F main pump
600 kg/cm2
F main pump
R main pump
600 kg/cm2
R main pump
600 kg/cm2
R main pump
600 kg/cm2
600 kg/cm2
F main pump
600 kg/cm2
Control circuit
pressure
60 kg/cm2
600 kg/cm2
60 kg/cm2
PC
EPC
60 kg/cm2
Remarks
LS
EPC
60 kg/cm2
Control circuit
pressure
60 kg/cm2
When one pump relieved: 1.5MPa {15kg/cm2}
At neutral: 2.9MPa {30kg/cm2}
When 2 pumps relieved: 0MPa {0kg/cm2}
<34>
< 3>
<14>
<21>
<16>
Remarks <Reference value: kg/cm2>
Connection to be changed to hoses and , and gauge to be replaced with
one with 60 K capacity.
Main servo pressure balance
/ = / = 3/5
Remarks
38.2 MPa {390 kg/cm2}
30.9 MPa {315 kg/cm2}
MainLS=2.2 MPa{22.0 kg/cm2} (LS pressure)
MainLS=3.9 MPa{40 kg/cm2}
(LS differential pressure = Unload pressure)
Circuit pressure 3.2 MPa {33 kg/cm2}
34.8 37.3 MPa
{355 380 kg/cm2}
Connection to be changed to hoses and
R pump LS
600 kg/cm2
circuit
F pump servo R pump servo Control
pressure
600 kg/cm2
F pump LS
600 kg/cm2
20-182
PC200/220(LC)-7
PC200/220(LC)-7
20-183
Engine (PC220, 220LC)
Hydraulic system (PC220, 220LC)
20-184
PC200/220(LC)-7
Full
Low
Full
Fuel dial
ON
OFF
OFF
ON
OFF
Condition setting
Working
Auto
One-touch pomode decelerator wer max. switch
Full
Fuel dial
E
( L)
Boom and arm held level
Boom held level
Bucket DIGGING
Arm DIGGING
Fully extended
Swing (5 turns)
No.
Engine stop
Fuel dial
Boom and arm held
level, Bucket loaded
Hydraulic drift amount at
bucket tooth tip (15 min.)
Hydraulic oil temperature (45 55oC)
Condition setting
Measurement item
Working
mode Work equipment posture
3. Work equipment hydraulic drift amount (PC220, 220LC-7)
Right
Left
Right
Lo
Left
A
Right
Track
shoe
raised
Travel
( Mi)
8
at one side
Left
(5 turns)
Right
Hi
Left
: The "Mi" and "L" modes are on the multi-monitor specification machine only.
1
2
3
4
5
6
No.
Hydraulic oil temperature (45 55 C)
Condition setting
Working Work equipment posture Measurement item
mode
No load, fully extended
Boom RAISE
Arm DUMPING
A
mm
Unit
Sec.
Unit
All control levers in NEUTRAL
Arm (extended) relief
All control levers in NEUTRAL
Operating travel control lever
(Do not travel machine)
26.7 31.5
26.7 29.5
600
Max. 900
600
New model
28.9 31.9
38.6 47.2
52.8 64.6
23.3 28.5
3.1 3.9
2.7 3.3
3.4 4.2
2.6 3.2
New model
0.25{2.6}
0.09{2.9}
5.1{520}
Failure judgement
Max. 900
PC220LC-7
Failure judgement
28.9 33.9
38.6 51.2
52.8 68.6
Max. 31
Max. 4.9
Max. 3.5
Max. 4.5
Max. 3.3
PC220LC-7
Failure judgement
2,130 2,270
0.39 0.64{4.0 6.5}
980 1,080
Min. 0.15{Min. 1.5}
1,850 2,050
Max. 1.2{Max. 123}
1,300 1,500
Standard value
Failure judgement
35.6 47.6
35.6 43.6
New model
48.7 63.6
48.7 59.6
PC220-7
Max. 31
Max. 4.9
Max. 3.5
Max. 4.5
Max. 3.3
3.1 3.9
2.7 3.3
3.4 4.2
2.6 3.2
23.3 28.5
Failure judgement
New model
Implemented on:
Standard value
New machine
Standard value
rpm
MPa{kg/cm2}
rpm
MPa{kg/cm2}
rpm
kPa{mmH2O}
rpm
Engine rotation
Engine oil pressure
Engine rotation
Engine oil pressure
Engine rotation
Blow-by pressure
Engine rotation
PC220-7
Unit
Client user's name
Measurement item
Service meter reading
Work equipment operation
Serial No.
2. Work equipment speed (PC220, 220LC-7)
1
2
3
4
5
6
7
No.
1. Engine (PC220, 220LC-7)
Model
Measured value
Measured value
Measured value
Good / No good
Judgement
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Judgement
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Good / No good
Judgement
Inspected by:
PC200/220(LC)-7
20-185
Part to be checked
Servo
Part to be checked
PC-EPC valve
No.
No.
Full
Full
Low
Fuel dial
Full
Fuel dial
Full
Fuel dial
L)
L)
Working
mode
Working
mode
Working
mode
: The "L" mode is on the multi-monitor specification machine only.
LS-EPC valve
Main relief valve,
Travel safety valve,
Travel interlocking valve
Swing safety valve
Self-decompression valve
Main relief valve
(When power increased)
Part to be checked
LS valve
(LS differential
pressure valve)
No.
Condition setting
OFF
Condition setting
OFF
OFF
OFF
OFF
OFF
AutoOne-touch podecelerator wer max. switch
OFF
One-touch poAutodecelerator wer max. switch
OFF
ON
OFF
Auto-dece- One-touch polerator wer max. switch
Condition setting
4. Inspection of hydraulic circuit (PC220, 220LC-7)
Left reverse
Left forward
Right reverse
Right forward
Left relief
Right
i relief
Left
Right
Arm dumping relief
Neutral
Arm dumping relief
Work equipment operation
Arm dumping relief
Work equipment operation
Track shoe
locked
Swing lock
switch ON
Travel without load,
engine at Hi idling and
control lever at half stroke
Neutral
Arm dumping relief
Work equipment operation
F main pump
600 kg/cm2
F main pump
R main pump
600 kg/cm2
R main pump
600 kg/cm2
R main pump
600 kg/cm2
600 kg/cm2
F main pump
600 kg/cm2
Control circuit
pressure
60 kg/cm2
600 kg/cm2
60 kg/cm2
PC
EPC
60 kg/cm2
Remarks
LS
EPC
60 kg/cm2
Control circuit
pressure
60 kg/cm2
When one pump relieved: 1.5MPa {15kg/cm2}
At neutral: 2.9MPa {30kg/cm2}
When 2 pumps relieved: 0MPa {0kg/cm2}
<34>
< 3>
<14>
<21>
<16>
Remarks <Reference value: kg/cm2>
Connection to be changed to hoses and , and gauge to be replaced with
one with 60 K capacity.
Main servo pressure balance
/ = / = 3/5
Remarks
38.7 MPa {395 kg/cm2}
30.9 MPa {315 kg/cm2}
MainLS=2.2 MPa{22.0 kg/cm2} (LS pressure)
MainLS=3.9 MPa{40 kg/cm2}
(LS differential pressure = Unload pressure)
Circuit pressure 3.2 MPa {33 kg/cm2}
34.8 37.3 MPa
{355 380 kg/cm2}
Connection to be changed to hoses and
R pump LS
600 kg/cm2
circuit
F pump servo R pump servo Control
pressure
600 kg/cm2
F pump LS
600 kg/cm2
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202
SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...................... 20-218
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-236
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE
"MECHANICAL SYSTEM" ARE INDICATED ...................................................................................... 20-301
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................. 20-501
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) ................................. 20-601
PC200/220(LC)-7
20-201
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
k
k
k
k
k
k
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
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.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always 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 carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand 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 symptoms.
1. When carrying out troubleshooting, do not hurry
to disassemble the components.
If components are disassembled immediately
any failure occurs:
Parts that have no connection with the failure
or other unnecessary parts will be disassembled.
It will become impossible to find the cause of
the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in
accordance with the fixed procedure.
2. Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure?
When were these repairs carried out?
6) Has the same kind of failure occurred
before?
3. Check before troubleshooting
1) Check the oil level
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202
5) Other maintenance items can be checked
externally, so check any item that is considered to be necessary.
4. Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation,
etc.
When operating the machine to reenact
the troubleshooting symptoms, do not
carry out any investigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the
causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly.
The basic procedure for troubleshooting
is as follows.
1)Start from the simple points.
2)Start from the most likely points.
3)Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root
cause of the failure is not repaired, the same
failure will occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root
cause.
PC200/220(LC)-7
TESTING AND ADJUSTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC200/220(LC)-7
20-203
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric
equipment
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely careful when handling wiring harnesses.
Main failures occurring in wiring harness
1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
2) Defective crimping or soldering of connectors
The pins of the male and female connectors
are in contact at the crimped terminal or soldered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper connection or breakage.
20-204
PC200/220(LC)-7
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the soldering may be damaged, or the wiring may be
broken.
4) High-pressure water entering connector
The connector is designed to make it difficult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the connector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water
should get into the connector, the pins will
be short-circuited by the water, so if any
water gets in, immediately dry the connector
or take other appropriate action before
passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a contact restorer.
When wiping the mating portion of the
connector, be careful not to use excessive force or deform the pins.
If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.
PC200/220(LC)-7
20-205
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
2) Removing, installing, and drying connectors
and wiring harnesses
Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For connectors held by a screw, loosen the screw
fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
Never pull with one hand.
2) When removing from clips
When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
If the connector is twisted up and down
or to the left or right, the housing may
break.
3) Action to take after removing connectors
After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
If the machine is left disassembled for a
long time, it is particularly easy for improper contact to occur, so always cover
the connector.
20-206
PC200/220(LC)-7
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating portion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or breakage to the outside of the connector.
If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connector, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
If there is any damage or breakage, replace the connector.
2) Fix the connector securely.
Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3) Correct any protrusion of the boot and any
misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is
out of position, adjust it to its correct position.
If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
4) If the connector clamp has been removed,
be sure to return it to its original position.
Check also that there are no loose clamps.
PC200/220(LC)-7
20-207
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Drying wiring harness
If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as follows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
If the connector is blown dry with compressed air, there is the risk that oil in the
air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
2) Dry the inside of the connector with a dryer.
If water gets inside the connector, use a
dryer to dry the connector.
Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
3) Carry out a continuity test on the connector.
After drying, leave the wiring harness disconnected and carry out a continuity test to
check for any short circuits between pins
caused by water.
After completely drying the connector,
blow it with contact restorer and reassemble.
20-208
PC200/220(LC)-7
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Handling control box
1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.
3) Do not place objects on top of the control
box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) During rainy weather, do not leave the control box in a place where it is exposed to
rain.
6) Do not place the control box on oil, water, or
soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits
1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
If there is any change, there is probably
defective contact in that circuit.
PC200/220(LC)-7
20-209
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3. Points to remember when handling hydraulic
equipment
With the increase in pressure and precision of
hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is
necessary to be particularly careful.
1) Be careful of the operating environment.
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the
field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be confirmed with special test
equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt or dust get in during refilling operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210
PC200/220(LC)-7
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
5) Change hydraulic oil when the temperature
is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and secondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
PC200/220(LC)-7
20-211
TESTING AND ADJUSTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Electrics, electrical equipment
Hydraulic, Electrical
mechanical equipment
equipment
Lubricating oil,
coolant
Item
Judgement
value
Action
Add fuel
Clean, drain
Add oil
Clean, drain
Add oil
Add oil
Add water
Clean or replace
Replace
Add oil
1. Check for looseness, corrosion of battery terminal, wiring
2. Check for looseness, corrosion of alternator terminal, wiring
3. Check for looseness, corrosion of starting motor terminal, wiring
Tighten or replace
Tighten or replace
Tighten or replace
1. Check for abnormal noise, smell
2. Check for oil leakage
3. Carry out air bleeding
Repair
Repair
Bleed air
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Check fuel level, type of fuel
Check for impurities in fuel
Check hydraulic oil level
Check hydraulic oil strainer
Check swing machinery oil level
Check engine oil level (oil pan oil level)
Check coolant level
Check dust indicator for clogging
Check hydraulic filter
Check final drive oil level
20 30V
Check battery voltage (engine stopped)
Check battery electrolyte level
Check for discolored, burnt, exposed wiring
Check for missing wiring clamps, hanging wiring
Check for water leaking on wiring (be particularly careful attention
to water leaking on connectors or terminals)
6. Check for blown, corroded fuses
7. Check alternator voltage (engine running at 1/2 throttle or above) After
running for
several
minutes :
27.5 29.5V
8. Check operating sound of battery relay
(when switch is turned ON/OFF)
1.
2.
3.
4.
5.
20-212
Replace
Add or replace
Replace
Repair
Disconnect
connector and dry
Replace
Replace
Replace
PC200/220(LC)-7
TESTING AND ADJUSTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Classification of troubleshooting
Mode
Content
Code display
Troubleshooting when Service Code (electrical system) and Failure Code (mechanical
system) are displayed.
E mode
Troubleshooting of electrical system
H mode
Troubleshooting of hydraulic and mechanical systems
(Engine)
Troubleshooting of engine assembly (refer to the shop manual for engine in 102 series)
Steps for troubleshooting
If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting
No. and proceed to the explanations for diagnosis.
1. Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [ ] switch to display Service Code. Following displayed Service Code for the electrical system, carry out the troubleshooting along the corresponding code display.
2. Troubleshooting steps when the electrical system Service Code or mechanical system Failure Code
is recorded in the failure history:
If not calling User Code in the monitor panel, check the electrical system Service Code or mechanical system Failure Code, using the failure history function of the monitor panel.
If Service Code in the electrical system is recorded, delete the all codes once and revive the code in the
display again to check if the same abnormality still persists.
Failure Code in the mechanical system cannot be deleted.
3. Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that
the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechanical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from
among "Failure like Phenomena and Troubleshooting No." and carry out E mode or H mode troubleshooting
related to the phenomenon in question.
PC200/220(LC)-7
20-213
TESTING AND ADJUSTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Failure-looking Phenomenon and Troubleshooting No.
Troubleshooting
No.
Failure-looking phenomenon
Code
display
E mode H mode (Engine)
Action to be taken concerning Service Code, User Code and Failure Code
1 Display User Code in monitor panel
Display Service Code in electrical system after checking failure
2
history
3
Display Failure Code in mechanical system after checking failure
history
According to
displayed
code
Engine-related failure
4
Engine does not start up easily. (It always takes some time to start
up the engine)
5
6
Engine does not rotate
Engine does not start
S-1
E-1
S-2
Engine rotates, but there is no exhaust gas
S-2
There is exhaust gas, but engine does not
start
S-2
8 Engine pickup is poor. (Engine does not follow acceleration)
S-3
9 Engine stops while in operation
E-2
10 Engine rotation is irregular. (There is hunting)
E-3
11 Engine is short of output, or lacks power
H-2
S-4
S-5
H-1
S-6
12 Color of exhaust gas is too dark. (Incomplete combustion)
S-7
13 Excessive engine oil consumption, or color of exhaust gas is blue
S-8
14 Premature engine oil contamination
S-9
15 Excessive fuel consumption
S-10
16
Engine cooling water is mixed with engine oil, spurts out or
decreases
S-11
17 Engine oil amount increases. (Water or fuel gets in)
S-13
18 Abnormal noises are heard
S-15
19 Excessive vibrations are caused
S-16
20 Engine does not stop
E-4
21 Auto-decelerator does not work
E-5
22 Engine auto warming-up device does not work
E-6
23 Engine preheater does not work
E-7
H-5
Failure related to work equipment, swing and travel
24
Speeds of all work equipment, travel and swing are slow, or they
lack power
25 Engine rotation drops sharply or stalls
26 All work equipment, travel and swing do not move
E-8
H-1
S-6
H-2
S-4
H-3
27 There are abnormal noises from around hydraulic pump
H-4
28 Fine control mode function works poorly, or shows slow response
H-6
20-214
PC200/220(LC)-7
TESTING AND ADJUSTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting
No.
Failure-looking phenomenon
Code
display
E mode H mode (Engine)
Work equipment-related failure
29 Boom moves slowly or lacks power
E-21, 22
H-7
30 Arm moves slowly or lacks power
E-23, 24
H-8
31 Bucket moves slowly or lacks power
E-25, 26
H-9
32 Boom, arm or bucket does not move
H-10
33 Natural drift of work equipment is too fast
H-11
34 Work equipment time lag is too big
H-12
35
Other work equipment moves, when specific work equipment is
relieved
H-13
36 One-touch power max. switch does not work
E-9, 2126
H-14
Compound operation-related failure
37
In compound operation, work equipment with larger load moves
slowly
H-15
38 In swing + boom RAISE operation, boom moves slowly
H-16
39 In swing + travel operation, travel speed drops sharply
H-17
Travel-related failure
40 Machine tends to swerve while in travel
H-18
41 Travel speed is slow
42 Machine is difficult to steer, or lacks power
43 Travel speed cannot be shifted or is slow or fast
E-28
H-19
E-28, 29
H-20
E-28
H-21
44 Track shoe does not move (only on one side)
H-22
Swing-related failure
45 Machine does not swing
E-27
H-23
46 Swing acceleration is poor, or swing speed is slow
H-24
47 Upper structure overruns excessively, when stopping swing
H-25
48 There is a big shock caused when stopping swing
H-26
49 There is abnormal noise generated when stopping swing
H-27
50 There is natural drift while in swing
H-28
Monitor panel-related failure (Operator's Menu: ordinary display)
51 No display appears in monitor panel at all
E-10
52 Part of display is missing in monitor panel
E-11
53 Descriptions on monitor panel do not apply to the machine model
E-12
In startup inspection, radiator water level monitor lamp lights up
red ( )
B@BCZK
55 In startup inspection, engine oil level monitor lamp lights up red
B@BAZK
54
: The multi-monitor specification machine only.
PC200/220(LC)-7
20-215
TESTING AND ADJUSTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting
No.
Failure-looking phenomenon
56 In startup inspection, maintenance hour monitor lamp lights up red
57
Code
display
E mode H mode (Engine)
Refer to Operation and Maintenance
Manual
While engine is running, battery charging level monitor lamp lights
AB00KE
up red
58 While engine is running, fuel level monitor lamp lights up red
E-13
59
While engine is running, air cleaner clogging monitor lamp lights up
AA10NX
red
60
While engine is running, engine cooling water temperature monitor
B@BCNS
lamp lights up red
61
While engine is running, hydraulic oil temperature monitor lamp
lights up red ( )
B@HANS
62 Engine cooling water temperature gauge does not display correctly
E-14
63 Hydraulic oil temperature gauge does not display correctly ( )
E-15
64 Fuel gauge does not display correctly
E-16
65 Swing lock monitor does not display correctly
E-17
66 When operating monitor switch, no display appears
E-18
67 Windshield wiper does not work
E-19
68 Warning buzzer cannot be stopped
E-20
Monitor panel-related failure (Service Menu: Special Function Display)
69
In monitoring function, "Boom RAISE" cannot be displayed correctly
E-21
70
In monitoring function, "Boom LOWER" cannot be displayed correctly
E-22
71
In monitoring function, "Arm DIGGING" cannot be displayed correctly
E-23
72
In monitoring function, "Arm DUMPING" cannot be displayed correctly
E-24
73
In monitoring function, "Bucket DIGGING" cannot be displayed
correctly
E-25
74
In monitoring function, "Bucket DUMPING" cannot be displayed
correctly
E-26
75 In monitoring function, "Swing" cannot be displayed correctly
E-27
76 In monitoring function, "Travel" cannot be displayed correctly
E-28
77
In monitoring function, "Travel Differential Pressure" cannot be displayed correctly
78 In monitoring function, "Service" cannot be displayed correctly
E-29
E-30
Other failure
79 Air conditioner does not work
E-31
80 Travel alarm does not sound
E-32
: The multi-monitor specification machine only.
20-216
PC200/220(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
TESTING AND ADJUSTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT
DIAGRAM BY SYSTEM
Connector table
Address
Connector
No.
Type
No. of
pin
A01
Intermediate connector
T-1
H-6
I-5
A02
Intermediate connector
T-1
H-6
I-4
A03
12
Intermediate connector
N-1
H-6
I-2
A04
SWP
12
Intermediate connector
O-1
A05
SWP
14
Intermediate connector
T-1
H-5
I-6
A06
SWP
14
Intermediate connector
N-1
H-5
I-5
A07
SWP
16
Intermediate connector
S-1
H-3
A08
SWP
12
Intermediate connector
N-2
A09
SWP
Intermediate connector
N-2
A10
Terminal
Revolving frame grounding
H-1
H-1
A11
Terminal
Revolving frame grounding
H-1
I-1
A12
Terminal
Revolving frame grounding
H-2
I-1
A13
Terminal
Revolving frame grounding
I-2
I-1
A14
Terminal
Revolving frame grounding
K-2
I-1
A15
Terminal
Revolving frame grounding
I-2
I-1
J-4
A16
Terminal
Revolving frame grounding
I-2
I-1
J-1
A20
Terminal
Battery relay (E terminal)
J-1
I-2
J-4
A21
Terminal
Battery relay (BR terminal)
J-1
I-1
J-4
A22
Terminal
Battery relay (M terminal)
J-1
J-2
K-4
A23
Terminal
Battery relay (B terminal)
J-2
J-1
K-4
A25
Terminal
Heater relay (coil)
L-3
A26
Terminal
Heater relay (contact)
L-3
K-2
A27
Starter safety relay (S and R terminals)
K-2
J-2
A29
Terminal
Starter safety relay (C terminal)
L-3
A30
YAZAKI
Air conditioner outside air temperature sensor
L-4
A31
Air cleaner clogging sensor
L-4
K-4
A33
Radiator water level sensor
L-4
K-5
A34
Fusible link (65A)
A-4
K-6
K-5
A35
Fusible link (30A)
A-5
K-6
K-4
A40
AMP
Alarm horn (low tone)
H-1
A41
AMP
Alarm horn (high tone)
H-1
A42
Intermediate connector
I-9
A43
Travel alarm
I-2
A44
Front right lamp
A-6
20-218
Name of device
Stereo
M
G
P
-gram circuit circuit circuit
I-8
I-8
I-7
I-1
I-4
I-3
J-5
J-4
J-4
J-8
K-6
J-7
K-4
K-7
PC200/220(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
TESTING AND ADJUSTING
Address
Connector
No.
Type
No. of
pin
A50
KES0
Window washer monitor (tank)
K-3
A51
F pump hydraulic oil pressure sensor
K-3
K-5
A52
R pump hydraulic oil pressure sensor
J-9
K-5
A60
Fuel level sensor
D-9
K-4
A61
Hydraulic oil temperature sensor
H-9
K-5
C01
DRC
24
Governor pump controller
V-9
A-3
A-8
A-8
C02
DRC
40
Governor pump controller
W-9
A-3
A-7
A-7
C03
DRC
40
Governor pump controller
W-9
A-2
A-4
A-4
C09
Model selection connector
W-6
D01
SWP
Assembled type diode
W-7
A-9
D-1
D02
SWP
Assembled type diode
W-7
A-8
D-1
D03
SWP
Assembled type diode
P-1
D04
SWP
Assembled type diode
Q-1
A-8
F-1
E01
Terminal
Suction type air heater
(electrical intake air heater)
J-9
L-2
L-6
E02
Terminal
Engine hydraulic switch
L-8
K-6
E03
Engine oil level switch
L-6
K-5
E04
Engine rotation sensor
K-9
E05
Engine cooling water temperature sensor
J-9
E06
Fuel dial
K-8
E06
Air conditioner compressor electromagnetic
switch
O-8
E08
Intermediate connector
L-7
E10
Governor potentiometer
J-9
K-3
E11
Governor motor
K-9
K-2
E12
Alternator
L-7
F02
YAZAKI
Revolving warning lamp
AA-9
FB1
Fuse box
W-5
G01
V-2
G02
V-3
G03
V-3
G04
V-2
G05
V-3
H08
Intermediate connector
W-4
K-8
H09
Intermediate connector
W-4
J-8
H10
16
Intermediate connector
T-9
D-6
I-8
H11
16
Intermediate connector
S-9
D-5
I-8
H12
12
Intermediate connector
S-9
D-5
I-7
H15
S090
20
Intermediate connector
N-7
C-2
E-2
PC200/220(LC)-7
Name of device
Stereo
M
G
P
-gram circuit circuit circuit
K-5
C-9
G-1
H-1
I-1
K-8
K-4
J-3
J-5
K-3
K-5
I-9
C-4
F-9
B-9
C-2
20-219
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
TESTING AND ADJUSTING
Address
Connector
No.
Type
No. of
pin
J01
20
Junction connector (black)
W-8
C-9
D-9
C-9
J02
20
Junction connector (black)
W-8
D-9
D-9
D-9
J03
20
Junction connector (green)
W-8
D-9
J04
20
Junction connector (green)
W-7
E-9
E-9
E-9
J05
20
Junction connector (pink)
W-6
E-9
E-9
E-9
J06
20
Junction connector (orange)
W-6
F-9
J07
20
Junction connector (orange)
U-9
F-9
J08
20
Junction connector (pink)
U-9
I-9
K19
Pump resistor (for driving emergency pump)
U-2
E-3
K30
CAN terminating resistor
T-9
A-2
C-1
K31
CAN terminating resistor
N-4
A-4
K-7
M07
Lamp switch
P-8
C-2
M09
Working lamp (front right)
E-9
K-7
M13
KES0
Speaker (right)
AC-8
M19
YAZAKI
Cigarette lighter
N-3
M21
PA
Radio
U-2
M22
Y090
Horn switch
N-7
M23
Y090
One-touch power max. switch
T-1
M26
12
Air conditioner unit
W-5
M27
SWP
16
Air conditioner unit
W-5
M28
SWP
12
Air conditioner unit
W-4
M29
040
20
Air control panel
W-3
M30
040
16
Air control panel
W-3
M31
Option power source (2)
U-2
M32
Option power source (1)
S-9
M33
Option power source (3)
M33
SWP
Air conditioner unit
S-9
M34
YAZAKI
Air conditioner inside air sensor
W-8
M40
YAZAKI
Working lamp
Z-8
K-8
M41
YAZAKI
Working lamp (additional)
Y-7
K-8
M42
Intermediate connector
K-3
J-7
M43
Working lamp (rear)
K-7
M45
12
Intermediate connector
U-2
M46
S090
RS232C relaying connector
U-9
M71
Room lamp
Z-8
M72
DC/AC converter
U-2
M73
KES0
Speaker (left)
M79
YAZAKI
12V electrical equipment socket
20-220
Name of device
Stereo
M
G
P
-gram circuit circuit circuit
D-9
H-9
F-9
H-9
B-9
AD-8
V-9
PC200/220(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
TESTING AND ADJUSTING
Address
Connector
No.
Type
No. of
pin
P01
070
12
Monitor panel
N-6
A-7
K-8
P02
040
20
Monitor panel
N-5
A-6
K-8
P03
Buzzer canceling switch
P-9
D-1
P05
Revolving warning lamp switch
W-3
P15
Y050
Air conditioner sun light sensor
N-6
P70
040
16
Monitor panel
N-4
A-5
R10
Lamp relay
O-8
E-1
R11
Engine starting motor cutting relay (PPC lock)
P-8
E-1
R13
Engine starting motor cutting relay (personal
code)
Q-9
F-1
R20
Attachment circuit switching relay
W-6
R21
S01
Bucket digging oil pressure switch
S-8
K-2
S02
Boom lowering oil pressure switch
L-7
K-3
S03
Swing oil pressure switch, left
L-7
K-2
S04
Arm digging oil pressure switch
L-6
K-3
S05
Bucket dumping oil pressure switch
L-5
K-2
S06
Boom raise oil pressure switch
L-5
K-3
S07
Swing oil pressure switch, right
L-5
K-2
S08
Arm dumping oil pressure switch
L-4
K-3
S09
Service oil pressure switch (intermediate connector)
K-3
K-1
S10
Service oil pressure switch, front
K-1
S11
Service oil pressure switch, rear
K-1
S14
Safety lever lock switch
S-1
S21
Terminal
Pump emergency driving switch
R-9
E-2
S22
Terminal
Swing and parking brake emergency releasing
switch
R-9
F-2
S25
S090
16
Intermediate connector
Q-9
E-3
S30
Travel hydraulic switch
O-1
A-1
S31
Travel steering hydraulic switch
P-1
A-1
SC
Terminal
Engine starting motor (C terminal)
K-8
SSW
Terminal
Engine starting switch
N-7
T05
Terminal
Floor frame grounding
W-3
T06
Terminal
Radio body grounding
T06A
Intermediate connector
T-2
T11
Terminal
Operator's cab grounding
T13
Engine starting motor (C terminal)
PC200/220(LC)-7
Name of device
Stereo
M
G
P
-gram circuit circuit circuit
A-9
K-7
C-9
W-7
K-9
F-8
J-8
AD-3
L-6
J-3
20-221
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
TESTING AND ADJUSTING
Address
Connector
No.
Type
No. of
pin
V01
PPC hydraulic lock solenoid valve
J-2
K-6
V02
Travel interlocking solenoid valve
J-2
K-6
V03
Merge/divide valve solenoid valve
J-2
K-6
V04
Travel speed solenoid valve
J-3
K-5
V05
Swing and parking brake solenoid valve
J-3
K-5
V06
2-stage relief solenoid valve
K-3
K-6
V12
Attachment return switching solenoid valve
I-9
K-4
V21
PC-EPC solenoid valve
I-9
K-7
V22
LS-EPC solenoid valve
I-9
K-7
V30
Attachment oil flow rate adjusting EPC solenoid
valve
P-1
A-1
W03
Rear limit switch (window)
W04
X05
Y08
G-9
Y09
G-1
Y10
G-9
Y11
A-6
Y12
G-9
Y13
G-1
Y16
G-9
20-222
Name of device
Stereo
M
G
P
-gram circuit circuit circuit
AB-9
L-8
Windshield wiper motor
Y-4
B-9
Swing lock switch
Q-9
D-2
C-2
PC200/220(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
TESTING AND ADJUSTING
Connector No.
D or DT
Detailed information
Japanese and German makes DT type connector (08192-XXXXX)
Product of Yazaki Corporation L type connector (08056-2XXXX)
Product of Sumitomo Wiring Systems 090 type splice
Product of Yazaki M type connector (08056-0XXXX)
Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
Product of Yazaki S type connector (08056-1XXXX)
Product of Yazaki X type connector (08055-0XXXX)
PA
Product of Yazaki PA type connector
SWP
Product of Yazaki SWP type connector (08055-1XXXX)
DRC
Japanese and German makes DRC type connector
040
Product of Japan AMP 040 type connector
070
Product of Japan AMP 070 type connector
Y050
Product of Yazaki 050 type connector
S090
Product of Sumitomo 090 type connector
Y090
Product of Yazaki 090 type connector
YAZAKI
KES0
Yazaki-made connector
KESO type connector (08027-0XXXX)
Terminal
Round pin type single terminal connector
Terminal
Round terminal
*An affiliated company of Mitsubishi Cable Industries, Ltd.
PC200/220(LC)-7
20-223
TESTING AND ADJUSTING
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
CONNECTOR LOCATION STEREOGRAM
20-224
PC200/220(LC)-7
TESTING AND ADJUSTING
PC200/220(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
20-225
TESTING AND ADJUSTING
20-226
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
PC200/220(LC)-7
TESTING AND ADJUSTING
PC200/220(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
20-227
TESTING AND ADJUSTING
20-228
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
PC200/220(LC)-7
TESTING AND ADJUSTING
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
Monitor Panel System Circuit Diagram (M Circuit)
20-230
PC200/220(LC)-7
TESTING AND ADJUSTING
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
This circuit diagram has been compiled by extracting the monitor panel system and engine starting system
from the overall electrical circuit diagram.
PC200/220(LC)-7
20-231
TESTING AND ADJUSTING
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
Governor Control System Circuit Diagram (G Circuit) of GovernorPump Controller
20-232
PC200/220(LC)-7
TESTING AND ADJUSTING
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
This circuit diagram has been compiled by extracting the governorpump controller system (power source,
governor control, model selection and communication) from the overall electrical circuit diagram.
PC200/220(LC)-7
20-233
TESTING AND ADJUSTING
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
Pump Control System Circuit Diagram (P Circuit) of GovernorPump Controller
20-234
PC200/220(LC)-7
TESTING AND ADJUSTING
CONNECTOR LOCATION CHART AND ELECTRICAL
CIRCUIT DIAGRAM BY SYSTEM
This circuit diagram has been compiled by extracting the governorpump controller system (pump control),
PPC lock system and backup alarm system from the overall electrical circuit diagram.
PC200/220(LC)-7
20-235
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins
Male (female housing)
Female (male housing)
T-adapter
Part No.
Part No.: 08055-00181
Part No.: 08055-00191
799-601-7010
799-601-7020
Part No.: 08055-00282
Part No.: 08055-00292
799-601-7030
Part No.: 08055-00381
Part No.: 08055-00391
799-601-7040
Part No.: 08055-00481
Part No.: 08055-00491
Terminal part No.: 79A-222-3370
Electric wire size: 0.85
Grommet: Black
Qty: 20
Terminal part No.: 79A-222-3390
Electric wire size: 0.85
Grommet: Black
Qty : 20
Terminal part No.: 79A-222-3380
Electric wire size: 2.0
Grommet: Red
Qty: 20
Terminal part No.: 79A-222-3410
Electric wire size: 2.0
Grommet: Red
Qty: 20
20-236
PC200/220(LC)-7
TESTING AND ADJUSTING
No.of
pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
SWP type connector
Male (female housing)
Female (male housing)
T-adapter
Part No.
799-601-7050
Part No.: 08055-10681
Part No.: 08055-10691
799-601-7060
Part No.: 08055-10881
Part No.: 08055-10891
12
799-601-7310
Part No.: 08055-11281
Part No.: 08055-11291
14
799-601-7070
Part No.: 08055-11481
PC200/220(LC)-7
Part No.: 08055-11491
20-237
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
SWP type connector
No. of
pins
Male (female housing)
Female (male housing)
16
T-adapter
Part No.
799-601-7320
Part No.: 08055-11681
Part No.: 08055-11691
Terminal part No.:
Electric wire size: 0.85
Grommet: Black
Qty: 20
Terminal part No.:
Electric wire size: 0.85
Grommet: Black
Qty: 20
Terminal part No.:
Electric wire size: 1.25
Grommet: Red
Qty: 20
Terminal part No.:
Electric wire size: 1.25
Grommet: Red
Qty: 20
20-238
PC200/220(LC)-7
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M type connector
No.of
pins
Male (female housing)
Female (male housing)
T-adapter Part
No.
Part No.: 08056-00171
Part No.: 08056-00181
799-601-7080
799-601-7090
Part No.: 08056-00271
Part No.: 08056-00281
799-601-7110
Part No.: 08056-00371
Part No.: 08056-00381
799-601-7120
Part No.: 08056-00471
Part No.: 08056-00481
799-601-7130
Part No.: 08056-00671
Part No.: 08056-00681
799-601-7390
Part No.: 08056-00871
PC200/220(LC)-7
Part No.: 08056-00881
20-239
TESTING AND ADJUSTING
No.of
pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector
Male (female housing)
Female (male housing)
799-601-7140
Part No.: 08056-10871
Part No.: 08056-10881
10
(White)
799-601-7150
Part No.: 08056-11071
Part No.: 08056-11081
12
(White)
799-601-7350
Part No.: 08056-11271
Part No.: 08056-11281
16
(White)
799-601-7330
Part No.: 08056-11671
20-240
T-adapter
Part No.
Part No.: 08056-11681
PC200/220(LC)-7
TESTING AND ADJUSTING
No.of
pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector
Male (female housing)
Female (male housing)
10
(Blue)
12
(Blue)
799-601-7160
Part No.: 08056-11272
Part No.: 08056-11282
16
(Blue)
799-601-7170
Part No.: 08056-11672
PC200/220(LC)-7
T-adapter
Part No.
Part No.: 08056-11682
20-241
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
MIC type connector
No.of
pins
Male (female housing)
Female (male housing)
T-adapter Part
No.
Body part No.: 79A-222-2640 (Qty: 5)
Body part No.: 79A-222-2630 (Qty: 5)
11
Body part No.: 79A-222-2680 (Qty: 5)
Body part No.: 79A-222-2670 (Qty: 5)
799-601-2710
Body part No.: 79A-222-2620 (Qty: 5)
Body part No.: 79A-222-2610 (Qty: 5)
799-601-2950
Body part No.: 79A-222-2660 (Qty: 5)
Body part No.: 79A-222-2650 (Qty: 5)
13
799-601-2720
Body part No.: 79A-222-2710 (Qty: 2)
20-242
Body part No.: 79A-222-2690 (Qty: 2)
PC200/220(LC)-7
TESTING AND ADJUSTING
No.of
pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
MIC type connector
Male (female housing)
Female (male housing)
17
T-adapter Part
No.
799-601-2730
Body part No.: 79A-222-2730 (Qty: 2)
Body part No.: 79A-222-2720 (Qty: 2)
21
799-601-2740
Body part No.: 79A-222-2750 (Qty: 2)
Body part No.: 79A-222-2740 (Qty: 2)
Terminal part No.: 79A-222-2770
(Qty: 50)
Terminal part No.: 79A-222-2760
(Qty: 50)
PC200/220(LC)-7
20-243
TESTING AND ADJUSTING
No.of
pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
AMP040 type connector
Male (female housing)
Female (male housing)
T-adapter Part
No.
799-601-7180
Housing part No.: 79A-222-3430 (Qty: 5)
12
799-601-7190
Housing part No.: 79A-222-3440 (Qty: 5)
16
799-601-7210
Housing part No.: 79A-222-3450 (Qty: 5)
20
799-601-7220
Housing part No.: 79A-222-3460 (Qty: 5)
Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-244
PC200/220(LC)-7
TESTING AND ADJUSTING
No.of
pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
AMP070 type connector
Male (female housing)
Female (male housing)
10
799-601-7510
Part No.: 08195-10210
12
799-601-7520
Part No.: 08195-12210
14
799-601-7530
Part No.: 08195-14210
18
799-601-7540
Part No.: 08195-18210
20
799-601-7550
PC200/220(LC)-7
T-adapter Part
No.
Part No.: 08195-20210
20-245
TESTING AND ADJUSTING
No.of
pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L type connector
Male (female housing)
Female (male housing)
No.of
pins
Connector for PA
Male (female housing)
Female (male housing)
Bendix MS connector
Male (female housing)
Female (male housing)
10
T-adapter Part
No.
799-601-3460
20-246
T-adapter Part
No.
No.of
pins
T-adapter Part
No.
PC200/220(LC)-7
TESTING AND ADJUSTING
No.of
pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
KES 1 (Automobile) connector
Male (female housing)
Female (male housing)
T-adapter Part
No.
Part No.: 08027-10210 (Natural color)
08027-10220 (Black)
Part No.: 08027-10260 (Natural color)
08027-10270 (Black)
Part No.:08027-10310
Part No.:08027-10360
Part No.: 08027-10410 (Natural color)
08027-10420 (Black)
Part No.: 08027-10460 (Natural color)
08027-10470 (Black)
Part No.: 08027-10610 (Natural color)
08027-10620 (Black)
PC200/220(LC)-7
Part No.: 08027-10660 (Natural color)
08027-10670 (Black)
20-247
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
KES 1 (Automobile) connector
No.of
pins
Male (female housing)
Female (male housing)
T-adapter Part
No.
Part No.: 08027-10810 (Natural color)
08027-10820 (Black)
No.of
pins
Part No.: 08027-10860 (Natural color)
08027-10870 (Black)
Connector for relay (Socket type)
Male (female housing)
Female (male housing)
799-601-7360
799-601-7370
20-248
T-adapter Part
No.
PC200/220(LC)-7
TESTING AND ADJUSTING
No.of
pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
F type connector
Male (female housing)
Female (male housing)
PC200/220(LC)-7
T-adapter
Part No.
20-249
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector
Type
(shell
size
code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter
Part No.
799-601-9210
18-8
(1)
Part No.: 08191-11201, 08191-11202,
08191-11205, 08191-11206
Pin (female terminal)
Part No.: 08191-14101, 08191-14102,
08191-14105, 08191-14106
Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202,
08191-12205, 08191-12206
Pin (male terminal)
Part No.: 08191-13101, 08191-13102,
08191-13105, 08191-13106
Pin (female termial)
799-601-9220
Part No.: 08191-21201, 08191-12202,
08191-21205, 08191-12206
18-14
(2)
Pin (female terminal)
Part No.: 08191-24101, 08191-24102,
08191-24105, 08191-24106
Pin (male termial)
799-601-9220
Part No.: 08191-22201, 08191-22202,
08191-22205, 08191-22206
20-250
Part No.: 08191-23101, 08191-23102,
08191-23105, 08191-23106
PC200/220(LC)-7
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector
Type
(shell
size
code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter
Part No.
799-601-9230
18-20
(3)
Part No.:08191-31201, 08191-31202
Part No.:08191-34101, 08191-34102
Pin (female terminal)
Pin (male termial)
799-601-9230
Part No.:08191-32201, 08191-32202
Part No.:08191-33101, 08191-33102
Pin (male terminal)
Pin (female termial)
799-601-9240
18-21
(4)
Part No.:08191-41201, 08191-42202
Part No.:08191-44101, 08191-44102
Pin (female terminal)
Pin (male termial)
799-601-9240
Part No.:08191-42201, 08191-42202
PC200/220(LC)-7
Part No.:08191-43101, 08191-43102
20-251
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector
Type
(shell
size
code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter
Part No.
799-601-9250
24-9
(5)
Part No.:08191-51201, 08191-51202
Part No.:08191-54101, 08191-54102
Pin (female terminal)
Pin (male termial)
799-601-9250
Part No.:08191-52201, 08191-52202
Part No.:08191-53101, 08191-53102
Pin (male terminal)
Pin (female termial)
799-601-9260
Part No.: 08191-61201, 08191-62202,
08191-61205, 08191-62206
24-16
(6)
Pin (female terminal)
Part No.: 08191-64101, 08191-64102,
08191-64105, 08191-64106
Pin (male termial)
799-601-9260
Part No.: 08191-62201, 08191-62202,
08191-62205, 08191-62206
20-252
Part No.: 08191-63101, 08191-63102,
08191-63105, 08191-63106
PC200/220(LC)-7
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector
Type
(shell
size
code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter
Part No.
799-601-9270
24-21
(7)
Part No.: 08191-71201, 08191-71202,
08191-71205, 08191-71206
Pin (female terminal)
Part No.: 08191-74101, 08191-74102,
08191-74105, 08191-74106
Pin (male termial)
799-601-9270
Part No.: 08191-72201, 08191-72202,
08191-72205, 08191-72206
Pin (male terminal)
Part No.: 08191-73101, 08191-73102,
08191-73105, 08191-73106
Pin (female termial)
799-601-9280
Part No.: 08191-81201, 08191-81202
08191-81203, 08191-81204
08191-81205, 08191-80206
24-22
(8)
Pin (female terminal)
Part No.: 08191-84101,
08191-84103,
08191-84105,
08191-84102
08191-84104
08191-84106
Pin (male termial)
799-601-9280
Part No.: 08191-82201,
08191-82203,
08191-82205,
PC200/220(LC)-7
08191-82202
08191-82204
08191-82206
Part No.: 08191-83101,
08191-83103,
08191-83105,
08191-83102
08191-83104
08191-83106
20-253
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector
Type
(shell
size
code)
Body (plug)
Body (receptacle)
Pin (male termial)
Pin (female terminal)
T-adapter
Part No.
799-601-9290
24-31
(9)
Part No.: 08191-91203, 08191-91204,
08191-91205, 08191-91206
Pin (female terminal)
Part No.: 08191-94103, 08191-94104,
08191-94105, 08191-94106
Pin (male termial)
799-601-9290
Part No.: 08191-92203, 08191-92204,
08191-92205, 08191-92206
20-254
Part No.: 08191-93103, 08191-93104,
08191-93105, 08191-93106
PC200/220(LC)-7
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No.of
pins
Body (plug)
Body (receptacle)
T-adapter
Part No.
799-601-9020
Part No.: 08192-12200 (normal type)
08192-22200 (fine wire type)
Part No.: 08192-12100 (normal type)
08192-22100 (fine wire type)
799-601-9030
Part No.: 08192-13200 (normal type)
08192-23200 (fine wire type)
Part No.: 08192-13100 (normal type)
08192-23100 (fine wire type)
799-601-9040
Part No.: 08192-14200 (normal type)
08192-24200 (fine wire type)
Part No.: 08192-14100 (normal type)
08192-24100 (fine wire type)
799-601-9050
Part No.: 08192-16200 (normal type)
08192-26200 (fine wire type)
PC200/220(LC)-7
Part No.: 08192-16100 (normal type)
08192-26100 (fine wire type)
20-255
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No.of
pins
Body (plug)
Body (receptacle)
T-adapter Part No.
8GR:
8B:
8G:
8BR:
799-601-9060
799-601-9070
799-601-9080
799-601-9090
Part No.: 08192-1820$ (normal type) Part No.: 08192-1810$ (normal type)
08192-2820$ (fine wire type)
08192-2810$ (fine wire type)
12GR:
12B:
12G:
12BR:
10
799-601-9110
799-601-9120
799-601-9130
799-601-9140
Part No.: 08192-1920$ (normal type) Part No.: 08192-1910$ (normal type)
08192-2920$ (fine wire type)
08192-2910$ (fine wire type)
20-256
PC200/220(LC)-7
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DTM Series connector
No.of
pins
Body (plug)
Body (receptacle)
T-adapter Part
No.
799-601-9010
Part No.: 08192-02200
Part No.: 08192-02100
[The pin No. is also marked on the connector (electric wire insertion end)]
DTHD Series connector
No.of
pins
Body (plug)
Body (receptacle)
T-adapter Part
No.
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8)
08192-41100 (Contact size #8)
08192-51200 (Contact size #4)
08192-51100 (Contact size #4)
PC200/220(LC)-7
20-257
TROUBLESHOOTING WHEN SERVICE CODE
"ELECTRICAL SYSTEM" AND FAILURE CODE
"MECHANICAL SYSTEM" ARE INDICATED
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-304
Service Code in Electrical System E101 (Abnormal data in Error History) ................................................ 20-306
Service Code in Electrical System E112 (Short-circuiting in normal rotation system of
windshield wiper motor drive)............................................................................................................... 20-308
Service Code in Electrical System E113 (Short-circuiting in reverse rotation system of
windshield wiper motor drive)............................................................................................................... 20-310
Service Code in Electrical System E114 (Short-circuiting in window washer drive system) ...................... 20-312
Service Code in Electrical System E115 (Abnormal Windshield Wiper Motion) ........................................ 20-314
Service Code in Electrical System E116 (Abnormality in retracting windshield wiper) .............................. 20-316
Service Code in Electrical System E201 (Short-circuiting in travel interlocking solenoid) ......................... 20-318
Service Code in Electrical System E203 (Short-circuiting in swing and parking brake solenoid in governor pump controller system).................................................................................................. 20-320
Service Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)................................. 20-322
Service Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)................................. 20-324
Service Code in Electrical System E206 (Short-circuiting in travel speed shifting solenoid) ..................... 20-326
Service Code in Electrical System E211 (Disconnection in travel interlocking solenoid)........................... 20-328
Service Code in Electrical System E213 (Disconnection in Swing Parking Brake Solenoid)..................... 20-330
Service Code in Electrical System E214 (Disconnection of merge/divide solenoid) .................................. 20-332
Service Code in Electrical System E215 (Disconnection in 2-stage relief solenoid) .................................. 20-334
Service Code in Electrical System E216 (Disconnection in travel speed shifting solenoid)....................... 20-336
Service Code in Electrical System E217 (Abnormality in inputting model code)........................................ 20-338
Service Code in Electrical System E218 Disconnection of S-NET signal) ................................................. 20-342
Service Code in Electrical System E222 (Short-circuiting in LS-EPC solenoid) ........................................ 20-344
Service Code in Electrical System E223 (Disconnection in LS-EPC solenoid system) ............................. 20-345
Service Code in Electrical System E224 (Abnormality in F pump pressure sensor).................................. 20-346
Service Code in Electrical System E225 (Abnormality in R pump pressure sensor) ................................. 20-348
Service Code in Electrical System E226 (Abnormality in Pressure sensor power source) ........................ 20-350
Service Code in Electrical System E227 (Abnormality in engine rotation sensor
in governor pump controller system).................................................................................................. 20-352
Service Code in Electrical System E228 (Short-circuiting in attachment return switching relay) ............... 20-353
Service Code in Electrical System E232 (Short-circuiting in PC-EPC Solenoid ........................................ 20-354
Service Code in Electrical System E233 (Disconnection in PC-EPC solenoid system)............................. 20-356
Service Code in Electrical System E238 (Disconnection in attachment return switching relay) ................ 20-358
Service Code in Electrical Equipment E245 (Short-circuiting in attachment oil flow rate adjusting EPC)
(Multi-monitor only)............................................................................................................................... 20-360
Service Code in Electrical System E246 (Disconnection in attachment oil flow rate adjusting EPC)
(Multi-monitor only)............................................................................................................................... 20-361
Service Code in Electrical System E256 (Incorrect nonvolatile memory data) .......................................... 20-362
Service Code in Electrical System E306 (Abnormality in governor potentiometer).................................... 20-364
Service Code in Electrical System E308 (Abnormality in fuel dial) ............................................................ 20-366
PC200/220(LC)-7
20-301
TESTING AND ADJUSTING
Service Code in Electrical System E315 (Short-circuiting in battery relay) ................................................ 20-368
Service Code in Electrical System E316 (Step-out in governor motor) ...................................................... 20-370
Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B) .................... 20-372
Service Code in Electrical System E318 (Short-circuiting in governor motor Phase A and Phase B) ....... 20-374
Service Code in Electrical System E501 ("Model Selection" function not provided yet) ............................ 20-376
Service Mode in Electrical System E502 (Model selecting signal fault) ..................................................... 20-377
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling) .......................... 20-378
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)............................ 20-378
Failure Code in Mechanical System AA10NX (Air cleaner clogging) ......................................................... 20-379
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage).............................. 20-380
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure) ........................ 20-382
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)............................... 20-383
Failure Code in Mechanical System B@BCNS (Engine cooling water overheating).................................. 20-384
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level) ........................ 20-385
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)................................................ 20-386
20-302
PC200/220(LC)-7
TESTING AND ADJUSTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
The troubleshooting table and the related circuit diagrams contain the following information. Grasp their contents fully before proceeding to actual troubleshooting work.
User Code
Service Code
Failure Code
Display in
monitor panel
Display in
monitor panel
Display in
monitor panel
Failure
phenomenon
Title of failure phenomenon shown in failure history
Failure content
Failure status as detected by monitor panel or controller
Response from
monitor panel
or controller
Action taken by the monitor panel or controller to protect an affected system or equipment, when they
detect some failure.
Phenomenon
occurring on
machine
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or
controller
Relative
information
Information on the failure occurred as well as the troubleshooting
Cause
Presumed cause and standard value in normalcy
Cause that presumably
triggered failure in question
3 (The assigned No. is for
filing purpose only. It
does not stand for any
priority)
20-304
Standard value in normalcy and references for troubleshooting
<Content Included>
Standard value in normalcy by which to pass "Good" or "No good" judgement over the
presumed cause
Reference for passing the above "Good" or "No Good" judgement
<Phenomenon of Wiring Harness Failure>
Disconnection
There is a faulty contact at the connector or disconnection of wiring harness occurred.
Defective grounding
A wiring harness that is not connected with a grounding circuit has a contact with the
grounding circuit.
Short-circuiting
A wiring harness that is not connected with a 24 V electric circuit has a contact with the
electric circuit.
<Precaution for Troubleshooting>
1) Connector No. display method and handling of T-adapter
Insert or connect T-adapters in the following manner before starting troubleshooting
unless otherwise instructed.
If there is no indication of "male" or "female" in a specific connector No., disconnect
the connector and insert the T-adapter into both male and female sides.
If there is an indication of "male" or "female" in a specific connector No., disconnect
the connector and connect the T-adepter with only one side of either "male" or "female".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative () lead OFF a circuit tester in the following manner unless otherwise instructed.
Connect the positive (+) lead with the pin No. indicated at the front or the wiring harness.
Connect the negative () lead with the pin No. indicated at the front or the wiring harness.
PC200/220(LC)-7
TESTING AND ADJUSTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
Connector No.: Indicates (Type - numbers of a pin) (color)
Arrow: Roughly indicates the location in the machine where it is installed.
PC200/220(LC)-7
20-305
TESTING AND ADJUSTING
E101
Service Code in Electrical System E101 (Abnormal data in Error History)
User Code
Service Code
Failure Code
E101
DAF0KT
Failure
phenomenon
Abnormal data in the error history
(in Monitor Panel system)
Failure content
The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or
exceeded 36 V.
Response from
Monitor Panel
None in particular
Phenomenon
occurring on
machine
A display for information on the failure history (in the electrical system) cannot be called.
Cause
1 Fuse No. 12 defective
Presumed cause and standard value in normalcy
Fusible link No. A35
defective
Standard value in normalcy and references for troubleshooting
If the fuse is blown, there is a big possibility that the circuit has a grounding fault.
If the fusible link is blown, there is a big possibility that the circuit has a grounding fault.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
Disconnection of wiring
harness
3
(Disconnection or
connector contact fault)
Resistance
value
Above 1
Wiring harness between FB1-17 inlet and A35 (male)
Resistance
value
Above 1
Wiring harness between A35 (male)
nal)
Resistance
value
Above 1
Wiring harness from P01 (female)
let
to J07 to FB1-17 out-
and A23 (B termi-
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
Grounding fault of wiring
harness
4
(Contact with grounding
circuit)
Resistance
value
Above
1 M
Between wiring harness between FB1-17 inlet and A35
(male)
and grounding
Resistance
value
Above
1 M
Between wiring harness between A35 (male)
(B terminal) and grounding
Resistance
value
Above
1 M
Between wiring harness between P01 (female)
and FB1-17 outlet and grounding
to J07
and A23
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
5 Monitor Panel defective
C03
Between
20-306
and
Voltage
20 30 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E101
Monitor Panel Power Source Electric Circuit Diagram
PC200/220(LC)-7
20-307
TESTING AND ADJUSTING
E112
Service Code in Electrical System E112
(Short-circuiting in normal rotation system of windshield wiper motor drive)
User Code
Service Code
Failure Code
E112
DY2DKB
Failure
phenomenon
Short-circuiting in normal rotation system of windshield wiper motor drive (in monitor panel system)
Failure content
Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.
Response from
Monitor Panel
Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Phenomenon
occurring on
machine
The windshield wiper stops moving.
Presumed cause and standard value in normalcy
Cause
Windshield wiper motor
defective
1
(Internal short-circuiting
or grounding fault)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
W04 (female)
Between
Between
Grounding fault of wiring
harness
2
(Contact with grounding
circuit)
Continuity and resistance value
Continued
and
Above 1 M
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
Between wiring harness between P01 (female)
W04 (male)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01
3 Monitor panel defective
20-308
Between
and grounding
Windshield wiper switch
Voltage
OFF
Below 3 V
ON
Below 3 V20 30 V
(at constant cycle)
PC200/220(LC)-7
TESTING AND ADJUSTING
E112
Electric Circuit Diagram for Monitor Panel Windshield Wiper Motor
PC200/220(LC)-7
20-309
TESTING AND ADJUSTING
E113
Service Code in Electrical System E113
(Short-circuiting in reverse rotation system of windshield wiper motor drive)
User Code
Service Code
Failure Code
E113
DY2EKB
Failure
phenomenon
Short-circuiting in reverse rotation system of windshield wiper motor drive (in Monitor Panel system)
Failure content
Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the
windshield wiper was set in motion.
Response from
Monitor Panel
Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.
Phenomenon
occurring on
machine
The windshield wiper stopped moving.
Presumed cause and standard value in normalcy
Cause
Windshield wiper motor
defective
1
(Internal short-circuiting
or grounding fault)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
W04 (female)
Between
Between
Grounding fault of wiring
harness
2
(Contact with grounding
circuit)
Continuity and resistance value
Continued
and
Above 1 M
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
Between wiring harness between P01 (female)
W04 (male)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01
3 Monitor panel defective
20-310
Between
and grounding
Windshield wiper switch
Voltage
OFF
Below 3 V
ON
Below 3 V20 30 V
(at constant cycle)
PC200/220(LC)-7
TESTING AND ADJUSTING
E113
Electric Circuit Diagram for Monitor Panel Windshield Wiper Motor
PC200/220(LC)-7
20-311
TESTING AND ADJUSTING
E114
Service Code in Electrical System E114
(Short-circuiting in window washer drive system)
User Code
Service Code
Failure Code
E114
DY2CKB
Failure
phenomenon
Short-circuiting in window washer drive system
(in Monitor Panel system)
Failure content
Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was
switched ON.
Response from
Monitor Panel
Power supply to the grounding in the window washer motor circuit was switched OFF.
Phenomenon
occurring on
machine
The window washer stopped moving.
Presumed cause and standard value in normalcy
Cause
Window washer drive
1 motor defective
(Internal short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
A50 (male)
Between
Short-circuiting of wiring
harness
2
(Contact with 24 V
circuit)
Resistance value
5 20
and
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
Between wiring harness from P01 (female)
to J04 to
A50 (female)
and grounding, or between wiring harness between P01 (female)
and D04 (female)
and
grounding
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01
3 Monitor panel defective
20-312
Between
and grounding
Window washer switch
Voltage
OFF
20 30 V
ON
Below 1 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E114
Monitor Panel Window Washer Motor Electrical Circuit Diagram
PC200/220(LC)-7
20-313
TESTING AND ADJUSTING
E115
Service Code in Electrical System E115 (Abnormal Windshield Wiper Motion)
User Code
Service Code
Failure Code
E115
DY20KA
Failure
phenomenon
Abnormal operation of windshield wiper
(in Monitor Panel system)
Failure content
A W signal is not inputted at both ends of movement, when it is in motion.
Response from
Monitor Panel
Power to the windshield wiper motor is turned OFF.
Phenomenon
occurring on
machine
The windshield wiper motor does not work.
Relative
information
Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
(Code No. 049: Monitor input 3)
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
Windshield wiper motor
1 defective
(Internal disconnection)
W04 (female)
Between
Disconnection of wiring
harness
2
(Disconnection or faulty
contact with connector)
and
Windshield wiper blade
Resistance value
At upper end of operation
range
Below 1
Outside upper end of
operation range
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
Wiring harness between P01 (female)
Wiring harness between W04 (male)
and W04 (male)
and grounding
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01
3 Monitor panel defective
Between
20-314
and grounding
Windshield wiper blade
Voltage
At upper end of operation
range
Below 1 V
Outside upper end of
operation range
20 30 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E115
Monitor Panel Windshield Wiper Motor Electrical Circuit Diagram
PC200/220(LC)-7
20-315
TESTING AND ADJUSTING
E116
Service Code in Electrical System E116 (Abnormality in retracting windshield wiper)
User Code
Service Code
Failure Code
E116
DY20MA
Failure
phenomenon
Abnormal operation of retracting windshield wiper
(in Monitor Panel system)
Failure content
P signal in the retraction range is not inputted, when the wiper is retracted.
Response from
Monitor Panel
Power supply to the windshield wiper motor is switched OFF, when the wiper is
retracted.
Phenomenon
occurring on
machine
The windshield wiper cannot be retracted completely.
Relative
information
It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
range is inputted or not. (Code No. 049: Monitor Input 3)
Presumed cause and standard value in normalcy
Cause
Windshield wiper motor
1 defective
(Internal disconnection)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
W04 (female)
Between
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
and
Windshield wiper blade
Resistance value
Retraction range
Below 1
Operation range
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness between P01 (female)
Between wiring harness W04 (male)
and W04 (male)
and grounding
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
P01
3 Monitor panel defective
Between
20-316
and grounding
Windshield wiper blade
Voltage
Retraction range
Below 1V
Operation range
20 30 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E116
Monitor Panel Windshield Wiper Motor Electrical Circuit Diagram
PC200/220(LC)-7
20-317
TESTING AND ADJUSTING
E201
Service Code in Electrical System E201
(Short-circuiting in travel interlocking solenoid)
User Code
Service Code
Failure Code
E201
DW91KB
Failure
phenomenon
Short-circuiting in travel interlocking solenoid
(in governor pump controller system)
Failure content
Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
Response from
controller
Power supply to the travel interlocking circuit is switched OFF.
Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
It is difficult to steer the machine at turns.
Relative
information
Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid)
Presumed cause and standard value in normalcy
Cause
Travel interlocking solenoid defective
1
(Internal short-circuiting
or grounding fault)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V02 (male)
Between
Between
Assembled-type diode
2 D03 defective
(Internal short-circuiting)
20 60
and
Above 1 M
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
D03 (male)
Between
Grounding fault of wiring
harness
3
(Contact with grounding
circuit)
Resistance value
Resistance value
Above 1 M
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness from C03 (female)
to J06 to
V02 (female)
and grounding, or between wiring harness between C03 (female)
and D03 (female)
and
grounding
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
4
Governor pump
controller defective
C03
Between
20-318
and grounding
Travel control lever
Voltage
Straight forward
Below 1 V
Steering
20 30 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E201
Electrical Circuit for Travel Interlocking Solenoid in Governor Pump Controller
PC200/220(LC)-7
20-319
TESTING AND ADJUSTING
E203
Service Code in Electrical System E203
(Short-circuiting in swing and parking brake solenoid - in governor pump controller
system)
User Code
Service Code
Failure Code
E03
E203
DW45KB
Failure
phenomenon
Short-circuiting in swing and parking brake solenoid
(in governor pump controller system)
Failure content
Abnormal current flew to the swing and parking brake solenoid circuit, when power was supplied to the
circuit.
Response from
controller
Power supply to the swing and parking brake solenoid circuit is switched OFF.
Even after the failure cause disappears of itself, the swing and steering brake does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
The upper structure cannot swing.
Relative
information
Operation of the swing and parking brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)
If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
the emergency swing brake releasing switch to the FREE position.
(In this case, however, the parking brake does not work, when stopping the machine)
Presumed cause and standard value in normalcy
Cause
Swing and parking brake
solenoid defective
1
(Internal short-circuiting
or grounding fault)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V05 (male)
Between
Between
Assembled-type diode
2 D03 defective
(Internal short-circuiting)
20 60
and
Above 1 M
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
D03 (male)
Between
Grounding fault of wiring
harness
3
(Contact with grounding
circuit)
Resistance value
Resistance value
Above 1 M
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness from C03 (female)
to D01 to J02 to X05
to J06 to V05 (female) , or between wiring harness
between C03 (female)
and D03 (female)
and
grounding
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
4
Governor pump
controller defective
C03
Between
20-320
and grounding
Swing control lever
Voltage
NEUTRAL
Below 1 V
Swing
20 30 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E203
Electrical Circuit Diagram for Swing and Parking Brake of Governor Pump Controller
PC200/220(LC)-7
20-321
TESTING AND ADJUSTING
E204
Service Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)
User Code
Service Code
Failure Code
E204
DWJ0KB
Failure
phenomenon
Short-circuiting in merge/divide solenoid
(in governor pump controller system)
Failure content
Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
Response from
controller
Power supply to the merge/divide solenoid circuit is switched OFF.
Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
Relative
information
Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Presumed cause and standard value in normalcy
Cause
Merge/divide solenoid
defective
1
(Internal short-circuiting
or grounding fault)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V03 (male)
Between
Between
Assembled-type diode
2 D03 defective
(Internal short-circuiting)
20 60
and
Above 1 M
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
D03 (male)
Between
Grounding fault of wiring
harness
3
(Contact with grounding
circuit)
Resistance value
Resistance value
Above 1 M
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness from C03 (female)
to J06 to V03
(female) , or between wiring harness between C03
(female)
and D03 (female)
and grounding
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
4
C03
Governor pump
controller defective
Between
20-322
and grounding
Travel control lever
Voltage
NEUTRAL
Below 1 V
When operating one side
only
20 30 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E204
Electrical Circuit Diagram for Merge/Divide Solenoid in Governor Pump Controller
PC200/220(LC)-7
20-323
TESTING AND ADJUSTING
E205
Service Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)
User Code
Service Code
Failure Code
E205
DWK0KB
Failure
phenomenon
Short-circuiting in 2-stage relief solenoid
(in governor pump controller system)
Failure content
Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
Response from
controller
Power supply to the 2-stage relief solenoid circuit is switched OFF.
Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
The one-touch power max. switch does not work.
Relative
information
Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Presumed cause and standard value in normalcy
Cause
2-stage relief solenoid
defective
1
(Internal short-circuiting
or grounding fault)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V06 (male)
Between
Between
Assembled-type diode
2 D03 defective
(Internal short-circuiting)
20 60
and
Above 1 M
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
D03 (male)
Between
Grounding fault of wiring
harness
3
(Contact with grounding
circuit)
Resistance value
Resistance value
Above 1 M
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness from C03 (female)
to J06 to V06
(female) , or between wiring harness between C03
(female)
and D03 (female)
and grounding
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4
Governor pump
controller defective
C03
Between
20-324
and grounding
Working mode
Voltage
Other than L mode
Below 1 V
L mode
20 30 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E205
Electric Circuit Diagram for 2-stage Relief Solenoid in Governor Pump Controller
PC200/220(LC)-7
20-325
TESTING AND ADJUSTING
E206
Service Code in Electrical System E206
(Short-circuiting in travel speed shifting solenoid)
User Code
Service Code
Failure Code
E206
DW43KB
Failure
phenomenon
Short-circuiting in travel speed shifting solenoid
(in governor pump controller system)
Failure content
Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
Response from
controller
Power supply to the travel speed shifting solenoid circuit is switched OFF.
Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
The travel speed does not turn to Hi.
(The display in the monitor panel changes correctly)
Relative
information
Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Presumed cause and standard value in normalcy
Cause
Travel speed shifting
solenoid defective
1
(Internal short-circuiting
or grounding fault)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V04 (male)
Between
Between
Assembled-type diode
2 D04 defective
(Internal short-circuiting)
20 60
and
Above 1 M
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
D04 (male)
Between
Grounding fault of wiring
harness
3
(Contact with grounding
circuit)
Resistance value
Resistance value
Above 1 M
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness from C03 (female)
to J06 to V04
(female) , or between wiring harness between C03
(female)
and D04 (female)
and grounding
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
4
Governor pump
controller defective
C03
Between
20-326
and grounding
Travel speed
Voltage
Lo
Below 1 V
Hi + Travel operation
20 30 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E206
Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor Pump Controller
PC200/220(LC)-7
20-327
TESTING AND ADJUSTING
E211
Service Code in Electrical System E211 (Disconnection in travel interlocking solenoid)
User Code
Service Code
Failure Code
E211
DW91KA
Failure
phenomenon
Disconnection in travel interlocking solenoid
(in governor pump controller system)
Failure content
No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from
controller
None in particular (The solenoid does not function as there is current flowing to it)
When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
It is difficult to steer the machine while traveling.
Relative
information
Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E201].)
Presumed cause and standard value in normalcy
Cause
Travel interlocking
1 solenoid defective
(Internal disconnection)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V02 (male)
Between
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
Short-circuiting of wiring
harness
3
(Contact with 24 V circuit)
Governor pump
controller defective
20 60
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness from C03 (female)
(female)
to J06 to V02
Wiring harness between V02 (female)
and grounding
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Wiring harness from C03 (female)
to J06 to V02
(female) , or between wiring harness C03 (female)
and D03 (female)
and grounding
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
C03 (female)
Between
20-328
Resistance value
and grounding
Resistance value
20 60
PC200/220(LC)-7
TESTING AND ADJUSTING
E211
Electrical Circuit Diagram for Travel Interlocking Solenoid in Governor Pump Controller
PC200/220(LC)-7
20-329
TESTING AND ADJUSTING
E213
Service Code in Electrical System E213
(Disconnection in Swing Parking Brake Solenoid)
User Code
Service Code
Failure Code
E03
E213
DW45KA
Failure
phenomenon
Disconnection in swing and parking brake solenoid
(in governor pump controller system)
Failure content
No current flows to the swing parking brake solenoid circuit, when power is supplied to the circuit.
Response from
controller
None in particular (The solenoid does not function as there is no current flowing to it)
When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
The machine's upper structure does not swing.
Relative
information
Operation of the swing parking brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing
by moving the emergency swing brake release switch to the FREE position. (In this case, however, the
parking brake does not work, when stopping the machine)
While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in the
OFF position.
The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E203].)
Cause
Presumed cause and standard value in normalcy
Swing parking brake
solenoid defective
1
(Internal disconnection)
Swing lock switch
defective
2
(Internal disconnection)
Assembled-type
diode D01 defective
3
(Internal disconnection)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V05 (male)
Between
Resistance value
20 60
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
X05 (female)
Between
Swing lock switch
and
Resistance value
OFF
Below 1
LOCK
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
D01 (male)
Between
Digital type circuit tester
Continuity
Diode mode
Continued
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of
wiring harness
4 (Disconnection or
defective contact
with connector)
Resistance
value
Below 1
to J02 to X05 (male)
Resistance
value
Below 1
to J06 to V05 (female)
Resistance
value
Below 1
Resistance
value
Below 1
Wiring harness between C03 (female)
Wiring harness from D01 (female)
Wiring harness from X05 (male)
Wiring harness between V05 (female)
Short-circuiting of
Wiring harness
5
(Contact with 24V
circuit)
Governor pump
controller defective
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C03 (female)
(female)
and grounding
and D01
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
C03 (female)
Between
20-330
and D01 (female)
and grounding
Disconnect D01 and connect pins
and
of the
male side.
Resistance value
20 60
PC200/220(LC)-7
TESTING AND ADJUSTING
E213
Electrical Circuit Diagram for Swing and Parking Brake Solenoid in Governor Pump Controller
PC200/220(LC)-7
20-331
TESTING AND ADJUSTING
E214
Service Code in Electrical System E214 (Disconnection of merge/divide solenoid)
User Code
Service Code
Failure Code
E214
DWJ0KA
Failure
phenomenon
Disconnection in merge/divide solenoid
(in governor pump controller system)
Failure content
No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Response from
controller
None in particular (The solenoid does not function as there is no current flowing to it)
When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
In L mode, speeds of the work equipment and swing in its single operation are too fast
Relative
information
Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E204].)
Presumed cause and standard value in normalcy
Cause
Merge/divide solenoid
1 defective
(Internal disconnection)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V03 (male)
Between
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
Short-circuiting of wiring
harness
3
(Contact with 24 V circuit)
Governor pump
controller defective
20 60
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness from C03 (female)
(female)
to J06 to V03
Wiring harness between V03 (female)
and grounding
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Wiring harness from C03 (female)
to J06 to V03
(female) , or between wiring harness between C03
(female)
and D03 (female)
and grounding
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
C03 (female)
Between
20-332
Resistance value
and grounding
Resistance value
20 60
PC200/220(LC)-7
TESTING AND ADJUSTING
E214
Electrical Circuit Diagram for Merge/Divide Solenoid in Governor Pump Controller
PC200/220(LC)-7
20-333
TESTING AND ADJUSTING
E215
Service Code in Electrical System E215 (Disconnection in 2-stage relief solenoid)
User Code
Service Code
Failure Code
E215
DWK0KA
Failure
phenomenon
Disconnection in 2-stage relief solenoid
(in governor pump controller system)
Failure content
No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from
controller
None in particular (The solenoid does not function as there is no current flowing to it)
When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
The one-touch power max. switch does not work.
Relative
information
Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E205].)
Presumed cause and standard value in normalcy
Cause
2-stage relief solenoid
1 defective
(Internal disconnection)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V06 (male)
Between
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
Short-circuiting of wiring
harness
3
(Contact with 24 V circuit)
Governor pump
controller defective
20 60
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness from C03 (female)
(female)
to J06 to V06
Wiring harness between V06 (female)
and grounding
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Wiring harness from C03 (female)
to J06 to V06
(female) , or between wiring harness between C03
(female)
and D03 (female)
and grounding
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
C03 (female)
Between
20-334
Resistance value
and grounding
Resistance value
20 60
PC200/220(LC)-7
TESTING AND ADJUSTING
E215
Electrical Circuit Diagram for 2-stage Relief Solenoid in Governor Pump Controller
PC200/220(LC)-7
20-335
TESTING AND ADJUSTING
E215
Service Code in Electrical System E216
(Disconnection in travel speed shifting solenoid)
User Code
Service Code
Failure Code
E216
DW43KA
Failure
phenomenon
Disconnection in travel speed shifting solenoid
(in governor pump controller system)
Failure content
No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Response from
controller
None in particular (The solenoid does not function as there is no current flowing to it)
When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
The travel speed does not shift to Hi.
(The display changes normally in the monitor panel)
Relative
information
Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E206].)
Presumed cause and standard value in normalcy
Cause
Travel speed shifting
1 solenoid defective
(Internal disconnection)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V04 (male)
Between
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
Short-circuiting of wiring
harness
3
(Contact with 24 V circuit)
Governor pump
controller defective
20 60
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness from C03 (female)
(female)
to J06 to V04
Wiring harness between V06 (female)
and grounding
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Wiring harness from C03 (female)
to J06 to V04
(female) , or between wiring harness between C03
(female)
and D04 (female)
and grounding
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
C03 (female)
Between
20-336
Resistance value
and grounding
Resistance value
20 60
PC200/220(LC)-7
TESTING AND ADJUSTING
E215
Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor Pump Controller
PC200/220(LC)-7
20-337
TESTING AND ADJUSTING
E217
Service Code in Electrical System E217 (Abnormality in inputting model code)
PC200-7
User Code
Service Code
Failure Code
E217
DA2SKQ
Failure
phenomenon
Abnormality in inputting model code
(in governor pump controller system)
Failure content
A model code signal was inputted which indicates another model that is not registered in the controller.
Response from
controller
The controller treats it as a default-set model (PC200).
Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
None in particular with PC200 model
Relative
information
Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
function. (Code No. 002 and 003: Controller Model Code)
Input of model selecting signals (ON or OFF) can be confirmed in the monitoring
function.(Code No. 027:Switch Input 2)
Cause
Model selecting connector defective
1
(Internal disconnection
or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
C09 (female)
Between
Presumed cause and standard value in normalcy
Between
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
Resistance value
Below 1
and
,
or
Above 1 M
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness between C03 (female)
(male)
and C09
Between wiring harness between C09 (male)
and grounding
and J05
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of wiring
harness
3
(Contact with grounding
circuit)
Between wiring harness between C03 (female)
C09 (male)
and grounding
and
Resistance
value
Above 1 M
Between wiring harness between C03 (female)
C09 (male)
and grounding
and
Resistance
value
Above 1 M
Between wiring harness between C03 (female)
C09 (male)
and grounding
and
Resistance
value
Above 1 M
Between wiring harness between C03 (female)
C09 (male)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4
Governor pump
controller defective
C03
Between
Between
20-338
or
Voltage
and grounding
and grounding
20 30 V
Below 1 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E217
Electrical Circuit Diagram for Model Selecting Connector in Governor Pump Controller
PC200-7
PC200/220(LC)-7
20-339
TESTING AND ADJUSTING
E217
PC220-7
User Code
Service Code
Failure Code
E217
DA2SKQ
Failure
phenomenon
Abnormality in inputting model code
(in governor pump controller system)
Failure content
A model code signal was inputted which indicates another model that is not registered in the controller.
Response from
controller
The controller treats it as a default-set model (PC200).
Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
None in particular with PC200 model
Relative
information
Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
function. (Code No. 002 and 003: Controller Model Code)
Input of model selecting signals (ON or OFF) can be confirmed in the monitoring
function.(Code No. 027:Switch Input 2)
Cause
Model selecting connector defective
1
(Internal disconnection
or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
C09 (female)
Between
Presumed cause and standard value in normalcy
Between
,
,
Resistance value
Below 1
and
or
Above 1 M
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
Wiring harness between C03 (female)
(male)
and C09
Resistance
value
Below 1
Wiring harness between C03 (female)
(male)
and C09
Resistance
value
Below 1
Resistance
value
Below 1
Between wiring harness between C09 (male)
and grounding
and J05
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of wiring
harness
3
(Contact with grounding
circuit)
Between wiring harness between C03 (female)
C09 (male)
and grounding
and
Resistance
value
Above 1 M
Between wiring harness between C03 (female)
C09 (male)
and grounding
and
Resistance
value
Above 1 M
Between wiring harness between C03 (female)
C09 (male)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4
Governor pump
controller defective
20-340
C03
Between
or
and grounding
Between
and grounding
Voltage
20 30 V
Below 1 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E217
Electrical Circuit Diagram for Model Selecting Connector in Governor Pump Controller
PC220-7
PC200/220(LC)-7
20-341
TESTING AND ADJUSTING
E218
Service Code in Electrical System E218 Disconnection of S-NET signal)
User Code
Service Code
Failure Code
E218
DA2SKA
Failure
phenomenon
Disconnection in S-NET signal
(in governor pump controller system)
Failure content
A failure occurred in S-NET communication between the monitor and controller in the past.
(The machine operation returned to normalcy, when the display was resumed)
Response from
controller
While the failure is still continuing, the machine operation is controlled by the following default setting.
1) Working mode: E mode
2) Travel speed: Lo
3) Auto-decelerator: ON
4) Attachment oil flow rate: Minimum ( )
When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
Relative
information
This Service Code No. is displayed to inform that there was a failure occurred in the past, when S-NET
communication between the monitor panel and the governor pump controller is returned to normalcy.
The communication has already returned to normalcy by the time this Service Code No. is displayed.
But thoroughly diagnose all the related equipment and circuits, and remove all potential causes for a
failure in order to prevent recurrence of failures.
The working mode cannot be changed. (The display changes normally in the monitor panel)
The travel speed cannot be shifted. (The display changes normally in the monitor panel)
The auto-decelerator cannot be released. (The display changes normally in the monitor panel)
The attachment oil flow rate cannot be changed. (The display changes normally in the monitor panel) ( )
: The multi-monitor specification machine only.
Presumed cause and standard value in normalcy
Cause
Disconnection of wiring
harness
1 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness between P02 (female)
(female)
Wiring harness between P02 (female)
(female)
and C02
and C02
Resistance
value
Below 1
Resistance
value
Below 1
Grounding fault of wiring
harness
2
(Contact with grounding
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Short-circuiting of wiring
harness
3
(Contact with 24 V circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Between wiring harness between P02 (female)
C02 (female)
and grounding
Between wiring harness between P02 (female)
C02 (female)
and grounding
and
and
Resistance
value
Voltage
Above 1 M
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4 Monitor panel defective
P02 (male)
Between
Governor pump
controller defective
69V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
C02 (male)
Between
20-342
and
Voltage
and
Voltage
69V
PC200/220(LC)-7
TESTING AND ADJUSTING
E218
Electrical Circuit Diagram for S-NET Communication between Monitor Panel and Governor Pump
Controller
PC200/220(LC)-7
20-343
TESTING AND ADJUSTING
E222
Service Code in Electrical System E222 (Short-circuiting in LS-EPC solenoid)
User Code
Service Code
Failure Code
E222
DXE0KB
Failure
phenomenon
Disconnection in LS-EPC solenoid
(in governor pump controller system)
Failure content
Abnormal current flew to the LS-EPC solenoid circuit.
Response from
controller
The controller reduces the output to the LS-EPC solenoid circuit to 0.
Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
switch is once turned OFF.
Phenomenon
occurring on
machine
The travel speed is slow at Mi and Lo.
In L mode, speeds of the work equipment and swing are too fast.
Relative
information
Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 015: LS-EPC solenoid current)
Presumed cause and standard value in normalcy
Cause
LS-EPC solenoid defective
1
(Internal short-circuiting
or grounding fault)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V22 (male)
Between
Between
Grounding fault of wiring
harness
2
(Contact with grounding
circuit)
Resistance value
7 14
and
Above 1 M
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between C03 (female)
V22 (female)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
3
Governor pump
controller defective
C03 (female)
Between
Between
Resistance value
and
and grounding
7 14
Above 1 M
Electrical Circuit Diagram for LS-EPC Solenoid in Governor Pump Controller
20-344
PC200/220(LC)-7
TESTING AND ADJUSTING
E223
Service Code in Electrical System E223 (Disconnection in LS-EPC solenoid system)
User Code
Service Code
Failure Code
E223
DXE0KA
Failure
phenomenon
Disconnection in LS-EPC solenoid
(in governor pump controller system)
Failure content
No current flows to the LS-EPC solenoid circuit.
Response from
controller
None in particular (The solenoid does not function as there is no current flowing to it)
When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
The travel speed is slow at Mi and Lo.
In L mode, speeds of the work equipment and swing are too fast.
Relative
information
Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 015: LS-EPC solenoid current)
Presumed cause and standard value in normalcy
Cause
LS-EPC solenoid defec1 tive
(Internal short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V22 (male)
Between
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
Short-circuiting of wiring
harness
3
(Contact with 24 V circuit)
Governor pump
controller defective
Resistance value
7 14
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between C03 (female)
V22 (female)
and grounding
Wiring harness between C03 (female)
(female)
and
and V22
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Between wiring harness between C03 (female)
V22 (female)
and grounding
and
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
C03 (female)
Between
Resistance value
and
7 14
Electrical Circuit Diagram for LS-EPC Solenoid in Governor Pump Controller
PC200/220(LC)-7
20-345
TESTING AND ADJUSTING
E224
Service Code in Electrical System E224 (Abnormality in F pump pressure sensor)
User Code
Service Code
Failure Code
E224
DHPAMA
Failure
phenomenon
Abnormality in F pump pressure sensor
(in governor pump controller system)
Failure content
Signal voltage from the F pump pressure sensor dropped below 0.3 V or exceeded 4.72 V.
Response from
controller
The controller controls the F pump pressure at 0 MPa{0 kg/cm2}.
If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on
machine
The travel speed does not shift automatically.
Relative
information
Input from the F pump pressure sensor (pressure) can be confirmed in the monitor function.
(Code No. 011: F pump pressure)
Cause
Sensor power source
fault
Presumed cause and standard value in normalcy
F pump pressure sensor
2 defective
(Internal failure)
Standard value in normalcy and references for troubleshooting
If the Service Code No. [E226] is displayed, troubleshoot the failure first.
Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
A51
Voltage
Between
and
4.5 5.5 V
Between
and
0.5 4.5 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring
harness
3 (Disconnection or defective contact with connector)
Grounding fault of wiring
harness
4
(Contact with grounding
circuit)
Short-circuiting of wiring
harness
5
(Contact with 24 V circuit)
Wiring harness from C01 (female)
(female)
to J07 to A51
Resistance
value
Below 1
Wiring harness between C01 (female)
(female)
and A51
Resistance
value
Below 1
Wiring harness between C01 (female)
(female)
and A51
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between C01 (female)
A51 (female)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Between wiring harness between C01 (female)
and A51 (female)
and grounding
, J07
Between wiring harness between C01 (female)
A51 (female)
ang grounding
and
Voltage
Below 1 V
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
6
Governor pump
controller defective
20-346
C01
Voltage
Between
and
4.5 5.5 V
Between
and
0.5 4.5 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E224
Electrical Circuit Diagram for F Pump Pressure Sensor in Governor Pump Controller
PC200/220(LC)-7
20-347
TESTING AND ADJUSTING
E225
Service Code in Electrical System E225 (Abnormality in R pump pressure sensor)
User Code
Service Code
Failure Code
E225
DHPBMA
Failure
phenomenon
Abnormality in R pump pressure sensor
(in governor pump controller system)
Failure content
Signal voltage from the R pump pressure sensor dropped below 0.3 V or exceeded 4.42 V.
Response from
controller
The controller controls the R pump pressure as 0 MPa {0 kg/cm2}.
If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on
machine
The travel speed does not shift automatically.
Relative
information
Input from the R pump pressure sensor (pressure) can be confirmed in the monitor function.
(Code No. 012: R pump pressure)
Cause
Sensor power source
fault
Presumed cause and standard value in normalcy
R pump pressure sen2 sor defective
(Internal failure)
Standard value in normalcy and references for troubleshooting
If the Service Code No. [E226] is displayed, troubleshoot the failure first.
Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
A52
Voltage
Between
and
4.5 5.5 V
Between
and
0.5 4.5 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring
harness
3 (Disconnection or defective contact with connector)
Grounding fault of wiring
harness
4
(Contact with grounding
circuit)
Short-circuiting of wiring
harness
5
(Contact with 24 V circuit)
Wiring harness from C01 (female)
(female)
to J07 to A52
Resistance
value
Below 1
Wiring harness between C01 (female)
(female)
and A52
Resistance
value
Below 1
Wiring harness between C01 (female)
(female)
and A52
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between C01 (female)
A52 (female)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Between wiring harness between C01 (female)
and A52 (female)
and grounding
, J07
Between wiring harness between C01 (female)
A52 (female)
and grounding
and
Voltage
Below 1 V
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
6
Governor pump
controller defective
20-348
C01
Voltage
Between
and
4.5 5.5 V
Between
and
0.5 4.5 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E225
Electrical Circuit Diagram for R Pump Pressure Sensor in Governor Pump Controller
PC200/220(LC)-7
20-349
TESTING AND ADJUSTING
E226
Service Code in Electrical System E226 (Abnormality in Pressure sensor power source)
User Code
Service Code
Failure Code
E226
DA25KP
Failure
phenomenon
Abnormality in pressure sensor power source
(in governor pump controller system)
Failure content
Abnormal current flew to the power source circuit (5 V) for the pressure sensors and potentiometer.
Response from
controller
The controller turns OFF power supply to the power source circuit (5 V).
Even when the failure cause disappears of itself, the current does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
Signals from the pressure sensors and potentiometer are not inputted correctly.
The Service Code of "pressure sensor abnormal" and that of "potentiometer abnormal" are displayed at
the same time.
Cause
Presumed cause and standard value in normalcy
Pressure sensor or
1 potentiometer defective
(Internal short-circuit)
Standard value in normalcy and references for troubleshooting
Disconnect the following equipment one by one. Equipment that shows no service code
is defective, having an internal failure.
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Fuel dial
E06 Connector
Governor motor potentiometer
E10 Connector
F pump pressure sensor
A51 Connector
R pump pressure sensor
A52 Connector
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of wiring
harness
2
(Contact with grounding
circuit)
Governor pump
controller defective
Between wiring harness from C01 (female)
to J07 to
E06 (female)
and grounding [Fuel dial system]
Resistance
value
Above 1 M
Between wiring harness from C01 (female)
E10 (female)
and grounding
[Governor potentiometer system]
to J07 to
Resistance
value
Above 1 M
Between wiring harness from C01 (female)
A51 (female)
and grounding
[F pump pressure sensor system]
to J07 to
Resistance
value
Above 1 M
Between wiring harness from C01 (female)
A52 (female)
and grounding
[R pump pressure sensor system]
to J07 to
Resistance
value
Above 1 M
Between wiring harness from C01 (female)
A08 (male)
and grounding
[Attachment system]
to J07 to
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
C01
Between
20-350
and
Voltage
4.5 5.5 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E226
Electrical Circuit Diagram for Sensor Power Source in Governor Pump Controller
PC200/220(LC)-7
20-351
TESTING AND ADJUSTING
E227
Service Code in Electrical System E227
(Abnormality in engine rotation sensor in governor pump controller system)
User Code
Service Code
Failure Code
E227
DLE2MA
Failure
phenomenon
Abnormality in engine rotation sensor
(in governor pump controller system)
Failure content
A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.
Response from
controller
The controller exercises a control equivalent to E mode.
If the failure cause disappears of itself, the signal input returns to normalcy.
Phenomenon
occurring on
machine
The machine lacks power a bit.
Relative
information
Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
(Code No. 010: Engine RPM)
Presumed cause and standard value in normalcy
Cause
Engine rotation sensor
fault
1
(Internal short-circuiting
or disconnection)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
E04 (male)
Between
Between
Engine rotation sensor
adjustment improper
Disconnection of wiring
harness
3 (Disconnection or defective contact with connector)
Short-circuiting of wiring
harness
Resistance value
500 1,000
and
Above 1 M
and grounding
For the inspection and adjustment, refer to the section of "Adjusting Engine Rotation
Sensor" in this manual.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness between C02 (female)
(female)
Wiring harness between C02 (female)
(female)
and E04
and E04
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
(Contact with 24 V cir- Between wiring harness between C02 (female)
cuit)
E04 (female)
and grounding
and
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
5
Governor pump
controller defective
C02 (female)
Between
Between
and
and grounding
Resistance value
500 1,000
Above 1 M
Electrical Circuit Diagram for Monitor Panel Power Source
20-352
PC200/220(LC)-7
TESTING AND ADJUSTING
E228
Service Code in Electrical System E228
(Short-circuiting in attachment return switching relay)
User Code
Service Code
Failure Code
E228
D196KB
Failure
phenomenon
Short-circuiting in attachment return switching relay
(in governor pump controller system)
Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power ON).
Response from
controller
The controller turned OFF power to the attachment return switching relay circuit.
Even when the failure cause disappears of itself, the current does not return to normalcy.
Phenomenon
occurring on
machine
The hydraulic circuit for attachments is not switched to the single operation circuit.
Relative
information
It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
or OFF). (Code No. 024:Solenoid 2)
Presumed cause and standard value in normalcy
Failure content
Cause
Attachment return
1 switching relay defective
(Internal short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
R20 (male)
Between
Short-circuiting of wiring
harness
2
(Contact with 24 V circuit)
Resistance value
100 500
and
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Between wiring harness between C02 (female)
R20 (female)
and grounding
and
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
3
Governor pump
controller defective
C03
Between
and grounding
Working mode
Voltage
Other than B mode
20 30 V
B mode
Below 1 V
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC200/220(LC)-7
20-353
TESTING AND ADJUSTING
E232
Service Code in Electrical System E232 (Short-circuiting in PC-EPC Solenoid
User Code
Service Code
Failure Code
E02
E232
DXA0KB
Failure
phenomenon
Disconnection in PC-EPC solenoid
(in governor pump controller system)
Abnormal current flew to the PC-EPC solenoid circuit.
Response from
controller
The controller reduces the output to the PC-EPC solenoid circuit to 0.
Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
switch is once turned OFF.
Phenomenon
occurring on
machine
As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
Relative
information
Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated
in a working mode equivalent to E mode by turning the emergency drive switch ON.
(At that time the monitor panel continues to display service code No. [E232], but this is not abnormal)
Turn the emergency driving switch ON during the troubleshooting.
Presumed cause and standard value in normalcy
Failure content
Cause
PC-EPC solenoid defective
1
(Internal short-circuiting
or grounding fault)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V21 (male)
Between
Between
Grounding fault of wiring
harness
2
(Contact with grounding
circuit)
Resistance value
7 14
and
Above 1 M
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness from C03 (female)
V21 (female)
and grounding
to S21 to
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
3
Governor pump
controller defective
20-354
C03 (female)
Between
Between
and
and grounding
Resistance value
7 14
Above 1 M
PC200/220(LC)-7
TESTING AND ADJUSTING
E232
Electrical Circuit Diagram for PC-EPC Solenoid in Governor Pump Controller
PC200/220(LC)-7
20-355
TESTING AND ADJUSTING
E233
Service Code in Electrical System E233 (Disconnection in PC-EPC solenoid system)
User Code
Service Code
Failure Code
E02
E233
DXA0KA
Failure
phenomenon
Disconnection in PC-EPC solenoid
(in governor pump controller system)
Failure content
No current flows to the PC-EPC solenoid circuit.
Response from
controller
None in particular (The solenoid does not function as there is no current flowing to it)
When the failure cause disappears of itself, the current returns to normalcy.
Phenomenon
occurring on
machine
As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
Relative
information
Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated
in a working mode equivalent to E mode by turning the emergency driving switch ON. (At that time the
monitor panel continues to display Service Code No. [E233], but this is not abnormal)
Cause
PC-EPC solenoid
1 defective
(Internal short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V21 (male)
Between
Resistance value
7 14
and
Presumed cause and standard value in normalcy
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Emergency pump driving
2 switch defective
(Internal disconnection)
S21
Between
Between
and
and
Switch
Resistance value
OFF
Below 1
ON
Above 1 M
OFF
Below 1
ON
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring
harness
3 (Disconnection or defective contact with connector)
Wiring harness between S21
Governor pump
controller defective
Below 1
and V21 (female)
Resistance
value
Below 1
Resistance
value
Below 1
Resistance
value
Below 1
and S21
and V21 (female)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Between wiring harness between C03 (female)
S21
and grounding
Between wiring harness between S21
(female)
and grounding
and V21
and
Voltage
Below 1 V
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
C03 (female)
Between
20-356
Resistance
value
Wiring harness between C03 (female)
Wiring harness between S21
Short-circuiting of wiring
harness
4
(Contact with 24 V circuit)
and S21
Wiring harness between C03 (female)
and
Resistance value
7 14
PC200/220(LC)-7
TESTING AND ADJUSTING
E233
Electrical Circuit Diagram for PC-EPC Solenoid in Governor Pump Controller
PC200/220(LC)-7
20-357
TESTING AND ADJUSTING
E238
Service Code in Electrical System E238
(Disconnection in attachment return switching relay)
User Code
Service Code
Failure Code
E238
D196KA
Failure
phenomenon
Disconnection in attachment return switching relay
(in governor pump controller system)
Failure content
When the attachment switching relay circuit is disconnected from grounding (power OFF), 24 V voltage
is not generated.
Response from
controller
None in particular
If the failure cause disappears, the governor returns to normalcy.
Phenomenon
occurring on
machine
The hydraulic circuit for attachments cannot be switched to the single operation
Relative
information
It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
or OFF). (Code No. 024:Solenoid 2)
Cause
Presumed cause and standard value in normalcy
1 Fuse No. 2 fault
Attachment return
2 switching relay defective
(Internal disconnection)
Standard value in normalcy and references for troubleshooting
If the fuse has been blown, there is a big possibility that grounding fault occurred in the
relay circuit.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
R20 (male)
Between
Resistance value
100 500
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Emergency pump driving
3 switch defective
(Internal disconnection)
Wiring harness between C02 (female)
(female)
Wiring harness from R20 (female)
outlet
Grounding fault of wiring
harness
4
(Contact with grounding
circuit)
and R20
Resistance
value
Below 1
to J03 to FB1-2
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between C02 (female)
R20 (female)
and grounding
Between wiring harness from R20 (female)
FB1-2 outlet and grounding
and
to J03 to
Resistance
value
Above 1 M
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
5
Governor pump
controller defective
C03
Between
20-358
and grounding
Working mode
Voltage
Other than B mode
20 30 V
B mode
Below 1 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E238
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid in Governor Pump
Controller
PC200/220(LC)-7
20-359
TESTING AND ADJUSTING
E245
Service Code in Electrical Equipment E245
(Short-circuiting in attachment oil flow rate adjusting EPC) (Multi-monitor only)
User Code
Service Code
Failure Code
E245
DXE4KB
Failure
phenomenon
Short-circuiting in attachment oil flow rate adjusting
EPC (in governor pump controller system)
Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from
controller
The controller reduces to zero (0) power to the attachment oil flow rate adjusting EPC solenoid circuit.
Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless
the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
The attachments do not move.
Relative
information
It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)
Presumed cause and standard value in normalcy
Failure content
Cause
Attachment oil flow rate
adjusting EPC defective
1
(Internal short-circuiting
or grounding fault)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V30 (male)
Between
Between
Grounding fault of wiring
harness
2
(Contact with grounding
circuit)
Resistance value
7 14
and
Above 1 M
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between C03 (female)
V30 (female)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
3
Governor pump
controller defective
C03 (female)
Between
Between
and
and grounding
Resistance value
7 14
Above 1 M
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor Pump
Controller
20-360
PC200/220(LC)-7
TESTING AND ADJUSTING
E246
Service Code in Electrical System E246
(Disconnection in attachment oil flow rate adjusting EPC) (Multi-monitor only)
User Code
Service Code
Failure Code
E246
DXE4KA
Failure
phenomenon
Disconnection in attachment oil flow rate adjusting
EPC (in governor pump controller system)
Failure content
No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from
controller
None in particular (The solenoid does not work, as there is no current flowing to it)
If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself.
Phenomenon
occurring on
machine
The attachments do not move.
Relative
information
It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)
Presumed cause and standard value in normalcy
Cause
Attachment oil flow rate
adjusting EPC defective
1
(Internal short-circuiting
or grounding fault)
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
Short-circuiting of wiring
harness
3
(Contact with 24 V circuit)
Governor pump
controller defective
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V30 (male)
Between
Resistance value
7 14
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between C03 (female)
V30 (male)
and grounding
and
Between wiring harness between C03 (female)
and V30 (male)
and grounding
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Between wiring harness between C03 (female)
V30 (female)
and grounding
and
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
C03 (female)
Between
and
Resistance value
7 14
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor Pump
Controller
PC200/220(LC)-7
20-361
TESTING AND ADJUSTING
E256
Service Code in Electrical System E256 (Incorrect nonvolatile memory data)
User Code
Service Code
Failure Code
E256
DA20KT
Failure
phenomenon
Incorrect nonvolatile memory data
(in governor pump controller)
Failure content
The data in the nonvolatile memory in the controller cannot be updated.
Response from
controller
None in particular
Even if the failure cause disappears, the nonvolatile memory does not return to normalcy, unless the
engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
In some cases control parameters of the machines change, resulting in increase or decrease of the machine's power.
Relative
information
Recorded in the nonvolatile memory are part of the machine control parameters
Presumed
cause and
standard value
in normalcy
20-362
Cause
Standard value in normalcy and references for troubleshooting
Governor pump
controller defective
As it is an internal failure, troubleshooting is impossible.
(There is no problem with continuing with use of the controller, so long as no
failure is visually evident)
PC200/220(LC)-7
TESTING AND ADJUSTING
E306
Service Code in Electrical System E306 (Abnormality in governor potentiometer)
User Code
Service Code
Failure Code
E306
DK54KZ
Failure
phenomenon
Abnormality in governor potentiometer
(in governor pump controller)
Failure content
Signal voltage from the governor potentiometer dropped below 0.4 V or exceeded 4.6 V.
Response from
controller
The controller exercises control by computing the motor position through voltage right before a failure
occurred.
Even if the failure cause disappears of itself, the governor potentiometer does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
Relative
information
Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
(Code No. 031: Governor potentiometer voltage)
The engine cannot attain the specified rotation at high idling. (A bit lower)
The engine cannot attain the specified rotation at low idling (A bit higher)
The auto-decelerator or automatic warming-up function does not work.
There is hunting while the engine is running.
The engine stalls.
The engine does not stop.
Cause
1
Sensor power source
defective
Standard value in normalcy and references for troubleshooting
If Service Code No. [E226] is displayed, troubleshoot the failure first.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Presumed cause and standard value in normalcy
Governor potentiometer
2 defective
(Internal failure)
E10 (male)
Resistance value
Between
and
4.0 6.0 k
Between
and
0.25 5.0 k
Between
and
0.25 5.0 k
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring
harness
3 (Disconnection or defective contact with connector)
Grounding fault of wiring
harness
4
(Contact with grounding
circuit)
Short-circuiting of wiring
harness
5
(Contact with 24 V circuit)
Wiring harness from C01 (female)
(female)
to J07 to E10
Resistance
value
Below 1
Wiring harness between C01 (female)
(female)
and E10
Resistance
value
Below 1
Wiring harness between C01 (female)
(female)
and E10
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between C01 (female)
E10 (female)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Between wiring harness from C01 (female)
E10 (female)
and grounding
to J07 to
Between wiring harness between C01 (female)
E10 (female)
and grounding
and
Voltage
Below 1 V
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
6
Governor pump
controller defective
20-364
C01
Resistance value
Between
and
4.5 5.5 V
Between
and
0.5 4.5 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E306
Electrical Circuit Diagram for Governor Motor in Governor Pump Controller
PC200/220(LC)-7
20-365
TESTING AND ADJUSTING
E308
Service Code in Electrical System E308 (Abnormality in fuel dial)
User Code
Service Code
Failure Code
E05
E308
DK10KZ
Failure
phenomenon
Abnormality in governor fuel dial
(in governor pump controller)
Failure content
Signal voltage from the from fuel dropped below 0.23 V or exceeded 4.77 V.
Response from
controller
The controller exercises control by computing the fuel dial position through voltage right before a failure
occurred.
If the failure cause disappears, the fuel dial returns to normalcy.
Phenomenon
occurring on
machine
Relative
information
Input from the fuel dial (voltage) can be confirmed in the monitor function.
(Code No. 030: Fuel dial voltage)
If the fuel dial had been set at FULL before a failure occurred, it does not change to PARTIAL.
If the fuel dial had been set at PARTIALLY before a failure occurred, it does not change to FULL.
There is hunting while the engine is running.
The engine cannot attain the specified rotation at high idling and lacks power.
Cause
Sensor power source
1
defective
Presumed cause and standard value in normalcy
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting
If Service Code No. [E226] is displayed, troubleshoot the failure first.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
E06 (male)
Resistance value
Between
and
4.0 6.0 k
Between
and
0.25 5.0 k
Between
and
0.25 5.0 k
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring
harness
3 (Disconnection or defective contact with connector)
Grounding fault of wiring
harness
4
(Contact with grounding
circuit)
Short-circuiting of wiring
harness
5
(Contact with 24 V circuit)
Wiring harness from C01 (female)
(female)
to J07 to E06
Resistance
value
Below 1
Wiring harness between C01 (female)
(female)
and E06
Resistance
value
Below 1
Wiring harness between C01 (female)
(female)
and E06
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between C01 (female)
E06 (female)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Between wiring harness from C01 (female)
E06 (female)
and grounding
to J07 to
Between wiring harness between C01 (female)
E06 (female)
and grounding
and
Voltage
Below 1 V
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
6
Governor pump
controller defective
20-366
C01
Resistance value
Between
and
4.5 5.5 V
Between
and
0.5 4.5 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E308
Electrical Circuit Diagram for Fuel Dial in Governor Pump Controller
PC200/220(LC)-7
20-367
TESTING AND ADJUSTING
E315
Service Code in Electrical System E315 (Short-circuiting in battery relay)
User Code
Service Code
Failure Code
E315
D110KB
Failure
phenomenon
Short-circuiting in battery relay
(in governor pump controller)
Abnormal current flew to the battery relay drive circuit, when power was supplied to the circuit.
Response from
controller
The controller turns OFF power to the battery drive circuit.
Even when the failure cause disappears, the relay does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
The engine does not stop.
Relative
information
It can be confirmed in the monitor function how the battery relay works (ON or OFF).
(Code No. 037: Controller output)
Presumed cause and standard value in normalcy
Failure content
Cause
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Battery relay defective
(Internal failure)
Battery relay
Continuity & Resistance value
Between A21 (BR terminal) and A20 (E
terminal)
Continued
Between A21 (BR terminal) and grounding
Grounding fault of wiring
harness
2
(Contact with grounding
circuit)
Governor pump
controller defective
20-368
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness from C03 (female)
J01 to A21 (BR terminal) and grounding
to D01 to
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
C03 (female)
Between
and grounding
Engine starting switch OFF
Voltage
ON OFF
20 30 V
(for 4 to 7 seconds)
PC200/220(LC)-7
TESTING AND ADJUSTING
E315
Electrical Circuit Diagram for Battery Relay in Governor Pump Controller
PC200/220(LC)-7
20-369
TESTING AND ADJUSTING
E316
Service Code in Electrical System E316 (Step-out in governor motor)
User Code
Service Code
Failure Code
E316
DY10K4
Failure
phenomenon
Step-out in governor motor
(in governor pump controller)
Failure content
There is a big difference between signals from the potentiometer and the set values in the controller.
Response from
controller
The controller repeats the same controlling motions (step-out).
Even when the failure cause disappears, the governor motor does not return to normalcy, unless the
engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
The engine rotation cannot be controlled.
There is hunting in the rotation.
The engine does not stop.
Presumed cause and standard
value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
1 Fuel dial defective
If Service Code [E308] is displayed, troubleshoot that failure first.
2 Governor potentiometer defective
If Service Code [E306] is displayed, troubleshoot that failure first.
3 Governor motor defective (disconnection)
If Service Code [E317] is displayed, troubleshoot that failure first.
4 Governor motor defective (short-circuiting) If Service Code [E318] is displayed, troubleshoot that failure first.
5 Governor lever adjustment improper
Refer to the section of "Inspection and Adjustment - Special Function of Monitor Panel" in this manual.
6 Engine fuel control system defective
Refer to Engine Shop Manual.
7 Governor pump controller defective
As this is an internal failure, no troubleshooting can be carried out.
(If there is none of the failures listed above, the controller is judged
as defective)
20-370
PC200/220(LC)-7
TESTING AND ADJUSTING
E317
Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B)
User Code
Service Code
Failure Code
E05
E317
DY10KA
Failure
phenomenon
Disconnection in governor motor Phase A and B
(in governor pump controller)
Failure content
No current flew to the governor motor, when power was supplied to the motor.
Response from
controller
None in particular.
If the failure cause disappears, the governor returns to normalcy.
Phenomenon
occurring on
machine
Relative
information
Operation of the governor motor (current) can be confirmed in the monitor function.
(Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)
The engine rotation drops to low idling.
There is hunting in the rotation
The engine does not stop.
The governor motor steps out.
Presumed cause and standard value in normalcy
Cause
Governor motor defec1 tive
(Internal disconnection)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
E11 (male)
Resistance value
Between
and
2.5 7.5
Between
and
2.5 7.5
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
Wiring harness between C03 (female)
(female)
and E11
Resistance
value
Below 1
Wiring harness between C03 (female)
(female)
and E11
Resistance
value
Below 1
Wiring harness between C03 (female)
(female)
and E11
Resistance
value
Below 1
Wiring harness between C03 (female)
(female)
and E11
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
3
Governor pump
controller defective
20-372
C03 (female)
Resistance value
Between
and
2.5 7.5
Between
and
2.5 7.5
PC200/220(LC)-7
TESTING AND ADJUSTING
E317
Electrical Circuit Diagram for Governor Motor in Governor Pump Controller
PC200/220(LC)-7
20-373
TESTING AND ADJUSTING
E318
Service Code in Electrical System E318
(Short-circuiting in governor motor Phase A and Phase B)
User Code
Service Code
Failure Code
E318
DY10KB
E05
Failure
phenomenon
Disconnection in governor motor Phase A and
Phase B (in governor pump controller system)
Failure content
Abnormal current flew to the governor motor, when power is supplied to the motor.
Response from
controller
None in particular
If the failure cause disappears, the governor motor returns to normalcy.
Phenomenon
occurring on
machine
Relative
information
Operation of the governor motor (current) can be confirmed in the monitor function.
(Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)
The engine rotation cannot be controlled.
The engine rotation drops to low idling.
There is hunting in the rotation.
The engine does not stop.
Cause
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Presumed cause and standard value in normalcy
Governor motor defective
1
(Internal short-circuiting
or grounding fault)
E11 (male)
Resistance value
Between
and
2.5 7.5
Between
and
2.5 7.5
Between
and grounding
Above 1 M
Between
and grounding
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
Between wiring harness between C03 (female)
E11 (female)
and grounding
and
Resistance
value
Above 1 M
Between wiring harness between C03 (female)
E11 (female)
and grounding
and
Resistance
value
Above 1 M
Between wiring harness between C03 (female)
E11 (female)
and grounding
and
Resistance
value
Above 1 M
Between wiring harness between C03 (female)
E11 (female)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
C03 (female)
Governor pump
controller defective
20-374
Resistance value
Between
and
2.5 7.5
Between
and
2.5 7.5
Between
and grounding
Above 1 M
Between
and grounding
Above 1 M
Between
and grounding
Above 1 M
Between
and grounding
Above 1 M
PC200/220(LC)-7
TESTING AND ADJUSTING
E318
Electrical Circuit Diagram for Governor Motor in Governor Pump Controller
PC200/220(LC)-7
20-375
TESTING AND ADJUSTING
E501 / E502
Service Code in Electrical System E501 ("Model Selection" function not provided yet)
User Code
Service Code
Failure Code
E501
DA2AKM
Failure
phenomenon
"Model Selection" function not provided yet
(in governor pump controller system)
Failure content
Model Code is not inputted yet.
Response from
controller
Model data and rated load cannot be set.
Even when the failure cause disappears, Service Code does not return to normalcy, unless the engine
starting switch is once turned OFF.
Phenomenon
occurring on
machine
The excess load alarm does not work normally.
Relative
information
Model names that the controller recognizes (figure) can be confirmed in the monitor function.
(Code No. 150: Model Code)
Cause
Presumed
cause and
standard value
in normalcy
Setting work not finished
1
yet
20-376
Governor pump
controller defective
Standard value in normalcy and references for troubleshooting
Refer to the section "Special Function of Monitor Panel" in this manual.
There is a possibility that model selection operation has never been
tried with that specific model from its delivery ex-works up to this moment.
As this is an internal failure, no troubleshooting can be conducted.
(If there is no problem with the setting work above, the controller may be
judged as defective.)
PC200/220(LC)-7
TESTING AND ADJUSTING
E501 / E502
Service Mode in Electrical System E502 (Model selecting signal fault)
User Code
Service Code
Failure Code
E502
DA20KT
Failure
phenomenon
Model selecting signal fault
(in governor pump controller system)
Failure content
Information on the models stored in the controller have been damaged.
Response from
controller
Model data and rated load cannot be set.
Even when the failure cause disappears, the signal does not return to normal, unless the engine starting
switch is once turned OFF.
Phenomenon
occurring on
machine
The excess load alarm does not work normally.
Relative
information
(Model names that the controller recognizes (figure) can be confirmed in the monitor function.
(Code No. 150: Model Code)
Cause
Presumed
cause and
standard value
in normalcy
Standard value in normalcy and references for troubleshooting
Setting work not finished
yet
Refer to the section "Special Function of Monitor Panel" in this manual.
Governor pump
controller defective
As this is an internal failure, no troubleshooting can be conducted.
(If there is no problem with the setting work above, the controller may be
judged as defective.)
PC200/220(LC)-7
20-377
TESTING AND ADJUSTING
A000N1 / A000N2
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling)
User Code
Service Code
Failure Code
A000N1
Failure
phenomenon
Engine rotation at high idling out of rate
(in mechanical system)
Failure content
Engine rotation above 2,350 rpm was detected for more than 10 seconds, while the engine was running.
Response from
controller
None in particular
If the failure cause disappears of itself, the engine rotation returns to normalcy.
Phenomenon
occurring on
machine
There is a possibility that the engine is damaged, if is used continuously without adjustment.
Relative
information
Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
(Code No. 010: Engine rotation)
Cause
Presumed
cause and
standard value
in normalcy
Standard value in normalcy and references for troubleshooting
Check if there has been an internal or external factor that would cause
Failure in engine mechanthe engine to overrun at high idling, and troubleshoot the mechanical
ical system
system of the engine.
Governor pump
controller defective
As this is an internal failure, troubleshooting cannot be conducted.
(Unless there is any visible trouble found in the machine, use of the controller may be continued as it is)
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)
User Code
Service Code
Failure Code
A000N2
Failure
phenomenon
Out-of-rate engine rotation at low idling
(in mechanical system)
Failure content
Engine rotation below 500 rpm was detected for more than 10 seconds, while the engine was running.
Response from
controller
None in particular
If the failure cause disappears of itself, the rotation returns to normalcy.
Phenomenon
occurring on
machine
There is a possibility that the engine is damaged, if it is used continuously without adjustment.
Relative
information
Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
(Code No. 010: Engine rotation)
Cause
Presumed
cause and
standard value
in normalcy
20-378
Standard value in normalcy and references for troubleshooting
Check if there has been an internal or external factor that would cause
Failure in engine mechanthe engine to overrun at high idling, and troubleshoot the mechanical
ical system
system of the engine.
Governor pump
controller defective
As this is an internal failure, troubleshooting cannot be conducted.
(Unless there is any visible trouble found in the machine, use of the controller may be continued as it is)
PC200/220(LC)-7
TESTING AND ADJUSTING
AA10NX
Failure Code in Mechanical System AA10NX (Air cleaner clogging)
User Code
Service Code
Failure Code
AA10NX
Failure
phenomenon
Air cleaner clogged
(in mechanical system)
Failure content
While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e. disconnected from grounding circuit).
Response from
controller
None in particular
Phenomenon
occurring on
machine
There is a possibility that the engine is damaged, if it is used continuously without corrective action.
Relative
information
This Failure Code is recorded, when the air cleaner clogging caution symbol is displayed in the monitor
panel while the engine is running.
Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the monitor panel.
(Code No. 046: Monitor input 2)
Presumed cause and standard value in normalcy
Cause
Air cleaner clogged
1 (when the system is in
normal condition)
Air cleaner clogging
2 switch defective
(Internal disconnection)
Standard value in normalcy and references for troubleshooting
Check the air cleaner for clogging. If it is clogged, clean or replace it with new one.
Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
A31 (male)
Between
Disconnection of wiring
harness
3 (Disconnection or defective contact with connector)
and
Air cleaner
Resistance value
When in normal condition
Below 1
When clogged
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Wiring harness between P02 (female)
(female)
and A31
Between wiring harness A31 (female)
and grounding
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
P02
4 Monitor panel defective
Between
and grounding
Air cleaner
Voltage
When in normal condition
Below 1 V
When clogged
20 30 V
Electrical Circuit for Air Cleaner Clogging Switch in Monitor Panel
PC200/220(LC)-7
20-379
TESTING AND ADJUSTING
AB00KE
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage)
User Code
Service Code
Failure Code
AB00KE
Failure
phenomenon
Charging voltage abnormally lowered
(in mechanical system)
Failure content
Generation signal from the alternator is not inputted, while the engine is running.
Response from
controller
None in particular
Phenomenon
occurring on
machine
There is a possibility that the battery may not be charged, if charging is continued without corrective
action.
Relative
information
This Failure Code is recorded, if the charging caution symbol is displayed in the monitor panel, while the
engine is running.
Input from the alternator (voltage) can be confirmed in the monitor function.
(Code No. 043: Charging voltage)
Presumed cause and standard value in normalcy
Cause
Alternator defective
(short generating output)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
E12 (male)
Between
Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)
Grounding fault of wiring
harness
3
(Contact with grounding
circuit)
and grounding
Engine rotation
Voltage
Above medium speed
27.5 29.5 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness from P02 (female)
(female)
to J02 to E12
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness from P02 (female)
to J02 to E12
(female) , or between P02 (female)
and D01 (female)
, or between P02 (female)
and A27 (female)
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
4 Monitor panel defective
P02
Between
20-380
and grounding
Engine rotation
Voltage
Above medium speed
27.5 29.5 V
PC200/220(LC)-7
TESTING AND ADJUSTING
AB00KE
Electrical Circuit Diagram for Engine Start, Stop and Charging in Monitor Panel
PC200/220(LC)-7
20-381
TESTING AND ADJUSTING
B@BAZG
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure)
User Code
Service Code
Failure Code
B@BAZG
Failure
phenomenon
Engine oil pressure abnormally lowered
(in mechanical system)
Failure content
The signal circuit in the engine oil pressure switch was closed (i.e. connected with grounding), while the
engine was running.
Response from
controller
None in particular
Phenomenon
occurring on
machine
There is a possibility that the engine may seize, if the engine is kept running without corrective action.
Relative
information
This Failure Code is recorded, if the engine oil pressure caution symbol is displayed in the monitor panel,
while the engine is running.
Input from the engine oil pressure switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 046: Monitor input 2)
Presumed cause and standard value in normalcy
Cause
Engine oil pressure low1 ered (the system in normal condition)
Engine oil pressure
2 switch defective
(Internal short-circuiting)
Grounding fault of wiring
harness
3
(Contact with grounding
circuit)
Standard value in normalcy and references for troubleshooting
Check the failure cause and damage to the engine, and then make repairs.
Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
E02 (on switch side)
Engine oil pressure
Resistance value
Between terminal and
grounding
When in normal condition
Above 1 M
When lowered
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between P02 (female) (7) and E02
(terminal) and grounding
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
P02
4 Monitor panel defective
Between
and grounding
Engine oil pressure
Voltage
When in normal condition
20 30 V
When lowered
Below 1 V
Electrical Circuit Diagram for Engine Oil Pressure Switch in Monitor Panel
20-382
PC200/220(LC)-7
TESTING AND ADJUSTING
B@BAZK
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)
User Code
Service Code
Failure Code
B@BAZK
Failure
phenomenon
Engine oil level abnormally lowered
(in mechanical system)
Failure content
The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding), when the
engine is stopped (with the starting switch in the ON position).
Response from
controller
None in particular
Phenomenon
occurring on
machine
There is a possibility that the engine seizes if it is kept running without a corrective action.
Relative
information
This Failure Code is recorded if the engine oil level caution symbol is displayed, when the engine is
stopped (with the starting key in the ON position).
Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code No.
046: Monitor input 2)
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Engine oil level lowered
Check the engine oil level, and refill oil.
1 (System in normal condi(If the phenomenon occurs frequently, check the cause)
tion)
Engine oil level switch
2 defective
(Internal disconnection)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
E03 (male)
Between
Disconnection of wiring
harness
3 (Disconnection or defective contact with connector)
and grounding
Engine oil level
Resistance value
When in normal condition
Below 1
When lowered
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness between P02 (female)
and E03 (female)
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
P02
4 Monitor panel defective
Between
and grounding
Engine oil pressure
Voltage
When in normal condition
Below 1 V
When lowered
20 30 V
Electrical Circuit Diagram for Engine Oil Level Switch in Monitor Panel
PC200/220(LC)-7
20-383
TESTING AND ADJUSTING
B@BCNS
Failure Code in Mechanical System B@BCNS (Engine cooling water overheating)
User Code
Service Code
Failure Code
B@BCNS
Failure
phenomenon
Engine cooling water overheated
(in mechanical system)
Failure content
The engine cooling water sensor inputted a signal of 102C, while the engine was running.
Response from
controller
Response from controller
Phenomenon
occurring on
machine
There is a possibility that the engine seizes, if it is kept running without a corrective action.
Relative
information
This Failure Code is recorded, if the engine cooling water temperature gauge is displayed in the red
range, when the engine is running.
Input from the engine cooling water temperature sensor (temperature) can be confirmed in the monitor
function. (Code No. 041: Engine cooling water temperature)
Presumed cause and standard value in normalcy
Cause
Engine Overheating
1 (system in normal condition)
Engine cooling water
temperature sensor
2
defective
(Internal short-circuiting)
Standard value in normalcy and references for troubleshooting
Check the engine for the cause and damage, and repair it.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
E05 (male)
Between
Between
Grounding fault of wiring
harness
3
(Contact with grounding
circuit)
and
and grounding
Engine cooling water temperature
Resistance value
90 3.5k
10 100 C
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between P02 (female)
E05 (female)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
4 Monitor panel defective
P02 (female)
Between
Between
and
and grounding
Engine water temperature
10 100 C
Resistance value
90 3.5k
Above 1 M
Electrical Circuit Diagram for Engine Cooling Water Temperature Sensor in Monitor Panel
20-384
PC200/220(LC)-7
TESTING AND ADJUSTING
B@BCZK
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level)
(Multi-monitor only)
User Code
Service Code
Failure Code
B@BCZK
Failure
phenomenon
Radiator water level abnormally lowered
(in mechanical system)
Failure content
The signal circuit in the radiator water level switch was opened (i.e. disconnected from grounding).
Response from
controller
None in particular
Phenomenon
occurring on
machine
There is a possibility that the engine seizes, if it is kept running without a corrective action.
Relative
information
This Failure Code is recorded, if the radiator water level caution symbol is displayed in the monitor panel,
when the engine is running.
Input from the radiator water level switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 045: Monitor input 1)
Presumed cause and standard value in normalcy
Cause
Radiator water level low1 ered (system in normal
condition)
Radiator water level
2 switch defective
(Internal disconnection)
Standard value in normalcy and references for troubleshooting
Check the water level and refill cooling water.
(If this phenomenon occurs frequently, check the cause)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
A33 (male)
Between
Disconnection of wiring
harness
3 (Disconnection or defective contact with connector)
and
Engine cooling water level
Resistance value
When in normal condition
Below 1
When lowered
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness between P02 (female)
and A33 (female)
Wiring harness between A33 (female)
and grounding
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
P02
4 Monitor panel defective
Between
and grounding
Engine water temperature
Resistance value
When in normal condition
Below 1 V
When lowered
20 30 V
Electrical Circuit Diagram for Radiator Water Level Switch in Monitor Panel
PC200/220(LC)-7
20-385
TESTING AND ADJUSTING
B@HANS
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)
(Multi-monitor only)
User Code
Service Code
Failure Code
B@HANS
Failure
phenomenon
Hydraulic oil overheated
(in mechanical system)
Failure content
The hydraulic oil temperature sensor inputted a signal of 102C, while the engine was running.
Response from
controller
None in particular
Phenomenon
occurring on
machine
There is a possibility that the engine seizes, if it is kept running without a corrective action.
Relative
information
This Failure Code is recorded, if the hydraulic oil temperature gauge is displayed in the red range, when
the engine is running.
Input from the hydraulic oil temperature sensor (temperature) can be confirmed in the monitor function.
(Code No. 044: Engine cooling water temperature)
Presumed cause and standard value in normalcy
Cause
Hydraulic oil overheat1 ing (system in normal
condition)
Hydraulic oil temperature
2 sensor defective
(Internal short-circuiting)
Standard value in normalcy and references for troubleshooting
Check the cause and damage to the hydraulic equipment, and repair it.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
A61 (male)
Between
Between
Grounding fault of wiring
harness
3
(Contact with grounding
circuit)
and
and grounding
Hydraulic oil temperature
Resistance value
90 3.5k
10 100 C
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between P02 (female)
A61 (female)
and grounding
and
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
4 Monitor panel defective
P02 (female)
Between
Between
and
and grounding
Engine water temperature
10 100 C
Resistance value
90 3.5k
Above 1 M
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor in Monitor Panel
20-386
PC200/220(LC)-7
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-502
E-1 Engine does not start (Engine does not rotate) ................................................................................ 20-503
E-2 Engine stops while in operation ........................................................................................................ 20-506
E-3 Engine speed is irregular, or there is hunting ................................................................................... 20-508
E-4 Engine does not stop ........................................................................................................................ 20-510
E-5 Auto-decelerator does not work ........................................................................................................ 20-512
E-6 Auto engine warm-up device does not work ..................................................................................... 20-513
E-7 Preheater does not work................................................................................................................... 20-514
E-8 All work equipment, swing and travel do not move........................................................................... 20-516
E-9 One-touch Power Max Switch does not work ................................................................................... 20-518
E-10 No display in monitor panel at all ...................................................................................................... 20-519
E-11 Part of display on monitor panel is missing ...................................................................................... 20-520
E-12 Monitor panel displays contents irrelevant to the model ................................................................... 20-520
E-13 Fuel level monitor red lamp lights up while engine is running .......................................................... 20-521
E-14 Engine cooling water temperature gauge does not indicate correctly .............................................. 20-522
E-15 Hydraulic oil temperature gauge does not display correctly ............................................................. 20-523
E-16 Fuel gauge does not display correctly .............................................................................................. 20-524
E-17 Swing lock monitor does not display correctly .................................................................................. 20-526
E-18 When the monitor switch is operated, no display appears ............................................................... 20-528
E-19 Windshield wiper does not work ....................................................................................................... 20-530
E-20 Alarming buzzer cannot be cancelled ............................................................................................... 20-532
E-21 "Boom RAISE" is not correctly displayed in monitor function ........................................................... 20-533
E-22 "Boom LOWER" is not correctly displayed in monitor function ......................................................... 20-534
E-23 "Arm DIGGING" is not correctly displayed in monitor function ......................................................... 20-535
E-24 "Arm DUMPING" is not correctly displayed in monitor function ........................................................ 20-536
E-25 "Bucket DIGGING" is not correctly displayed in monitor function ..................................................... 20-537
E-26 "Bucket DUMPING" is not correctly displayed in monitor function.................................................... 20-538
E-27 "SWING" is not correctly displayed in monitor function .................................................................... 20-540
E-28 "TRAVEL" is not correctly displayed in monitor function................................................................... 20-542
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function ..................................... 20-544
E-30 "Service" is not correctly displayed in monitor function..................................................................... 20-546
E-31 Air Conditioner does not work........................................................................................................... 20-548
E-32 Travel alarm does not sound ............................................................................................................ 20-549
PC200/220(LC)-7
20-501
TESTING AND ADJUSTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
The following information are edited and contained in the "Information Contained in Troubleshooting Table".
You are required to proceed with troubleshooting after fully grasping the contents.
Failure
information
Phenomena occurring on machine
Relative
information
Information on occurred failures and troubleshooting
Cause
<Contents>
The standard values in normalcy by which to judge "good" or "no good" about presumed causes.
References for making judgement of "good" or "no good"
Presumed cause and standard value in normalcy
Standard value in normalcy and references for troubleshooting
Cause for presumed
failure
(The attached No. for
filing and reference
purpose only. It does not
stand for any priority)
<Phenomena of wiring harness fault>
Failure due to disconnection
Defective contact with connector or disconnection of wiring harness has occurred.
Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in contact
with it.
Failure due to short-circuiting
A wiring harness that is not originally connected with a power source circuit (24 V) is
in contact with it.
<Points to remember in troubleshooting>
1) Connector denotation method and handling of T-adapters
Insert or connect T-adapters in the following manner, unless specifically otherwise
instructed.
If there is no indication of (male) or (female) in the connector No., pull off a connector and insert a T-adapter into both sides of male and female.
If there is an indication of (male9 and (female) in the connection No., pull off a connector and insert a T-adapter into only one side of (male) or (female).
2) Description sequence of pin No. and handling of circuit tester leads
Connect the positive lead (+) and negative lead () for troubleshooting in the following manner unless specifically otherwise instructed.
Connect the positive lead (+) to a pin No. marked at the front or wiring harness.
Connect the negative lead () to a pin No. marked at the rear or wiring harness.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
Connector No.: Indicates (Type - numbers of a pin) (color)
Arrow: Roughly indicates the location in the machine where it is installed.
20-502
PC200/220(LC)-7
TESTING AND ADJUSTING
E-1
E-1 Engine does not start (Engine does not rotate)
Failure
information
The engine does not start (the engine does not rotate).
Relative
information
The following two engine start locking mechanisms are provided in the engine starting circuit.
1) Engine start locking by means of password in the monitor panel ( )
2) Engine start locking by means of safety lock lever
: The multi-monitor specification machine only.
Presumed cause and standard value in normalcy
Cause
1
Shortage in battery
capacity
Fuse Nos. 3 and 18
and Fusible Link A35
fault
Engine starting
switch fault
(Internal
disconnection)
Safety lock switch
fault
(Internal
short-circuiting)
Engine starting
motor cut relay, R11
and R13 defective
(Internal
disconnection or
short-circuiting)
Standard value in normalcy and references for troubleshooting
Battery voltage
Battery electrolyte specific gravity
Above 24 V
Above 1.26
When a fuse or fusible link is blown, there is a big possibility that grounding fault occurred in
the circuit.
If a monitor lamp does not light up in the monitor panel, check the power source circuit
between the battery and the specific fuse.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
H15 (male)
Between
Position
Resistance value
OFF
Above 1 M
Start
Below 1
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
S14 (female)
Between
Lock lever
and
Resistance value
Release
Below 1
LOCK
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
R11 (female) & R13 (male)
Resistance value
Between
and
100 500
Between
and
Above 1 M
Between
and
Below 1
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. (If all of the power source, grounding (GND), generation signal and
engine start input are normal and yet the engine start output is not normal, the engine starting motor relay is defective)
Engine starting
motor fault
(Internal
disconnection or
short-circuiting)
Engine starting
motor fault
(Internal disconnection or damage)
Voltage
Power source: Between B terminal and grounding
20 30 V
GND (grounding): Between E terminal and grounding
Connected
Generation signal: Between R terminal (A27
grounding
) and
Start
Below 1 V
Engine start input: Between C terminal and grounding
20 30 V
Engine start output: Between S terminal (A27
grounding
20 30 V
) and
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. (If all of the power source, grounding (GND), generation signal and
engine start input are normal and yet the engine start output is not normal, the engine starting motor relay is defective)
Engine starting motor
Power source: B terminal and grounding
Engine start input: C terminal and grounding
PC200/220(LC)-7
Engine starting switch
Safety relay
Engine startVoltage
ing switch
Start
20 30 V
20 30 V
20-503
TESTING AND ADJUSTING
Cause
Alternator fault
(Internal
short-circuit)
E-1
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the ON position or
running during the troubleshooting.
E12 (male)
Between
Voltage
Below 1 V
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Presumed cause and standard value in normalcy
Wiring harness between FB1-18 outlet and H15 (female)
Resistance
value
Below 1
Wiring harness from H15 (female)
Resistance
value
Below 1
Resistance
value
Below 1
Resistance
value
Below 1
Resistance
value
Below 1
to J01 to R11 (female)
and A27 (female)
Disconnection of wir- Wiring harness between R11 (female)
ing harness
Wiring harness between engine starting motor relay C termi(Disconnection or
nal and engine starting motor C terminal
defective contact
with connector)
Wiring harness between FB1-3 and S14 (female)
Wiring harness between S14 (female)
and R11 (female)
Resistance
value
Below 1
Wiring harness between R11 (female)
and R13 (female)
Resistance
value
Below 1
Resistance
value
Below 1
Wiring harness from R13 (female)
to J04 to grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness
10
(Contact with
grounding circuit)
Between wiring harness from battery relay B terminal (A23)
to A35 to FB1-18 and grounding
Resistance
value
Above 1 M
Between wiring harness between FB1-18 outlet and H15
(female)
and grounding
Resistance
value
Above 1 M
Between wiring harness from H15 (female)
(female)
and grounding
Resistance
value
Above 1 M
Resistance
value
Above 1 M
Between wiring harness between engine starting motor relay
C terminal and engine starting motor C terminal and grounding
Resistance
value
Above 1 M
Between wiring harness between FB1-3 and S14 (female)
and grounding
Resistance
value
Above 1 M
Between wiring harness between S14 (female)
(female)
and grounding
Resistance
value
Above 1 M
Resistance
value
Above 1 M
Between wiring harness between R11 (female)
(female)
and grounding
Between wiring harness from R13 (female)
(female)
and grounding
Short-circuiting of
wiring harness
11
(Contact with 24 V
circuit)
20-504
to J01 to R11
and A27
and R11
to J05 to P02
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Wiring harness between A27 (female)
and E12 (female)
, or wiring harness from A27 (female)
to J02 to D01
(female) , or between wiring harness between A27
(female)
and P02 (female)
and grounding
Voltage
Below 1 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E-1
Electrical Circuit Diagram for Engine Start, Stop and Battery Charging
PC200/220(LC)-7
20-505
TESTING AND ADJUSTING
E-2
E-2 Engine stops while in operation
Failure
information
The engine suddenly stopped while in operation.
Relative
information
Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
(Code No. 031: governor potentiometer voltage)
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
1
Governor potentiometer fault
(Internal failure)
E06 (male)
Resistance value
Between
and
4.0 6.0 k
Between
and
0.25 5.0 k
Between
and
0.25 5.0 k
Disconnection of wir- Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness
during the troubleshooting.
(Disconnection or
Wiring harness between C01 (female)
and E10 (female)
Resistance
defective contact
Below 1
value
with connector)
Grounding fault of
wiring harness
(Contact with
grounding circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between C01 (female)
(female)
and grounding
and E10
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4
Governor pump
controller defective
C01
Voltage
Between
and
4.5 5.5 V
Between
and
0.5 4.5 V
Electrical Circuit Diagram for Fuel Dial
20-506
PC200/220(LC)-7
TESTING AND ADJUSTING
E-3
E-3 Engine speed is irregular, or there is hunting
Failure
information
Engine speed is irregular at low idling.
There is hunting.
Engine speed is lower than specified at high idling.
Relative
information
Engine rotation can be confirmed in the monitor function.
(Code No. 010: Engine rotation)
Cause
Presumed cause and standard value in normalcy
Model code signal
fault
(Internal failure)
Standard value in normalcy and references for troubleshooting
If the monitor display is not normal, proceed to Service Code [E217].
Monitoring Code
Item
Normal display
002
003
Controller model code
200
Governor lever
improperly adjusted
Refer to the section "Special Function of Monitor Panel" in this manual.
Governor motor
improperly working
If the governor motor lever moves smoothly in the following operations, it is judged as normal.
The fuel dial is operated between low idling and high idling.
The engine is stopped with the fuel dial.
Engine fuel control
system defective
Refer to the Engine Shop Manual.
Disconnection of wir- Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness
during the troubleshooting.
(Disconnection or
Wiring harness from C01 (female)
to J07 to H15 (female)
Resistance
defective contact
Below 1
value
with connector)
Grounding fault of
wiring harness
(Contact with
grounding circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor pump
controller defective
As this is an internal failure, troubleshooting cannot be conducted.
(If there is none of the causes from Item 1 to 6 above, the controller is judged as defective)
20-508
Between wiring harness between C01 (female)
H15 (female)
and grounding
to J17 and
Resistance
value
Above 1 M
PC200/220(LC)-7
TESTING AND ADJUSTING
E-3
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging
PC200/220(LC)-7
20-509
TESTING AND ADJUSTING
E-4
E-4 Engine does not stop
The engine does not stop.
Relative
information
The Governor pump controller drives the battery relay for the min. 4 seconds and max. 7 seconds from
the moment the engine starting switch is turned OFF to the moment the engine completely stops.
It can be confirmed in the monitor function how the battery relay works (ON or OFF)
(Code No. 037: Controller output)
Presumed cause and standard value in normalcy
Failure
information
Cause
Standard value in normalcy and references for troubleshooting
Battery relay fault
If operating sound is heard from the battery relay contact, when turning the engine starting
switch, the battery relay is judged as normal.
Starting switch OFFONOFF
Assembled-type
diode D01 fault
(Internal disconnection)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
D01 (male)
Between
and
Digital type circuit tester
Continuity
Diode mode
Continued
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wirWiring harness between C03 (female)
and D01 (female)
ing harness
(Disconnection or
Wiring harness from D01 (female)
to J01 to battery relay
defective contact
BR terminal (A21)
with connector)
Wiring harness between battery relay E terminal (A20) and
grounding
Governor pump
controller defective
Below 1
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
C03
Between
20-510
Resistance
value
and grounding
Engine starting switch
Voltage
ONOFF
20 30 V
(for 4 to 7 seconds)
PC200/220(LC)-7
TESTING AND ADJUSTING
E-4
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging
PC200/220(LC)-7
20-511
TESTING AND ADJUSTING
E-5
E-5 Auto-decelerator does not work
Failure
information
The auto-decelerator does not work.
Relative
information
Rotation of the auto-decelerator is set at 1,400 rpm. If the fuel dial is not set adjusting to this level, the
auto-decelerator does not work.
Confirm the display on the monitor panel, when the engine is running.
Cause
Standard value in normalcy and references for troubleshooting
If the display on the monitor panel is not normal, proceed to No. E-21 Troubleshooting.
Boom RAISE signal
fault
Monitoring code
Item
Normal display
019
Boom RAISE
Lever operation: ON
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-22 Troubleshooting.
2
Boom LOWER signal fault
Monitoring code
Item
Normal display
019
Boom LOWER
Lever operation: ON
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-23 Troubleshooting.
Presumed cause and standard value in normalcy
Arm DIGGING signal
fault
Monitoring code
Item
Normal display
019
Arm DIGGING
Lever operation: ON
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-24 Troubleshooting.
4
Arm DUMPING
signal fault
Monitoring code
Item
Normal display
019
Arm DUMPING
Lever operation: ON
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-26 Troubleshooting.
5
Bucket DIGGING
signal fault
Monitoring code
Item
Normal display
021
Bucket DIGGING
Lever operation: ON
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-27 Troubleshooting.
6
Bucket DUMPING
signal fault
Monitoring code
Item
Normal display
021
Bucket DUMPING
Lever operation: ON
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-28 Troubleshooting.
7
Swing signal fault
Monitoring code
Item
Normal display
019
Swing
Lever operation: ON
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-29 Troubleshooting.
8
Travel signal fault
Monitoring code
Item
Normal display
019
Travel
Lever operation: ON
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-30 Troubleshooting.
9
10
Attachment signal
fault
Governor pump
controller defective
20-512
Monitoring code
Item
Normal display
021
Service
Lever operation: ON
Lever NEUTRAL: OFF
As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the
causes listed in Item 1 through 9, the controller is judged as defective.
PC200/220(LC)-7
TESTING AND ADJUSTING
E-6
E-6 Auto engine warm-up device does not work
The auto engine warm-up device does not work.
Relative
information
The auto engine warm-up device is activated, when the engine cooling water temperature is below 30C,
and raise the engine rotation up to 1,200 rpm.
The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.
Presumed cause and standard
value in normalcy
Failure
information
Cause
Engine cooling water
temperature signal
fault
Governor pump
controller defective
PC200/220(LC)-7
Standard value in normalcy and references for troubleshooting
If the display on the monitor panel is not normal, proceed to No. E-14
Troubleshooting.
Monitoring code
041
Item
Normal display
Engine cooling water temperature
Compare with the actual
engine cooling water temperature.
As this is an internal failure, troubleshooting cannot be conducted.
(If the fault mentioned in the above item is not found, the Governor pump controller is
judged as defective)
20-513
TESTING AND ADJUSTING
E-7
E-7 Preheater does not work
Failure
information (1)
Even if the preheater switch is turned to the PREHEAT position, the preheating monitor lamp does not
light up.
Relative
information
Input of the preheating signal (ON or OFF) can be confirmed in the monitor function.
(Code No. 045: Monitor input 1)
Presumed cause and standard
value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Engine starting
switch fault
If preheating does not occur (the heater is not warmed up), refer to Failure Phenomenon (2) below.
Disconnection of wir- Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
ing harness
(Disconnection or
Resistance
defective contact
Below 1
Wiring harness between P02 (female)
and J02
value
with connector)
Turn the engine starting switch OFF for the preparations.
P02
Monitor panel fault
Between
Engine starting switch
Voltage
OFF
Below 1 V
HEAT
20 30 V
and grounding
Failure
information (2)
Even if the preheater switch is turned to the PREHEAT position, the preheater does not become warm.
Relative
information
In low cooling water temperature (lower than 30C), the governor pump controller drives the heater
relay for 100 seconds after the engine is started and automatically warms up the engine.
Cause
Presumed cause and standard
value in normalcy
20-514
Engine starting
switch fault
(Internal disconnection)
Heater relay fault
(Internal disconnection)
Electrical intake air
heater
(Internal disconnection)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations.
H15 (male)
Between
Engine starting switch
Resistance value
OFF
Above 1 M
HEAT
Below 1
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Heater relay
Continuity and resistance value
Between coil terminal and grounding
Continued
Between contact terminals
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Between heater terminals
Normal if continuity is established.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posiDisconnection of wirtion during the troubleshooting.
ing harness
Resistance
Wiring harness from H15 (female)
to J02 to heater
(Disconnection or
Below 1
value
relay terminal (A25)
defective contact
Wiring harness between battery relay M terminal (A22)
Resistance
with connector)
Below 1
and heater relay terminal
value
PC200/220(LC)-7
TESTING AND ADJUSTING
E-7
Electrical Circuit Diagram for Engine Preheater
PC200/220(LC)-7
20-515
TESTING AND ADJUSTING
E-8
E-8 All work equipment, swing and travel do not move
Failure
information
All the work equipment, swing and travel do not move.
Relative
information
Presumed cause and standard value in normalcy
Cause
1
Fuse No. 3 fault
Safety switch lock
defective
(Internal disconnection)
PPC lock solenoid
fault
(Internal disconnection or short-circuiting)
Assembled-type
diode D01 fault
(Internal short-circuiting)
Standard value in normalcy and references for troubleshooting
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
S14 (female)
Between
Safety control lever
Resistance value
Lock
Above 1 M
Release
Below 1
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
V01 (male)
Between
Between
Resistance value
20 60
and
Above 1 M
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
D01 (male)
Between
Resistance value
Above 1 M
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wirWiring harness between FB1-3 outlet and S14 (male)
ing harness
(Disconnection or
defective contact
Wiring harness from S14 (male)
to J02 to V01 (female)
with connector)
Wiring harness between V01 (female)
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
20-516
and grounding
Resistance
value
Below 1
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between FB1-3 outlet and S14
(male)
and grounding
Resistance
value
Above 1 M
Wiring harness from S14 (male)
to J02 to V01 (female) ,
or between wiring harness between S14 (male)
and D01
(female)
and grounding
Resistance
value
Above 1 M
PC200/220(LC)-7
TESTING AND ADJUSTING
E-8
Electrical Circuit Diagram for PPC Lock Solenoid
PC200/220(LC)-7
20-517
TESTING AND ADJUSTING
E-9
E-9 One-touch Power Max Switch does not work
Failure
information
The one-touch power max. switch does not work.
Relative
information
If the one touch-power max. switch is pressed while the engine is running, the symbol mark is displayed
in the monitor panel.
Input from the one-touch power max. switch (left knob switch) can be confirmed in the monitor function.
(Code No. 022: Switch input 1)
Presumed cause and standard value in normalcy
Cause
1
Fuse No. 9 fault
One-touch power
max. switch fault
(Internal disconnection)
Standard value in normalcy and references for troubleshooting
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
M23 (male)
Between
One-touch power max. switch
Resistance value
Release
Above 1 M
Depress
Below 1
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Above 1 M
Wiring harness between FB1-9 outlet and M23 (female)
value
defective contact
Resistance
with connector)
Above 1 M
Wiring harness between M23 (female)
and C01 (female)
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between FB1-9 outlet and M23
(female)
and grounding
Resistance
value
Above 1 M
Between wiring harness between M23 (female)
(female)
and grounding
Resistance
value
Above 1 M
and C01
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
5
Governor pump
controller defective
C01
Between
One-touch power max. switch
Voltage
Release
Below 1 V
Depress
20 30 V
and grounding
Electric Circuit Diagram for One-Touch Power Max. Switch
20-518
PC200/220(LC)-7
TESTING AND ADJUSTING
E-10
E-10 No display in monitor panel at all
Failure
information
When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
Relative
information
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Fuse No. 12 fault
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
Below 1
(Disconnection or
Wiring harness from P01 (female)
to J07 to FB1-12
value
defect contact with
Resistance
connector)
Below 1
Wiring harness between P01 (female)
and grounding
value
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness from P01 (female)
FB1-12 outlet and grounding
to J07 to
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4
Governor pump
controller defective
C03
Voltage and resistance value
Between
and grounding
Voltage: 20 30 V
Between
and grounding
Resistance value: Below 1
Electrical Circuit Diagram for Power Source in Monitor Panel
PC200/220(LC)-7
20-519
TESTING AND ADJUSTING
E-11, E-12
E-11 Part of display on monitor panel is missing
Part of the display in the monitor panel is missing.
Relative
information
Presumed cause and
standard value in normalcy
Failure
information
Cause
Standard value in normalcy and references for troubleshooting
Monitor panel LCD
fault
If all the LCD in the monitor panel light up (i.e. the screen becomes totally white) by the
following switching operation, then the monitor panel is normal.
Switching operation: [ ] + [ A ] (simultaneous switching operation)
Monitor panel
defective
As this is an internal failure, troubleshooting cannot be conducted. (If there is no problem with the above switching operation, the monitor panel is judged as defective)
E-12 Monitor panel displays contents irrelevant to the model
The monitor panels displays contents that have nothing to do with the model on which it is installed.
Relative
information
Presumed cause and
standard value in normalcy
Failure
information
Cause
20-520
Model code signal
fault
(Internal failure)
Monitor panel
defective
Standard value in normalcy and references for troubleshooting
If the display on the monitor panel is normal, proceed to Service Code [E217].
Monitoring code
Item
Normal display
002
003
Controller model code
200
As this is an internal failure, troubleshooting cannot be conducted. (If there is no problem with the above switching operation, the monitor panel is judged as defective)
PC200/220(LC)-7
TESTING AND ADJUSTING
E-13
E-13 Fuel level monitor red lamp lights up while engine is running
Failure
information
The fuel level monitor red lamp lighted up while the engine was running.
Relative
information
If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
(5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
(Code No. 042: Fuel level sensor)
Presumed cause and standard value in normalcy
Cause
1
Fuel level lowered
(system in normal
condition)
Fuel level sensor
fault
(Internal
disconnection)
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Standard value in normalcy and references for troubleshooting
Refill fuel.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
A60 (male)
Between
and grounding
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12
EMPTY (Lower limit)
85 110
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness between P02 (female)
and A60 (female)
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
4
Governor pump
controller defective
P02 (female)
Between
and grounding
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12
EMPTY (Lower limit)
85 110
Electrical Circuit Diagram for Fuel Level Sensor
PC200/220(LC)-7
20-521
TESTING AND ADJUSTING
E-14
E-14 Engine cooling water temperature gauge does not indicate correctly
Failure
information
The engine cooling water rises normally, but the display does not exceed the white range (C).
The engine cooling water temperature remains stable, but the display rises to the red range (H).
Relative
information
Input from the engine cooling water temperature sensor can be confirmed in the monitor function.
(Code No. 041: Engine cooling water temperature)
Cause
Presumed cause and standard value in normalcy
Engine cooling water
temperature sensor
fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Engine cooling water
temperature
E05
Between
Between
and
and grounding
10 100 C
Resistance value
90 3.5 k
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between P02 (female)
and E05 (female)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness between P02 (female)
and E05 (female)
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between P02 (female)
(female)
and grounding
Between wiring harness between P02 (female)
(female)
and grounding
and E05
and E05
Resistance
value
Voltage
Above 1 M
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
5
Governor pump
controller defective
Engine cooling water
temperature
P02
Between
Between
and
and grounding
10 100 C
Resistance value
90 3.5 k
Above 1 M
Electrical Circuit Diagram for Engine Cooling Water Temperature Sensor
20-522
PC200/220(LC)-7
TESTING AND ADJUSTING
E-15
E-15 Hydraulic oil temperature gauge does not display correctly
(Multi-monitor only)
Failure
information
Hydraulic oil temperature rises normally, but the display does not exceed the white range (C).
Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Relative
information
Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
(Code No. 044: Hydraulic oil temperature)
Cause
Presumed cause and standard value in normalcy
Hydraulic oil temperature sensor fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Engine cooling water
temperature
A61
Between
Between
and
and grounding
10 100 C
Resistance value
90 3.5 k
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between P02 (female)
and A61 (female)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness between P02 (female)
and A61 (female)
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between P02 (female)
(female)
and grounding
Between wiring harness between P02 (female)
(female)
and grounding
and A61
and A61
Resistance
value
Voltage
Above 1 M
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
5
Governor pump
controller defective
Engine cooling water
temperature
P02
Between
Between
and
and grounding
10 100 C
Resistance value
90 3.5 k
Above 1 M
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
PC200/220(LC)-7
20-523
TESTING AND ADJUSTING
E-16
E-16 Fuel gauge does not display correctly
Failure
information
Though fuel was refilled, the display does not exceed the red range (E).
Though the remaining fuel level is low, the display does not drop below the green range (F).
Relative
information
Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
(Code No. 042: Fuel sensor voltage)
Cause
Presumed cause and standard value in normalcy
Fuel level sensor
fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
A60 (male)
Between
and grounding
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12
EMPTY (Lower limit)
85 110
Disconnection of wir- Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
ing harness
(Disconnection or
Resistance
defective contact
Below 1
Wiring harness between P02 (female)
and A60 (female)
value
with connector)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between P02 (female)
(female)
and grounding
Between wiring harness between P02 (female)
(female)
and grounding
and A60
and A60
Resistance
value
Voltage
Above 1 M
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
5
Governor pump
controller defective
P01
Between
and grounding
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12
EMPTY (Lower limit)
85 110
Electrical Circuit Diagram for Fuel Level Sensor
20-524
PC200/220(LC)-7
TESTING AND ADJUSTING
E-17
E-17 Swing lock monitor does not display correctly
Failure
information
Though the swing lock switch was turned ON, the swing lock monitor does not light up.
Though the swing lock switch was turned OFF, the swing lock monitor lights up.
Relative
information
Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 049: Monitor input 3)
Cause
Presumed cause and standard value in normalcy
Swing lock switch
fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
X05 (female)
Between
Swing lock switch
Resistance value
OFF
Above 1 M
ON
Below 1
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness from P02 (female)
to J02 to X05 (male)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness from X05 (male)
to J05 to grounding
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness from P02 (female)
(male)
and grounding
Between wiring harness from P02 (female)
(male)
and grounding
to J02 to X05
to J02 to X05
Resistance
value
Voltage
Above 1 M
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
5
Monitor panel
defective
P02
Between
20-526
and grounding
Swing lock switch
Voltage
OFF
20 30 V
ON
Below 1 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E-17
Electrical Circuit Diagram for Swing Lock Switch
PC200/220(LC)-7
20-527
TESTING AND ADJUSTING
E-18
E-18 When the monitor switch is operated, no display appears
Failure
information (1)
When operating the working mode changing switch, the working mode monitor does not appear.
Relative
information
Presumed
cause and
standard value
in normalcy
Cause
1
Monitor panel
defective
Standard value in normalcy and references for troubleshooting
As this is an internal failure, troubleshooting cannot be conducted.
Failure
information (2)
When operating the auto-decelerator switch, the auto-deceleration monitor does not appear.
Relative
information
If the auto-decelerator itself does not work, either, carry out No. E-5 Troubleshooting.
Presumed
cause and
standard value
in normalcy
Cause
1
Monitor panel
defective
Standard value in normalcy and references for troubleshooting
As this is an internal failure, troubleshooting cannot be conducted.
Failure
information (3)
When operating the travel speed shifting switch, the travel speed monitor does not appear.
Relative
information
If the travel speed does not actually change, carry out No. H-21 Troubleshooting.
Presumed
cause and
standard value
in normalcy
Cause
1
Monitor panel
defective
Standard value in normalcy and references for troubleshooting
As this is an internal failure, troubleshooting cannot be conducted.
Failure
information (4)
When operating the windshield wiper switch, the windshield wiper monitor does not appear.
Relative
information
If the windshield wiper itself does not work, either, carry out No. E-19 Troubleshooting.
Presumed
cause and
standard value
in normalcy
Cause
1
Monitor panel
defective
Standard value in normalcy and references for troubleshooting
As this is an internal failure, troubleshooting cannot be conducted.
Failure
information (5)
When operating the select switch, the adjustment display does not appear.
When operating the LCD monitor adjusting switch, the adjustment display does not appear.
When operating the maintenance switch, the item display does not appear.
Relative
information
Presumed
cause and
standard value
in normalcy
20-528
Cause
1
Monitor panel
defective
Standard value in normalcy and references for troubleshooting
As this is an internal failure, troubleshooting cannot be conducted.
PC200/220(LC)-7
TESTING AND ADJUSTING
E-19
E-19 Windshield wiper does not work
Failure
information
The windshield wiper does not work.
Relative
information
Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 049: Monitor input 3)
Cause
Presumed cause and standard value in normalcy
Window rear limit
switch fault
(Internal disconnection or short-circuiting)
Windshield wiper
motor fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
W03 (Switch side)
Between
and
Front window
Resistance value
When installed at front
Above 1 M
When retracted at rear
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
W04 (male)
Between
Between
Continuity and resistance value
Continued
and
Above 1 M
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between P01 (female)
and W04 (female)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness between P01 (female)
and W04 (female)
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Grounding fault of
during the troubleshooting.
wiring harness
(Contact with
Resistance
grounding (GND) cir- Between wiring harness between P02 (female)
Above 1 M
and W03
value
cuit)
Monitor panel fault
(Rear limit switch
system)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
P02
Between
and grounding
Front window
Voltage
When installed at front
20 30 V
When retracted at rear
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Monitor panel fault
(Windshield wiper
motor system)
20-530
P02
Between
Between
and grounding
and grounding
Windshield wiper switch
Resistance value
OFF
Below 3 V
ON
Below 3 V 20 30 V
(Constant cycle)
PC200/220(LC)-7
TESTING AND ADJUSTING
E-19
Electrical Circuit Diagram for Windshield Wiper Motor
PC200/220(LC)-7
20-531
TESTING AND ADJUSTING
E-20
E-20 Alarming buzzer cannot be cancelled
Failure
information
The alarming buzzer cannot be cancelled.
Relative
information
Input from the alarming buzzer cancellation switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 049: Monitor input 3)
Presumed cause and standard value in normalcy
Cause
Alarming buzzer
cancellation switch
fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
P03 (female)
Between
and
Alarming buzzer
cancellation switch
Resistance value
Release
Above 1 M
Depress
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between P02 (female)
and P03 (male)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness from P03 (male)
to J05 to grounding
value
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between P02 (female)
(male)
and grounding
and P03
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4
P02
Monitor panel fault
Between
and grounding
Alarming buzzer
cancellation switch
Voltage
Release
20 30 V
Depress
Below 1 V
Electrical Circuit Diagram for Alarming Buzzer Cancellation Switch
20-532
PC200/220(LC)-7
TESTING AND ADJUSTING
E-21
E-21 "Boom RAISE" is not correctly displayed in monitor function
Failure
information
"Boom RAISE" is not correctly displayed in the monitor function on the monitor panel.
Relative
information
Cause
Presumed cause and standard value in normalcy
Boom RAISE PPC
hydraulic switch fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
S06 (male)
Between
and
Boom control lever
Resistance value
NEUTRAL
Above 1 M
RAISE
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between C03 (female)
and S06 (female)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness between S06 (female)
and grounding
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C03 (female)
(female)
and grounding
Between wiring harness between C03 (female)
(female)
and grounding
and S06
and S06
Resistance
value
Voltage
Above 1 M
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
5
Governor pump
controller defective
C03
Between
and grounding
Boom control lever
Voltage
NEUTRAL
20 30 V
RAISE
Below 1 V
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC200/220(LC)-7
20-533
TESTING AND ADJUSTING
E-22
E-22 "Boom LOWER" is not correctly displayed in monitor function
Failure
information
"Boom LOWER" is not correctly displayed in the monitor function on the monitor panel.
Relative
information
Cause
Presumed cause and standard value in normalcy
Boom LOWER PPC
hydraulic switch fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
S02 (male)
Between
and
Boom control lever
Resistance value
NEUTRAL
Above 1 M
LOWER
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between C03 (female)
and S02 (female)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness between S02 (female)
and grounding
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C03 (female)
(female)
and grounding
Between wiring harness between C03 (female)
(female)
and grounding
and S02
and S02
Resistance
value
Voltage
Above 1 M
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
5
Governor pump
controller defective
C03
Between
and grounding
Boom control lever
Voltage
NEUTRAL
20 30 V
LOWER
Below 1 V
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
20-534
PC200/220(LC)-7
TESTING AND ADJUSTING
E-23
E-23 "Arm DIGGING" is not correctly displayed in monitor function
Failure
information
"Arm DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Cause
Presumed cause and standard value in normalcy
Arm DIGGING PPC
hydraulic switch fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
S04 (male)
Between
and
Arm control lever
Resistance value
NEUTRAL
Above 1 M
DIGGING
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between C03 (female)
and S04 (female)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness between S04 (female)
and grounding
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C03 (female)
(female)
and grounding
Between wiring harness between C03 (female)
(female)
and grounding
and S04
and S04
Resistance
value
Voltage
Above 1 M
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
5
Governor pump
controller defective
C03
Between
and grounding
Arm control lever
Voltage
NEUTRAL
20 30 V
DIGGING
Below 1 V
Electrical Circuit Diagram for Arm DIGGING PPC Hydraulic Switch
PC200/220(LC)-7
20-535
TESTING AND ADJUSTING
E-24
E-24 "Arm DUMPING" is not correctly displayed in monitor function
Failure
information
"Arm DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Arm DUMPING PPC Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
hydraulic switch
defect
S08 (male)
Arm control lever
Resistance value
(Internal disconnecNEUTRAL
Above 1 M
tion and short-circuitBetween
and
ing)
DUMPING
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between C03 (female)
and S08 (female)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness between S08 (female)
and grounding
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C03 (female)
(female)
and grounding
Between wiring harness between C03 (female)
(female)
and grounding
and S08
and S08
Resistance
value
Voltage
Above 1 M
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
5
Governor pump
controller defective
C03
Between
and grounding
Arm control lever
Voltage
NEUTRAL
20 30 V
DUMPING
Below 1 V
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
20-536
PC200/220(LC)-7
TESTING AND ADJUSTING
E-25
E-25 "Bucket DIGGING" is not correctly displayed in monitor function
Failure
information
"Bucket DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and keep the engine running durBucket DIGGING
ing the troubleshooting.
PPC hydraulic
switch fault
S01 (male)
Bucket control lever
Resistance value
(Internal disconnecNEUTRAL
Above 1 M
tion and short-circuitBetween
and
ing)
DIGGING
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between C03 (female)
and S01 (female)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness between S01 (female)
and grounding
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C03 (female)
(female)
and grounding
Between wiring harness between C03 (female)
(female)
and grounding
and S01
and S01
Resistance
value
Voltage
Above 1 M
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
5
Governor pump
controller defective
C03
Between
and grounding
Bucket control lever
Voltage
NEUTRAL
20 30 V
DIGGING
Below 1 V
Electrical Circuit Diagram for Bucket DIGGING PPC hydraulic Switch
PC200/220(LC)-7
20-537
TESTING AND ADJUSTING
E-26
E-26 "Bucket DUMPING" is not correctly displayed in monitor function
Failure
information
"Bucket DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and keep the engine running durBucket DUMPING
ing the troubleshooting.
PPC hydraulic
switch fault
S05 (male)
Bucket control lever
Resistance value
(Internal disconnecNEUTRAL
Above 1 M
tion and short-circuitBetween
and
ing)
DUMPING
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between C03 (female)
and S05 (female)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness between S05 (female)
and grounding
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C03 (female)
(female)
and grounding
Between wiring harness between C03 (female)
(female)
and grounding
and S05
and S05
Resistance
value
Voltage
Above 1 M
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
5
Governor pump
controller defective
C03
Between
and grounding
Bucket control lever
Voltage
NEUTRAL
20 30 V
DUMPING
Below 1 V
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
20-538
PC200/220(LC)-7
TESTING AND ADJUSTING
E-27
E-27 "SWING" is not correctly displayed in monitor function
Failure
information
"SWING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Cause
Presumed cause and standard value in normalcy
Swing PPC hydraulic
switch, left, fault
(Internal disconnection or short-circuiting)
Swing PPC hydraulic
switch, right, fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
S03 (male)
Between
Swing control lever
Resistance value
NEUTRAL
Above 1 M
Left
Below 1
and
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
S07 (male)
Between
Swing control lever
Resistance value
NEUTRAL
Above 1 M
Right
Below 1
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wir- Wiring harness between C03 (female) and S03 (female) ,
or wiring harness between C03 (female)
and S07 (female)
ing harness
(Disconnection or
defective contact
Wiring harness between S03 (female)
and grounding
with connector)
Wiring harness between S07 (female)
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
and grounding
Resistance
value
Below 1
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness between C03 (female) and S03 (female) ,
or wiring harness between C03 (female)
and S07 (female)
and grounding
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Wiring harness between C03 (female) and S03 (female) ,
or wiring harness between C03 (female)
and S07 (female)
and grounding
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
6
Governor pump
controller defective
C03
Between
20-540
and grounding
Swing control lever
Voltage
NEUTRAL
20 30 V
Right or left
Below 1 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E-27
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
PC200/220(LC)-7
20-541
TESTING AND ADJUSTING
E-28
E-28 "TRAVEL" is not correctly displayed in monitor function
Failure
information
"TRAVEL" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Cause
Presumed cause and standard value in normalcy
Travel PPC hydraulic
switch fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
S30 (male)
Between
and
Travel control lever
Resistance value
NEUTRAL
Above 1 M
Forward or reverse
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness from C03 (female)
to J01 to S30 (female)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness from S30 (female)
to J05 to grounding
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness from C03 (female)
to J01 to S30 (female)
, or between wiring harness between C03 (female)
and
A43 (female)
and grounding
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Wiring harness from C03 (female)
to J01 to S30 (female)
, or between wiring harness between C03 (female)
and
A43 (female)
and grounding
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
5
Governor pump
controller defective
C03
Between
20-542
and grounding
Travel control lever
Voltage
NEUTRAL
20 30 V
Forward or backward
Below 1 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E-28
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
PC200/220(LC)-7
20-543
TESTING AND ADJUSTING
E-29
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function
Failure
information
"Travel Differential Pressure" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
When pressure difference is created between the right and left travel PPC circuits (in steering), the travel
differential mechanism is turned ON.
Cause
Presumed cause and standard value in normalcy
Travel steering PPC
hydraulic switch fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
S31 (male)
Between
and
Travel control lever
Resistance value
NEUTRAL
Above 1 M
One side of right or left only
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between C03 (female)
and S31 (female)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness from S31 (female)
to J05 to grounding
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C03 (female)
(female)
and grounding
Between wiring harness between C03 (female)
(female)
and grounding
and S31
and S31
Resistance
value
Voltage
Above 1 M
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
5
Governor pump
controller defective
C03
Between
20-544
and grounding
Travel control lever
Voltage
NEUTRAL
20 30 V
One side of right or left only
Below 1 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E-29
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
PC200/220(LC)-7
20-545
TESTING AND ADJUSTING
E-30
E-30 "Service" is not correctly displayed in monitor function
Failure
information
"Service" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Cause
Presumed cause and standard value in normalcy
Service (front) PPC
hydraulic switch fault
(Internal disconnection or short-circuiting)
Service (rear) PPC
hydraulic switch fault
(Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
S10 (male)
Between
and
Service pedal
Resistance value
NEUTRAL
Above 1 M
Front
Below 1
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
S11 (male)
Between
and
Service pedal
Resistance value
NEUTRAL
Above 1 M
Rear
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wirWiring harness between C03 (female)
and S10 (female)
ing harness
(Disconnection or
, or wiring harness between C03 (female)
and S11
defective contact
(female)
with connector)
Wiring harness between S10 (female)
and grounding
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Resistance
value
Below 1
Resistance
value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness between C03 (female) and S10 (female) ,
or between wiring harness between C03 (female)
and S11
(female)
and grounding
Resistance
value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Wiring harness between C03 (female) and S10 (female) ,
or between wiring harness between C03 (female)
and S11
(female)
and grounding
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
6
Governor pump
controller defective
C03
Between
20-546
and grounding
Service pedal
Voltage
NEUTRAL
20 30 V
Front or rear
Below 1 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E-30
Electrical Circuit Diagram for Service PPC hydraulic Switch
PC200/220(LC)-7
20-547
TESTING AND ADJUSTING
E-31
E-31 Air Conditioner does not work
The air conditioner does not work.
Relative
information
For the electrical circuit diagram inside the air conditioner unit, refer to the section of STRUCTURE AND
FUNCTION - Air Conditioner in this manual.
Presumed cause and standard value in normalcy
Failure
information
Cause
Standard value in normalcy and references for troubleshooting
Fuse No. 11 fault
When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between FB1-11 outlet and M26 (male)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness between M26 (male)
and grounding
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Air conditioner unit
defective
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between FB1-11 outlet and M26
(male)
and grounding
Voltage
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
M26
Between
Voltage
and
20 30 V
Electrical Circuit Diagram for Air Conditioner
20-548
PC200/220(LC)-7
TESTING AND ADJUSTING
E-32
E-32 Travel alarm does not sound
Failure
information
The travel alarm does not sound while the machine is traveling.
The alarm begins to sound when the machine is at a standstill.
Relative
information
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Fuse No. 15 fault
When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
If the monitor display is not correct, proceed to No. E-21 Troubleshooting.
Travel signal fault
Monitoring code
019
Item
Normal display
Travel
Control lever operation: ON
Control lever NEUTRAL: OFF
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wirduring the troubleshooting.
ing harness
Wiring harness between FB1-15 outlet to J03 and A43
Resistance
(Disconnection or
Below 1
value
(female)
defective contact
Resistance
with connector)
Below 1
Wiring harness between A43 (female)
and J01
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Travel alarm fault
PC200/220(LC)-7
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between FB1-15 outlet to J03 and
A43 (female)
and grounding
Resistance
value
Above 1 M
As this is an internal failure, troubleshooting cannot be conducted. (If none of the causes
listed in Item 1 through 4 above is found, the travel alarm is judged as defective)
20-549
TESTING AND ADJUSTING
E-32
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm
20-550
PC200/220(LC)-7
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H-MODE)
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS ...................................................... 20-602
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-604
H-1 All work equipment lack power, or travel and swing speeds are slow .............................................. 20-605
H-2 Engine speed sharply drops or engine stalls .................................................................................... 20-606
H-3 No work equipment, travel or swing move ........................................................................................ 20-607
H-4 Abnormal noise is heard from around hydraulic pump ..................................................................... 20-607
H-5 Auto-decelerator does not work ........................................................................................................ 20-608
H-6 Fine control mode does not function................................................................................................. 20-608
H-7 Boom moves slowly or lacks power .................................................................................................. 20-609
H-8 Arm moves slowly or lacks power..................................................................................................... 20-610
H-9 Bucket moves slowly or lacks power ................................................................................................ 20- 611
H-10 Work equipment does not move in its single operation .................................................................... 20-611
H-11 Work equipment has a bit too fast hydraulic drift .............................................................................. 20-612
H-12 Work equipment has big time lag...................................................................................................... 20-613
H-13 Other work equipment moves when relieving single circuit .............................................................. 20-613
H-14 One-touch power max. switch does not operate .............................................................................. 20-613
H-15 In compound operation, work equipment with larger load moves slowly .......................................... 20-614
H-16 In swing + boom RAISE operation, boom moves slowly .................................................................. 20-614
H-17 In swing + travel, travel speed drops sharply.................................................................................... 20-614
H-18 Machine swerves in travel ................................................................................................................ 20-615
H-19 Machine travels slowly ...................................................................................................................... 20-616
H-20 Machine cannot be easily steered or lacks power ............................................................................ 20-617
H-21 Travel speed does not shift, or it is too slow or fast. ......................................................................... 20-618
H-22 Track shoe does not turn (on one side only)..................................................................................... 20-619
H-23 Machine does not swing ................................................................................................................... 20-620
H-24 Swing acceleration is poor, or swing speed is slow .......................................................................... 20-621
H-25 Excessive overrun when stopping swing .......................................................................................... 20-622
H-26 There is big shock when stopping swing .......................................................................................... 20-623
H-27 There is big abnormal noise caused when stopping swing .............................................................. 20-623
H-28 Swing natural drift is too big.............................................................................................................. 20-624
PC200/220(LC)-7
20-601
TESTING AND ADJUSTING
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
20-602
PC200/220(LC)-7
TESTING AND ADJUSTING
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a
reference material when troubleshooting the hydraulic and mechanical systems.
PC200/220(LC)-7
20-603
TESTING AND ADJUSTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Phenomena occurring on machine
Relative information
Information on occurred failures and troubleshooting
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
Cause for presumed
failure
(The attached No. for
filing and reference
purpose only. It does not stand
for any priority)
<Contents>
The standard values in normalcy by which to judge "good" or "no good" about
presumed causes.
References for making judgement of "good" or "no good"
20-604
PC200/220(LC)-7
TESTING AND ADJUSTING
H-1
H-1 All work equipment lack power, or travel and swing speeds are slow
Failure information
All the work equipment lack power, or their travel and swing speeds are slow.
Relative information
Set the working mode at A mode for troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of unload valve
Control lever
Unload pressure
All control levers in NEUTRAL
3.9 1.0 MPa
{40 10kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
Improper adjustment or malfunctioning of main relief valve
Control lever
Main relief pressure
Arm, DIGGING
33.3 36.8 MPa
{340 375kg/cm2}
If the pressure does not return to normalcy even after the adjustment, malfunctioning of main relief valve or its internal failure is suspected. In that case, check
the valve itself.
Presumed cause and standard value in normalcy
Stop engine for preparations. Start troubleshooting at engine high idling.
3
Malfunctioning of self pressure
decompression valve
Control lever
Control circuit source pressure
All control levers in NEUTRAL
2.83 3.43 MPa
{29 35kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure to be measured
4
Improper adjustment or malfunctioning of PC valve
Pump delivery pressure
PC valve output pressure
Measurement condition
Oil pressure ratio
Swing lock: ON
Arm digging relief
Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of PC valve or its internal failure is suspected. In that case, check the valve
itself.
Stop engine for preparations. Start troubleshooting at engine high idling.
5
Malfunctioning of LS-EPC
valve
Travel speed
Travel control lever
LS-EPC output pressure
Lo
NEUTRAL
Approx. 2.9 MPa
{Approx. 30 kg/cm2}
Hi
Travel control lever
0{0}
Stop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure ratio
Oil pressure to be measured
6
Improper adjustment or malfunctioning of LS valve
Pump delivery pressure
LS valve output pressure
All control levers in
NEUTRAL
Nearly equal pressure
Travel without load (control lever held at half
stroke)
1
Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of LS valve or its internal failure is suspected. In that case, check the valve
itself.
7
Malfunctioning of servo piston
Malfunctioning of servo piston is suspected. Check the piston itself.
Piston pump defective
If none of the above listed causes is detected, the piston pump is suspected of
deteriorated performance, malfunctioning or internal failure.
PC200/220(LC)-7
20-605
TESTING AND ADJUSTING
H-2
H-2 Engine speed sharply drops or engine stalls
Failure information
The engine speed sharply drops or the engine stalls.
Relative information
Relative Information
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Improper adjustment or malfunctioning of main relief valve
Control lever
Main relief pressure
Arm, DIGGING
33.3 36.8 MPa
{340 375kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the main relief valve or its internal failure is suspected. In that case,
check the valve itself.
Stop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure to be measured
2
Improper adjustment or malfunctioning of PC valve
Pump delivery pressure
PC valve output pressure
Measurement condition
Oil pressure ratio
Swing lock: ON
Arm digging relief
1
Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the PC valve or its internal failure is suspected. In that case, check the
valve itself.
Stop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure ratio
Oil pressure to be measured
3
Improper adjustment or malfunctioning of LS valve
Pump delivery pressure
LS valve output pressure
All control levers in
NEUTRAL
Nearly equal pressure
Travel without load
(control lever held at half
stroke)
1
Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its internal failure is suspected. In that case, check the
valve itself.
4
Orifice or filter in servo equipment clogged
The orifice or filter in the pump servo equipment is suspected of clogging. Check
the equipment itself.
Malfunction of servo piston
The servo piston is suspected of malfunction. Check the piston itself.
20-606
PC200/220(LC)-7
TESTING AND ADJUSTING
H-3, H-4
H-3 No work equipment, travel or swing move
No work equipment nor travel and swing functions can be set in motion.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of PPC lock
solenoid valve
Safety lock lever
Main relief pressure
Locked
0{0}
Released
2.84 3.43 MPa
{29 35kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
2
Malfunctioning of self pressure
decompression valve
Control lever
Control circuit source pressure
All control levers in NEUTRAL position
2.83 3.43 MPa
{29 35kg/cm2}
Piston pump defective
The piston pump is suspected of malfunctioning or an internal failure. Diagnose it
in the following manner.
Remove the oil pressure measurement plug and crank the engine. If oil flows out,
it is in normal condition.
Damper defective
It is presumed that the pump shaft does not rotate due to some internal failure of
the dumper. Check the damper itself.
H-4 Abnormal noise is heard from around hydraulic pump
An abnormal noise is heard from around the hydraulic pump.
Relative information
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
Hydraulic oil level lowered
Make a visual check.
Quality of hydraulic oil bad
Air may have get mixed with the oil. Make a visual check.
Hydraulic tank cap breather
clogged
It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby
causing negative pressure inside the tank. Make a visual check.
Hydraulic tank strainer
clogged
It is presumed that the strainer in the hydraulic tank is clogged, thereby causing
negative pressure in the suction circuit. Make a visual check.
Piston pump defective
The piston pump is suspected of an internal failure. Check the pump itself.
PC200/220(LC)-7
20-607
TESTING AND ADJUSTING
H-5, H-6
H-5 Auto-decelerator does not work
The auto-decelerator does not work.
Relative information
This troubleshooting mode is applied when the auto-decelerator does not work, while operating
the travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch
only in the travel circuit -actually located inside PPC valve)
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever
PPC valve output pressure
NEUTRAL
0{0}
Operation
Above 2.7 MPa
{Above 28 kg/cm2}
Malfunctioning of
travel PPC valve
(shuttle valve)
H-6 Fine control mode does not function
Failure information
The fine control mode poorly functions or its response is slow.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Malfunctioning of
LS-EPC valve
Orifice in LS circuit
clogged
Travel speed
Travel control lever
LS-EPC valve output
pressure
Lo
NEUTRAL
Approx. 2.9 MPa
{Approx. 30 kg/cm2}
Hi
Travel control lever
0{0}
The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
Stop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure ratio
Oil pressure to be measured
Improper adjustment or malfunctioning of LS valve
Pump delivery pressure
PC valve output pressure
All control levers in
NEUTRAL
Nearly equal oil pressure
Travel without load
(control lever held at half
stroke)
1
Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its internal failure is suspected. In that case, check the valve
itself.
4
20-608
Malfunctioning of
servo piston
Malfunctioning of the servo piston is suspected. Check the piston itself.
PC200/220(LC)-7
TESTING AND ADJUSTING
H-7
H-7 Boom moves slowly or lacks power
Failure information
The boom moves slowly or lacks power
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of right PPC
valve (in boom circuit)
Boom lever
PPC valve output pressure
NEUTRAL
0{0}
RAISE or LOWER
Above 2.7 MPa
{Above 28 kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Malfunction of merge/divide
solenoid valve
Working mode
Solenoid output pressure
A mode
0{0}
Other than A mode
2.84 3.43 MPa
{29 35 kg/cm2}
Malfunctioning of merge/divide
valve (main and LS valves)
The merge/divide valve (main and LS valves) is presumed to malfunction. Check
the valve itself.
Malfunctioning of boom control
valve (spool)
The spool in the boom control valve is presumed to malfunction. Check the valve
itself.
Malfunctioning of boom control
valve (pressure compensation
valve)
The pressure compensation valve in the boom control valve is presumed to malfunction. Check the valve itself.
Malfunctioning of boom control
valve (regeneration valve)
The regeneration valve in the boom control valve or the seal is presumed to malfunction. Check the valve itself.
Malfunctioning of boom control
valve (lock valve)
The lock valve in the boom control valve is presumed to malfunction. Check the
valve itself.
Malfunctioning of safety valve
for lock valve or seal defective
The safety valve for the lock valve is presumed to malfunction, or the seal is suspected to be defective. Check the valve itself.
Malfunctioning of boom control
valve (suction valve) or seal
defective
The suction valve in the boom control valve is presumed to malfunction, or the
seal is suspected to be defective.
Malfunctioning of boom control
10 valve (safety and suction
valves) or seal defective
The safety and suction valves in the boom control valve are presumed to malfunction, or the seal is suspected to be defective. Check those valves themselves.
Malfunctioning of LS shuttle
11 valve (left travel, bucket and
service valves)
LS shuttle valves in the left travel control valve, bucket control valve and service
control valve are presumed to malfunction. Check those valves themselves.
Stop engine for preparations. Start troubleshooting at engine high idling.
12 Boom cylinder defective
PC200/220(LC)-7
Boom lever
Amount oil leakage from cylinder
Raise relief
20 cc/min
20-609
TESTING AND ADJUSTING
H-8
H-8 Arm moves slowly or lacks power
Failure information
The arm moves slowly, or lacks power.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of left PPC
valve (arm circuit)
Arm lever
PPC valve output pressure
NEUTRAL
0{0}
DIGGING or DUMPING
Above 2.7 MPa
{Above 28 kg/cm2}
Presumed cause and standard value in normalcy
Stop engine for preparations. Start troubleshooting at engine high idling.
2
Malfunctioning of merge/divide
solenoid valve
Working mode
Solenoid output pressure
A mode
0{0}
Other than A mode
2.84 3.43 MPa
{29 35 kg/cm2}
Malfunctioning of merge/divide
valve (main and LS valves)
The merge/divide valve (main and LS valves) is presumed to malfunction. Check
the valve itself.
Malfunctioning of arm control
valve (spool)
The spool in the arm control valve is presumed to malfunction. Check the valve
itself.
Malfunctioning of arm control
valve (pressure compensation
valve)
The pressure compensation valve in the arm control valve is presumed to malfunction. Check the valve itself.
Malfunctioning of arm control
valve (regeneration valve)
The generation valve in the arm control valve is presumed to malfunction, or the
seal is suspected to be defective. Check the valve itself.
Malfunctioning of arm control
valve (safety and suction
valves) or seal defective
The safety and suction valves in the arm control valve are presumed to malfunction, or the seal is suspected of defect. Check those valves themselves.
Malfunctioning of LS shuttle
valve (right travel, boom, left
travel, bucket and service
valves)
LS shuttle valves in the right travel control valve, boom control valve, left travel
control valve, bucket control valve and service valve are presumed to malfunction. Check those valves themselves.
Stop engine for preparations. Start troubleshooting at engine high idling.
Arm cylinder defective
20-610
Arm lever
Amount oil leakage from cylinder
Digging relief
20 cc/min
PC200/220(LC)-7
TESTING AND ADJUSTING
H-9, H-10
H-9 Bucket moves slowly or lacks power
Failure information
The bucket moves slowly, or lacks power.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Malfunctioning of right PPC
valve (bucket circuit)
Bucket lever
PPC valve output pressure
NEUTRAL
0{0}
DIGGING or DUMPING
Above 2.7 MPa
{Above 28 kg/cm2}
Malfunctioning of bucket control valve (spool)
The spool in the bucket control valve is presumed to malfunction. Check the
valve itself.
Malfunctioning of bucket control valve (pressure compensation valve)
The pressure compensation valve in the bucket control valve is presumed to
malfunction. Check the valve itself.
Malfunctioning of bucket control valve (safety and suction
valves) or seal defective
The safety and suction valves in the bucket control valve are presumed to
malfunction, or the seal is suspected to be defective. Check those valves
themselves.
Malfunction of LS shuttle valve
(service valve)
The LS shuttle valve in the service control valve is presumed to malfunction.
Check the valve itself.
Bucket cylinder defective
Stop engine for preparations. Start troubleshooting at engine high idling.
Bucket lever
Amount oil leakage from cylinder
Digging relief
20 cc/min
H-10 Work equipment does not move in its single operation
The boom does not move when operated independently.
The arm does not move when operated independently.
The bucket does not move when operated independently.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of PPC valve
Malfunctioning of work equipment control valve (spool)
PC200/220(LC)-7
Work equipment control lever
PPC valve output pressure
NEUTRAL
0{0}
Operation
Above 2.7 MPa
{Above 28 kg/cm2}
The spool in the work equipment control valve is presumed to malfunction.
Check the valve itself.
20-611
TESTING AND ADJUSTING
H-11
H-11 Work equipment has a bit too fast hydraulic drift
Failure information (1) Hydraulic drift of the boom is a bit too fast.
Presumed cause and standard value in normalcy
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Boom control lever
Amount oil leakage from cylinder
Raise relief
20 cc/min
Boom cylinder defective
Boom control lever (lock valve)
seal defective
The seal at lock valve in the boom control lever is suspected to be defective.
Check the valve itself.
Seal at safety valve for lock
valve defective
The seal at the safety valve in the lock valve is suspected to be defective.
Check the valve itself.
Failure information (2) Hydraulic drift of the arm is a bit too fast.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Arm cylinder defective
Arm control lever
Amount oil leakage from cylinder
Digging relief
20 cc/min
Arm control valve (safety and
suction valves) seal defective
The seal for safety and suction valves in the arm control valve is suspected
to be defective. Check the valve itself.
Whether the seal is defective or not may well be determined by changing
for other safety and suction valves. (Do not attempt to change them for the
safety and suction valves for the boom LOWER and the lock valve, because the set pressure differs)
Arm control valve (spool) seal
defective
The seal for spool in the arm control valve is suspected to be defective.
Check the seal itself.
Arm control valve (pressure
compensation valve) seal
defective
The seal for pressure compensation valve in the arm control valve is suspected to be defective. Check the seal itself.
Failure information (3) Hydraulic drift of the bucket is a bit too fast.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Bucket cylinder defective
Bucket control lever
Amount oil leakage from cylinder
Digging relief
20 cc/min
Bucket control valve (safety
and suction valves) seal
defective
The seal for the safety and suction valves in the bucket control lever is suspected to be defective. Check the seal itself.
Whether the seal is defective or not may well be determined by changing
for other safety and suction valves. (Do not attempt to change them for the
safety and suction valves for the boom LOWER and the lock valve, because the set pressure differs)
Bucket control valve (spool)
seal defective
The seal for spool in the bucket control valve is suspected to be defective.
Check the seal itself.
Bucket control valve (pressure compensation valve) seal
defective
The seal for pressure compensation valve in the bucket control valve is suspected to be defective. Check the seal itself.
20-612
PC200/220(LC)-7
TESTING AND ADJUSTING
H-12, H-13, H-14
H-12 Work equipment has big time lag
Failure information
The work equipment has a big time lag.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Malfunctioning of LS-EPC
valve
Travel speed
Travel control lever
LS-EPC valve output
pressure
Lo
NEUTRAL
Approx. 2.9 MPa
{approx. 30 kg/cm2}
Hi
Operation
0{0}
Malfunctioning of control valve
(regeneration valve) - with
boom and arm only
The regeneration valve in the control valve is presumed to malfunction.
Check the valve itself.
Malfunctioning of control
valves (safety & suction valve)
The safety and suction valves of the control valve are presumed to malfunction. Check those valves themselves directly.
For the arm and boom, whether they are defective or not may well be determined by changing them for other safety and suction valves. (Do not attempt to change them for the safety and suction valves for the boom
LOWER and the lock valve, because each set pressure differs)
Malfunctioning of control valve
(pressure compensation
valve)
The pressure compensation valve of the control valve is presumed to malfunction. Check the valve itself directly.
H-13 Other work equipment moves when relieving single circuit
Other work equipment moves when relieving the single circuit of specific work equipment.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
Control valve (pressure comThe seal for pressure compression valve in the control valve is suspected to
pensation valve) seal defective be defective. Check the seal itself.
H-14 One-touch power max. switch does not operate
The one-touch power max. switch does not operate.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of 2-stage solenoid valve
Malfunctioning of main relief
valve
PC200/220(LC)-7
Swing lock switch
Solenoid valve output pressure
OFF
0{0}
ON
2.84 3.43 MPa
{29 35kg/cm2}
The main relief valve is presumed to malfunction. Check the valve itself.
20-613
TESTING AND ADJUSTING
H-15, H-16, H-17
H-15 In compound operation, work equipment with larger load moves slowly
In a compound operation, work equipment with larger load tends to move slowly.
Relative information
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
The pressure compensation valve for the work equipment with larger load is
presumed to malfunction. Check the valve itself.
Malfunctioning of pressure
compensation valve for work
equipment with larger load
Combination of compound operation
Work equipment with larger load
Boom RAISE + arm DIGGING
Boom RAISE
Boom RAISE + arm DUMPING
Arm DUMPING
Boom RAISE + bucket DIGGING
Boom RAISE
Arm DUMPING + bucket DIGGING
Arm DUMPING
Boom LOWER + arm DUMPING
Arm DUMPING
H-16 In swing + boom RAISE operation, boom moves slowly
In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Relative information
If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
Malfunctioning of LS select
valve or seal defective
The LS select valve is presumed to malfunction, or the seal is suspected to
be defective. Check the valve and seal themselves.
H-17 In swing + travel, travel speed drops sharply
In a compound operation of swing + travel, the travel speed drops sharply.
Relative information
If the travel speed is slow in the single operation of travel, carry out the H-19 check first.
Presumed cause and standard value in normalcy
Failure information
20-614
Cause
Standard value in normalcy and references for troubleshooting
Malfunctioning of LS shuttle
valve (left travel and swing)
The LS shuttle valve in the left travel control valve or the swing control valve
is presumed to malfunction. Check both of them directly.
PC200/220(LC)-7
TESTING AND ADJUSTING
H-18
H-18 Machine swerves in travel
Failure information
The machine tends to swerve while traveling.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of travel PPC
valve
Travel control lever
PPC valve output pressure
Forward or reverse
Above 2.7 MPa
{Above 28 kg/cm2}
Differential output between right
and left sides
0.4 MPa {4 kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Malfunctioning of self-pressure
decompression valve
Control lever
Control circuit source pressure
All control levers in NEUTRAL
2.83 3.43 MPa
{29 35 kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
Oil Pressure ratio
3
Improper adjustment or malfunctioning of LS valve
Oil pressure to be
measured
Pump delivery pressure
LS valve output pressure
All control levers in
NEUTRAL
Nearly equal pressure
Travel without load
(control lever held at half
stroke)
1
Approx. 3/5
Stop engine for preparations. Start troubleshooting at engine high idling.
4
Malfunctioning of travel interlocking solenoid valve
Travel control lever
PPC valve output pressure
Operating one side only
0 {0}
Operating both sides
2.84 3.43 MPa
{29 35 kg/cm2}
Malfunctioning of travel interlocking valve
The travel interlocking valve is presumed to malfunction. Check the valve itself.
Malfunctioning of travel control
valve (spool)
The spool in the travel interlocking valve is presumed to malfunction. Check the
spool itself.
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunction of travel motor
Travel control lever
Travel relief
Final drive defective
PC200/220(LC)-7
Amount of oil leakage from travel motor
27.2 /min
The final drive is suspected of an internal failure. Check the inside of the final
drive directly.
An internal failure in the final drive may well be determined by an abnormal noise
from within, abnormal heat or metal chip or dust contained in the drained oil.
20-615
TESTING AND ADJUSTING
H-19
H-19 Machine travels slowly
Failure information
The machine's travel speed is slow.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of travel PPC
valve
Travel control lever
PPC valve output pressure
Forward or reverse
Above 2.7 MPa
{Above 28 kg/cm2}
Output differential between right and
left or front and rear
Below 0.4 MPa
{Below 4 kg/cm2}
Presumed cause and standard value in normalcy
Stop engine for preparations. Start troubleshooting at engine high idling.
2
Malfunctioning of self-pressure
decompression valve
Control lever
Control circuit source pressure
All control levers in NEUTRAL
2.83 3.43 MPa
{29 35kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of LS-EPC
valve
Travel speed
Travel control lever
LS-EPC valve output
pressure
Lo
NEUTRAL
Approx. 2.9 MPa
{approx. 30 kg/cm2}
Hi
Travel control lever
0 {0}
Malfunction of travel control
valve (spool)
The spool in the travel control valve is presumed to malfunction. Check the spool
itself.
Malfunctioning of travel control
valve (pressure compensation
valve)
The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve itself.
Malfunctioning of travel control
valve (suction valve)
The suction valve in the travel control valve is presumed to malfunction. Check
the valve itself.
Malfunctioning of LS shuttle
valve (bucket)
The LS shuttle valve in the bucket control valve is presumed to malfunction.
Check the valve itself.
Malfunction of travel motor
Stop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever
Travel relief
8
Final drive defective
20-616
Amount of oil leakage from travel motor
27.2 /min
The final drive is suspected of an internal failure. Check the inside of the final
drive directly.
An internal failure in the final drive may well be determined by an abnormal noise
from within, abnormal heat or metal chip or dust contained in the drained oil.
PC200/220(LC)-7
TESTING AND ADJUSTING
H-20
H-20 Machine cannot be easily steered or lacks power
Failure information
The machine cannot be easily steered.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of travel PPC
valve (steering spool)
Travel control lever
PPC valve output pressure (steering)
NEUTRAL on both sides
0 {0}
Operating one side only
Above 2.7 MPa
{Above 28 kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Malfunctioning of travel interlocking solenoid valve
Malfunctioning of travel interlocking valve
Travel control lever
Solenoid valve output pressure
Operating both sides
0 {0}
Operating one side only
2.84 3.43 MPa
{29 35 kg/cm2}
The travel interlocking valve is presumed to malfunction. Check the valve itself.
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of merge/divide
solenoid valve
Travel control lever
Solenoid valve output pressure
Operating both sides
0 {0}
Operating one side only
2.84 3.43 MPa
{29 35 kg/cm2}
Malfunctioning of merge/divide
valve
The merge/divide valve is presumed to malfunction. Check the valve itself.
Malfunction of travel control
valve (spool)
The spool in the travel control valve is presumed to malfunction. Check the spool
itself.
Malfunctioning of travel control
valve (pressure compensation
valve)
The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve itself.
Malfunctioning of travel control
valve (suction valve)
The suction valve in the travel control valve is presumed to malfunction. Check
the valve itself.
Malfunctioning of LS shuttle
valve (bucket)
The LS shuttle valve in the bucket control valve is presumed to malfunction.
Check the valve itself.
10
Check valve seal defective at
LS oil pressure pickup port
The seal in the check valve of LS oil pressure pickup port is suspected to be
defective. Check the seal itself.
Malfunctioning of travel motor
11
(safety valve)
The seal in the check valve of the travel motor is suspected to be defective.
Check the seal itself.
Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.
Malfunctioning of travel motor
12
(check valve)
The seal in the check valve of the travel motor is suspected of defect. Check the
seal itself.
Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.
PC200/220(LC)-7
20-617
TESTING AND ADJUSTING
H-21
H-21 Travel speed does not shift, or it is too slow or fast.
Failure information
Travel speed does not shift, or it is either too fast or slow.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
Stop engine for preparations. Start troubleshooting at engine high idling.
Travel speed
Travel control lever
Monitoring [15]
Lo
Fine control
(to the extent that the
decelerator is released)
810 mA
(
1
Malfunctioning of LS-EPC
valve
Mi)
Hi
470 mA
0 mA
Stop engine for preparations. Start troubleshooting at engine high idling.
Travel speed
Travel control lever
LS-EPC valve output
pressure
Lo
NEUTRAL
Approx. 2.9 MPa
{approx. 30 kg/cm2}
Hi
Operation
0 {0}
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of travel speed
solenoid valve
Malfunctioning of travel motor
(speed shifting)
Travel speed
Travel control lever
LS-EPC valve output
pressure
Lo
NEUTRAL
0 {0}
Hi
Operation
2.84 3.43 MPa
{29 35 kg/cm2}
The travel motor is presumed to malfunction when shifting speed. Check the
speed shifting portion directly.
: The "Mi" mode is on the multi-monitor specification machine only.
20-618
PC200/220(LC)-7
TESTING AND ADJUSTING
H-22
H-22 Track shoe does not turn (on one side only)
A track shoe does not turn (only on one side).
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
Travel control valve (suction
valve) seat defective
The suction valve seat in the travel control valve is suspected of defect. Check
the seat itself.
Travel motor (safety valve)
seat defective
The safety valve seat in the travel motor is suspected of defect. Check the seat
itself.
Travel motor (check valve)
seat defective
The check valve seat in the travel motor is suspected of defect. Check the seat
itself.
Stop engine for preparations. Start troubleshooting at engine high idling.
Travel Motor speed reduced
Travel control lever
Travel relief
Final drive defective
PC200/220(LC)-7
Amount of oil leakage from travel motor
27.2 /min
The final drive is suspected of an internal failure. Check the inside of the final
drive directly.
A failure inside the final drive may well be determined by an abnormal noise from
within, abnormal heat generated or metal dust or chips contained in the drained
oil.
20-619
TESTING AND ADJUSTING
H-23
H-23 Machine does not swing
Failure information (1) The machine swings neither to the right nor to the left.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Malfunctioning of swing parking brake solenoid valve
Malfunctioning of swing motor
(parking brake)
Swing
Solenoid valve
NEUTRAL
0 {0}
Operation
2.84 3.43 MPa {29 35 kg/cm2}
The parking brake portion of the swing motor is presumed to malfunction.
Check it directly.
Stop engine for preparations. Start troubleshooting at engine high idling.
Improper adjustment or malfunctioning of swing motor
(safety valve)
Swing lock switch
Swing control lever
Swing relief pressure
ON
Swing relief
28.9 32.9 MPa
{295 335 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the
safety valve is presumed to malfunction, or suspected of an internal failure.
Check the valve itself.
Stop engine for preparations. Start troubleshooting at engine high idling.
Swing motor defective
Swing control lever
Amount of oil leakage from swing motor
Swing relief
Swing machinery defective
Below 10 /min
The swing machinery is suspected of an internal failure. Check the inside of the
swing machinery directly.
A failure inside the swing machinery may well be determined by an abnormal
noise from within, abnormal heat generated or metal dust or chips contained in
the drained oil.
Failure information (2) The machine does not swing in one direction.
Presumed cause and standard value in normalcy
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of PPC valve
Left control lever
PPC valve output pressure
NEUTRAL
0 {0}
Swing operation
Above 2.7 MPa {Above 28 kg/cm2}
Malfunctioning of swing control
valve (spool)
The spool in the swing control valve is presumed to malfunction. Check the spool
itself.
Swing motor (suction valve)
seal defective
The seal in the suction valve of the swing motor is suspected of defect. Check the
seal itself.
Whether the seal is defective or not may well be determined by swapping the
right and left suction valves and watching if there is any change.
Swing motor (check valve)
seal defective
The seal in the check valve of the swing motor is suspected of defect. Check the
seal itself.
Whether the seal is defective or not may well be determined by swapping the
right and left check valves and watching the result.
20-620
PC200/220(LC)-7
TESTING AND ADJUSTING
H-24
H-24 Swing acceleration is poor, or swing speed is slow
Failure information (1) Swing acceleration is poor, or swing speed is slow.
Presumed cause and standard value in normalcy
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Malfunctioning of LS shuttle
valve (all LS shuttles)
The LS shuttle valves for all the control valves are presumed to malfunction.
Check them directly.
Malfunctioning of swing motor
(parking brake)
The parking brake portion of the swing motor is presumed to malfunction. Check
it directly.
Stop engine for preparations. Start troubleshooting at engine high idling.
Improper adjustment or malfunctioning of swing motor
(safety valve)
Swing lock switch
Swing control lever
Swing relief pressure
ON
Swing relief
28.9 32.9 MPa
{295 335 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the
safety valve is presumed to malfunction, or suspected of an internal failure.
Check the valve itself.
Stop engine for preparations. Start troubleshooting at engine high idling.
Swing motor defective
Swing control lever
Amount of oil leakage from swing motor
Swing relief
Below 10 /min
Failure information (2) Swing acceleration is poor only on one side, or swing speed is slow.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of PPC valve
Swing control lever
PPC valve output pressure
NEUTRAL
0 {0}
Left or right
Above 2.7 MPa {Above 28 kg/cm2}
Malfunctioning of swing control
valve (spool)
The spool in the swing control valve is presumed to malfunction. Check the valve
itself.
Malfunctioning of swing motor
(pressure compensation
valve)
The pressure compensation valve in the swing motor is presumed to malfunction.
Check the valve itself.
Swing motor (suction valve)
seal defective
The seal in the suction valve of the swing motor is suspected of defect. Check the
seal itself.
Whether the seal is defective or not may well be determined by swapping the
right and left suction valves and watching the result.
Swing motor (check valve)
seal defective
The seal in the check valve of the swing motor is suspected of defect. Check the
seal itself.
Whether the seal is defective or not may well be determined by swapping the
right and left check valves and watching the result.
PC200/220(LC)-7
20-621
TESTING AND ADJUSTING
H-25
H-25 Excessive overrun when stopping swing
Failure information (1) The work equipment overruns excessively when stopping swing.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
Stop engine for preparations. Start troubleshooting at engine high idling.
Improper adjustment or malfunctioning of swing motor
(safety valve)
Swing lock switch
Swing control lever
Swing relief pressure
ON
Swing relief
28.9 32.9 MPa
{295 335 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the
safety valve is presumed to malfunction, or suspected of an internal failure.
Check the valve itself.
Stop engine for preparations. Start troubleshooting at engine high idling.
Swing motor defective
Control lever
Amount of oil leakage from swing
motor
Below 10 /min
Swing relief
Failure information (2) Swing acceleration is poor only on one side, or swing speed is slow.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Malfunctioning of PPC valve
Swing control lever
PPC valve output pressure
NEUTRAL
0 {0}
Left or right
Above 2.7 MPa {Above 28 kg/cm2}
Swing PPC slow return valve
clogged
The PPC slow return valve is suspected of clogging. Check the valve itself.
Whether the valve is clogged or not may well be determined by swapping
the right and left valves and watching the result.
Malfunctioning of swing control
valve (spool)
The spool in the swing control valve is resumed to malfunction. Check the
valve itself.
Swing motor (suction valve)
seal defective
The seal in the suction valve of the swing motor is suspected of defect.
Check the seal itself.
Whether the seal is defective or not may well be determined by swapping
the right and left suction valves and watching the result.
Swing motor (check valve)
seal defective
The seal in the check valve of the swing motor is suspected of defect.
Check the seal itself.
Whether the seal is defective or not may well be determined by swapping
the right and left check valves and watching the result.
20-622
PC200/220(LC)-7
TESTING AND ADJUSTING
H-26, H-27
H-26 There is big shock when stopping swing
There is a big shock caused when stopping a swing motion.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of swing PPC
valve
Malfunctioning of swing PPC
slow return valve
Swing control lever
PPC valve output pressure
NEUTRAL
0 {0}
Left or right
Above 2.7 MPa {Above 28 kg/cm2}
The swing PPC slow return valve is presumed to malfunction. Check the
valve itself.
Whether the valve malfunctions or not may well be determined by swapping the right and left valves and watching the result.
H-27 There is big abnormal noise caused when stopping swing
There is a big abnormal noise caused when stopping a swing motion.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
Malfunctioning of backpressure valve
The backpressure valve is presumed to malfunction. Check the valve itself.
Malfunction of swing motor
(safety valve)
The safety valve in the swing motor is presumed to malfunction. Check the
valve itself.
Malfunction of swing motor
(suction valve)
The seal in suction valve of the swing motor is suspected of defect. Check
the seal itself.
Whether the seal is defective or not may well be determined by swapping
the right and left valves and watching the result.
Swing machinery defective
The swing machinery is suspected of an internal failure. Check the inside of
the machinery itself.
A failure inside the swing machinery may well be determined by monitoring
abnormal noise, abnormal heat generated or metal dust or chips contained
in the drained oil.
PC200/220(LC)-7
20-623
TESTING AND ADJUSTING
H-28
H-28 Swing natural drift is too big
Failure information (1) Natural drift of the swing is too big (when the parking brake is activated).
Presumed cause and standard value in normalcy
Relative information
When the emergency swing release switch is in the OFF position (this is a normal condition), the
swing and parking brake is activated and the swing is fixed with a disc brake.
Cause
Standard value in normalcy and references for troubleshooting
Stop engine for preparations. Start troubleshooting at engine high idling.
Swing and parking brake solenoid valve malfunctioned
Swing motor (parking brake
portion) malfunctioned
Swing control lever
Solenoid valve output pressure
NEUTRAL
0 {0}
Left or right
2.84 3.43 MPa {29 35 kg/cm2}
The parking portion of the swing motor is suspected of malfunctioning and
interior failure. Check that portion directly.
Failure information (2) Natural drift of the swing is too big (when the parking brake is released).
Relative information
When the emergency swing release switch is in the ON condition (this is an emergent condition),
the swing and parking brake is released and the swing is retained only hydraulically.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Swing control valve (spool)
malfunctioned
The seal in the spool of the swing control valve is suspected of defect.
Check the spool itself directly.
Swing control valve (pressure
compensation valve) malfunctioned
The pressure compensation valve seal in the swing control valve is suspected of defect. Check the valve itself directly.
Swing motor (safety valve)
defective
The safety valve seal in the swing motor is suspected of defect. Check the
valve itself directly.
Swing motor (suction valve)
defective
The suction valve seal in the swing motor is suspected of defect. Check the
valve itself directly.
Swing motor (check valve)
defective
The check valve seal in the swing motor is suspected of defect. Check the
valve itself directly.
20-624
PC200/220(LC)-7
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM
PC200-7, PC200LC-7 .......................................................................................................................... 90- 3
PC220-7, PC220LC-7 .......................................................................................................................... 90- 5
ELECTRICAL CIRCUIT DIAGRAM
FOR MULTI MONITOR ........................................................................................................................ 90- 7
FOR 7-SEGMENT MONITOR .............................................................................................................. 90- 15
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER................................................................... 90- 19
PC200/220(LC)-7
90-1
You might also like
- Komatsu Pc210 210lc 210nlc 240lc 240nlc 7k Shop Manual100% (59)Komatsu Pc210 210lc 210nlc 240lc 240nlc 7k Shop Manual20 pages
- Komatsu PC120-5K PC130-5K PC150-5K PC180-5K Shop Manual SEBMK203P502 PDF100% (8)Komatsu PC120-5K PC130-5K PC150-5K PC180-5K Shop Manual SEBMK203P502 PDF646 pages
- Ysjtpa6gixj 2002-2004 Mercury 40HP 50HP 60HP Service Repair Manual PDF83% (6)Ysjtpa6gixj 2002-2004 Mercury 40HP 50HP 60HP Service Repair Manual PDF590 pages
- 2011 Nissan Pathfinder Service Repair Manual PDF0% (3)2011 Nissan Pathfinder Service Repair Manual PDF16 pages
- Galeo Pc200-220lc-8-1009-Seno 0084-03 DemoNo ratings yetGaleo Pc200-220lc-8-1009-Seno 0084-03 Demo50 pages
- 390D L Excavator WAP00001-UP (MACHINE) POWERED BY C18 Engine (SEBP5236 - 43) - Sistemas y ComponentesNo ratings yet390D L Excavator WAP00001-UP (MACHINE) POWERED BY C18 Engine (SEBP5236 - 43) - Sistemas y Componentes2 pages
- Pc200-6 Main Pump Standard Value Sebh537572 - 10697100% (3)Pc200-6 Main Pump Standard Value Sebh537572 - 1069721 pages
- Komatsu PC200-7 Error Code On The Monitor, CMP Technology Co., LimitedNo ratings yetKomatsu PC200-7 Error Code On The Monitor, CMP Technology Co., Limited5 pages
- Sales Manual - Comparison With 3a - Ps-En240100% (2)Sales Manual - Comparison With 3a - Ps-En240128 pages
- Caterpillar Cat 312D2 and 312D2 L Excavator (Prefix WHJ) Service Repair Manual Instant DownloadNo ratings yetCaterpillar Cat 312D2 and 312D2 L Excavator (Prefix WHJ) Service Repair Manual Instant Download29 pages
- Komatsu Hydraulic Excavator Pc138us 11 Shop Manual Sen06662 00No ratings yetKomatsu Hydraulic Excavator Pc138us 11 Shop Manual Sen06662 0022 pages
- MEO Class 4 Oral and Written Questions Part 480% (5)MEO Class 4 Oral and Written Questions Part 443 pages
- Fdocuments - in Otto Cycle PresentationNo ratings yetFdocuments - in Otto Cycle Presentation97 pages
- Results of Very High Cycle Fatigue Tests On Helical Compression SpringsNo ratings yetResults of Very High Cycle Fatigue Tests On Helical Compression Springs6 pages
- A Guide To Physics Problems. Part 2. Thermodynamics, Statistical Physics, and Quantum Mechanics - S.cahn, B.nadgorny100% (3)A Guide To Physics Problems. Part 2. Thermodynamics, Statistical Physics, and Quantum Mechanics - S.cahn, B.nadgorny374 pages
- Philippine Agricultural Engineering StandardNo ratings yetPhilippine Agricultural Engineering Standard17 pages
- United States Patent (19) 4,513,568: BajulazNo ratings yetUnited States Patent (19) 4,513,568: Bajulaz9 pages
- Design Calculations To Evaluate Performance Parameters of Compressor Valve-Ijaerdv04i0749408No ratings yetDesign Calculations To Evaluate Performance Parameters of Compressor Valve-Ijaerdv04i07494087 pages
- Jabatan Kejuruteraan Mekanikal Politeknik Sultan Azlan ShahNo ratings yetJabatan Kejuruteraan Mekanikal Politeknik Sultan Azlan Shah24 pages