Pc200 Trobleshooting

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
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ............................................................................... 20-259
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE ....................................................................... 20-262
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
(14)
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k 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.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k 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 func-
tion.
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 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1)Start from the simple points.
problems with the machine condition before 2)Start from the most likely points.
this? 3)Investigate other related parts or infor-
4) Under what conditions did the failure occur? mation.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
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 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, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing 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 care-
ful 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 connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-204 PC200/220(LC)-7
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 solder-
ing may be damaged, or the wiring may be
broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, 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 sur-
face 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 connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
When wiping the mating portion of the
connector, be careful not to use exces-
sive 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
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 con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors 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 im-
proper contact to occur, so always cover
the connector.
20-206 PC200/220(LC)-7
• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age 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 connec-
tor, 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, re-
place 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 wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
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.
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
PC200/220(LC)-7 20-207
• 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 fol-

lows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed 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 re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected 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 reas-
semble.
20-208 PC200/220(LC)-7
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 con-
trol 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
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 cir-
cuit. When adding hydraulic oil, or when disassem-
bling 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. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a spec ially
prepared dustproof workshop, and the perfor-
mance 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 enter-
ing. 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, col-
lect 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 refill-

ing 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 clean-
ing 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
TROUBLESHOOTING 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 con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o nt ro l va lv e , e tc . ) o r wh en ru nn i n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
PC200/220(LC)-7 20-211
(1)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil,
4. Check hydraulic oil strainer — Clean, drain

coolant
5. Check swing machinery oil level — Add oil

6. Check engine oil level (oil pan oil level) — Add oil
7. Check coolant level — Add coolant
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
mechanical equipment
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Hydraulic, Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
equipment
1. Check for abnormal noise, smell — Repair

2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30V Replace
2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment
3. Check for discolored, burnt, exposed wiring — Replace

4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention — Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After Replace
running for
several
minutes :
27.5 – 29.5V
8. Check operating sound of battery relay — Replace
(when switch is turned ON/OFF)
20-212 PC200/220(LC)-7
(11)
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Classification of troubleshooting
Mode Content
Troubleshooting when Service Code (electrical system) and Failure Code (mechanical
Code display
system) are displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine assembly
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 Ser-
vice 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 sys-
tem Failure Code, using the failure history function of the monitor panel.
a 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.
a 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 mechan-
ical 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
(5)
Failure-looking Phenomenon and Troubleshooting No.
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Action to be taken concerning Service Code, User Code and Failure Code
1 Display User Code in monitor panel Accord-
Display Service Code in electrical system after checking failure ing to
2
history dis-
Display Failure Code in mechanical system after checking failure played
3 code
history
Engine-related failure
Engine does not start up easily. (It always takes some time to start
4 S-1
up the engine)
5 Engine does not rotate E-1 S-2 (1)
6 Engine rotates, but there is no exhaust gas S-2 (2)
Engine does not start
There is exhaust gas, but engine does not
7 S-2 (3)
start
8 Engine pickup is poor. (Engine does not follow acceleration) S-3
9 Engine stops while in operation E-2 H-2 S-4
10 Engine rotation is irregular. (There is hunting) E-3 S-5
11 Engine is short of output, or lacks power 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 coolant 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 H-5
22 Engine auto warming-up device does not work E-6
23 Engine preheater does not work E-7
Failure related to work equipment, swing and travel
Speeds of all work equipment, travel and swing are slow, or they
24 H-1 S-6
lack power
25 Engine rotation drops sharply or stalls H-2 S-4
26 All work equipment, travel and swing do not move E-8 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
(11)
Troubleshooting
display
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 Work equipment does not move when individual operation H-10
33 Natural drift of work equipment is too fast H-11
34 Work equipment time lag is too big H-12
Other work equipment moves, when specific work equipment is
35 H-13
relieved
36 One-touch power max. switch does not work E-9, 21–26 H-14
Compound operation-related failure
In compound operation, work equipment receiving larger load
37 H-15
moves slowly.
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 E-28 H-19
42 Machine is difficult to steer, or lacks power E-28, 29 H-20
43 Travel speed cannot be shifted or is slow or fast 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 Hydraulic drift of swing is large. 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 coolant level monitor lamp lights up
54 B@BCZK
red ( )
55 In startup inspection, engine oil level monitor lamp lights up red B@BAZK
: The multi-monitor specification machine only.
PC200/220(LC)-7 20-215
(11)
Troubleshooting
display
Refer to Operation and Maintenance
56 In startup inspection, maintenance hour monitor lamp lights up red
Manual
While engine is running, battery charging level monitor lamp lights
57 AB00KE
up red
58 While engine is running, fuel level monitor lamp lights up red E-13
While engine is running, air cleaner clogging monitor lamp lights up
59 AA10NX
red
While engine is running, engine coolant temperature monitor lamp
60 B@BCNS
lights up red
While engine is running, hydraulic oil temperature monitor lamp
61 B@HANS
lights up red ( )
62 Engine coolant 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)
In monitoring function, "Boom RAISE" cannot be displayed cor-
69 E-21
rectly
In monitoring function, "Boom LOWER" cannot be displayed cor-
70 E-22
rectly
In monitoring function, "Arm DIGGING" cannot be displayed cor-
71 E-23
rectly
In monitoring function, "Arm DUMPING" cannot be displayed cor-
72 E-24
rectly
In monitoring function, "Bucket DIGGING" cannot be displayed
73 E-25
correctly
In monitoring function, "Bucket DUMPING" cannot be displayed
74 E-26
correctly
75 In monitoring function, "Swing" cannot be displayed correctly E-27
76 In monitoring function, "Travel" cannot be displayed correctly E-28
In monitoring function, "Travel Differential Pressure" cannot be dis-
77 E-29
played correctly
78 In monitoring function, "Service" cannot be displayed correctly E-30
Other failure
79 Air conditioner does not work E-31
80 Travel alarm does not sound E-32
20-216 PC200/220(LC)-7
(11)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT

DIAGRAM BY SYSTEM
Connector table
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
A01 X 4 Intermediate connector T-1 H-6 I-5 I-8
A02 X 4 Intermediate connector T-1 H-6 I-4
A03 D 12 Intermediate connector N-1 H-6 I-2 I-8
A04 SWP 12 Intermediate connector O-1 I-7
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 I-1 I-4
A08 SWP 12 Intermediate connector N-2
A09 SWP 8 Intermediate connector N-2 I-3
A10 Terminal 1 Revolving frame grounding H-1 H-1 J-5 J-4
A11 Terminal 1 Revolving frame grounding H-1 I-1
A13 Terminal 1 Revolving frame grounding I-2 I-1 J-4 J-8
A14 Terminal 1 Revolving frame grounding K-2 I-1
A15 Terminal 1 Revolving frame grounding I-2 I-1 J-4
A20 Terminal 1 Battery relay (E terminal) J-1 I-2 J-4
A21 Terminal 1 Battery relay (BR terminal) J-1 I-1 J-4
A22 Terminal 1 Battery relay (M terminal) J-1 J-2 K-4
A23 Terminal 1 Battery relay (B terminal) J-2 J-1 K-4
A25 Terminal 1 Heater relay (coil) L-3 K-6
A26 Terminal 1 Heater relay (contact) L-3 K-2
A27 X 2 Starter safety relay (S and R terminals) K-2 J-2
A29 Terminal 1 Starter safety relay (C terminal) L-3
A30 YAZAKI 2 Air conditioner outside air temperature sensor L-4
A31 D 2 Air cleaner clogging sensor L-4 K-4
A33 X 2 Radiator coolant level sensor L-4 K-5
A34 L 2 Fusible link (65A) A-4 K-6 K-5
A35 M 2 Fusible link (30A) A-5 K-6 K-4
A40 AMP 1 Alarm horn (low tone) H-1
A41 AMP 1 Alarm horn (high tone) H-1
A42 X 1 Intermediate connector I-9 J-7
A43 X 2 Travel alarm I-2 K-4
A44 M 1 Front right lamp A-6 K-7
20-218 PC200/220(LC)-7
(11)
Address
Connector No. of
No. pin
A50 KES0 2 Window washer monitor (tank) K-3 K-5
A51 D 3 F pump hydraulic oil pressure sensor K-3 K-5
A52 D 3 R pump hydraulic oil pressure sensor J-9 K-5
A60 X 1 Fuel level sensor D-9 K-4
A61 D 2 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
C09 S 8 Model selection connector W-6 C-9
D01 SWP 8 Assembled type diode W-7 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-7 A-8 D-1
D03 SWP 8 Assembled type diode P-1 H-1
D04 SWP 8 Assembled type diode Q-1 A-8 F-1 I-1
Suction type air heater
E01 Terminal 1 J-9 L-2 L-6
(electrical intake air heater)
E02 Terminal 1 Engine hydraulic switch L-8 K-6
E03 D 2 Engine oil level switch L-6 K-5
E04 D 2 Engine rotation sensor K-9 K-8
E05 D 2 Engine coolant temperature sensor J-9 K-4
E06 M 3 Fuel dial K-8
Air conditioner compressor electromagnetic
E06 X 1 O-8
switch
E08 X 1 Intermediate connector L-7 J-3 J-5
E10 D 3 Governor potentiometer J-9 K-3
E11 D 4 Governor motor K-9 K-2
E12 X 2 Alternator L-7 K-3 K-5
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 – – Fuse box W-5 I-9 C-4 F-9
G01 – – – V-2
G02 – – – V-3
G03 – – – V-3
G04 – – – V-2
G05 – – – V-3
H08 M 8 Intermediate connector W-4 K-8
H09 S 8 Intermediate connector W-4 J-8
H10 S 16 Intermediate connector T-9 D-6 I-8
H11 S 16 Intermediate connector S-9 D-5 I-8 B-9
H12 S 12 Intermediate connector S-9 D-5 I-7
H15 S090 20 Intermediate connector N-7 C-2 E-2 C-2
PC200/220(LC)-7 20-219
(11)
Address
Connector No. of
No. pin
J01 J 20 Junction connector (black) W-8 C-9 D-9 C-9
J02 J 20 Junction connector (black) W-8 D-9 D-9 D-9
J03 J 20 Junction connector (green) W-8 D-9 D-9
J04 J 20 Junction connector (green) W-7 E-9 E-9 E-9
J05 J 20 Junction connector (pink) W-6 E-9 E-9 E-9
J06 J 20 Junction connector (orange) W-6 F-9 H-9
J07 J 20 Junction connector (orange) U-9 F-9 F-9 H-9
J08 J 20 Junction connector (pink) U-9 I-9
K19 M 2 Pump resistor (for driving emergency pump) U-2 E-3
K30 D 3 CAN terminating resistor T-9 A-2 C-1
K31 D 3 CAN terminating resistor N-4 A-4 K-7
M07 M 3 Lamp switch P-8 C-2
M09 M 1 Working lamp (front right) E-9 K-7
M13 KES0 2 Speaker (right) AC-8
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio U-2
M22 Y090 2 Horn switch N-7
M23 Y090 2 Knob switch T-1
M26 S 12 Air conditioner unit W-5
M27 SWP 16 Air conditioner unit W-5
M29 040 20 Air control panel W-3
M30 040 16 Air control panel W-3
M31 M 2 Option power source (2) U-2
M32 M 2 Option power source (1) S-9
M33 M 2 Option power source (3) –
M33 SWP 8 Air conditioner unit S-9
M34 YAZAKI 2 Air conditioner inside air sensor W-8
M40 YAZAKI 2 Working lamp Z-8 K-8
M41 YAZAKI 2 Working lamp (additional) Y-7 K-8
M42 M 1 Intermediate connector K-3 J-7
M43 M 1 Working lamp (rear) – K-7
M45 D 12 Intermediate connector U-2
M46 S090 4 RS232C relaying connector U-9 B-9
M71 M 2 Room lamp Z-8
M72 M 4 DC/AC converter U-2
M73 KES0 2 Speaker (left) AD-8
M79 YAZAKI 2 12V electrical equipment socket V-9
20-220 PC200/220(LC)-7
(11)
Address
Connector No. of
No. pin
P01 070 12 Monitor panel N-6 A-7 K-8
P02 040 20 Monitor panel N-5 A-6 K-8 A-9
P03 M 2 Buzzer canceling switch P-9 D-1
P05 M 2 Revolving warning lamp switch W-3
P15 Y050 2 Air conditioner sun light sensor N-6
R10 R 5 Lamp relay O-8 E-1
R11 R 5 Engine starting motor cutting relay (PPC lock) P-8 E-1
Engine starting motor cutting relay (personal
R13 R 5 Q-9 F-1
code)
R20 R 5 Attachment circuit switching relay W-6 C-9
R21 – – – W-7
S01 X 2 Bucket digging oil pressure switch S-8 K-2
S02 X 2 Boom lowering oil pressure switch L-7 K-3
S03 X 2 Swing oil pressure switch, left L-7 K-2
S04 X 2 Arm digging oil pressure switch L-6 K-3
S05 X 2 Bucket dumping oil pressure switch L-5 K-2
S06 X 2 Boom raise oil pressure switch L-5 K-3
S07 X 2 Swing oil pressure switch, right L-5 K-2
S08 X 2 Arm dumping oil pressure switch L-4 K-3
Service oil pressure switch (intermediate con-
S09 X 2 K-3 K-1
nector)
S10 X 2 Service oil pressure switch, front – K-1
S11 X 2 Service oil pressure switch, rear – K-1
S14 M 3 Lever lock switch S-1 K-9 F-8
S21 Terminal 6 Pump emergency driving switch R-9 E-2
Swing and parking brake emergency releasing
S22 Terminal 6 R-9 F-2
switch
S25 S090 16 Intermediate connector Q-9 E-3
S30 X 2 Travel hydraulic switch O-1 A-1
S31 X 2 Travel steering hydraulic switch P-1 A-1
SC Terminal 1 Engine starting motor (C terminal) K-8
SSW Terminal 5 Engine starting switch N-7
T05 Terminal 1 Floor frame grounding W-3 J-8
T06 Terminal 1 Radio body grounding –
T06A M 1 Intermediate connector T-2
T11 Terminal 1 Operator's cab grounding AD-3
T13 D 1 Engine starting motor (C terminal) L-6 J-3
PC200/220(LC)-7 20-221
(11)
Address
Connector No. of
No. pin
V01 D 2 PPC hydraulic lock solenoid valve J-2 K-6
V02 D 2 Travel interlocking solenoid valve J-2 K-6
V03 D 2 Merge/divide valve solenoid valve J-2 K-6
V04 D 2 Travel speed solenoid valve J-3 K-5
V05 D 2 Swing and parking brake solenoid valve J-3 K-5
V06 D 2 2-stage relief solenoid valve K-3 K-6
V12 D 2 Attachment return switching solenoid valve I-9 K-4
V21 D 2 PC-EPC solenoid valve I-9 K-7
V22 D 2 LS-EPC solenoid valve I-9 K-7
Attachment oil flow rate adjusting EPC solenoid
V30 X 2 P-1 A-1
valve
W03 X 2 Rear limit switch (window) AB-9 L-8
W04 M 6 Windshield wiper motor Y-4 B-9
X05 M 4 Swing lock switch Q-9 D-2 C-2
Y08 – – – G-9
Y09 – – – G-1
Y10 – – – G-9
Y11 – – – A-6
Y12 – – – G-9
Y13 – – – G-1
Y16 – – – G-9
20-222 PC200/220(LC)-7
(1)
Connector No. Detailed information

D or DT Japanese and German makes DT type connector (08192-XXXXX)
L Product of Yazaki Corporation L type connector (08056-2XXXX)
J Product of Sumitomo Wiring Systems 090 type splice
M Product of Yazaki M type connector (08056-0XXXX)
R Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S Product of Yazaki S type connector (08056-1XXXX)
X 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
Y050 Product of Yazaki 050 type connector
S090 Product of Sumitomo 090 type connector
YAZAKI Yazaki-made connector
KES0 KES0 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
(5)
Connector table
PC200, 200LC-7 Serial No. 250001 and up
Address
Connector No. of
No. pin
A01 X 4 Intermediate connector M-8 H-6 I-5 I-8
A02 X 4 Intermediate connector M-9 H-6 I-4
A03 D 12 Intermediate connector M-9 H-6 I-2 I-8
A05 SWP 14 Intermediate connector M-8 H-5 I-7
A06 SWP 14 Intermediate connector O-9 H-5 I-5
A07 SWP 16 Intermediate connector M-8 H-4 I-5 I-4
A08 SWP 12 Intermediate connector O-9
A14 Terminal 1 Revolving frame grounding K-2 I-1 J-4
A29 Terminal 1 Starter safety relay (C terminal) L-3 K-2
A42 X 1 Intermediate connector I-9
20-223-1 PC200/220(LC)-7
(11)
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
No. pin
P05 M 2 Revolving warning lamp switch W-3
Engine starting motor cutting relay (personal
R13 R 5 Q-9 F-1
code)
R20 R 5 Attachment circuit switching relay W-6 C-9
R21 – – – W-7
S01 X 2 Bucket digging oil pressure switch S-8 K-2
Service oil pressure switch (intermediate con-
S09 X 2 K-3 K-1
nector)
S14 M 3 Safety lever lock switch S-1 K-9 F-8
switch
SC Terminal 1 Engine starting motor (C terminal) K-8
T05 Terminal 1 Floor frame grounding W-3 J-8
T06 Terminal 1 Radio body grounding –
PC200/220(LC)-7 20-221
Address
Connector No. of
No. pin
V01 D 2 PPC hydraulic lock solenoid valve J-2 K-6
V30 X 2 P-1 A-1
valve
Y08 – – – G-9
Y09 – – – G-1
Y10 – – – G-9
Y11 – – – A-6
Y12 – – – G-9
Y13 – – – G-1
Y16 – – – G-9
20-222 PC200/220(LC)-7

PC200/220(LC)-7 20-223
(5)
Connector table
Address
Connector No. of
No. pin
A01 X 4 Intermediate connector M-8 H-6 I-5 I-8
A02 X 4 Intermediate connector M-9 H-6 I-4
A03 D 12 Intermediate connector M-9 H-6 I-2 I-8
A05 SWP 14 Intermediate connector M-8 H-5 I-7
A06 SWP 14 Intermediate connector O-9 H-5 I-5
A07 SWP 16 Intermediate connector M-8 H-4 I-5 I-4
A08 SWP 12 Intermediate connector O-9
A14 Terminal 1 Revolving frame grounding K-2 I-1 J-4
A29 Terminal 1 Starter safety relay (C terminal) L-3 K-2
A42 X 1 Intermediate connector I-9
20-223-1 PC200/220(LC)-7
(11)
Address
Connector No. of
No. pin
A70 D 3 Boom cylinder bottom pressure sensor for over- G-1 K-4
load alarm
C01 DRC 24 Governor pump controller U-9 A-3 A-8 A-8
C02 DRC 40 Governor pump controller V-9 A-3 A-7 A-7
C09 S 8 Model selection connector U-9 C-9
D01 SWP 8 Assembled type diode W-9 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-7 A-8 D-1
Suction type air heater
E01 Terminal 1 J-9 L-2 L-6
(electrical intake air heater)
E02 Terminal 1 Engine hydraulic switch L-8 K-6
E03 D 2 Engine oil level switch L-6 K-6
E04 D 2 Engine rotation sensor K-9 K-8
E05 D 2 Engine coolant temperature sensor J-9 K-4
E06 M 3 Fuel dial O-8 F-1
E06 X 1 Air conditioner compressor electromagnetic K-8

switch
E08 X 1 Intermediate connector L-8 J-3 J-5
E10 D 3 Governor potentiometer J-9 K-3
E11 D 4 Governor motor K-9 K-2
E12 X 2 Alternator L-7 K-3 K-5
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 – – Fuse box U-2 I-9 C-4 F-9
G01 – – –
G02 – – –
G03 – – –
G04 – – –
G05 – – –
H08 M 8 Intermediate connector W-6 K-8
H09 S 8 Intermediate connector W-6 J-8
H11 S 16 Intermediate connector S-9 D-5 I-8 B-9
H15 S090 20 Intermediate connector N-7 C-2 E-2 C-2
J01 J 20 Junction connector (black) T-9 C-9 D-9 C-9
J02 J 20 Junction connector (black) V-2 D-9 D-9 D-9
J03 J 20 Junction connector (green) V-2 D-9 D-9
J04 J 20 Junction connector (green) V-3 E-9 E-9 E-9
J05 J 20 Junction connector (pink) V-3 E-9 E-9 E-9
J06 J 20 Junction connector (orange) V-3 F-9
J07 J 20 Junction connector (orange) W-3 F-9 F-9 H-9
K19 M 2 Pump resistor (for driving emergency pump) W-3 E-3
PC200/220(LC)-7 20-223-2
(11)
Address
Connector No. of
No. pin
K30 D 3 CAN terminating resistor T-9 A-2 C-1
K31 D 3 CAN terminating resistor N-4 A-4 K-7
M07 M 3 Lamp switch P-8 C-1
M09 M 1 Working lamp (front right) E-9 K-7
M13 KES0 2 Speaker (right) AC-8
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio T-1
M22 Y090 2 Horn switch N-7
M23 Y090 2 One-touch power max. switch S-1
M26 S 12 Intermediate connector W-3
M29 040 20 Air control panel T-2
M30 040 16 Air control panel U-2
M31 M 2 Option power source (2) W-6
SUMIT-
M33 4 Air conditioner unit W-5
OMO
M40 YAZAKI 2 Working lamp Z-8 K-8
M41 YAZAKI 2 Working lamp (additional) Y-7 K-8
M42 M 1 Intermediate connector K-3 K-7
M43 M 1 Working lamp (rear) – K-7
M45 D 12 Intermediate connector W-7
M46 S090 4 RS232C relaying connector V-9 B-9
M71 M 2 Room lamp Z-8
M72 M 4 DC/AC converter W-7
M73 KES0 2 Speaker (left) AD-8
M79 YAZAKI 2 12V electrical equipment socket W-8
P05 M 2 Revolving warning lamp switch U-2
P17 S09 2 Air conditioner high/low pressure switch –
Engine starting motor cutting relay
R13 R 5 Q-9 F-1
(personal code)
R20 R 5 Attachment circuit switching relay U-9 C-9
R21 – – –
20-223-3 PC200/220(LC)-7
(5)
Address
Connector No. of
No. pin
R30 R 5 Air conditioner blower relay W-4
R31 R 4 Air conditioner compressor relay W-4
S01 X 2 Bucket digging oil pressure switch L-8 K-3
Service oil pressure switch
S09 X 2 K-3 K-2
(intermediate connector)
S14 M 3 Lever lock switch S-1 K-9 F-8
switch
SC Terminal 1 Engine starting motor (C terminal) K-8 K-3
T05 Terminal 1 Floor frame grounding U-2
T06 Terminal 1 Radio body grounding T-1
V01 D 2 PPC hydraulic lock solenoid valve I-2 K-6
V30 X 2 P-1 A-1
valve
PC200/220(LC)-7 20-223-4
(11)
Address
Connector No. of
No. pin
Y08 – – –
Y09 – – –
Y10 – – –
Y11 – – –
Y12 – – –
Y13 – – –
Y16 – – –
Y27 – – –
20-223-5 PC200/220(LC)-7
(5)

PC200/220(LC)-7 20-223-6
(5)
CONNECTOR LOCATION STEREOGRAM

PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
20-224 PC200/220(LC)-7
(7)
PC200/220(LC)-7 20-225
(9)
20-226 PC200/220(LC)-7
(1)
PC200/220(LC)-7 20-227
20-228 PC200/220(LC)-7
CONNECTOR LOCATION STEREOGRAM

20-229-1 PC200/220(LC)-7
(7)
PC200/220(LC)-7 20-229-2
(9)
20-229-3 PC200/220(LC)-7
(5)
PC200/220(LC)-7 20-229-4
(5)
20-229-5 PC200/220(LC)-7
(5)
Monitor Panel System Circuit Diagram (M Circuit)

PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
20-230 PC200/220(LC)-7
(7)
a 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
(5)
Monitor Panel System Circuit Diagram (M Circuit)

20-231-1 PC200/220(LC)-7
(7)
a 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 20-231-2
(5)
Governor Control System Circuit Diagram (G Circuit) of GovernorPump Controller

PC200, 200LC-7 Serial No. 200001 – 250000
20-232 PC200/220(LC)-7
(5)
a 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
(5)
Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controller

20-233-1 PC200/220(LC)-7
(7)
a 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 20-233-2
(5)
Pump Control System Circuit Diagram (P Circuit) of GovernorPump Controller

PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
20-234 PC200/220(LC)-7
(7)
a 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
(5)
Pump Control System Circuit Diagram (P Circuit) of GovernorPump Controller

20-235-1 PC200/220(LC)-7
(9)
a 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 20-235-2
(9)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

(Rev. 2007.12)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer to
the mating portion of the housing.
20-236 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-237
(14)
20-238 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-239
(14)
20-240 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-241
(14)
20-242 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-243
(14)
20-244 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-245
(14)
20-246 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-247
(14)
20-248 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-249
(14)
20-250 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-251
(14)
20-252 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-253
(14)
20-254 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-255
(14)
20-256 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-257
(14)
20-258 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-258-1
(14)
20-258-2 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-258-3
(14)
20-258-4 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-258-5
(14)
20-258-6 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-258-7
(14)
20-258-8 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-258-9
(14)
20-258-10 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-258-11
(14)
20-258-12 PC200/220(LC)-7
(14)
PC200/220(LC)-7 20-258-13
(14)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE

(Rev. 2008.02)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column
indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
PC200/220(LC)-7 20-259
(14)
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
20-260 PC200/220(LC)-7
(14)
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280 Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
PC200/220(LC)-7 20-261
(14)
TROUBLESHOOTING BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE

Error codes, failure codes, and possible causes
20-262 PC200/220(LC)-7
(5)
PC200/220(LC)-7 20-263
(5)
20-264 PC200/220(LC)-7
(5)
PC200/220(LC)-7 20-265
(5)
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power directly
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting for an electric system, you should check its fuse box and fusible link to
see if the power is supplied normally.
Type of power
Fuse No. Fuse capacity Destination of power
supply
Engine throttle and pump controller (Controller power supply)
1 10A Emergency pump drive resistor
Swing holding brake release switch
Switch power Engine throttle and pump controller (Solenoid power supply)
supply 2 20A
Attachment return switching relay (Coil side and contact side)
(Fusible link:
A34) 3 10A Lock switch
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn switch
6 10A (Spare)
Rotary lamp switch
7 10A
Switch power Additional relay (Coil side and contact side)
supply
8 10A Light relay (Contact side)
(Fusible link:
A34) One-touch power maximizing switch
9 10A
Radio
10 10A (Spare)
11 20A Air conditioner unit
Starting motor cut-out (Personal code) relay (Coil side)
12 20A
Switch power Monitor panel
supply
13 20A Light switch
(Fusible link:
A34) 14 10A Service power supply (M32 connector)
Travel alarm
15 10A
DC/DC converter
Radio
16 10A
Air conditioner unit
Constant power
supply 17 20A Monitor panel
(Fusible link: 18 10A Starting switch
A35)
19 10A Room lamp
20 10A (Spare)
20-266 PC200/220(LC)-7
(11)
Problems which occur when controller power supply of engine throttle and pump controller is defective
a The controller power supply (FB1-1) of the engine throttle and pump controller drives the controller system.
a Accordingly, if the controller power supply is turned off, the controller cannot control the governor motor and
battery relay and the following problems occur.
1) The engine can be started but cannot be stopped.
2) The engine speed cannot be controlled with the fuel control dial.
a If the above problems occur, check the related fuse (FB1-1) and "green LED" of the engine throttle and pump
controller to see if the power is supplied normally.
• Lighting: The controller power is supplied (There is not an error and the power supply is normal).
• Flashing: The controller power is supplied (There is an error).
• Put out: The controller power is not supplied.
Green LED of engine throttle and pump controller (GREEN)
PC200/220(LC)-7 20-267
(5)
Problems which occur when solenoid power supply of engine throttle and pump controller is defective
a The solenoid power supply (FB1-2) of the engine throttle and pump controller is used by the controller to drive
the solenoids and relays.
a Accordingly, if the solenoid power supply is turned off, when the controller outputs the power to the solenoids
or relays, the power is not supplied to any of the solenoids and relays and all or some of the following error
codes are displayed simultaneously.
• [E212]: Disconnection in travel junction solenoid
• [E213]: Disconnection in swing holding brake solenoid
• [E214]: Disconnection in pump merge-divider solenoid
• [E215]: Disconnection in 2-stage relief solenoid
• [E216]: Disconnection in travel speed shifting solenoid
• [E223]: Disconnection in LS-EPC solenoid
• [E233]: Disconnection in PC-EPC solenoid
• [E248]: Disconnection in attachment flow rate adjustment EPC solenoid (when attachment is installed)
a If the above problems occur, check the related fuse (FB1-2) and inlet voltage of the engine throttle and pump
controller.
1) Disconnect connector C03 of the controller and connect a T-adapter to the wiring harness side.
2) Turn the starting switch ON.
3) Measure the voltage between each of pins (2) and (12) and each of pins (31), (32), and (33).
Pins (2) and (3) are the power supply pins and pins (31), (32), and (33) are the ground pins.
If the voltage is 20 – 30 V, it is normal.
Power supply connector (C03) of engine throttle and pump controller
20-268 PC200/220(LC)-7
(5)
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................ 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 holding 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) ..................................... 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).. 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
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
PC200/220(LC)-7 20-301
(5)
TROUBLESHOOTING
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 idle) ............................. 20-378
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idle) .............................. 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 coolant overheating) ........................................... 20-384
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator coolant level) ..................... 20-385
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)................................................ 20-386
20-302 PC200/220(LC)-7
(11)
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 con-
tents fully before proceeding to actual troubleshooting work.
User Code Service Code Failure Code

Failure
Display in Display in Display in Title of failure phenomenon shown in failure history
phenomenon
monitor panel monitor panel monitor panel
Failure content Failure status as detected by monitor panel or controller
Response from
Action taken by the monitor panel or controller to protect an affected system or equipment, when they
monitor panel
detect some failure.
or controller
Phenomenon
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or
occurring on
controller
machine
Relative
Information on the failure occurred as well as the troubleshooting
information
Cause 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
1
• Reference for passing the above "Good" or "No Good" judgement
<Phenomenon of Wiring Harness Failure>

Presumed cause and standard value in normalcy
• Disconnection
There is a faulty contact at the connector or disconnection of wiring harness occurred.
• Defective grounding
2 A wiring harness that is not connected with a grounding circuit has a contact with the
grounding circuit.
• Short-circuiting
Cause that presumably A wiring harness that is not connected with a 24 V electric circuit has a contact with the
triggered failure in ques- electric circuit.
tion
3 (The assigned No. is for <Precaution for Troubleshooting>
filing purpose only. It 1) Connector No. display method and handling of T-adapter
does not stand for any Insert or connect T-adapters in the following manner before starting troubleshooting
priority) 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.
4 • 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 "fe-
male".
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 fol-
lowing manner unless otherwise instructed.
• Connect the positive (+) lead with the pin No. indicated at the front or the wiring har-
5
ness.
• Connect the negative (–) lead with the pin No. indicated at the front or the wiring har-
ness.
20-304 PC200/220(LC)-7
TROUBLESHOOTING 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
(1)
TROUBLESHOOTING E101
Service Code in Electrical System E101 (Abnormal data in Error History)
User Code Service Code Failure Code Failure Abnormal data in the error history
— E101 DAF0KT phenomenon (in Monitor Panel system)
• The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or
Failure content
exceeded 36 V.
Response from
• None in particular
Monitor Panel
Phenomenon
occurring on • A display for information on the failure history (in the electrical system) cannot be called.
machine

If the fuse is blown, there is a big possibility that the circuit has a grounding fault.
1 Fuse No. 17 defective
(Refer to cause 4)
Fusible link No. A35
2 If the fusible link is blown, there is a big possibility that the circuit has a grounding fault.
defective
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.

Disconnection of wiring Wiring harness from P01 (female) (8) to J07 to FB1-17 out- Resistance
Below 1 z
harness let value
3
(Disconnection or Resistance
connector contact fault) Wiring harness between FB1-17 inlet and A35 (male) (2) Below 1 z
value
Wiring harness between A35 (male) (1) and A23 (B termi- Resistance
Below 1 z
nal) value
Grounding fault of wiring Between wiring harness between P01 (female) (8) to J07 Resistance Above
harness and FB1-17 outlet and grounding value 1 Mz
4
(Contact with grounding Between wiring harness between FB1-17 inlet and A35 Resistance Above
circuit) (male) (2) and grounding value 1 Mz
Between wiring harness between A35 (male) (1) and A23 Resistance Above
(B terminal) and grounding value 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
5 Monitor Panel defective
C03 Voltage
Between (8) and (6) (7) 20 – 30 V
20-306 PC200/220(LC)-7
(5)
TESTING AND ADJUSTING E101
Monitor Panel Power Source Electric Circuit Diagram
PC200/220(LC)-7 20-307
Service Code in Electrical System E112

(Short-circuiting in normal rotation system of windshield wiper motor drive)
User Code Service Code Failure Code Failure Short-circuiting in normal rotation system of wind-
— E112 DY2DKB phenomenon shield 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
• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stops moving.
machine

Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between and Continued
Between and grounding Above 1 M
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness for the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) and Resistance
circuit) Above 1 M
W04 (male) and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Below 3 V
Between and grounding Below 3 V 20 – 30 V
ON
(at constant cycle)
20-308 PC200/220(LC)-7
Electric Circuit Diagram for Monitor Panel Windshield Wiper Motor
PC200/220(LC)-7 20-309

(Short-circuiting in reverse rotation system of windshield wiper motor drive)
User Code Service Code Failure Code Failure Short-circuiting in reverse rotation system of wind-
— E113 DY2EKB phenomenon shield wiper motor drive (in Monitor Panel system)
• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the
Failure content
windshield wiper was set in motion.
Response from
• Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stopped moving.
machine

Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
or grounding fault) Between and Continued
Between and grounding Above 1 M
harness for the troubleshooting.
2
circuit) Above 1 M
W04 (male) and grounding value
P01 Windshield wiper switch Voltage
OFF Below 3 V
Between and grounding Below 3 V 20 – 30 V
ON
(at constant cycle)
20-310 PC200/220(LC)-7
Electric Circuit Diagram for Monitor Panel Windshield Wiper Motor
PC200/220(LC)-7 20-311
(1)

(Short-circuiting in window washer drive system)
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
User Code Service Code Failure Code Failure Short-circuiting in window washer drive system
— E114 DY2CKB phenomenon (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was
Failure content
switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Window washer drive tion for the troubleshooting.
1 motor defective
A50 (male) Resistance value
(Internal short-circuiting)
Between (1) and (2) 5 – 20 z
Short-circuiting of wiring for the troubleshooting.
harness Between wiring harness from P01 (female) (3) to J04 to
2
(Contact with 24 V A50 (female) (2) and grounding, or between wiring har-
circuit) Voltage Below 1 V
ness between P01 (female) (3) and D04 (female) (8) and
grounding
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
Between (3) and grounding
ON Below 1 V
20-312 PC200/220(LC)-7
(7)
Monitor Panel Window Washer Motor Electrical Circuit Diagram
PC200/220(LC)-7 20-313
(1)

User Code Service Code Failure Code Failure Short-circuiting in window washer drive system
— E114 DY2CKB phenomenon (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was
Failure content
switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine

Window washer drive tion for the troubleshooting.
1 motor defective
A50 (male) Resistance value
Between (1) and (2) 5 – 20 z
Short-circuiting of wiring for the troubleshooting.
harness Between wiring harness from P01 (female) (3) to J04 to
2
(Contact with 24 V A50 (female) (2) and grounding, or between wiring har-
ness between P01 (female) (3) and D02 (female) (7) and
grounding
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
ON Below 1 V
20-313-1 PC200/220(LC)-7
(11)
Monitor Panel Window Washer Motor Electrical Circuit Diagram
PC200/220(LC)-7 20-313-2
(5)
Service Code in Electrical System E115 (Abnormal windshield wiper motion)
User Code Service Code Failure Code Failure Abnormal operation of windshield wiper
— E115 DY20KA phenomenon (in Monitor Panel system)
Failure content • A W signal is not inputted at both ends of movement, when it is in motion.
Response from
• Power to the windshield wiper motor is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper motor does not work.
machine
Relative • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)

tion for the troubleshooting.
Windshield wiper motor W04 (female) Windshield wiper blade Resistance value
1 defective At upper end of operation
(Internal disconnection) Below 1 z
range
Between (6) and (5)
Outside upper end of
Above 1 Mz
operation range
Disconnection of wiring tion for the troubleshooting.
harness Wiring harness between P01 (female) (5) and W04 (male) Resistance
2 Below 1 z
(Disconnection or faulty (6) value
contact with connector) Resistance
Wiring harness between W04 (male) (5) and grounding Below 1 z
value
P01 Windshield wiper blade Voltage
3 Monitor panel defective At upper end of operation
Below 1 V
range
Outside upper end of
20 – 30 V
operation range
20-314 PC200/220(LC)-7
(5)
Monitor Panel Windshield Wiper Motor Electrical Circuit Diagram
PC200/220(LC)-7 20-315
Service Code in Electrical System E116 (Abnormality in retracting windshield wiper)
User Code Service Code Failure Code Failure Abnormal operation of retracting windshield wiper
— E116 DY20MA phenomenon (in Monitor Panel system)
Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is
Monitor Panel retracted.
Phenomenon
occurring on • The windshield wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No. 049: Monitor Input 3)


Windshield wiper motor
1 defective W04 (female) Windshield wiper blade Resistance value
(Internal disconnection) Retraction range Below 1
Between and
Operation range Above 1 M
Disconnection of wiring during the troubleshooting.
harness
Wiring harness between P01 (female) and W04 (male) Resistance
2 (Disconnection or defec- Below 1
value
tive contact with connec-
tor) Resistance
Between wiring harness W04 (male) and grounding Below 1
value
during the troubleshooting.
3 Monitor panel defective P01 Windshield wiper blade Voltage
Retraction range Below 1V
Between and grounding
Operation range 20 – 30 V
20-316 PC200/220(LC)-7
Monitor Panel Windshield Wiper Motor Electrical Circuit Diagram
PC200/220(LC)-7 20-317
(1)

(Short-circuiting in travel interlocking solenoid)
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
User Code Service Code Failure Code Failure Short-circuiting in travel interlocking solenoid
— E201 DW91KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
• Power supply to the travel interlocking circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
• It is difficult to steer the machine at turns.
occurring on
(The right and left travel circuits are not separated from each other)
machine
Relative • Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid)

Travel interlocking sole- tion during the troubleshooting.
noid defective V02 (male) Resistance value
1
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
Assembled-type diode tion during the troubleshooting.
2 D03 defective
D03 (male) Resistance value
Between (3) and (7) Above 1 Mz
Grounding fault of wiring tion during the troubleshooting.
harness Between wiring harness from C03 (female) (7) to J06 to
3
(Contact with grounding V02 (female) (1) and grounding, or between wiring har- Resistance
circuit) Above 1 Mz
ness between C03 (female) (7) and D03 (female) (3) and value
grounding
a Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Travel control lever Voltage
4
controller defective
Straight forward Below 1 V
Steering 20 – 30 V
20-318 PC200/220(LC)-7
(7)
Electrical Circuit for Travel Interlocking Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-319
(1)

User Code Service Code Failure Code Failure Short-circuiting in travel interlocking solenoid
Failure content • Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
• Power supply to the travel interlocking circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
Phenomenon
• It is difficult to steer the machine at turns.
occurring on
machine
Relative • Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid)

Travel interlocking sole- tion during the troubleshooting.
noid defective V02 (male) Resistance value
1
harness
2 Between wiring harness from C03 (female) (7) to V02
(Contact with grounding Resistance
circuit) (female) (1) and grounding, or between wiring harness Above 1 Mz
value
between C03 (female) (7) and grounding
troubleshooting.
3
Straight forward Below 1 V
Steering 20 – 30 V
20-319-1 PC200/220(LC)-7
(7)
Electrical Circuit for Travel Interlocking Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-319-2
(5)

(Short-circuiting in swing holding brake solenoid)
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
User Code Service Code Failure Code Failure Short-circuiting in swing holding brake solenoid (in
E03 E203 DW45KB phenomenon governor • pump controller system)
• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the cir-
Failure content
cuit.
• Power supply to the swing holding brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing holding brake does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The upper structure cannot swing. (The swing holding brake is not released)
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the emergency swing brake releasing switch to the FREE position.
(In this case, however, the swing holding brake does not work, when stopping the machine)

Swing holding brake tion during the troubleshooting.
solenoid defective V05 (male) Resistance value
1
2 D03 defective
harness Wiring harness from C03 (female) (37) to D01 to J02 to
3
(Contact with grounding X05 to J06 to V05 (female) (1), or between wiring harness Resistance
circuit) Above 1 Mz
between C03 (female) (37) and D03 (female) (4) and value
grounding
troubleshooting.
Governor • pump C03 Swing control lever Voltage
4
NEUTRAL Below 1 V
Swing 20 – 30 V
20-320 PC200/220(LC)-7
(7)
Electrical Circuit Diagram for Swing Holding Brake of Governor • Pump Controller
PC200/220(LC)-7 20-321
(1)

User Code Service Code Failure Code Failure Short-circuiting in swing holding brake solenoid (in
E03 E203 DW45KB phenomenon governor • pump controller system)
• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the cir-
Failure content
cuit.
• Power supply to the swing holding brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing holding brake does not return to normalcy,
controller
Phenomenon
occurring on • The upper structure cannot swing. (The swing holding brake is not released)
machine
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the emergency swing brake releasing switch to the FREE position.
(In this case, however, the swing holding brake does not work, when stopping the machine)

Swing holding brake tion during the troubleshooting.
1
harness
2 Wiring harness from C03 (female) (37) to D01 to J02 to
circuit) X05 to V05 (female) (1), or between wiring harness Above 1 Mz
value
between C03 (female) (37) and grounding
troubleshooting.
3
NEUTRAL Below 1 V
Swing 20 – 30 V
20-321-1 PC200/220(LC)-7
(7)
Electrical Circuit Diagram for Swing Holding Brake of Governor • Pump Controller
PC200/220(LC)-7 20-321-2
(5)
Service Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)

PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
User Code Service Code Failure Code Failure Short-circuiting in merge/divide solenoid
— E204 DWJ0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy, un-
controller
less the engine starting switch is once turned OFF.
Phenomenon
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
occurring on
(Front and rear pumps are not separated)
machine
Relative • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)

Merge/divide solenoid tion during the troubleshooting.
defective V03 (male) Resistance value
1
2 D03 defective
harness
3 Wiring harness from C03 (female) (17) to J06 to V03
circuit) (female) (1), or between wiring harness between C03 Above 1 Mz
value
(female) (17) and D03 (female) (1) and grounding
troubleshooting.
4
controller defective NEUTRAL Below 1 V
Between (17) and grounding When operating one side
20 – 30 V
only
20-322 PC200/220(LC)-7
(7)
Electrical Circuit Diagram for Merge/Divide Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-323
(1)

User Code Service Code Failure Code Failure Short-circuiting in merge/divide solenoid
— E204 DWJ0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy, un-
controller
less the engine starting switch is once turned OFF.
Phenomenon
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
occurring on
machine
Relative • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.


1
harness
2 Wiring harness from C03 (female) (17) to V03 (female)
circuit) (1), or between wiring harness between C03 (female) (17) Above 1 Mz
value
and grounding
troubleshooting.
3
controller defective NEUTRAL Below 1 V
Between (17) and grounding When operating one side
20 – 30 V
only
20-323-1 PC200/220(LC)-7
(7)
PC200/220(LC)-7 20-323-2
(5)
Service Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)

PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
User Code Service Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E205 DWK0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
Phenomenon
occurring on • The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

2-stage relief solenoid tion during the troubleshooting.
defective
1 V06 (male) Resistance value

2 D03 defective
harness
value
Governor • pump C03 Working mode Voltage
4
Other than L mode Below 1 V
L mode 20 – 30 V
20-324 PC200/220(LC)-7
(5)
Electric Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-325
(1)

User Code Service Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E205 DWK0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
controller
Phenomenon
occurring on • The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

1
harness
value
and grounding
3
Other than L mode Below 1 V
L mode 20 – 30 V
20-325-1 PC200/220(LC)-7
(7)
Electric Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-325-2
(5)

(Short-circuiting in travel speed shifting solenoid)
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
User Code Service Code Failure Code Failure Short-circuiting in travel speed shifting solenoid
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The travel motor swash plate angle is not set to the minimum)
machine
Relative • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.

Travel speed shifting tion during the troubleshooting.
1
2 D04 defective
harness
value
troubleshooting.
Governor • pump Travel speed &
4 C03 Voltage
controller defective Travel lever
Lo + Neutral Below 1 V
Hi + Travel 20 – 30 V
20-326 PC200/220(LC)-7
(7)
Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-327
(1)

User Code Service Code Failure Code Failure Short-circuiting in travel speed shifting solenoid
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The travel motor swash plate angle is not set to the minimum)
machine
Relative • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.


1
harness
value
and grounding
troubleshooting.
Governor • pump Travel speed &
3 C03 Voltage
controller defective Travel lever
Lo + Neutral Below 1 V
Hi + Travel 20 – 30 V
20-327-1 PC200/220(LC)-7
(7)
PC200/220(LC)-7 20-327-2
(5)
Service Code in Electrical System E211 (Disconnection in travel interlocking solenoid)

PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
User Code Service Code Failure Code Failure Disconnection in travel interlocking solenoid
— E211 DW91KA phenomenon (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 • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• It is difficult to steer the machine while traveling.
occurring on
machine
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information a 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].)

Travel interlocking tion during the troubleshooting.
1 solenoid defective
V02 (male) Resistance value

(Internal disconnection)
Between (1) and (2) 20 – 60 z
Disconnection of wiring tion during the troubleshooting.
harness
Wiring harness from C03 (female) (7) to J06 to V02 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tor) Resistance
Wiring harness between V02 (female) (2) and grounding Below 1 z
value
Short-circuiting of wiring during the troubleshooting.
harness
(Contact with 24 V cir-
cuit) (female) (1), or between wiring harness C03 (female) (7) Voltage Below 1 V
and D03 (female) (3) and grounding
Governor • pump tion during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (7) and grounding 20 – 60 z
20-328 PC200/220(LC)-7
(7)
Electrical Circuit Diagram for Travel Interlocking Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-329
(1)

User Code Service Code Failure Code Failure Disconnection in travel interlocking solenoid
Failure content • No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
Phenomenon
• It is difficult to steer the machine while traveling.
occurring on
machine
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.

Travel interlocking tion during the troubleshooting.

Between (1) and (2) 20 – 60 z
harness
Resistance
2 (Disconnection or defec- Wiring harness from C03 (female) (7) to V02 (female) (1) Below 1 z
value
tor) Wiring harness between C03 (female) (3) (13) (23) and Resistance
Below 1 z
V02 (female) (2) value
harness
3 Wiring harness from C03 (female) (7) to V02 (female) (1),
cuit) or between wiring harness C03 (female) (7) and ground- Voltage Below 1 V
ing
4
20-329-1 PC200/220(LC)-7
(7)
Electrical Circuit Diagram for Travel Interlocking Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-329-2
(5)

(Disconnection in swing holding brake solenoid)
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
User Code Service Code Failure Code Failure Disconnection in swing holding brake solenoid
E03 E213 DW45KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
Phenomenon
occurring on • The machine's upper structure does not swing. (The swing holding brake is not released)
machine
• 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
Relative
parking brake does not work, when stopping the machine)
information
a While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in
the OFF position.
a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
Swing holding brake a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
solenoid defective during the troubleshooting.
1
(Internal disconnec- V05 (male) Resistance value
tion) Between (1) and (2) 20 – 60 z
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
(Internal disconnec-
tion) OFF Below 1 z
Between (3) and (4)

LOCK Above 1 Mz
Assembled-type a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 defective during the troubleshooting.
3
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion) Between (7) and (3) Diode mode Continued
Resistance
Disconnection of Wiring harness between C03 (female) (37) and D01 (female) (7) Below 1 z
value
wiring harness
Resistance
4 (Disconnection or Wiring harness from D01 (female) (3) to J02 to X05 (male) (3) Below 1 z
value
defective contact
with connector) Resistance
Wiring harness from X05 (male) (4) to J06 to V05 (female) (1) Below 1 z
value
Resistance
value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Wiring harness ing the troubleshooting.
5
(Contact with 24V Between wiring harness between C03 (female) (37) and D01
(female) (7) and grounding
Governor • pump during the troubleshooting.
6
controller defective C03 (female) Disconnect D01 and connect pins Resistance value
Between (37) and grounding (3) and (7) of the female side. 20 – 60 z
20-330 PC200/220(LC)-7
(7)
Electrical Circuit Diagram for Swing Holding Brake Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-331
(5)

User Code Service Code Failure Code Failure Disconnection in swing holding brake solenoid
E03 E213 DW45KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Phenomenon
occurring on • The machine's upper structure does not swing. (The swing holding brake is not released)
machine
• 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
Relative
parking brake does not work, when stopping the machine)
information
a While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in
the OFF position.
a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
Swing holding brake a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
solenoid defective during the troubleshooting.
1
(Internal disconnec- V05 (male) Resistance value
tion) Between (1) and (2) 20 – 60 z
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
tion) OFF Below 1 z
Between (3) and (4)
LOCK Above 1 Mz
diode D01 defective during the troubleshooting.
3
Resistance
Disconnection of Wiring harness between C03 (female) (37) and D01 (female) (7) Below 1 z
value
wiring harness
Resistance
4 (Disconnection or Wiring harness from D01 (female) (3) to J02 to X05 (male) (3) Below 1 z
value
defective contact
Wiring harness from X05 (male) (4) to V05 (female) (1) Below 1 z
value
Wiring harness between C03 (female) (3) (13) (23) and V05 Resistance
Below 1 z
(female) (2) value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Wiring harness ing the troubleshooting.
5
(Contact with 24V Between wiring harness between C03 (female) (37) and D01
Governor • pump
6 C03 (female) Resistance value
controller defective Disconnect D01 and connect pins
Between (37) and (3) (13) (3) and (7) of the female side. 20 – 60 z
(23)
20-331-1 PC200/220(LC)-7
(7)
Electrical Circuit Diagram for Swing Holding Brake Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-331-2
(5)
Service Code in Electrical System E214 (Disconnection of merge/divide solenoid)

PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
User Code Service Code Failure Code Failure Disconnection in merge/divide solenoid
— E214 DWJ0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Phenomenon
• In L mode, speeds of the work equipment and swing in its single operation are too fast
occurring on
machine
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.

1 defective

Between (1) and (2) 20 – 60 z
harness
2 (Disconnection or defec- Below 1 z
(female) (1) value
tor) Resistance
value
harness
cuit) (female) (1), or between wiring harness between C03 Voltage Below 1 V
4
20-332 PC200/220(LC)-7
(7)
PC200/220(LC)-7 20-333
(1)

User Code Service Code Failure Code Failure Disconnection in merge/divide solenoid
— E214 DWJ0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Phenomenon
• In L mode, speeds of the work equipment and swing in its single operation are too fast
occurring on
machine
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.

1 defective
Between (1) and (2) 20 – 60 z
harness
Resistance
2 (Disconnection or defec- Wiring harness from C03 (female) (17) to V03 (female) (1) Below 1 z
value
Below 1 z
Short-circuiting of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
3
(Contact with 24 V cir- Wiring harness from C03 (female) (17) to V03 (female) (1)
cuit) Voltage Below 1 V
and grounding
4
Between (17) and (3) (13) (23) 20 – 60 z
20-333-1 PC200/220(LC)-7
(7)
PC200/220(LC)-7 20-333-2
(5)
Service Code in Electrical System E215 (Disconnection in 2-stage relief solenoid)

PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
User Code Service Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E215 DWK0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Phenomenon
• The one-touch power max. switch does not work.
occurring on
(The main relief valve cannot be set to high-pressure set)
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

1 defective

Between (1) and (2) 20 – 60 z
harness
2 (Disconnection or defec- Max. 1 z
(female) (1) value
tor) Resistance
Wiring harness between V06 (female) (2) and grounding Max. 1 z
value
harness
cuit) (female) (1), or between wiring harness between C03 Voltage Max. 1 V
4
20-334 PC200/220(LC)-7
(7)
Electrical Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-335
(1)

User Code Service Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E215 DWK0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Phenomenon
• The one-touch power max. switch does not work.
occurring on
(The main relief valve cannot be set to high-pressure set)
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

1 defective
Between (1) and (2) 20 – 60 z
harness
Wiring harness between C03 (female) (28) and V06 Resistance
(female) (1) value
Max. 1 z
3
cuit) Voltage Max. 1 V
and grounding
4
Between (28) and (3) (13) (23) 20 – 60 z
20-335-1 PC200/220(LC)-7
(7)
Electrical Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-335-2
(5)

(Disconnection in travel speed shifting solenoid)
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
User Code Service Code Failure Code Failure Disconnection in travel speed shifting solenoid
Failure content • No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Phenomenon
• The travel speed does not shift to Hi.
occurring on
(The travel motor swash plate angle does not turn to minimum)
machine
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.


Between (1) and (2) 20 – 60 z
harness
(female) (1) value
tor) Resistance
value
harness
cuit) (female) (1), or between wiring harness between C03 Voltage Max. 1 V
4
20-336 PC200/220(LC)-7
(7)
PC200/220(LC)-7 20-337
(1)

User Code Service Code Failure Code Failure Disconnection in travel speed shifting solenoid
Failure content • No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Phenomenon
• The travel speed does not shift to Hi.
occurring on
(The travel motor swash plate angle does not turn to minimum)
machine
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.

Between (1) and (2) 20 – 60 z
harness
Wiring harness between C03 (female) (27) and V04 Resistance
(female) (1) value
Max. 1 z
V04 (female) (2) and grounding value
3
and grounding
4
Between (27) and (3) (13) (23) 20 – 60 z
20-337-1 PC200/220(LC)-7
(7)
PC200/220(LC)-7 20-337-2
(5)
Service Code in Electrical System E217 (Abnormality in inputting model code)

PC200-7
User Code Service Code Failure Code Failure Abnormality in inputting model code
— E217 DA2SKQ phenomenon (in governor • pump controller system)
Failure content • A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC200).
Response from
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • None in particular with PC200 model
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
Relative function. (Code No. 002 and 003: Controller Model Code)
information a Input of model selecting signals (ON or OFF) can be confirmed in the monitoring
function.(Code No. 027:Switch Input 2)

Model selecting connection during the troubleshooting.
tor defective C09 (female) Resistance value
1
(Internal disconnection
or short-circuiting) Between (3) and (8) Max. 1 z
Between (1), (2), (4) or (7) and (8) Min. 1 Mz

harness
Wiring harness between C02 (female) (17) and C09 Resistance
(male) (3) value
tor) Between wiring harness between C09 (male) (8) and J05 Resistance
Max. 1 z
and grounding value
tion during the troubleshooting.
Between wiring harness between C02 (female) (7) and Resistance
Min. 1 Mz
Grounding fault of wiring C09 (male) (4) and grounding value
harness Between wiring harness between C02 (female) (13) and Resistance
3 Min. 1 Mz
(Contact with grounding C09 (male) (7) and grounding value
circuit) Between wiring harness between C02 (female) (27) and Resistance
Min. 1 Mz
C09 (male) (2) and grounding value
Min. 1 Mz
Governor • pump C02 Voltage
4
controller defective Between (7), (13), (27) or (37) and
20 – 30 V
grounding
Between (17) and grounding Max. 1 V
20-338 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for Model Selecting Connector in Governor • Pump Controller
PC200-7
PC200/220(LC)-7 20-339
(1)
PC220-7
User Code Service Code Failure Code Failure Abnormality in inputting model code
— E217 DA2SKQ phenomenon (in governor • pump controller system)
Failure content • A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC200).
Response from
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
Phenomenon
occurring on • None in particular with PC200 model
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
Relative function. (Code No. 002 and 003: Controller Model Code)
information a Input of model selecting signals (ON or OFF) can be confirmed in the monitoring
function.(Code No. 027:Switch Input 2)

Model selecting connection during the troubleshooting.
tor defective C09 (female) Resistance value
1
(Internal disconnection
or short-circuiting) Between (1), (3) and (8) Max. 1 z
Between (2), (4) or (7) and (8) Min. 1 Mz
Disconnection of wiring Wiring harness between C02 (female) (37) and C09 Resistance
harness Max. 1 z
(male) (1) value
2 (Disconnection or defec-
tive contact with connec- Wiring harness between C02 (female) (17) and C09 Resistance
Max. 1 z
tor) (male) (3) value
Between wiring harness between C09 (male) (8) and J05 Resistance
Max. 1 z
and grounding value
Grounding fault of wiring Between wiring harness between C02 (female) (7) and Resistance
Min. 1 Mz
harness C09 (male) (4) and grounding value
3
(Contact with grounding Between wiring harness between C02 (female) (13) and Resistance
circuit) Min. 1 Mz
Min. 1 Mz
4
Between (7), (13) or (27) and grounding 20 – 30 V
Between (37), (17) and grounding Max. 1 V
20-340 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for Model Selecting Connector in Governor Pump Controller
PC220-7
PC200/220(LC)-7 20-341
Service Code in Electrical System E218 Disconnection of S-NET signal)
User Code Service Code Failure Code Failure Disconnection in S-NET signal
— E218 DA2SKA phenomenon (in governor • pump controller system)
• A failure occurred in S-NET communication between the monitor and controller in the past.
Failure content
(The machine operation returned to normalcy, when the display was resumed)
• While the failure is still continuing, the machine operation is controlled by the following default setting.
1) Working mode: E mode
Response from 2) Travel speed: Lo
controller 3) Auto-decelerator: ON
4) Attachment oil flow rate: Minimum ( )
• When the failure cause disappears of itself, the machine operation returns to normalcy.
• The working mode cannot be changed. (The display changes normally in the monitor panel)
Phenomenon
• The travel speed cannot be shifted. (The display changes normally in the monitor panel)
occurring on
• The auto-decelerator cannot be released. (The display changes normally in the monitor panel)
machine
• The attachment oil flow rate cannot be changed. (The display changes normally in the monitor panel) ( )
• 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.
Relative
• The communication has already returned to normalcy by the time this Service Code No. is displayed.
information
But thoroughly diagnose all the related equipment and circuits, and remove all potential causes for a
failure in order to prevent recurrence of failures.

Disconnection of wiring during the troubleshooting.
harness Wiring harness between P02 (female) and C02 Resistance
1 (Disconnection or defec- Below 1
(female) value
tor) Wiring harness between P02 (female) and C02 Resistance

Below 1
(female) value
2
circuit) Above 1 M
C02 (female) and grounding value
Short-circuiting of wiring Turn the engine starting switch OFF for the preparations, and hold it in the ON position
3
(Contact with 24 V cir- Between wiring harness between P02 (female) and
cuit) Voltage Below 1 V
C02 (female) and grounding
4 Monitor panel defective P02 (male) Voltage
Between and 6–9V
Governor • pump
5 C02 (male) Voltage
Between and 6–9V
20-342 PC200/220(LC)-7
Electrical Circuit Diagram for S-NET Communication between Monitor Panel and Governor • Pump
Controller
PC200/220(LC)-7 20-343
(1)
Service Code in Electrical System E222 (Short-circuiting in LS-EPC solenoid)
User Code Service Code Failure Code Failure Disconnection in LS-EPC solenoid
— E222 DXE0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the LS-EPC solenoid circuit.
• The controller reduces the output to the LS-EPC solenoid circuit to 0.
Response from
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
• The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too
occurring on
fast. (The LS valve set pressure cannot be controlled)
machine
Relative • Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No. 015: LS-EPC solenoid current)

LS-EPC solenoid defec- tion during the troubleshooting.
tive V22 (male) Resistance value
1
Between (1) and grounding Min. 1 Mz
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
circuit) Min. 1 Mz
Governor • pump C03 (female) Resistance value
3
Between (6) and (3) (13) (23) 7 – 14 z
Electrical Circuit Diagram for LS-EPC Solenoid in Governor • Pump Controller
20-344 PC200/220(LC)-7
(5)
Service Code in Electrical System E223 (Disconnection in LS-EPC solenoid system)
User Code Service Code Failure Code Failure Disconnection in LS-EPC solenoid
— E223 DXE0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the LS-EPC solenoid circuit.
Phenomenon
• The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too
occurring on
fast. (The LS valve set pressure cannot be controlled)
machine
Relative • Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No. 015: LS-EPC solenoid current)

LS-EPC solenoid defec- tion during the troubleshooting.
1 tive
Between (1) and (2) 7 – 14 z
harness
Max. 1 z
3
(Contact with 24 V cir- Between wiring harness between C03 (female) (6) and
V22 (female) (1) and grounding
4
Between (6) and (3) (13) (23) 7 – 14 z
Electrical Circuit Diagram for LS-EPC Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-345
(5)
Service Code in Electrical System E224 (Abnormality in F pump pressure sensor)
User Code Service Code Failure Code Failure Abnormality in F pump pressure sensor
— E224 DHPAMA phenomenon (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 • The controller controls the F pump pressure at 0 MPa{0 kg/cm2}.
controller • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on • The travel speed does not shift automatically.
machine
Relative • Input from the F pump pressure sensor (pressure) can be confirmed in the monitor function.
information (Code No. 011: F pump pressure)

Sensor power source
1 If the Service Code No. [E226] is displayed, troubleshoot the failure first.
fault
a Turn the engine starting switch OFF for the preparations, and keep the engine running
A51 Voltage
F pump pressure sensor
Between (B) and (A) Power supply 4.5 – 5.5 V
2 defective
(Internal failure) Between (C) and (A) Signal 0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected.
Accrdinaly, if the voltage is abnormal, check the wiring harness and controller, too, for
another cause of the trouble, and then judge.

Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to A51 Resistance
harness Max. 1 z
(female) (B) value
tive contact with connec- Wiring harness between C01 (female) (10) and A51 Resistance
Max. 1 z
tor) (female) (A) value
Wiring harness between C01 (female) (8) and A51 Resistance
Max. 1 z
(female) (C) value
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
4
circuit) Min. 1 Mz
A51 (female) (C) and grounding value
harness Between wiring harness between C01 (female) (22), J07
5 Voltage Max. 1 V
(Contact with 24 V cir- and A51 (female) (B) and grounding
cuit) Between wiring harness between C01 (female) (8) and
Voltage Max. 1 V
A51 (female) (C) ang grounding
6
Between (22) and (10) Power supply 4.5 – 5.5 V
Between (8) and (10) Signal 0.5 – 4.5 V
20-346 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for F Pump Pressure Sensor in Governor • Pump Controller
PC200/220(LC)-7 20-347
(1)
Service Code in Electrical System E225 (Abnormality in R pump pressure sensor)
User Code Service Code Failure Code Failure Abnormality in R pump pressure sensor
— E225 DHPBMA phenomenon (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 • The controller controls the R pump pressure as 0 MPa {0 kg/cm2}.
controller • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on • The travel speed does not shift automatically.
machine
Relative • Input from the R pump pressure sensor (pressure) can be confirmed in the monitor function.
information (Code No. 012: R pump pressure)

Sensor power source
1 If the Service Code No. [E226] is displayed, troubleshoot the failure first.
fault
A52 Voltage
R pump pressure sen-
Between (B) and (A) Power supply 4.5 – 5.5 V
2 sor defective
(Internal failure) Between (C) and (A) Signal 0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected.
Accrdinaly, if the voltage is abnormal, check the wiring harness and controller, too, for
another cause of the trouble, and then judge.

Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to A52 Resistance
harness Max. 1 z
(female) (B) value
tive contact with connec- Wiring harness between C01 (female) (10) and A52 Resistance
Max. 1 z
tor) (female) (A) value
Wiring harness between C01 (female) (2) and A52 Resistance
Max. 1 z
(female) (C) value
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
4
circuit) Min. 1 Mz
A52 (female) (C) and grounding value
harness Between wiring harness between C01 (female) (22), J07
5 Voltage Max. 1 V
(Contact with 24 V cir- and A52 (female) (B) and grounding
Voltage Max. 1 V
A52 (female) (C) and grounding
6
20-348 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for R Pump Pressure Sensor in Governor • Pump Controller
PC200/220(LC)-7 20-349
(1)
Service Code in Electrical System E226 (Abnormality in pressure sensor power source)
User Code Service Code Failure Code Failure Abnormality in pressure sensor power source
— E226 DA25KP phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the power source circuit (5 V) for the pressure sensors and potentiometer.
• The controller turns OFF power supply to the power source circuit (5 V).
Response from
• Even when the failure cause disappears of itself, the current does not return to normalcy, unless the en-
controller
gine starting switch is once turned OFF.
Phenomenon • Signals from the pressure sensors and potentiometer are not inputted correctly.
occurring on • The Service Code of "pressure sensor abnormal" and that of "potentiometer abnormal" are displayed at
machine the same time.

a Turn the engine starting switch OFF for the preparations,
Disconnect the parts and hold it in the ON position during the troubleshooting.
shown at right in order.
Pressure sensor or Fuel dial E06 Connector
If the error code goes off
1 potentiometer defective
when one of those parts Governor motor potentiometer E10 Connector
(Internal short-circuit)
is disconnected, that part F pump pressure sensor A51 Connector
is defective.
R pump pressure sensor A52 Connector

Between wiring harness from C01 (female) (22) to J07 to Resistance
Min. 1 Mz
E06 (female) (1) and grounding [Fuel dial system] value
Between wiring harness from C01 (female) (22) to J07 to
Resistance
E10 (female) (A) and grounding Min. 1 Mz
value
Grounding fault of wiring [Governor potentiometer system]
2 Resistance
(Contact with grounding A51 (female) (B) and grounding Min. 1 Mz
circuit) value
[F pump pressure sensor system]
Resistance
A52 (female) (B) and grounding Min. 1 Mz
value
[R pump pressure sensor system]
Resistance
A08 (male) (7) and grounding Min. 1 Mz
value
[Attachment system]
Governor • pump during the troubleshooting.
3
controller defective C01 Voltage
Between (22) and (10) (21) 4.5 – 5.5 V
20-350 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for Sensor Power Source in Governor • Pump Controller
PC200/220(LC)-7 20-351
(1)

(Abnormality in engine rotation sensor)
User Code Service Code Failure Code Failure Abnormality in engine rotation sensor
— E227 DLE2MA phenomenon (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 • The controller exercises a control equivalent to E mode.
controller • If the failure cause disappears of itself, the signal input returns to normalcy.
Phenomenon
occurring on • The machine lacks power a bit.
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine RPM)

Engine rotation sensor tion during the troubleshooting.
fault E04 (male) Resistance value
1
Between (1) and (2) 500 – 1,000 z
or disconnection)
Engine rotation sensor For the inspection and adjustment, refer to the section of "Adjusting Engine Rotation
2
adjustment improper Sensor" in this manual.
harness
Wiring harness between C02 (female) (40) and E04 Resistance
(female) (1) value
tor) Wiring harness between C02 (female) (29) (39) and E04 Resistance
Max. 1 z
(female) (2) value
4
E04 (female) (1) and grounding
5
Between (40) and (29) (39) 500 – 1,000 z
Electrical Circuit Diagram for Engine Rotation Sensor of Governor • Pump Controller
20-352 PC200/220(LC)-7
(5)

(Short-circuiting in attachment return switching relay)
User Code Service Code Failure Code Failure Short-circuiting in attachment return switching relay
— E228 D196KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power ON).
Response from • The controller turned OFF power to the attachment return switching relay circuit.
controller • Even when the failure cause disappears of itself, the current does not return to normalcy.
Phenomenon
• The hydraulic circuit for attachments is not switched to the single operation circuit.
occurring on
(The switching valve is not switched to the tank circuit)
machine
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
Relative or OFF). (Code No. 024:Solenoid 2)
information • This error code detects abnormality on the primary side (coil side) of the attachment return selector relay
and cannot detect abnormality on the secondary side (contact side).

Attachment return tion during the troubleshooting.
1 switching relay defective
R20 (male) Resistance value
Between (1) and (2) 100 – 500 z
2
R20 (female) (2) and grounding
3
controller defective Other than B mode 20 – 30 V
B mode Max. 1 V
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC200/220(LC)-7 20-353
(5)
Service Code in Electrical System E232 (Short-circuiting in PC-EPC solenoid)
User Code Service Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E232 DXA0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the PC-EPC solenoid circuit.
• The controller reduces the output to the PC-EPC solenoid circuit to 0.
Response from
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
Phenomenon
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
occurring on
(The pump absorption torque cannot be controlled)
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative • If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated
information 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)
a Turn the emergency driving switch ON during the troubleshooting.

PC-EPC solenoid defec- tion during the troubleshooting.
tive V21 (male) Resistance value
1
Between (1) and (2) 7 – 14 z
or grounding fault)
Emergency pump driving
switch defective Emergency pump
2 S25 (male) Resistance value
(Internal short-circuiting drive switch
or grounding fault) Between (3) and (4) Min. 1 Mz
Normal
harness Between wiring harness from C03 (female) (16) to S25 Resistance
3 Min. 1 Mz
(Contact with grounding (female) (3) and grounding value
circuit) Between wiring harness from S25 (female) (2) to V21 Resistance
Min. 1 Mz
(female) (1) and grounding value
4
Between (16) and (3) (13) (23) 7 – 14 z
20-354 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for PC-EPC Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-355
(1)
Service Code in Electrical System E233 (Disconnection in PC-EPC solenoid system)
User Code Service Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E233 DXA0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the PC-EPC solenoid circuit.
controller • When the failure cause disappears of itself, the current returns to normalcy.
Phenomenon
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
occurring on
(The pump absorption torque cannot be controlled)
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative
• If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated
information
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)

PC-EPC solenoid tion during the troubleshooting.
1 defective
Between (1) and (2) 7 – 14 z
Emergency pump
S25 Resistance value
Emergency pump driving driving switch
2 switch defective Normal Max. 1 z
(Internal disconnection) Between (2) and (5)

Emergency Min. 1 Mz
Normal Max. 1 z
Between (5) and (6)
Emergency Min. 1 Mz
Wiring harness between C03 (female) (16) and S25 Resistance
Disconnection of wiring Max. 1 z
(female) (3) value
harness
Wiring harness between S25 (female) (2) and V21 Resistance
3 (Disconnection or Max. 1 z
(female) (1) value
defective contact with
connector) Wiring harness between C03 (female) (3) (13) (23) and Resistance
Max. 1 z
S25 (female) (6) value
Wiring harness between S25 (female) (5) and V21 Resistance
Max. 1 z
(female) (2) value
harness Between wiring harness between C03 (female) (16) and
4 Voltage Max. 1 V
(Contact with 24 V cir- S25 (female) (3) and grounding
cuit) Between wiring harness between S25 (female) (2) and
Voltage Max. 1 V
5
Between (16) and (3) (13) (23) 7 – 14 z
20-356 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for PC-EPC Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-357
(1)

(Disconnection in attachment return switching relay)
User Code Service Code Failure Code Failure Disconnection in attachment return switching relay
— E238 D196KA phenomenon (in governor • pump controller system)
• When the attachment switching relay circuit is disconnected from grounding (power OFF), 24 V voltage
Failure content
is not generated.
Response from • None in particular
controller • If the failure cause disappears, the governor returns to normalcy.
Phenomenon
• The hydraulic circuit for attachments cannot be switched to the single operation
occurring on
(The switch valve cannot be switched to the tank circuit)
machine
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
Relative or OFF). (Code No. 024:Solenoid 2)
information This error code detects abnormality on the primary side (coil side) of the attachment return selector relay
and cannot detect abnormality on the secondary side (contact side).

If the fuse has been blown, there is a big possibility that grounding fault occurred in the
1 Fuse No. 2 fault
relay circuit. (Refer to cause 4)
Attachment return tion during the troubleshooting.
2 switching relay defective
R20 (male) Resistance value

Between (1) and (2) 100 – 500 z
harness
Wiring harness between C02 (female) (8) and R20 Resistance
(female) (2) value
defective contact with
connector) Wiring harness from R20 (female) (1) to J03 to FB1-2 Resistance
Max. 1 z
outlet value
harness Between wiring harness between C02 (female) (8) and Resistance
4 Min. 1 Mz
(Contact with grounding R20 (female) (2) and grounding value
circuit) Between wiring harness from R20 (female) (1) to J03 to Resistance
Min. 1 Mz
FB1-2 outlet and grounding value
5
Other than B mode 20 – 30 V
B mode Max. 1 V
20-358 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid in Governor • Pump
Controller
PC200/220(LC)-7 20-359
(1)
Service Code in Electrical Equipment E245

(Short-circuiting in attachment oil flow rate adjusting EPC)
User Code Service Code Failure Code Failure Short-circuiting in attachment oil flow rate adjusting
— E245 DXE4KB phenomenon EPC (in governor • pump controller system)
Failure content • Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
• The controller reduces to zero (0) power to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from
• Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless
controller
Phenomenon
occurring on • The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve)
machine
Relative • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)

Attachment oil flow rate tion during the troubleshooting.
adjusting EPC defective V30 (male) Resistance value
1
2
circuit) Min. 1 Mz
3
Between (26) and (3) (13) (23) 7 – 14 z
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor • Pump
Controller
20-360 PC200/220(LC)-7
(5)

(Disconnection in attachment oil flow rate adjusting EPC) (Multi-monitor only)
User Code Service Code Failure Code Failure Disconnection in attachment oil flow rate adjusting
— E246 DXE4KA phenomenon EPC (in governor • pump controller system)
Failure content • No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from • None in particular (The solenoid does not work, as there is no current flowing to it)
controller • If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself.
Phenomenon
occurring on • The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve)
machine
Relative • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)
Attachment oil flow rate a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
adjusting EPC defective

1
(Internal short-circuiting V30 (male) Resistance value
harness
V30 (male) (1) and grounding value
tor) Between wiring harness between C03 (female) (3) (13) Resistance
Max. 1 z
(23) and V30 (male) (2) and grounding value
3
4
Between (26) and (3) (13) (23) 7 – 14 z
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor • Pump
Controller
PC200/220(LC)-7 20-361
(5)
Service Code in Electrical System E256 (Incorrect nonvolatile memory data)
User Code Service Code Failure Code Failure Incorrect nonvolatile memory data
— E256 DA20KT phenomenon (in governor • pump controller)
Failure content • The data in the nonvolatile memory in the controller cannot be updated.
Response from
• Even if the failure cause disappears, the nonvolatile memory does not return to normalcy, unless the
controller
Phenomenon
• In some cases control parameters of the machines change, resulting in increase or decrease of the ma-
occurring on
chine's power.
machine
Relative
• Recorded in the nonvolatile memory are part of the machine control parameters
information
Presumed Cause Standard value in normalcy and references for troubleshooting

cause and As it is an internal failure, troubleshooting is impossible.
standard value Governor • pump
1 (There is no problem with continuing with use of the controller, so long as no
in normalcy controller defective
failure is visually evident)
20-362 PC200/220(LC)-7
(1)
Service Code in Electrical System E306 (Abnormality in governor potentiometer)
User Code Service Code Failure Code Failure Abnormality in governor potentiometer
— E306 DK54KZ phenomenon (in governor • pump controller)
Failure content • Signal voltage from the governor potentiometer dropped below 0.4 V or exceeded 4.6 V.
• The controller exercises control by computing the motor position through voltage right before a failure
Response from occurred.
controller • Even if the failure cause disappears of itself, the governor potentiometer does not return to normalcy,
• The engine cannot attain the specified rotation at high idle. (A bit lower)
• The engine cannot attain the specified rotation at low idle (A bit higher)
Phenomenon
• The auto-decelerator or automatic warming-up function does not work.
occurring on
• There is hunting while the engine is running.
machine
• The engine stalls.
• The engine does not stop.
Relative • Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
information (Code No. 031: Governor potentiometer voltage)

Sensor power source
1 If Service Code No. [E226] is displayed, troubleshoot the failure first.
defective
Governor potentiometer E10 (male) Resistance value
2 defective
Between (A) and (C) 4.0 – 6.0 kz
(Internal failure)
Between (B) and (A) 0.25 – 5.0 kz
Between (B) and (C) 0.25 – 5.0 kz
Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to E10 Resistance
harness Max. 1 z
(female) (A) value
tive contact with connec- Wiring harness between C01 (female) (21) and E10 Resistance
Max. 1 z
tor) (female) (C) value
Max. 1 z
(female) (B) value
4
circuit) Min. 1 Mz
E10 (female) (B) and grounding value
5 Voltage Max. 1 V
(Contact with 24 V cir- E10 (female) (A) and grounding
Voltage Max. 1 V
E10 (female) (B) and grounding
Governor • pump C01 Resistance value
6
20-364 PC200/220(LC)-7
(11)
Electrical Circuit Diagram for Governor Motor in Governor • Pump Controller
PC200/220(LC)-7 20-365
(1)
Service Code in Electrical System E308 (Abnormality in fuel dial)
User Code Service Code Failure Code Failure Abnormality in fuel dial
E05 E308 DK10KZ phenomenon (in governor • pump controller)
Failure content • Signal voltage from the from fuel dropped below 0.23 V or exceeded 4.77 V.
• The controller exercises control by computing the fuel dial position through voltage right before a failure
Response from
occurred.
controller
• If the failure cause disappears, the fuel dial returns to normalcy.
• If the fuel dial had been set at FULL before a failure occurred, it does not change to PARTIAL.
Phenomenon
• If the fuel dial had been set at PARTIALLY before a failure occurred, it does not change to FULL.
occurring on
• There is hunting while the engine is running.
machine
• The engine cannot attain the specified rotation at high idle and lacks power.
Relative • Input from the fuel dial (voltage) can be confirmed in the monitor function.
information (Code No. 030: Fuel dial voltage)

Sensor power source
1 If Service Code No. [E226] is displayed, troubleshoot the failure first.
defective
harness E06 (male) Resistance value
Between (1) and (3) 4.0 – 6.0 kz
tor) Between (2) and (1) 0.25 – 5.0 kz
Between (2) and (3) 0.25 – 5.0 kz
Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to E06 Resistance
harness Max. 1 z
(female) (1) value
tive contact with connec- Wiring harness between C01 (female) (21) and E06 Resistance
Max. 1 z
tor) (female) (3) value
Max. 1 z
(female) (2) value
4
circuit) Min. 1 Mz
E06 (female) (2) and grounding value
5 Voltage Max. 1 V
(Contact with 24 V cir- E06 (female) (1) and grounding
Voltage Max. 1 V
E06 (female) (2) and grounding
Governor • pump C01 Resistance value
6
20-366 PC200/220(LC)-7
(11)
Electrical Circuit Diagram for Fuel Dial in Governor • Pump Controller
PC200/220(LC)-7 20-367
(1)
Service Code in Electrical System E315 (Short-circuiting in battery relay)
User Code Service Code Failure Code Failure Short-circuiting in battery relay
— E315 D110KB phenomenon (in governor • pump controller)
Failure content • Abnormal current flew to the battery relay drive circuit, when power was supplied to the circuit.
• The controller turns OFF power to the battery drive circuit.
Response from
• Even when the failure cause disappears, the relay does not return to normalcy, unless the engine start-
controller
ing switch is once turned OFF.
Phenomenon
occurring on • The engine does not stop.
machine
Relative • It can be confirmed in the monitor function how the battery relay works (ON or OFF).
information (Code No. 037: Controller output)

Battery relay defective Battery relay Continuity & Resistance value
1
(Internal failure) Between A21 (BR terminal) and A20 (E
Continued
terminal)
Between A21 (BR terminal) and grounding Min. 1 Mz
2
(Contact with grounding Between wiring harness from C03 (female) (4) to D01 to Resistance
circuit) Min. 1 Mz
J01 to A21 (BR terminal) and grounding value
Governor • pump
3 C03 Engine starting switch Voltage
20 – 30 V
Between (4) and grounding ON o OFF
(for 4 to 7 seconds)
20-368 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for Battery Relay in Governor Pump Controller
PC200/220(LC)-7 20-369
Service Code in Electrical System E316 (Step-out in governor motor)
User Code Service Code Failure Code Failure Step-out in governor motor
— E316 DY10K4 phenomenon (in governor • pump controller)
Failure content • There is a big difference between signals from the potentiometer and the set values in the controller.
• The controller repeats the same controlling motions (step-out).
Response from
• Even when the failure cause disappears, the governor motor does not return to normalcy, unless the
controller
Phenomenon • The engine rotation cannot be controlled.
occurring on • There is hunting in the rotation.
machine • The engine does not stop.

Presumed cause and standard
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.
value in normalcy
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.
Refer to the section of "Inspection and Adjustment - Special Func-
5 Governor lever adjustment improper
tion of Monitor Panel" in this manual.
6 Engine fuel control system defective Refer to Engine Shop Manual.
As this is an internal failure, no troubleshooting can be carried out.
7 Governor • pump controller defective (If there is none of the failures listed above, the controller is judged
as defective)
20-370 PC200/220(LC)-7
Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B)
User Code Service Code Failure Code Failure Disconnection in governor motor Phase A and B
E05 E317 DY10KA phenomenon (in governor • pump controller)
Failure content • No current flew to the governor motor, when power was supplied to the motor.
Response from • None in particular.
controller • If the failure cause disappears, the governor returns to normalcy.
• The engine rotation drops to low idle.
Phenomenon
• There is hunting in the rotation
occurring on
machine
• The governor motor steps out.
Relative • Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)

Governor motor defec-
1 tive E11 (male) Resistance value
(Internal disconnection) Between and 2.5 – 7.5 z

Between and 2.5 – 7.5 z
Wiring harness between C03 (female) and E11 Resistance
Max. 1 z
Disconnection of wiring (female) value
harness Wiring harness between C03 (female) and E11 Resistance
(female) value
tor) Wiring harness between C03 (female) and E11 Resistance
Max. 1 z
(female) value
Wiring harness between C03 (female) and E11 Resistance
Max. 1 z
(female) value
3
20-372 PC200/220(LC)-7
(11)
Electrical Circuit Diagram for Governor Motor in Governor • Pump Controller
PC200/220(LC)-7 20-373
(1)

(Short-circuiting in governor motor Phase A and Phase B)
User Code Service Code Failure Code Failure Disconnection in governor motor Phase A and
E05 E318 DY10KB phenomenon Phase B (in governor • pump controller system)
Failure content • Abnormal current flew to the governor motor, when power is supplied to the motor.
controller • If the failure cause disappears, the governor motor returns to normalcy.
• The engine rotation cannot be controlled.
Phenomenon
• The engine rotation drops to low idle.
occurring on
• There is hunting in the rotation.
machine
Relative • Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)

Governor motor defec- E11 (male) Resistance value

tive Between and 2.5 – 7.5 z
1
or grounding fault) Between and 2.5 – 7.5 z
Between and grounding Min. 1 Mz

Between wiring harness between C03 (female) and Resistance
Min. 1 Mz
Disconnection of wiring E11 (female) and grounding value
harness Between wiring harness between C03 (female) and Resistance
2 (Disconnection or defec- Min. 1 Mz
E11 (female) and grounding value
tor) Between wiring harness between C03 (female) and Resistance
Min. 1 Mz
Between wiring harness between C03 (female) and Resistance
Min. 1 Mz
C03 (female) Resistance value
Governor • pump Between and 2.5 – 7.5 z
3
20-374 PC200/220(LC)-7
(11)
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 Failure "Model Selection" function not provided yet
— E501 DA2AKM phenomenon (in governor • pump controller system)
Failure content • Model Code is not inputted yet.
• Model data and rated load cannot be set.
Response from
• Even when the failure cause disappears, Service Code does not return to normalcy, unless the engine
controller
starting switch is once turned OFF.
Phenomenon
occurring on • The excess load alarm does not work normally.
machine
Relative • Model names that the controller recognizes (figure) can be confirmed in the monitor function.
information (Code No. 150: Model Code)

Refer to the section "Special Function of Monitor Panel" in this manual.
Presumed Setting work not finished There is a possibility that model selection operation has never been
1
cause and yet tried with that specific model from its delivery ex-works up to this mo-
standard value ment.
in normalcy As this is an internal failure, no troubleshooting can be conducted.
Governor • pump
2 (If there is no problem with the setting work above, the controller may be
judged as defective.)
20-376 PC200/220(LC)-7
TROUBLESHOOTING E501 / E502
Service Mode in Electrical System E502 (Model selecting signal fault)
User Code Service Code Failure Code Failure Model selecting signal fault
— E502 DA20KT phenomenon (in governor • pump controller system)
Failure content • Information on the models stored in the controller have been damaged.
• Model data and rated load cannot be set.
Response from
• Even when the failure cause disappears, the signal does not return to normal, unless the engine starting
controller
Phenomenon
occurring on • The excess load alarm does not work normally.
machine
Relative • (Model names that the controller recognizes (figure) can be confirmed in the monitor function.
information (Code No. 150: Model Code)

Presumed Setting work not finished
1 Refer to the section "Special Function of Monitor Panel" in this manual.
cause and yet
standard value As this is an internal failure, no troubleshooting can be conducted.
in normalcy Governor • pump
2 (If there is no problem with the setting work above, the controller may be
judged as defective.)
PC200/220(LC)-7 20-377
(1)
TROUBLESHOOTING A000N1 / A000N2
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idle)
User Code Service Code Failure Code Failure Engine rotation at high idle out of rate
— — A000N1 phenomenon (in mechanical system)
Failure content • Engine rotation above 2,350 rpm was detected for more than 10 seconds, while the engine was running.
controller • If the failure cause disappears of itself, the engine rotation returns to normalcy.
Phenomenon
occurring on • There is a possibility that the engine is damaged, if is used continuously without adjustment.
machine
information (Code No. 010: Engine rotation)

Check if there has been an internal or external factor that would cause
Presumed Failure in engine mechan-
1 the engine to overrun at high idle, and troubleshoot the mechanical sys-
cause and ical system
tem of the engine.
standard value
in normalcy As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (Unless there is any visible trouble found in the machine, use of the con-
troller may be continued as it is)
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idle)
User Code Service Code Failure Code Failure Out-of-rate engine rotation at low idle
— — A000N2 phenomenon (in mechanical system)
Failure content • Engine rotation below 500 rpm was detected for more than 10 seconds, while the engine was running.
controller • If the failure cause disappears of itself, the rotation returns to normalcy.
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without adjustment.
machine

Check if there has been an internal or external factor that would cause
Presumed Failure in engine mechan-
1 the engine to overrun at high idle, and troubleshoot the mechanical sys-
cause and ical system
tem of the engine.
standard value
in normalcy As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (Unless there is any visible trouble found in the machine, use of the con-
troller may be continued as it is)
20-378 PC200/220(LC)-7
(11)
TROUBLESHOOTING AA10NX
Failure Code in Mechanical System AA10NX (Air cleaner clogging)
User Code Service Code Failure Code Failure Air cleaner clogged
— — AA10NX phenomenon (in mechanical system)
• While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e. dis-
Failure content
connected from grounding circuit).
Response from
monitor panel
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without corrective action.
machine
• This Failure Code is recorded, when the air cleaner clogging caution symbol is displayed in the monitor
Relative panel while the engine is running.
information • Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the monitor panel.
(Code No. 046: Monitor input 2)

Air cleaner clogged
1 (when the system is in a Check the air cleaner for clogging. If it is clogged, clean or replace it with new one.
normal condition)
Air cleaner clogging
2 switch defective A31 (male) Air cleaner Resistance value
(Internal disconnection) When in normal condition Max. 1 z
Between (1) and (2)
When clogged Min. 1 Mz
Disconnection of wiring troubleshooting.
harness
Wiring harness between P02 (female) (5) and A31 Resistance
(female) (1) value
tor) Resistance
Between wiring harness A31 (female) (2) and grounding Max. 1 z
value
4 Monitor panel defective P02 Air cleaner Voltage
When in normal condition Max. 1 V
When clogged 20 – 30 V
Electrical Circuit for Air Cleaner Clogging Switch in Monitor Panel
PC200/220(LC)-7 20-379
(5)
TROUBLESHOOTING AB00KE
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage)
User Code Service Code Failure Code Failure Charging voltage abnormally lowered
— — AB00KE phenomenon (in mechanical system)
Failure content • Generation signal from the alternator is not inputted, while the engine is running.
Response from
monitor panel
Phenomenon
• There is a possibility that the battery may not be charged, if charging is continued without corrective
occurring on
action.
machine
• This Failure Code is recorded, if the charging caution symbol is displayed in the monitor panel, while the
Relative engine is running.
information • Input from the alternator (voltage) can be confirmed in the monitor function.
(Code No. 043: Charging voltage)

Alternator defective troubleshooting.

1
(short generating output) E12 (male) Engine rotation Voltage
Between (1) and grounding Above medium speed 27.5 – 29.5 V
Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tive contact with connec- Wiring harness from P02 (female) (11) to J02 to E12 Resistance
Max. 1 z
tor) (female) (1) value
harness
3 Wiring harness from P02 (female) (11) to J02 to E12
circuit) (female) (1), or between P02 (female) (11) and D01 (female) Min. 1 Mz
value
(6), or between P02 (female) (11) and A27 (female) (2)
P02 Engine rotation Voltage
Between (11) and grounding Above medium speed 27.5 – 29.5 V
20-380 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for Engine Start, Stop and Charging in Monitor Panel
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
PC200/220(LC)-7 20-381
(5)
Electrical Circuit Diagram for Engine Start, Stop and Charging in Monitor Panel
20-381-1 PC200/220(LC)-7
(8)
TROUBLESHOOTING B@BAZG
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure)
User Code Service Code Failure Code Failure Engine oil pressure abnormally lowered
— — B@BAZG phenomenon (in mechanical system)
• The signal circuit in the engine oil pressure switch was closed (i.e. connected with grounding), while the
Failure content
engine was running.
Response from
monitor panel
Phenomenon
occurring on • There is a possibility that the engine may seize, if the engine is kept running without corrective action.
machine
• This Failure Code is recorded, if the engine oil pressure caution symbol is displayed in the monitor panel,
Relative while the engine is running.
information • Input from the engine oil pressure switch (ON or OFF) can be confirmed in the monitor function.

Engine oil pressure low-
1 ered (the system in nor- a Check the failure cause and damage to the engine, and then make repairs.
mal condition)
Engine oil pressure
2 switch defective E02 (on switch side) Engine oil pressure Resistance value
(Internal short-circuiting) Between terminal and When in normal condition Min. 1 Mz
grounding When lowered Max. 1 z
3
(Contact with grounding Between wiring harness between P02 (female) (7) and E02 Resistance
circuit) Min. 1 Mz
(terminal) and grounding value
4 Monitor panel defective P02 Engine oil pressure Voltage
When in normal condition 20 – 30 V
When lowered Max. 1 V
Electrical Circuit Diagram for Engine Oil Pressure Switch in Monitor Panel
20-382 PC200/220(LC)-7
(5)
TROUBLESHOOTING B@BAZK
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)
User Code Service Code Failure Code Failure Engine oil level abnormally lowered
— — B@BAZK phenomenon (in mechanical system)
• The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding), when the
Failure content
engine is stopped (with the starting switch in the ON position).
Response from
monitor panel
Phenomenon
occurring on • There is a possibility that the engine seizes if it is kept running without a corrective action.
machine
• This Failure Code is recorded if the engine oil level caution symbol is displayed, when the engine is
Relative stopped (with the starting key in the ON position).
information • Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code No.
046: Monitor input 2)

Engine oil level lowered
a 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 E03 (male) Engine oil level Resistance value
When lowered Min. 1 Mz
Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tive contact with connec- Wiring harness between P02 (female) (8) and E03 (female) Resistance
Max. 1 z
tor) (1) value
4 Monitor panel defective P02 Engine oil pressure Voltage
When lowered 20 – 30 V
Electrical Circuit Diagram for Engine Oil Level Switch in Monitor Panel
PC200/220(LC)-7 20-383
(5)
TROUBLESHOOTING B@BCNS
Failure Code in Mechanical System B@BCNS (Engine coolant overheating)
User Code Service Code Failure Code Failure Engine coolant overheated
— — B@BCNS phenomenon (in mechanical system)
Failure content • The engine coolant sensor inputted a signal of 102°C, while the engine was running.
Response from
• Response from controller
monitor panel
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• This Failure Code is recorded, if the engine coolant temperature gauge is displayed in the red range,
Relative when the engine is running.
information • Input from the engine coolant temperature sensor (temperature) can be confirmed in the monitor func-
tion. (Code No. 041: Engine coolant temperature)

Engine Overheating
1 (system in normal condi- a Check the engine for the cause and damage, and repair it.
tion)
Engine coolant tempera- Engine coolant
2 ture sensor defective E05 (male) Resistance value
temperature
Between (1) and (2) 90 – 3.5 kz
10 – 100 °C
3
(Contact with grounding Between wiring harness between P02 (female) (1) and Resistance
circuit) Min. 1 Mz
E05 (female) (2) and grounding value
Engine coolant
4 Monitor panel defective P02 (female) Resistance value
temperature
Between (1) and (13) 90 – 3.5 kz
10 – 100 °C
Electrical Circuit Diagram for Engine Coolant Temperature Sensor in Monitor Panel
20-384 PC200/220(LC)-7
(11)
TROUBLESHOOTING B@BCZK
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator coolant level)
(Multi-monitor only)
User Code Service Code Failure Code Failure Radiator coolant level abnormally lowered
B@BCZK phenomenon (in mechanical system)
Failure content The signal circuit in the radiator coolant level switch was opened (i.e. disconnected from grounding).
Response from
None in particular
monitor panel
Phenomenon
occurring on There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
This Failure Code is recorded, if the radiator coolant level caution symbol is displayed in the monitor
Relative panel, when the engine is running.
information Input from the radiator coolant level switch (ON or OFF) can be confirmed in the monitor function.

Radiator coolant level
a Check the coolant level and refill coolant.
1 lowered (system in nor-
(If this phenomenon occurs frequently, check the cause)
mal condition)
Radiator coolant level
2 switch defective A33 (male) Engine coolant level Resistance value
Between (1) and (2)
When lowered Min. 1 Mz
harness
Wiring harness between P02 (female) (3) and A33 (female) Resistance
(1) value
tor) Resistance
Wiring harness between A33 (female) (2) and grounding Max. 1 z
value
Engine coolant
4 Monitor panel defective P02 Resistance value
temperature
When lowered 20 30 V
Electrical Circuit Diagram for Radiator Coolant Level Switch in Monitor Panel
PC200/220(LC)-7 20-385
(11)
TROUBLESHOOTING B@HANS
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)

User Code Service Code Failure Code Failure Hydraulic oil overheated
— — B@HANS phenomenon (in mechanical system)
Failure content • The hydraulic oil temperature sensor inputted a signal of 102°C, while the engine was running.
Response from
monitor panel
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• This Failure Code is recorded, if the hydraulic oil temperature gauge is displayed in the red range, when
Relative the engine is running.
information • Input from the hydraulic oil temperature sensor (temperature) can be confirmed in the monitor function.
(Code No. 044: Hydraulic oil temperature)

Hydraulic oil overheat-
1 ing (system in normal a Check the cause and damage to the hydraulic equipment, and repair it.
condition)
Hydraulic oil temperature
2 sensor defective A61 (male) Hydraulic oil temperature Resistance value
(Internal short-circuiting) Between (1) and (2) 90 – 3.5 kz
10 – 100 °C
3
(Contact with grounding Between wiring harness between P02 (female) (12) and Resistance
circuit) Min. 1 Mz
A61 (female) (2) and grounding value
4 Monitor panel defective P02 (female) Hydraulic oil temperature Resistance value
Between (12) and (13) 90 – 3.5 kz
10 – 100 °C
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor in Monitor Panel
20-386 PC200/220(LC)-7
(5)
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)

BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE ........................................................... 20-502-1
E-1 Engine does not start (Engine does not rotate) ................................................................................ 20-503
E-2 Engine stops while in operation ........................................................................................................ 20-507
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 maximizing function 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 coolant 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 Troubleshooting for air conditioner system ....................................................................................... 20-548
E-32 Travel alarm does not sound ............................................................................................................ 20-560
PC200/220(LC)-7 20-501
(11)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

a 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
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge "good" or "no good" about pre-
1 sumed causes.
• References for making judgement of "good" or "no good"
<Phenomena of wiring harness fault>

• Failure due to disconnection
Defective contact with connector or disconnection of wiring harness has occurred.
2
• Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in contact
with it.
Cause for presumed • Failure due to short-circuiting
failure A wiring harness that is not originally connected with a power source circuit (24 V) is
(The attached No. for in contact with it.
3
filing and reference
purpose only. It does not <Points to remember in troubleshooting>
stand for any priority) 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 connec-
4
tor 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 con-
nector 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 follow-
5 ing 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
(1)
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE
BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE
Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box supplies power directly
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting for an electric system, check its fuse box and fusible link to see if the pow-
er is supplied normally.
Type of power
Fuse No. Fuse capacity Destination of power
supply
Governor, pump controller (Controller power supply)
1 10A Emergency pump drive resistor
Swing holding brake release switch
Switch power Governor, pump controller (Solenoid power supply)

2 20A
supply (Fusible Attachment return switching relay (Coil side and contact side)
link: A34) 3 10A Lock switch
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn switch
6 10A (Spare)
Rotary lamp switch
7 10A
Switch power Additional relay (Coil side and contact side)
supply (Fusible 8 10A Light relay (Contact side)
link: A34) One-touch power maximizing switch
9 10A
Radio
10 10A (Spare)
11 20A Air conditioner unit
Starting motor cut-out (Personal code) relay (Coil side)
12 20A
Switch power Monitor panel
supply (Fusible 13 20A Light switch
link: A34) 14 10A Service power supply (M32 connector)
Travel alarm
15 10A
DC/DC converter
Radio
16 10A
Air conditioner unit
Constant power 17 20A Monitor panel
supply (Fusible
link: A35) 18 10A Starting switch
19 10A Room lamp
20 10A (Spare)
PC200/220(LC)-7 20-502-1
(11)
TROUBLESHOOTING E-1
E-1 Engine does not start (Engine does not rotate)
Failure
The engine does not start (the engine does not rotate).
information
The following two engine start locking mechanisms are provided in the engine starting circuit.
Relative
1) Engine start locking by means of password in the monitor panel
information
2) Engine start locking by means of lock lever

Shortage in battery Battery voltage Battery electrolyte specific gravity
1
capacity Min. 24 V Min. 1.26
When a fuse or fusible link is blown, there is a big possibility that grounding fault occurred in
Fuse Nos. 3 and 18
the circuit. (Refer to cause 10)
2 and Fusible Link A35
If a monitor lamp does not light up in the monitor panel, check the power source circuit
fault
between the battery and the specific fuse.
Engine starting during the troubleshooting.
switch fault H15 (male) Position Resistance value
3
(Internal
disconnection) OFF Min. 1 Mz
Between (1) and (4)
Start Max. 1 z
Lock switch fault
4 (Internal S14 (female) Lock lever Resistance value
short-circuiting) Release Min. 1 Mz

Between (1) and (3)
LOCK Max. 1 z
Engine starting during the troubleshooting.
motor cut relay, R11
and R13 defective R11 (female) & R13 (male) Resistance value
5
(Internal Between (1) and (2) 100 500 z
disconnection or Between (3) and (5) Min. 1 Mz
short-circuiting)
Between (3) and (6) Max. 1 z
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 start-
Engine starting Safety relay Voltage
ing switch
motor fault
6 (Internal Power source: Between B terminal and grounding 20 30 V
disconnection or GND (grounding): Between E terminal and grounding Connected
short-circuiting) Generation signal: Between R terminal (A27 (2)) and
Max. 1 V
grounding Start
Engine start input: Between S terminal (A27 (1)) and
20 30 V
grounding
Engine start output: Between C terminal and grounding 20 30 V
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
Engine starting
starting motor relay is defective)
motor fault
7 Engine start-
(Internal disconnec- Engine starting motor Voltage
tion or damage) ing switch
Power source: B terminal and grounding 20 30 V
Start
Engine start input: C terminal and grounding 20 30 V
PC200/220(LC)-7 20-503
(11)
TROUBLESHOOTING E-1

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position or
Alternator fault running during the troubleshooting.
8 (Internal
E12 (male) Voltage
short-circuit)
Between (1) and grounding Max. 1 V
Resistance
Wiring harness between FB1-18 outlet and H15 (female) (1) Max. 1 z
value
Wiring harness from H15 (female) (4) to J01 to R11 (female) Resistance
Max. 1 z
(5) value
Resistance
Disconnection of wir- Wiring harness between R11 (female) (3) and A27 (female) (1) Max. 1 z
value
ing harness
Wiring harness between engine starting motor relay C termi- Resistance
nal and engine starting motor C terminal value
defective contact
Wiring harness between FB1-3 and S14 (female) (1) Max. 1 z
value
Resistance
Wiring harness between S14 (female) (3) and R11 (female) (1) Max. 1 z
value
Resistance
Wiring harness between R11 (female) (2) and R13 (female) (6) Max. 1 z
value
Resistance
Wiring harness from R13 (female) (3) to J04 to grounding Max. 1 z
value
Between wiring harness from battery relay B terminal (A23) Resistance
Min. 1 Mz
to A35 to FB1-18 and grounding value
Between wiring harness between FB1-18 outlet and H15 Resistance
Min. 1 Mz
Between wiring harness from H15 (female) (4) to J01 to R11 Resistance
Min. 1 Mz
Grounding fault of (female) (5) and grounding value
wiring harness Between wiring harness between R11 (female) (3) and A27 Resistance
10 Min. 1 Mz
(Contact with (female) (1) and grounding value
grounding circuit) Between wiring harness between engine starting motor relay C Resistance
Min. 1 Mz
terminal and engine starting motor C terminal and grounding value
Between wiring harness between FB1-3 and S14 (female) (1) Resistance
Min. 1 Mz
and grounding value
Between wiring harness between S14 (female) (3) and R11 Resistance
Min. 1 Mz
Between wiring harness from R13 (female) (2) to J05 to P02 Resistance
Min. 1 Mz
Short-circuiting of during the troubleshooting.
wiring harness Wiring harness between A27 (female) (2) and E12 (female)
11
(Contact with 24 V (1), or wiring harness from A27 (female) (2) to J02 to D01
circuit) Voltage Max. 1 V
(female) (6), or between wiring harness between A27
(female) (2) and P02 (female) (11) and grounding
20-504 PC200/220(LC)-7
(1)
TROUBLESHOOTING E-1
Electrical Circuit Diagram for Engine Start, Stop and Battery Charging
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
PC200/220(LC)-7 20-505
(7)
TROUBLESHOOTING E-1
Electrical Circuit Diagram for Engine Start, Stop and Battery Charging
20-506 PC200/220(LC)-7
(7)
TROUBLESHOOTING E-2
E-2 Engine stops while in operation
Failure
• The engine suddenly stopped while in operation.
information
Relative • Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
information (Code No. 031: governor potentiometer voltage)

Governor potentiom- E06 (male) Resistance value
1 eter fault
Between (A) and (C) 4.0 – 6.0 kz
(Internal failure)
Between (B) and (A) 0.25 – 5.0 kz
Between (B) and (C) 0.25 – 5.0 kz
Disconnection of wir- a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness during the troubleshooting.
2 (Disconnection or
defective contact Wiring harness between C01 (female) (13) and E10 (female) Resistance
Max. 1 z
with connector) (B) value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3
(Contact with Between wiring harness between C01 (female) (13) and E10 Resistance
grounding circuit) Min. 1 Mz
(female) (B) and grounding value
4
Between (22) and (21) 4.5 – 5.5 V
Between (13) and (21) 0.5 – 4.5 V
Electrical Circuit Diagram for Fuel Dial
PC200/220(LC)-7 20-507
(5)
TROUBLESHOOTING E-3
E-3 Engine speed is irregular, or there is hunting
• Engine speed is irregular at low idle.

Failure
• There is hunting.
information
• Engine speed is lower than specified at high idle.
Relative • Engine rotation can be confirmed in the monitor function.

If the monitor display is not normal, proceed to Service Code [E217].
Model code signal
Monitoring Code Item Normal display
1 fault
(Internal failure) 002
Controller model code 200

003
Governor lever
2 Refer to the section "Special Function of Monitor Panel" in this manual.
improperly adjusted
If the governor motor lever moves smoothly in the following operations, it is judged as normal.
Governor motor
3 • The fuel dial is operated between low idle and high idle.
improperly working
• The engine is stopped with the fuel dial.
Engine fuel control
4 Refer to the Engine Shop Manual.
system defective
5 (Disconnection or
defective contact Wiring harness from C01 (female) (23) to J07 to H15 (female) Resistance
Max. 1 z
with connector) (5) value
6
(Contact with Between wiring harness between C01 (female) (23) to J17 Resistance
grounding circuit) Min. 1 Mz
and H15 (female) (5) and grounding value
Governor • pump As this is an internal failure, troubleshooting cannot be conducted.
7
controller defective (If there is none of the causes from Item 1 to 6 above, the controller is judged as defective)
20-508 PC200/220(LC)-7
(11)
TROUBLESHOOTING E-3
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
PC200/220(LC)-7 20-509
(7)
TROUBLESHOOTING E-3
20-509-1 PC200/220(LC)-7
(7)
TROUBLESHOOTING E-4
E-4 Engine does not stop
Failure
information
• The Governor • pump controller drives the battery relay for the min. 4 seconds and max. 7 seconds from
Relative the moment the engine starting switch is turned OFF to the moment the engine completely stops.
information • It can be confirmed in the monitor function how the battery relay works (ON or OFF)
(Code No. 037: Controller output)

If operating sound is heard from the battery relay contact, when turning the engine starting
1 Battery relay fault switch, the battery relay is judged as normal.
• Starting switch OFFoONoOFF
diode D01 fault during the troubleshooting.
2
Disconnection of wir- Wiring harness between C03 (female) (4) and D01 (female) Resistance
ing harness Max. 1 z
(5) value
3 (Disconnection or
defective contact Wiring harness from D01 (female) (1) to J01 to battery relay Resistance
Max. 1 z
with connector) BR terminal (A21) value
Wiring harness between battery relay E terminal (A20) and Resistance
Max. 1 z
grounding value
Governor • pump
4 C03 Engine starting switch Voltage
20 – 30 V
Between (4) and grounding ONoOFF
(for 4 to 7 seconds)
20-510 PC200/220(LC)-7
(5)
TROUBLESHOOTING E-4
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
PC200/220(LC)-7 20-511
(5)
TROUBLESHOOTING E-4
20-511-1 PC200/220(LC)-7
(7)
TROUBLESHOOTING E-5
E-5 Auto-decelerator does not work
Failure
• The auto-decelerator does not work.
information
• Rotation of the auto-decelerator is set at 1,400 rpm. If the fuel dial is not set adjusting to this level, the
Relative
auto-decelerator does not work.
information
• Confirm the display on the monitor panel, when the engine is running.

Monitoring code Item Normal display
Boom RAISE signal Lever operation: ON
1 019 Boom RAISE
fault Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-21 Troubleshooting.
Boom LOWER sig- Lever operation: ON
2 019 Boom LOWER
nal fault Lever NEUTRAL: OFF
Arm DIGGING signal Lever operation: ON
3 019 Arm DIGGING

Arm DUMPING Lever operation: ON
4 019 Arm DUMPING
signal fault Lever NEUTRAL: OFF
Bucket DIGGING Lever operation: ON
5 021 Bucket DIGGING
Bucket DUMPING Lever operation: ON
6 021 Bucket DUMPING
Lever operation: ON
7 Swing signal fault 019 Swing
Lever NEUTRAL: OFF
Lever operation: ON
8 Travel signal fault 019 Travel
Lever NEUTRAL: OFF
Attachment signal Lever operation: ON
9 021 Service
Governor • pump As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the
10
controller defective causes listed in Item 1 through 9, the controller is judged as defective.
20-512 PC200/220(LC)-7
(5)
TROUBLESHOOTING E-6
E-6 Auto engine warm-up device does not work
Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine coolant temperature is below 30°C, and
Relative raise the engine rotation up to 1,200 rpm.
information • 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.

If the display on the monitor panel is not normal, proceed to No. E-14
Troubleshooting.
value in normalcy
Engine coolant
1 temperature signal
fault Compare with the actual
Engine coolant
041 engine coolant
temperature
temperature.
As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (If the fault mentioned in the above item is not found, the Governor • pump controller is
judged as defective)
PC200/220(LC)-7 20-513
(11)
TROUBLESHOOTING E-7
E-7 Preheater does not work
Failure • Even if the preheater switch is turned to the PREHEAT position, the preheating monitor lamp does not
information (1) light up.
Relative • Input of the preheating signal (ON or OFF) can be confirmed in the monitor function.

Engine starting If preheating does not occur (the heater is not warmed up), refer to Failure Phenome-
1
switch fault non (2) below.
Disconnection of wir- a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
value in normalcy
ing harness tion during the troubleshooting.

2 (Disconnection or
defective contact Resistance
Wiring harness between P02 (female) and J02 Max. 1 z
with connector) value
a Turn the engine starting switch OFF for the preparations.

P02 Engine starting switch Voltage
3 Monitor panel fault
OFF Max. 1 V
HEAT 20 – 30 V
Failure
• Even if the preheater switch is turned to the PREHEAT position, the preheater does not become warm.
information (2)
Relative • In low coolant temperature (lower than 30°C), the governor • pump controller drives the heater relay for
information 100 seconds after the engine is started and automatically warms up the engine.

a Turn the engine starting switch OFF for the preparations.
Engine starting
switch fault H15 (male) Engine starting switch Resistance value
1
(Internal disconnec- OFF Min. 1 Mz
tion) Between and
HEAT Max. 1 z
Heater relay fault
value in normalcy
2 (Internal disconnec- Heater relay Continuity and resistance value

tion) Between coil terminal and grounding Continued
Between contact terminals Min. 1 Mz
Electrical intake air a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
heater tion during the troubleshooting.
3
tion) Between heater terminals Normal if continuity is established.
Disconnection of wir- tion during the troubleshooting.
ing harness
Wiring harness from H15 (female) to J02 to heater Resistance
relay terminal (A25) value
defective contact
with connector) Wiring harness between battery relay M terminal (A22) Resistance
Max. 1 z
and heater relay terminal value
20-514 PC200/220(LC)-7
(11)
TROUBLESHOOTING E-7
Electrical Circuit Diagram for Engine Preheater
PC200/220(LC)-7 20-515
(1)
TROUBLESHOOTING E-8
E-8 All work equipment, swing and travel do not move
Failure
• All the work equipment, swing and travel do not move.
information
Relative
—
information

If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
1 Fuse No. 3 fault
(Refer to cause 6)
Switch lock defective
2 (Internal disconnec- S14 (female) Lock lever Resistance value
tion) Lock Min. 1 Mz
Between (1) and (2)
Release Max. 1 z
PPC lock solenoid

fault
3 (Internal disconnec- V01 (male) Resistance value
tion or short-circuit- Between (1) and (2) 20 – 60 z
ing)
diode D01 fault during the troubleshooting.
4
(Internal short-cir- D01 (male) Resistance value
cuiting) Between (8) and (4) Min. 1 Mz
Disconnection of wir- Resistance
ing harness Wiring harness between FB1-3 outlet and S14 (male) (1) Max. 1 z
value
5 (Disconnection or
Wiring harness from S14 (male) (2) to J02 to V01 (female) (1) Max. 1 z
Resistance
value
Grounding fault of during the troubleshooting.
wiring harness Between wiring harness between FB1-3 outlet and S14 Resistance
Min. 1 Mz
6 (Contact with (male) (1) and grounding value
grounding (GND) Wiring harness from S14 (male) (2) to J02 to V01 (female)
circuit) Resistance
(1), or between wiring harness between S14 (male) (2) and Min. 1 Mz
value
D01 (female) (8) and grounding
20-516 PC200/220(LC)-7
(11)
TROUBLESHOOTING E-8
Electrical Circuit Diagram for PPC Lock Solenoid
PC200/220(LC)-7 20-517
(11)
TROUBLESHOOTING E-9
E-9 One-touch power maximizing function does not work
Failure
The one-touch power maximizing function does not work.
information
If the knob switch is pressed while the engine is running, the symbol mark is displayed in the monitor
Relative
panel.
information
Input from the knob switch can be confirmed in the monitor function. (Code No. 022: Switch input 1)

1 Fuse No. 9 fault
(Refer to cause 4)
One-touch power during the troubleshooting.
max. switch fault M23 (male) Knob switch Resistance value
2
tion) Release Min. 1 M z
Between (1) and (2)
Depress Max. 1 z
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
3 (Disconnection or Wiring harness between FB1-9 outlet and M23 (female) (1) Max. 1 z
value
defective contact
with connector) Wiring harness between M23 (female) (2) and C01 (female) Resistance
Max. 1 z
(11) value
Grounding fault of during the troubleshooting.
wiring harness
Between wiring harness between FB1-9 outlet and M23 Resistance
4 (Contact with Min. 1 Mz
grounding (GND)
circuit) Between wiring harness between M23 (female) (2) and C01 Resistance
Min. 1 Mz
Governor pump C01 Knob switch Voltage
5
Release Max. 1 V
Depress 20 30 V
Electric Circuit Diagram for One-Touch Power Maximizing Function
20-518 PC200/220(LC)-7
(11)
TROUBLESHOOTING E-10
E-10 No display in monitor panel at all
Failure
• When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
information
Relative
—
information

1 Fuse No. 12 fault
(Refer to cause 3)
ing harness
Resistance
2 (Disconnection or Wiring harness from P01 (female) (1) (2) to J07 to FB1-12 Max. 1 z
value
defect contact with
connector) Resistance
Wiring harness between P01 (female) (6) (7) and grounding Max. 1 z
value
3 (Contact with
grounding (GND) Between wiring harness from P01 (female) (1) (2) to J07 to Resistance
Min. 1 Mz
circuit) FB1-12 outlet and grounding value
Monitor panel P01 (female) Voltage and resistance value
4
defective
Between (1) (2) and grounding Voltage: 20 – 30 V
Between (6) (7) and grounding Resistance value: Max. 1 z
Electrical Circuit Diagram for Power Source in Monitor Panel
PC200/220(LC)-7 20-519
(5)
TROUBLESHOOTING E-11, E-12
E-11 Part of display on monitor panel is missing
Failure
• Part of the display in the monitor panel is missing.
information
Relative
—
information

standard value in normalcy
Presumed cause and
If all the LCD in the monitor panel light up (i.e. the screen becomes totally white) by the
Monitor panel LCD
1 following switching operation, then the monitor panel is normal.
fault
• Switching operation: [ ] + [ A ] (simultaneous switching operation)
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is no prob-
2
defective lem with the above switching operation, the monitor panel is judged as defective)
E-12 Monitor panel displays contents irrelevant to the model
Failure
• The monitor panels displays contents that have nothing to do with the model on which it is installed.
information
Relative
—
information

standard value in normalcy
Presumed cause and
If the display on the monitor panel is normal, proceed to Service Code [E217].
Model code signal
1 fault
(Internal failure) 002
Controller model code 200
003
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is no prob-
2
defective lem with the above switching operation, the monitor panel is judged as defective)
20-520 PC200/220(LC)-7
(1)
E-13 Fuel level monitor red lamp lights up while engine is running
Failure
• The fuel level monitor red lamp lighted up while the engine was running.
information
• If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
Relative
• (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
information
(Code No. 042: Fuel level sensor)

Fuel level lowered
1 (system in normal a Refill fuel.
condition)
Fuel level sensor during the troubleshooting.
fault A60 (male) Fuel level Resistance value
2
(Internal
disconnection) FULL (Upper limit) Approx. 12 z
EMPTY (Lower limit) 85 – 110 z
3 (Contact with
grounding (GND) Wiring harness between P02 (female) (2) and A60 (female) Resistance
Max. 1 z
circuit) (1) value
Monitor panel P02 (female) Fuel level Resistance value
4
defective
FULL (Upper limit) Approx. 12 z
Electrical Circuit Diagram for Fuel Level Sensor
PC200/220(LC)-7 20-521
(5)
E-14 Engine coolant temperature gauge does not indicate correctly
Failure The engine coolant temperature rises normally, but the display does not exceed the white range (C).
information The engine coolant temperature remains stable, but the display rises to the red range (H).
Relative Input from the engine coolant temperature sensor can be confirmed in the monitor function.
information (Code No. 041: Engine coolant temperature)

Engine coolant tem- during the troubleshooting.
perature sensor fault Engine coolant
1 (Internal disconnec- E05 Resistance value
temperature
tion or short-circuit-
ing) Between (1) and (2) 90 3.5 kz
10 100 °C
Between (2) and grounding Min. 1 M z
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) (1) and E05 (female) (2) Max. 1 z
value
defective contact
with connector) Wiring harness between P02 (female) (13) and E05 (female) Resistance
Max. 1 z
(1) value
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) (1) and E05 Resistance
Min. 1 Mz
circuit) (female) (2) and grounding value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
4
(Contact with 24 V Between wiring harness between P02 (female) (1) and E05
Monitor panel Engine coolant
5 P02 Resistance value
defective temperature
Between (1) and (13) 90 3.5 kz
10 100 °C
Between (1) and grounding Min. 1 M z
Electrical Circuit Diagram for Engine Coolant Temperature Sensor
20-522 PC200/220(LC)-7
(11)
E-15 Hydraulic oil temperature gauge does not display correctly

Failure Hydraulic oil temperature rises normally, but the display does not exceed the white range (C).
information Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Relative Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
information (Code No. 044: Hydraulic oil temperature)

Hydraulic oil temper- during the troubleshooting.
ature sensor fault Hydraulic oil
1 (Internal disconnec- A61 Resistance value
temperature
tion or short-circuit-
ing) Between (1) and (2) 90 3.5 kz
10 100 °C
ing harness
Wiring harness between P02 (female) (12) and A61 (female) Resistance
(2) value
defective contact
with connector) Wiring harness between P02 (female) (13) and A61 (female) Resistance
Max. 1 z
(1) value
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) (12) and A61 Resistance
Min. 1 Mz
4
(Contact with 24 V Between wiring harness between P02 (female) (12) and A61
Monitor panel Hydraulic oil
5 P02 Resistance value
defective temperature
Between (12) and (13) 90 3.5 kz
10 100 °C
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
PC200/220(LC)-7 20-523
(11)
E-16 Fuel gauge does not display correctly
Failure • Though fuel was refilled, the display does not exceed the red range (E).
information • Though the remaining fuel level is low, the display does not drop below the green range (F).
Relative • Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
information (Code No. 042: Fuel sensor voltage)

Fuel level sensor
fault
1 (Internal disconnec- A60 (male) Fuel level Resistance value
tion or short-circuit- FULL (Upper limit) Approx. 12 z
ing)
2 (Disconnection or
Wiring harness between P02 (female) (2) and A60 (female) (1) Max. 1 z
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) (2) and A60 Resistance
Min. 1 Mz
4
(Contact with 24 V Between wiring harness between P02 (female) (2) and A60
Monitor panel P01 Fuel level Resistance value
5
defective
FULL (Upper limit) Approx. 12 z
Electrical Circuit Diagram for Fuel Level Sensor
20-524 PC200/220(LC)-7
(5)
E-17 Swing lock monitor does not display correctly
Failure • Though the swing lock switch was turned ON, the swing lock monitor does not light up.
information • Though the swing lock switch was turned OFF, the swing lock monitor lights up.
Relative • Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.

Swing lock switch
fault
1 (Internal disconnec- X05 (female) Swing lock switch Resistance value
tion or short-circuit- OFF Min. 1 Mz
ing) Between (1) and (2)
ON Max. 1 z
ing harness
Wiring harness from P02 (female) (17) to J02 to X05 (male) Resistance
(1) value
defective contact
Wiring harness from X05 (male) (2) to J05 to grounding Max. 1 z
value
3 (Contact with
grounding (GND) Between wiring harness from P02 (female) (17) to J02 to X05 Resistance
Min. 1 Mz
circuit) (male) (1), to C02 (female) (38) and grounding value
4
(Contact with 24 V Between wiring harness from P02 (female) (17) to J02 to X05
(male) (1), to C02 (female) (38) and grounding
Monitor panel P02 Swing lock switch Voltage
5
defective
OFF 20 – 30 V
ON Max. 1 V
20-526 PC200/220(LC)-7
(5)
TESTING AND ADJUSTING E-17
Electrical Circuit Diagram for Swing Lock Switch
PC200/220(LC)-7 20-527
E-18 When the monitor switch is operated, no display appears
Failure
When operating the working mode changing switch, the working mode monitor does not appear.
information (1)
Relative
—
information

cause and
standard value Monitor panel
1 As this is an internal failure, troubleshooting cannot be conducted.
in normalcy defective
Failure
When operating the auto-decelerator switch, the auto-deceleration monitor does not appear.
information (2)
Relative
If the auto-decelerator itself does not work, either, carry out No. E-5 Troubleshooting.
information

cause and
Failure
When operating the travel speed shifting switch, the travel speed monitor does not appear.
information (3)
Relative
If the travel speed does not actually change, carry out No. H-21 Troubleshooting.
information

cause and
Failure
When operating the windshield wiper switch, the windshield wiper monitor does not appear.
information (4)
Relative
If the windshield wiper itself does not work, either, carry out No. E-19 Troubleshooting.
information

cause and
When operating the select switch, the adjustment display does not appear.
Failure
When operating the LCD monitor adjusting switch, the adjustment display does not appear.
information (5)
When operating the maintenance switch, the item display does not appear.
Relative
—
information

cause and
20-528 PC200/220(LC)-7
E-19 Windshield wiper does not work
Failure
• The windshield wiper does not work.
information
Relative • Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.

Window rear limit
switch fault
1 (Internal disconnec- W03 (Switch side) Front window Resistance value
tion or short-circuit- When installed at front Min. 1 Mz
When retracted at rear Max. 1 z
Windshield wiper
motor fault
2 (Internal disconnec- W04 (female) Continuity and resistance value
tion or short-circuit- Between (3) and (1) Continued

ing)
Between (3) (1) and grounding Min. 1 Mz
ing harness
Wiring harness between P01 (female) (9) and W04 (female) Resistance
(3) value
defective contact
with connector) Wiring harness between P01 (female) (10) and W04 (female) Resistance
Max. 1 z
(1) value
4 (Contact with
grounding (GND) cir- Between wiring harness between P02 (female) (15) and W03 Resistance
Min. 1 Mz
cuit) (1) value
Monitor panel fault
(Rear limit switch P02 Front window Voltage
system) When installed at front 20 – 30 V
When retracted at rear Max. 1 V
5 a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Monitor panel fault P01 Windshield wiper switch Voltage
(Windshield wiper
motor system) OFF Max. 3 V
Between (10) and grounding Max. 3 V 20 – 30 V
ON
(Constant cycle)
20-530 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for Windshield Wiper Motor
PC200/220(LC)-7 20-531
E-20 Alarming buzzer cannot be cancelled
Failure
The alarming buzzer cannot be cancelled.
information
Relative Input from the alarming buzzer cancellation switch (ON or OFF) can be confirmed in the monitor function.

Alarming buzzer
cancellation switch
fault Alarming buzzer
1 P03 (female) Resistance value
(Internal disconnec- cancellation switch
tion or short-circuit- Release Above 1 M

ing) Between and
Depress Below 1
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) and P03 (male) Below 1
value
defective contact
Wiring harness from P03 (male) to J05 to grounding Below 1
value
Short-circuiting of Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
3
(Contact with 24 V Between wiring harness between P02 (female) and P03
(male) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Alarming buzzer
4 Monitor panel fault P02 Voltage
cancellation switch
Release 20 – 30 V
Depress Below 1 V
Electrical Circuit Diagram for Alarming Buzzer Cancellation Switch
20-532 PC200/220(LC)-7
E-21 "Boom RAISE" is not correctly displayed in monitor function
Failure
• "Boom RAISE" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
—
information

Boom RAISE PPC
hydraulic switch fault
1 (Internal disconnec- S06 (male) Boom control lever Resistance value
tion or short-circuit- NEUTRAL Min. 1 Mz
RAISE Max. 1 z
ing harness
Wiring harness between C03 (female) (10) and S06 (female) Resistance
(1) value
defective contact
Wiring harness between S06 (female) (2) and grounding Max. 1 z
value
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (10) and S06 Resistance
Min. 1 Mz
4
(Contact with 24 V Between wiring harness between C03 (female) (10) and S06
a Turn the engine starting switch OFF for the preparations, start engine and carry out trou-
bleshooting.
Governor • pump C03 Boom control lever Voltage
5
NEUTRAL 20 – 30 V
RAISE Max. 1 V
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC200/220(LC)-7 20-533
(5)
E-22 "Boom LOWER" is not correctly displayed in monitor function
Failure
• "Boom LOWER" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
—
information

Boom LOWER PPC
1 (Internal disconnec- S02 (male) Boom control lever Resistance value
LOWER Max. 1 z
ing harness
(1) value
defective contact
value
3 (Contact with
Min. 1 Mz
4
bleshooting.
Governor • pump C03 Boom control lever Voltage
5
NEUTRAL 20 – 30 V
LOWER Max. 1 V
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
20-534 PC200/220(LC)-7
(5)
E-23 "Arm DIGGING" is not correctly displayed in monitor function
Failure
• "Arm DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Arm DIGGING PPC
1 (Internal disconnec- S04 (male) Arm control lever Resistance value
DIGGING Max. 1 z
ing harness
(1) value
defective contact
value
3 (Contact with
Min. 1 Mz
4
bleshooting.
Governor • pump C03 Arm control lever Voltage
5
NEUTRAL 20 – 30 V
DIGGING Max. 1 V
Electrical Circuit Diagram for Arm DIGGING PPC Hydraulic Switch
PC200/220(LC)-7 20-535
(5)
E-24 "Arm DUMPING" is not correctly displayed in monitor function
Failure
• "Arm DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Arm DUMPING PPC a Turn the engine starting switch OFF for the preparations, and keep the engine running
hydraulic switch during the troubleshooting.
defect S08 (male) Arm control lever Resistance value
1
tion and short-circuit- NEUTRAL Min. 1 Mz
Between (1) and (2)
ing) DUMPING Max. 1 z
ing harness
(1) value
defective contact
value
3 (Contact with
Min. 1 Mz
4
bleshooting.
Governor • pump C03 Arm control lever Voltage
5
NEUTRAL 20 – 30 V
DUMPING Max. 1 V
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
20-536 PC200/220(LC)-7
(5)
E-25 "Bucket DIGGING" is not correctly displayed in monitor function
Failure
• "Bucket DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Bucket DIGGING a Turn the engine starting switch OFF for the preparations, and keep the engine running
PPC hydraulic during the troubleshooting.
switch fault S01 (male) Bucket control lever Resistance value
1
Between (1) and (2)
ing) DIGGING Max. 1 z
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) (9) and S01 (female) (1) Max. 1 z
value
defective contact
value
3 (Contact with
Min. 1 Mz
4
bleshooting.
Governor • pump C03 Bucket control lever Voltage
5
NEUTRAL 20 – 30 V
DIGGING Max. 1 V
Electrical Circuit Diagram for Bucket DIGGING PPC hydraulic Switch
PC200/220(LC)-7 20-537
(5)
E-26 "Bucket DUMPING" is not correctly displayed in monitor function
Failure
• "Bucket DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Bucket DUMPING a Turn the engine starting switch OFF for the preparations, and keep the engine running
PPC hydraulic during the troubleshooting.
switch fault S05 (male) Bucket control lever Resistance value
1
Between (1) and (2)
ing) DUMPING Max. 1 z
ing harness
(1) value
defective contact
value
3 (Contact with
Min. 1 Mz
4
bleshooting.
Governor • pump C03 Bucket control lever Voltage
5
NEUTRAL 20 – 30 V
DUMPING Max. 1 V
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
20-538 PC200/220(LC)-7
(5)
E-27 "SWING" is not correctly displayed in monitor function
Failure
• "SWING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Swing PPC hydraulic
switch, left, fault
1 (Internal disconnec- S03 (male) Swing control lever Resistance value
Left Max. 1 z
Swing PPC hydraulic
switch, right, fault
2 (Internal disconnec- S07 (male) Swing control lever Resistance value
Between (1) and (2)
ing)
Right Max. 1 z
Disconnection of wir- Wiring harness between C03 (female) (29) and S03 (female)
Resistance
ing harness (1), or wiring harness between C03 (female) (29) and S07 Max. 1 z
value
3 (Disconnection or (female) (1)
with connector) Wiring harness between S03 (female) (2) and grounding Max. 1 z
value
Resistance
value
4 (Contact with Wiring harness between C03 (female) (29) and S03 (female)
grounding (GND) Resistance
(1), or wiring harness between C03 (female) (29) and S07 Min. 1 Mz
circuit) value
wiring harness
5 Wiring harness between C03 (female) (29) and S03 (female)
(Contact with 24 V
circuit) (1), or wiring harness between C03 (female) (29) and S07 Voltage Max. 1 V
bleshooting.
6
NEUTRAL 20 – 30 V
Right or left Max. 1 V
20-540 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
PC200/220(LC)-7 20-541
(1)
E-28 "TRAVEL" is not correctly displayed in monitor function
Failure
• "TRAVEL" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Travel PPC hydraulic
switch fault
1 (Internal disconnec- S30 (male) Travel control lever Resistance value
Forward or reverse Max. 1 z
ing harness
Wiring harness from C03 (female) (39) to J01 to S30 (female) Resistance
(2) value
defective contact
Wiring harness from S30 (female) (2) to J05 to grounding Max. 1 z
value
3 (Contact with Wiring harness from C03 (female) (39) to J01 to S30 (female)
(2), or between wiring harness between C03 (female) (39) and Min. 1 Mz
circuit) value
A43 (female) (2) and grounding
wiring harness
4 Wiring harness from C03 (female) (39) to J01 to S30 (female)
(Contact with 24 V
circuit) (2), or between wiring harness between C03 (female) (39) and Voltage Max. 1 V
A43 (female) (2) and grounding
bleshooting.
5
NEUTRAL 20 – 30 V
Forward or backward Max. 1 V
20-542 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
PC200/220(LC)-7 20-543
(1)
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function
Failure • "Travel Differential Pressure" is not correctly displayed in the monitor function (special function) on the mon-
information itor panel.
Relative • When pressure difference is created between the right and left travel PPC circuits (in steering), the travel
information differential mechanism is turned ON.

Travel steering PPC
1 (Internal disconnec- S31 (male) Travel control lever Resistance value
One side of right or left only Max. 1 z
ing harness
(2) value
defective contact
Wiring harness from S31 (female) (2) to J05 to grounding Max. 1 z
value
3 (Contact with
Min. 1 Mz
4
bleshooting.
5
NEUTRAL 20 – 30 V
One side of right or left only Max. 1 V
20-544 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
PC200/220(LC)-7 20-545
(1)
E-30 "Service" is not correctly displayed in monitor function

Equipped with attachment
Failure
• "Service" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Service (front) PPC
1 (Internal disconnec- S10 (male) Service pedal Resistance value
Front Max. 1 z
Service (rear) PPC
2 (Internal disconnec- S11 (male) Service pedal Resistance value

Rear Max. 1 z
ing harness Wiring harness between C03 (female) (35) and S10 (female)
Resistance
3 (Disconnection or (1), or wiring harness between C03 (female) (35) and S11 Max. 1 z
value
defective contact (female) (1)
value
4 (Contact with Wiring harness between C03 (female) (35) and S10 (female)
(1), or between wiring harness between C03 (female) (35) and Min. 1 Mz
circuit) value
S11 (female) (1) and grounding
wiring harness
5 Wiring harness between C03 (female) (35) and S10 (female)
(Contact with 24 V
circuit) (1), or between wiring harness between C03 (female) (35) and Voltage Max. 1 V
S11 (female) (1) and grounding
bleshooting.
Governor • pump C03 Service pedal Voltage
6
NEUTRAL 20 – 30 V
Front or rear Max. 1 V
20-546 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for Service PPC hydraulic Switch
PC200/220(LC)-7 20-547
(5)
E-31 Troubleshooting for air conditioner system

PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
Failure
• The air conditioner does not work.
information
Relative • For the electrical circuit diagram inside the air conditioner unit, refer to the section of STRUCTURE AND
information FUNCTION - Air Conditioner in this manual.

1 Fuse No. 11 fault When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
ing harness
Resistance
2 (Disconnection or Wiring harness between FB1-11 outlet and M26 (male) (4) (5) Max. 1 z
value
defective contact
Wiring harness between M26 (male) (8) and grounding Max. 1 z
value
3 (Contact with
grounding (GND) Between wiring harness between FB1-11 outlet and M26
Voltage Min. 1 Mz
circuit) (male) (4) (5) and grounding
Air conditioner unit during the troubleshooting.
4
defective M26 Voltage
Between (4) (5) and (8) 20 – 30 V
Electrical Circuit Diagram for Air Conditioner
20-548 PC200/220(LC)-7
(7)

Troubleshooting procedure for air conditioner system

a The control panel of the air conditioner constantly monitors the sensors and other devices in the system .
When it detects any abnormality, “Self-diagnosis notice” is displayed by operating switches specially.
a If you feel any abnormality in the air conditioner system, check the “Self-diagnosis notice” first according to
the procedure for “Troubleshooting by self-diagnosis notice”, and then;
• If the “Self-diagnosis notice” is displayed, continue the “Troubleshooting by self-diagnosis notice”.
• If the “Self-diagnosis notice” is not displayed, carry out the “Troubleshooting by failure phenomenon”.
Troubleshooting by self-diagnosis notice

a Check the “Self-diagnosis notice” on the control
panel according to the following procedure.
• How to display “Self-diagnosis notice”

1) Turn the starting switch ON.
2) Press OFF switch (1) and check that any-
thing is not displayed on display monitor (2).
3) Hold the UP switch ( ) and DOWN switch
( ) of temperature setting switch (3) simul-
taneously for 3 seconds or more.
4) Check the “Self-diagnosis notice” displayed
on display monitor (2).
• How to select “Self-diagnosis notice” Self-diagnosis

Failure mode
If multiple “Self-diagnosis notices” are recorded, notice
press the UP switch ( ) or DOWN switch ( ) E-- No failures
of temperature setting switch (3) to select Disconnection in recirculated air
E11
another notice. sensor
Short-circuit in recirculated air sen-
E12
• How to delete “Self-diagnosis notice” sor
When reproducing the “Self-diagnosis notices” Disconnection in coolant tempera-
E15
or after removing the cause of a failure, press ture sensor
the switches on both sides of recirc/fresh air Short-circuit in coolant temperature
E16
selector switch (4) simultaneously for 3 seconds sensor
or more, and all the “Self-diagnosis notices” are E18 Short-circuit in daylight sensor
deleted. E43 Abnormality in air outlet damper
E44 Abnormality in air mix damper
• Finishing display of “Self-diagnosis notice” Abnormality in recirculated and fresh
E45
To finish display of the “Self-diagnosis notice”, air damper
press OFF switch (1) or turn the starting switch
OFF.
PC200/220(LC)-7 20-549
(11)
Self-diagnosis
notice Trouble Disconnection in recirculated air sensor
E11
Contents of
• Disconnection in the recirculated air sensor system is detected.
trouble
• Fixes the recirculated air temperature for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective recirculated starting switch ON.
standard value in normal state
1 air sensor
THI (male) Resistance
Possible causes and
Between (1) and (2) 300 z – 430 kz
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Short circuit in recirculated air sensor
E12
Contents of
• Short circuit in the recirculated air sensor system is detected.
trouble
• Fixes the recirculated air temperature for control.
Related
information

Defective recirculated air starting switch ON.
1 sensor (Internal short cir-

THI (male) Resistance
Possible causes and
cuit)
Between (1) and (2) 300 z – 430 kz
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
3
20-550 PC200/220(LC)-7
(5)
Self-diagnosis
notice Trouble Disconnection in coolant temperature sensor
E15
Contents of
• Disconnection in the coolant temperature sensor system is detected.
trouble
• Ignores the warm-up control and fixes the engine coolant temperature at 60°C for control.
Related
information

Defective coolant tem-
starting switch ON.

1 perature sensor (Internal
THW (male) Resistance
Possible causes and
disconnection)
Between (1) and (2) 95 z – 455 kz
harness (Disconnection Wiring harness between M30 (female) (14) and THW
connector) Wiring harness between M29 (female) (11) and THW
Resistance Max. 1 z
(female) (1)
3
Self-diagnosis
notice Trouble Short circuit in coolant temperature sensor
E16
Contents of
• Short circuit in the coolant temperature sensor system is detected.
trouble
• Ignores the warm-up control and fixes the engine coolant temperature at 60°C for control.
Related
information

Defective coolant tem-
starting switch ON.

1 perature sensor (Internal
THW (male) Resistance
Possible causes and
short circuit)
Between (1) and (2) 95 z – 455 kz
harness (Disconnection Wiring harness between M30 (female) (14) and THW
connector) Wiring harness between M29 (female) (11) and THW
Resistance Max. 1 z
(female) (1)
3
PC200/220(LC)-7 20-551
(11)
Self-diagnosis
notice Trouble Short circuit in daylight sensor
E18
Contents of
• Short circuit in the daylight sensor system is detected.
trouble
• Assumes that the daylight sensor is not installed for control.
Related
information

Defective daylight sen-

1 The daylight sensor may be defective. Check it directly.
sor (Internal short circuit)
Possible causes and
harness (Disconnection Wiring harness between M30 (female) (16) and P15
connector) Wiring harness between M30 (female) (3) and P15
Resistance Max. 1 z
(female) (1)
3
Self-diagnosis
notice Trouble Abnormality in air outlet damper
E43
Contents of
• Abnormality in air outlet servomotor system is detected.
trouble
• Stops the air outlet servomotor.
control panel • <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
Related a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
information the motor output shaft and break the motor coils.

Defective air outlet servo-
1 The air outlet servomotor may be defective. Check it directly.
motor (Internal defect)
starting switch ON.

Wiring harness between MV1 (female) (1) and M30
Possible causes and
Resistance Max. 1 z
(female) (3)
Disconnection in wiring Wiring harness between MV1 (female) (3) and M29
harness (Disconnection Resistance Max. 1 z
(female) (11)
2 in wiring harness or
defective contact in con- Wiring harness between MV1 (female) (5) and M30
Resistance Max. 1 z
nector) (female) (9)
Resistance Max. 1 z
(female) (8)
Resistance Max. 1 z
(female) (9)
Defective air conditioner If none of causes 1 and 2 is the cause of the trouble, the air conditioner system may
3
system be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-552 PC200/220(LC)-7
(5)
Self-diagnosis
notice Trouble Abnormality in air mix damper
E44
Contents of
• Abnormality in air mix servomotor system is detected.
trouble
• Stops the air mix servomotor.

Defective air mix servo-
1 The air mix servomotor may be defective. Check it directly.
motor (Internal defect)
starting switch ON.

Wiring harness between MAM (female) (1) and M29
Possible causes and
Resistance Max. 1 z
(female) (11)
Disconnection in wiring Wiring harness between MAM (female) (3) and M30
(female) (3)
defective contact in con- Wiring harness between MAM (female) (5) and M30
Resistance Max. 1 z
Resistance Max. 1 z
(female) (4)
Resistance Max. 1 z
(female) (5)
3
PC200/220(LC)-7 20-553
(5)
Self-diagnosis
notice Trouble Abnormality in recirculated and fresh air damper
E45
Contents of
• Abnormality in recirculated and fresh air servomotor system is detected.
trouble
• Stops the recirculated and fresh air servomotor.

Defective recirculated
1 and fresh air servomotor The recirculated and fresh air servomotor may be defective. Check it directly.
(Internal defect)
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.
2 Defective fuse (in unit)
Possible causes and
Check the related circuits.

starting switch ON.
Disconnection in wiring Wiring harness between MRF (female) (1) and M29
(female) (6)
defective contact in con- Wiring harness between MRF (female) (3) and M29
Resistance Max. 1 z
Wiring harness between MRF (female) (7), fuse in unit,
Resistance Max. 1 z
and M33 (female) (3)
Defective air conditioner If none of causes 1 – 3 is the cause of the trouble, the air conditioner system may be
4
system defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-554 PC200/220(LC)-7
(5)
PC200/220(LC)-7 20-555
(5)
Troubleshooting by failure phenomenon
Trouble • The air conditioner does not operate. (1) The air conditioner does not operate at all.
Related
information

If the fuse is broken, the circuit probably has a grounding fault, etc. (Refer to cause
1 Defective fuse No. 11
3.)
starting switch ON.
Wiring harness between fuse 11 outlet and M33 (male)
Disconnection in wiring Resistance Max. 1z
(3)
harness (Disconnection
Wiring harness between M27 (female) (14) and M30
2 in wiring harness or Resistance Max. 1z
(female) (6)
defective contact in con-
nector) Wiring harness between M33 (male) (3) and chassis
Resistance Max. 1z
ground
Wiring harness between M29 (female) (12) and chassis

Resistance Max. 1z
ground
Possible causes and
Short circuit with chassis starting switch ON.
ground in wiring harness Between wiring harness between circuit breaker fuse 11
3 Resistance Min. 1 Mz
(Contact with ground cir- outlet and M33 (male) (3) and chassis ground
cuit) Between wiring harness between M27 (female) (14) and
Resistance Min. 1 Mz
M30 (female) (6) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out trou-
bleshooting.
Defective air conditioner M33 Voltage
4
unit Between (2) and (3) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the air condi-
tioner is defective.
bleshooting.
M30, M29 Voltage
5 Defective control panel
Between M30 (6) and M29 (12) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the control
panel is defective.
20-556 PC200/220(LC)-7
(5)
Trouble • The air conditioner does not operate. (2) Air does not come out (Air flow is insufficient).
Related
information

Defective blower relay starting switch ON.
2
(on coil side) R30 (male) Resistance
Between (1) and (3) 140 – 340 z
bleshooting.
Defective blower relay
3 R30 Fan switch Voltage
(on contact side)
Between (4) and
ON (Operated) 20 – 30 V
chassis ground
bleshooting.
Defective power transis-
4 Fan switch
tor (Internal defect) If air flow can be changed with fan switch,
Operate in range of Low, Medium, and power transistor is normal.
High
bleshooting.
Possible causes and
Defective blower motor MB (female) Fan switch Voltage

5
(Internal defect) Between (1) and (2) ON (Operated) 20 – 30 V
If the above voltage is normal and the blower motor does not rotate, the blower motor
is defective.
starting switch ON.
Wiring harness between fuse 11 outlet, fuse in unit, R30
Resistance Max. 1 z
(3), R31 (female) (1), and M30 (female) (6)
Wiring harness between M29 (female) (3) and R30
Resistance Max. 1 z
(female) (1)
Disconnection in wiring Resistance Max. 1 z
ground
harness (Disconnection
Wiring harness between MB (female) (1) and R30
6 in wiring harness or Resistance Max. 1 z
(female) (4)
defective contact in con-
nector) Wiring harness between MB (female) (2) and PTR
Resistance Max. 1 z
(female) (3)
Wiring harness between PTR (female) (1) and chassis
Resistance Max. 1 z
ground
Wiring harness between PTR (female) (2) and M30
Resistance Max. 1 z
(female) (7)
Wiring harness between PTR (female) (4) and M30
Resistance Max. 1 z
(female) (8)
7
PC200/220(LC)-7 20-557
(5)
Trouble • The air conditioner does not operate. (3) Air is not cooled (Cooling capacity is low).
Related
information

Defective compressor starting switch ON.
2
relay (on coil side) R31 (male) Resistance
Between (1) and (2) 140 – 340 z
bleshooting (Setting of temperature: Highest cooling position).
Defective compressor
3 R31 Fan switch Voltage
relay (on contact side)
Between (4) and chassis
ON (Operated) 20 – 30 V
ground
Defective thermostat
4 The thermostat may be defective. Check it directly.
(Internal defect)
Defective high/low pres- starting switch ON.
5 sure switch (Internal dis-

P17 (male) Resistance
connection)
Possible causes and
Between (1) and (2) Max. 1 z

6 The compressor clutch may be defective. Check it directly.
clutch (Internal defect)
7 The compressor may be defective. Check it directly.
(Internal defect)
starting switch ON.
Wiring harness between M30 (female) (4) and P17
Resistance Max. 1 z
(female) (1)
Wiring harness between P17 (female) (2) and chassis
Resistance Max. 1 z
ground
Disconnection in wiring Wiring harness between fuse 11 outlet, R31 (female)
(2), fuse in unit, R31 (female) (1), and M30 (female) (6)
defective contact in con- Wiring harness between ST1 (female) (1) and R31
Resistance Max. 1 z
Wiring harness between M29 (female) (2) and ST1
Resistance Max. 1 z
(female) (2)
Resistance Max. 1 z
ground
Wiring harness between R31 (female) (4) and M34
Resistance Max. 1 z
(female) (1)
9
20-558 PC200/220(LC)-7
(5)
PC200/220(LC)-7 20-559
(5)
E-32 Travel alarm does not sound

Equipped with travel alarm
Failure • The travel alarm does not sound while the machine is traveling.
information • The alarm begins to sound when the machine is at a standstill.
Relative
—
information

When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
1 Fuse No. 15 fault
(Refer to cause 4)
If the monitor display is not correct, proceed to No. E-21 Troubleshooting.

2 Travel signal fault
Control lever operation: ON
019 Travel
Control lever NEUTRAL: OFF
ing harness
Wiring harness between FB1-15 outlet to J03 and A43 Resistance
(female) (1) value
defective contact
Wiring harness between A43 (female) (2) and J01 (19) Max. 1 z
value
4 (Contact with
grounding (GND) Between wiring harness between FB1-15 outlet to J03 and Resistance
Min. 1 Mz
circuit) A43 (female) (1) and grounding value
As this is an internal failure, troubleshooting cannot be conducted. (If none of the causes
5 Travel alarm fault
listed in Item 1 through 4 above is found, the travel alarm is judged as defective)
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm
20-560 PC200/220(LC)-7
(5)
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H-MODE)
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS ...................................................... 20-602

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 maximizing function 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
(11)
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
20-602 PC200/220(LC)-7
(11)
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

Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure information Phenomena occurring on machine

Relative information Information on occurred failures and troubleshooting

2
Cause for presumed
failure <Contents>
(The attached No. for The standard values in normalcy by which to judge "good" or "no good" about
3
filing and reference presumed causes.
purpose only. It does not stand References for making judgement of "good" or "no good"
for any priority)
4
20-604 PC200/220(LC)-7
TROUBLESHOOTING 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.

a Stop engine for preparations. Start troubleshooting at engine high idle.
Control lever Unload pressure
1 Malfunctioning of unload valve
3.9 ± 1.0 MPa
All control levers in NEUTRAL
{40 ± 10kg/cm2}
Control lever Main relief pressure
Improper adjustment or mal- 33.3 – 36.8 MPa

2 Arm, DIGGING
functioning of main relief valve {340 – 375kg/cm2}
If the pressure does not return to normalcy even after the adjustment, malfunc-
tioning of main relief valve or its internal failure is suspected. In that case, check
the valve itself.
Malfunctioning of self pressure Control lever Control circuit source pressure
3
decompression valve 2.83 – 3.43 MPa

{29 – 35kg/cm2}
Oil pressure to be mea-
Measurement condition Oil pressure ratio
sured
Improper adjustment or mal- Pump delivery pressure Swing lock: ON 1
4
functioning of PC valve PC valve output pressure Arm digging relief Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunc-
tioning of PC valve or its internal failure is suspected. In that case, check the valve
itself.
Travel speed Travel control lever LS-EPC output pressure
Malfunctioning of LS-EPC
5 Approx. 2.9 MPa
valve Lo NEUTRAL
{Approx. 30 kg/cm2}
Hi Travel control lever 0{0}
Oil pressure ratio
Oil pressure to be mea- Travel without load (con-
sured All control levers in
trol lever held at half
NEUTRAL
Improper adjustment or mal- stroke)
6
functioning of LS valve Pump delivery pressure 1
Nearly equal pressure
LS valve output pressure Approx. 3/5
tioning 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.
If none of the above listed causes is detected, the piston pump is suspected of
8 Piston pump defective
deteriorated performance, malfunctioning or internal failure.
PC200/220(LC)-7 20-605
(11)
TROUBLESHOOTING H-2
H-2 Engine speed sharply drops or engine stalls
Failure information • The engine speed sharply drops or the engine stalls.
Relative information • Set the working mode at A mode for the troubleshooting.

Control lever Main relief pressure

1 Arm, DIGGING
functioning of main relief valve {340 – 375kg/cm2}
tioning of the main relief valve or its internal failure is suspected. In that case,
check the valve itself.

Oil pressure to be mea-
Measurement condition Oil pressure ratio
sured
Improper adjustment or mal- Pump delivery pressure Swing lock: ON 1
2
functioning of PC valve PC valve output pressure Arm digging relief Approx. 3/5
tioning of the PC valve or its internal failure is suspected. In that case, check the
valve itself.
Oil pressure ratio
Oil pressure to be mea- Travel without load
sured All control levers in
(control lever held at half
NEUTRAL
Improper adjustment or mal- stroke)
3
functioning of LS valve Pump delivery pressure 1
tioning of the LS valve or its internal failure is suspected. In that case, check the
valve itself.
Orifice or filter in servo equip- The orifice or filter in the pump servo equipment is suspected of clogging. Check
4
ment clogged the equipment itself.
5 Malfunction of servo piston The servo piston is suspected of malfunction. Check the piston itself.
20-606 PC200/220(LC)-7
(11)
TROUBLESHOOTING H-3, H-4
H-3 No work equipment, travel or swing move
Failure information • No work equipment nor travel and swing functions can be set in motion.


Lock lever Main relief pressure
Malfunctioning of PPC lock
1 Locked 0{0}
solenoid valve
2.84 – 3.43 MPa
Released
{29 – 35kg/cm2}
Malfunctioning of self pressure Control lever Control circuit source pressure
2
All control levers in NEUTRAL position
{29 – 35kg/cm2}
The piston pump is suspected of malfunctioning or an internal failure. Diagnose it
in the following manner.
3 Piston pump defective
• Remove the oil pressure measurement plug and crank the engine. If oil flows out,
it is in normal condition.
It is presumed that the pump shaft does not rotate due to some internal failure of
4 Damper defective
the dumper. Check the damper itself.
H-4 Abnormal noise is heard from around hydraulic pump
Failure information • An abnormal noise is heard from around the hydraulic pump.
Relative information —

1 Hydraulic oil level lowered Make a visual check.
2 Quality of hydraulic oil bad Air may have get mixed with the oil. Make a visual check.
Hydraulic tank cap breather It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby
3
clogged causing negative pressure inside the tank. Make a visual check.
Hydraulic tank strainer It is presumed that the strainer in the hydraulic tank is clogged, thereby causing
4
clogged negative pressure in the suction circuit. Make a visual check.
5 Piston pump defective The piston pump is suspected of an internal failure. Check the pump itself.
PC200/220(LC)-7 20-607
(11)
H-5 Auto-decelerator does not work
Failure information • The auto-decelerator does not work.

• 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
Relative information
only in the travel circuit -actually located inside PPC valve)
• Set the working mode at A mode for the troubleshooting.

Presumed cause and stan-
dard value in normalcy

Travel control lever PPC valve output pressure
Malfunctioning of NEUTRAL 0{0}
1 travel PPC valve
(shuttle valve)
Above 2.7 MPa
Operation
{Above 28 kg/cm2}
H-6 Fine control mode does not function
Failure information • The fine control mode poorly functions or its response is slow.

LS-EPC valve output
Travel speed Travel control lever
Malfunctioning of pressure
1
LS-EPC valve Approx. 2.9 MPa
Lo NEUTRAL
{Approx. 30 kg/cm2}
Hi Travel control lever 0{0}
Orifice in LS circuit
2 The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
clogged
Oil pressure ratio
Oil pressure to be measured Travel without load

All control levers in
(control lever held at half
Improper adjust- NEUTRAL
stroke)
3 ment or malfunction-
ing of LS valve Pump delivery pressure 1
Nearly equal oil pressure
PC valve output pressure Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunction-
ing of the LS valve or its internal failure is suspected. In that case, check the valve
itself.
Malfunctioning of
4 Malfunctioning of the servo piston is suspected. Check the piston itself.
servo piston
20-608 PC200/220(LC)-7
(11)
TROUBLESHOOTING H-7
H-7 Boom moves slowly or lacks power
Failure information • The boom moves slowly or lacks power


Boom lever PPC valve output pressure
Malfunctioning of right PPC
1 NEUTRAL 0{0}
valve (in boom circuit)
Above 2.7 MPa
RAISE or LOWER
{Above 28 kg/cm2}
Working mode Solenoid output pressure
Malfunction of merge/divide
2 A mode 0{0}
solenoid valve
2.84 – 3.43 MPa
Other than A mode
{29 – 35 kg/cm2}
Malfunctioning of merge/divide The merge/divide valve (main and LS valves) is presumed to malfunction. Check
3
valve (main and LS valves) the valve itself.
Malfunctioning of boom control The spool in the boom control valve is presumed to malfunction. Check the valve
4
valve (spool) itself.
Malfunctioning of boom control
The pressure compensation valve in the boom control valve is presumed to mal-
5 valve (pressure compensation
function. Check the valve itself.
valve)
Malfunctioning of boom control The regeneration valve in the boom control valve or the seal is presumed to mal-
6
valve (regeneration valve) function. Check the valve itself.
Malfunctioning of boom control The lock valve in the boom control valve is presumed to malfunction. Check the
7
valve (lock valve) valve itself.
Malfunctioning of safety valve The safety valve for the lock valve is presumed to malfunction, or the seal is sus-
8
for lock valve or seal defective pected to be defective. Check the valve itself.
The suction valve in the boom control valve is presumed to malfunction, or the
9 valve (suction valve) or seal
seal is suspected to be defective.
defective
The safety and suction valves in the boom control valve are presumed to mal-
10 valve (safety and suction
function, or the seal is suspected to be defective. Check those valves themselves.
valves) or seal defective
Malfunctioning of LS shuttle
LS shuttle valves in the left travel control valve, bucket control valve and service
11 valve (left travel, bucket and
control valve are presumed to malfunction. Check those valves themselves.
service valves)
12 Boom cylinder defective Boom lever Amount oil leakage from cylinder
Raise relief 20 cc/min
PC200/220(LC)-7 20-609
(11)
TROUBLESHOOTING H-8
H-8 Arm moves slowly or lacks power
Failure information • The arm moves slowly, or lacks power.


Arm lever PPC valve output pressure
Malfunctioning of left PPC
1 NEUTRAL 0{0}
valve (arm circuit)
Above 2.7 MPa
DIGGING or DUMPING
{Above 28 kg/cm2}
Working mode Solenoid output pressure
Malfunctioning of merge/divide
2 A mode 0{0}
solenoid valve
2.84 – 3.43 MPa
Other than A mode
{29 – 35 kg/cm2}
Malfunctioning of merge/divide The merge/divide valve (main and LS valves) is presumed to malfunction. Check
3
valve (main and LS valves) the valve itself.
Malfunctioning of arm control The spool in the arm control valve is presumed to malfunction. Check the valve
4
Malfunctioning of arm control
The pressure compensation valve in the arm control valve is presumed to mal-
valve)
Malfunctioning of arm control The generation valve in the arm control valve is presumed to malfunction, or the
6
valve (regeneration valve) seal is suspected to be defective. Check the valve itself.
Malfunctioning of arm control
The safety and suction valves in the arm control valve are presumed to malfunc-
7 valve (safety and suction
tion, or the seal is suspected of defect. Check those valves themselves.
valves) or seal defective
Malfunctioning of LS shuttle
LS shuttle valves in the right travel control valve, boom control valve, left travel
valve (right travel, boom, left
8 control valve, bucket control valve and service valve are presumed to malfunc-
travel, bucket and service
tion. Check those valves themselves.
valves)
9 Arm cylinder defective Arm lever Amount oil leakage from cylinder
Digging relief 20 cc/min
20-610 PC200/220(LC)-7
(11)
H-9 Bucket moves slowly or lacks power
Failure information • The bucket moves slowly, or lacks power.


Bucket lever PPC valve output pressure
Malfunctioning of right PPC
1 NEUTRAL 0{0}
valve (bucket circuit)
Above 2.7 MPa
DIGGING or DUMPING
{Above 28 kg/cm2}
Malfunctioning of bucket con- The spool in the bucket control valve is presumed to malfunction. Check the
2
trol valve (spool) valve itself.
Malfunctioning of bucket con-
The pressure compensation valve in the bucket control valve is presumed to
3 trol valve (pressure compen-
malfunction. Check the valve itself.
sation valve)
Malfunctioning of bucket con- The safety and suction valves in the bucket control valve are presumed to
4 trol valve (safety and suction malfunction, or the seal is suspected to be defective. Check those valves
valves) or seal defective themselves.
Malfunction of LS shuttle valve The LS shuttle valve in the service control valve is presumed to malfunction.
5
(service valve) Check the valve itself.
6 Bucket cylinder defective Bucket lever Amount oil leakage from cylinder
H-10 Work equipment does not move in its single operation
• The boom does not move when operated independently.

Failure information • The arm does not move when operated independently.
• The bucket does not move when operated independently.


Work equipment control lever PPC valve output pressure
1 Malfunctioning of PPC valve NEUTRAL 0{0}
Above 2.7 MPa
Operation
{Above 28 kg/cm2}
Malfunctioning of work equip- The spool in the work equipment control valve is presumed to malfunction.
2
ment control valve (spool) Check the valve itself.
PC200/220(LC)-7 20-611
(11)
TROUBLESHOOTING 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.


1 Boom cylinder defective Boom control lever Amount oil leakage from cylinder
Raise relief 20 cc/min
Boom control lever (lock valve) The seal at lock valve in the boom control lever is suspected to be defective.
2
seal defective Check the valve itself.
Seal at safety valve for lock The seal at the safety valve in the lock valve is suspected to be defective.
3
valve defective Check the valve itself.
Failure information (2) • Hydraulic drift of the arm is a bit too fast.

1 Arm cylinder defective Arm control lever Amount oil leakage from cylinder

The seal for safety and suction valves in the arm control valve is suspected
to be defective. Check the valve itself.
Arm control valve (safety and a Whether the seal is defective or not may well be determined by changing
2
suction valves) seal defective 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, be-
cause the set pressure differs)
Arm control valve (spool) seal The seal for spool in the arm control valve is suspected to be defective.
3
defective Check the seal itself.
Arm control valve (pressure
The seal for pressure compensation valve in the arm control valve is sus-
4 compensation valve) seal
pected to be defective. Check the seal itself.
defective
Failure information (3) • Hydraulic drift of the bucket is a bit too fast.

1 Bucket cylinder defective Bucket control lever Amount oil leakage from cylinder

The seal for the safety and suction valves in the bucket control lever is sus-
Bucket control valve (safety
a Whether the seal is defective or not may well be determined by changing
2 and suction valves) seal
for other safety and suction valves. (Do not attempt to change them for the
defective
safety and suction valves for the boom LOWER and the lock valve, be-
cause the set pressure differs)
Bucket control valve (spool) The seal for spool in the bucket control valve is suspected to be defective.
3
seal defective Check the seal itself.
Bucket control valve (pres-
The seal for pressure compensation valve in the bucket control valve is sus-
4 sure compensation valve) seal
defective
20-612 PC200/220(LC)-7
(11)
TROUBLESHOOTING H-12, H-13, H-14
H-12 Work equipment has big time lag
Failure information • The work equipment has a big time lag.


LS-EPC valve output
Malfunctioning of LS-EPC pressure
1
valve Approx. 2.9 MPa
Lo NEUTRAL
{approx. 30 kg/cm2}
Hi Operation 0{0}
Malfunctioning of control valve
The regeneration valve in the control valve is presumed to malfunction.
2 (regeneration valve) - with
Check the valve itself.
boom and arm only
The safety and suction valves of the control valve are presumed to malfunc-
tion. Check those valves themselves directly.
Malfunctioning of control a For the arm and boom, whether they are defective or not may well be de-
3
valves (safety & suction valve) termined by changing them for other safety and suction valves. (Do not at-
tempt 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
The pressure compensation valve of the control valve is presumed to mal-
4 (pressure compensation
function. Check the valve itself directly.
valve)
H-13 Other work equipment moves when relieving single circuit
Failure information • Other work equipment moves when relieving the single circuit of specific work equipment.

Control valve (pressure com- The seal for pressure compression valve in the control valve is suspected to
1
pensation valve) seal defective be defective. Check the seal itself.
H-14 One-touch power max. switch does not operate
Failure information • The one-touch power max. switch does not operate.


Swing lock switch Solenoid valve output pressure
Malfunctioning of 2-stage sole-
1 OFF 0{0}
noid valve
2.84 – 3.43 MPa
ON
{29 – 35kg/cm2}
Malfunctioning of main relief
2 The main relief valve is presumed to malfunction. Check the valve itself.
valve
PC200/220(LC)-7 20-613
(11)
TROUBLESHOOTING H-15, H-16, H-17
H-15 In compound operation, work equipment with larger load moves slowly
Failure information • In a compound operation, work equipment with larger load tends to move slowly.
Relative information —

The pressure compensation valve for the work equipment with larger load is
presumed to malfunction. Check the valve itself.

Combination of compound operation Work equipment with larger load
Malfunctioning of pressure Boom RAISE + arm DIGGING Boom RAISE
1 compensation valve for work
Boom RAISE + arm DUMPING Arm DUMPING
equipment with larger load
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
Failure information • 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.

Malfunctioning of LS select The LS select valve is presumed to malfunction, or the seal is suspected to
1
valve or seal defective be defective. Check the valve and seal themselves.
H-17 In swing + travel, travel speed drops sharply
Failure information • 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.

Malfunctioning of LS shuttle The LS shuttle valve in the left travel control valve or the swing control valve
1
valve (left travel and swing) is presumed to malfunction. Check both of them directly.
20-614 PC200/220(LC)-7
(1)
H-18 Machine swerves in travel
Failure information • The machine tends to swerve while traveling.


Malfunctioning of travel PPC Above 2.7 MPa
1 Forward or reverse
valve {Above 28 kg/cm2}
Differential output between right
0.4 MPa {4 kg/cm2}
and left sides
Malfunctioning of self-pressure Control lever Control circuit source pressure
2
{29 – 35 kg/cm2}

Oil Pressure ratio
Oil pressure to be Travel without load
Improper adjustment or mal- measured All control levers in
3 (control lever held at half
functioning of LS valve NEUTRAL
stroke)
Pump delivery pressure 1
Malfunctioning of travel inter-
4 Operating one side only 0 {0}
locking solenoid valve
2.84 – 3.43 MPa
Operating both sides
{29 – 35 kg/cm2}
5 The travel interlocking valve is presumed to malfunction. Check the valve itself.
locking valve
Malfunctioning of travel control The spool in the travel interlocking valve is presumed to malfunction. Check the
6
valve (spool) spool itself.
7 Malfunction of travel motor Travel control lever Amount of oil leakage from travel motor
Travel relief 27.2 ¬/min
The final drive is suspected of an internal failure. Check the inside of the final
drive directly.
8 Final drive defective a 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 20-615
(11)
H-19 Machine travels slowly
Failure information • The machine's travel speed is slow.


Malfunctioning of travel PPC Above 2.7 MPa
1 Forward or reverse
valve {Above 28 kg/cm2}
Output differential between right and Below 0.4 MPa
left or front and rear {Below 4 kg/cm2}
Malfunctioning of self-pressure Control lever Control circuit source pressure
2

{29 – 35kg/cm2}
LS-EPC valve output
Malfunctioning of LS-EPC pressure
3
valve Approx. 2.9 MPa
Lo NEUTRAL
{approx. 30 kg/cm2}
Hi Travel control lever 0 {0}
Malfunction of travel control The spool in the travel control valve is presumed to malfunction. Check the spool
4
Malfunctioning of travel control
The pressure compensation valve in the travel control valve is presumed to mal-
valve)
Malfunctioning of travel control The suction valve in the travel control valve is presumed to malfunction. Check
6
valve (suction valve) the valve itself.
Malfunctioning of LS shuttle The LS shuttle valve in the bucket control valve is presumed to malfunction.
7
valve (bucket) Check the valve itself.
7 Malfunction of travel motor Travel control lever Amount of oil leakage from travel motor
drive directly.
8 Final drive defective a 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.
20-616 PC200/220(LC)-7
(11)
H-20 Machine cannot be easily steered or lacks power
Failure information • The machine cannot be easily steered.


Travel control lever PPC valve output pressure (steering)
Malfunctioning of travel PPC
1 NEUTRAL on both sides 0 {0}
valve (steering spool)
Above 2.7 MPa
Operating one side only
{Above 28 kg/cm2}
Travel control lever Solenoid valve output pressure
2 Operating both sides 0 {0}
locking solenoid valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
3 The travel interlocking valve is presumed to malfunction. Check the valve itself.
locking valve
Travel control lever Solenoid valve output pressure
4 Operating both sides 0 {0}
solenoid valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
5 The merge/divide valve is presumed to malfunction. Check the valve itself.
valve
Malfunction of travel control The spool in the travel control valve is presumed to malfunction. Check the spool
6
Malfunctioning of travel control
The pressure compensation valve in the travel control valve is presumed to mal-
valve)
Malfunctioning of travel control The suction valve in the travel control valve is presumed to malfunction. Check
8
valve (suction valve) the valve itself.
Malfunctioning of LS shuttle The LS shuttle valve in the bucket control valve is presumed to malfunction.
9
valve (bucket) Check the valve itself.
Check valve seal defective at The seal in the check valve of LS oil pressure pickup port is suspected to be
10
LS oil pressure pickup port defective. Check the seal itself.
The seal in the check valve of the travel motor is suspected to be defective.
Malfunctioning of travel motor Check the seal itself.
11
(safety valve) a Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.
The seal in the check valve of the travel motor is suspected of defect. Check the
Malfunctioning of travel motor seal itself.
12
(check valve) a 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
(11)
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.

Travel speed Travel control lever Monitoring [15]
810 mA (PC200/200LC-7)
Lo
Fine control 635 mA (PC220/220LC-7)

(to the extent that the
470 mA (PC200/200LC-7)
( Mi) decelerator is
717 mA (PC220/220LC-7)
released)
Malfunctioning of LS-EPC
1 Hi 0 mA
valve
LS-EPC valve output pres-
sure
Approx. 2.9 MPa
Lo NEUTRAL
{approx. 30 kg/cm2}
Hi Operation 0 {0}
Solenoid valve output
Malfunctioning of travel speed pressure
2
solenoid valve Lo NEUTRAL 0 {0}
2.84 – 3.43 MPa
Hi Operation
{29 – 35 kg/cm2}
Malfunctioning of travel motor The travel motor is presumed to malfunction when shifting speed. Check the
3
(speed shifting) speed shifting portion directly.
: The "Mi" mode is on the multi-monitor specification machine only.
20-618 PC200/220(LC)-7
(11)
H-22 Track shoe does not turn (on one side only)
Failure information • A track shoe does not turn (only on one side).

Travel control valve (suction The suction valve seat in the travel control valve is suspected of defect. Check
1
valve) seat defective the seat itself.
Travel motor (safety valve) The safety valve seat in the travel motor is suspected of defect. Check the seat
2
seat defective itself.
Travel motor (check valve) The check valve seat in the travel motor is suspected of defect. Check the seat
3
seat defective itself.
4 Travel Motor speed reduced Travel control lever Amount of oil leakage from travel motor
drive directly.
5 Final drive defective a 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.
PC200/220(LC)-7 20-619
(11)
H-23 Machine does not swing
Failure information (1) • The machine swings neither to the right nor to the left.

Malfunctioning of swing park- Swing Solenoid valve
1
ing brake solenoid valve NEUTRAL 0 {0}
Operation 2.84 – 3.43 MPa {29 – 35 kg/cm2}

Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction.
2
(parking brake) Check it directly.
Swing lock switch Swing control lever Swing relief pressure
3 functioning of swing motor ON Swing relief
{295 – 335 kg/cm2}
(safety valve)
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.
4 Swing motor defective Swing control lever Amount of oil leakage from swing motor
Swing relief Below 10 ¬/min
The swing machinery is suspected of an internal failure. Check the inside of the
swing machinery directly.
5 Swing machinery defective a 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.


Left control lever PPC valve output pressure
1 Malfunctioning of PPC valve
NEUTRAL 0 {0}
Swing operation Above 2.7 MPa {Above 28 kg/cm2}
Malfunctioning of swing control The spool in the swing control valve is presumed to malfunction. Check the spool
2
The seal in the suction valve of the swing motor is suspected of defect. Check the
Swing motor (suction valve) seal itself.
3
seal defective a 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.
The seal in the check valve of the swing motor is suspected of defect. Check the
Swing motor (check valve) seal itself.
4
right and left check valves and watching the result.
20-620 PC200/220(LC)-7
(11)
H-24 Swing acceleration is poor, or swing speed is slow
Failure information (1) • Swing acceleration is poor, or swing speed is slow.


Malfunctioning of LS shuttle The LS shuttle valves for all the control valves are presumed to malfunction.
1
valve (all LS shuttles) Check them directly.
Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction. Check
2
(parking brake) it directly.
{295 – 335 kg/cm2}
(safety valve)
4 Swing motor defective Swing control lever Amount of oil leakage from swing motor
Swing relief Below 10 l/min
Failure information (2) • Swing acceleration is poor only on one side, or swing speed is slow.

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 The spool in the swing control valve is presumed to malfunction. Check the valve
2
Malfunctioning of swing motor
The pressure compensation valve in the swing motor is presumed to malfunction.
3 (pressure compensation
valve)
The seal in the suction valve of the swing motor is suspected of defect. Check the
Swing motor (suction valve) seal itself.
4
right and left suction valves and watching the result.
The seal in the check valve of the swing motor is suspected of defect. Check the
Swing motor (check valve) seal itself.
5
right and left check valves and watching the result.
PC200/220(LC)-7 20-621
(11)
H-25 Excessive overrun when stopping swing
Failure information (1) • The work equipment overruns excessively when stopping swing.



{295 – 335 kg/cm2}
(safety valve)
Amount of oil leakage from swing
2 Swing motor defective Control lever
motor
Swing relief Below 10 l/min
Failure information (2) • Swing only one side, and the work equipment overruns excessively when stopping swing.

Swing control lever PPC valve output pressure
NEUTRAL 0 {0}
The PPC slow return valve is suspected of clogging. Check the valve itself.
Swing PPC slow return valve
2 a Whether the valve is clogged or not may well be determined by swapping
clogged
the right and left valves and watching the result.
Malfunctioning of swing control The spool in the swing control valve is resumed to malfunction. Check the
3
valve (spool) valve itself.
The seal in the suction valve of the swing motor is suspected of defect.
Swing motor (suction valve) Check the seal itself.
4
seal defective a Whether the seal is defective or not may well be determined by swapping
the right and left suction valves and watching the result.
The seal in the check valve of the swing motor is suspected of defect.
Swing motor (check valve) Check the seal itself.
5
seal defective a 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
(11)
H-26 There is big shock when stopping swing
Failure information • There is a big shock caused when stopping a swing motion.


Malfunctioning of swing PPC Swing control lever PPC valve output pressure
1
valve NEUTRAL 0 {0}
The swing PPC slow return valve is presumed to malfunction. Check the
Malfunctioning of swing PPC valve itself.
2
slow return valve a Whether the valve malfunctions or not may well be determined by swap-
ping the right and left valves and watching the result.
H-27 There is big abnormal noise caused when stopping swing
Failure information • There is a big abnormal noise caused when stopping a swing motion.

Malfunctioning of backpres-
1 The backpressure valve is presumed to malfunction. Check the valve itself.
sure valve
Malfunction of swing motor The safety valve in the swing motor is presumed to malfunction. Check the
2
(safety valve) valve itself.
The seal in suction valve of the swing motor is suspected of defect. Check
Malfunction of swing motor the seal itself.
3
(suction valve) a Whether the seal is defective or not may well be determined by swapping
the right and left valves and watching the result.
The swing machinery is suspected of an internal failure. Check the inside of
the machinery itself.
4 Swing machinery defective a A failure inside the swing machinery may well be determined by monitoring
abnormal noise, abnormal heat generated or metal dust or chips con-
tained in the drained oil.
PC200/220(LC)-7 20-623
(11)
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).
• 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.


Swing and parking brake sole- Swing control lever Solenoid valve output pressure
1
noid valve malfunctioned NEUTRAL 0 {0}
Left or right 2.84 – 3.43 MPa {29 – 35 kg/cm2}
Swing motor (parking brake The parking portion of the swing motor is suspected of malfunctioning and
2
portion) malfunctioned interior failure. Check that portion directly.
Failure information (2) • Natural drift of the swing is too big (when the parking brake is released).
• 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.

Swing control valve (spool) The seal in the spool of the swing control valve is suspected of defect.
1
malfunctioned Check the spool itself directly.

Swing control valve (pressure

The pressure compensation valve seal in the swing control valve is sus-
2 compensation valve) malfunc-
pected of defect. Check the valve itself directly.
tioned
Swing motor (safety valve) The safety valve seal in the swing motor is suspected of defect. Check the
3
defective valve itself directly.
Swing motor (suction valve) The suction valve seal in the swing motor is suspected of defect. Check the
4
Swing motor (check valve) The check valve seal in the swing motor is suspected of defect. Check the
5
20-624 PC200/220(LC)-7
(11)
TROUBLESHOOTING OF ENGINE
(S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-702

S-1 Starting performance is poor (Starting always takes time) ................................................................ 20-706
S-2 Engine does not start ........................................................................................................................ 20-708
(1) Engine does not turn ................................................................................................................... 20-708
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) ............................... 20-709
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)............................. 20-710
S-3 Engine does not pick up smoothly (Follow-up is poor) ..................................................................... 20- 711
S-4 Engine stops during operations ........................................................................................................ 20-712
S-5 Engine does not rotate smoothly (Hunting)....................................................................................... 20-713
S-6 Engine lacks output (or lacks power) ................................................................................................ 20-714
S-7 Exhaust smoke is black (Incomplete combustion) ............................................................................ 20-715
S-8 Oil consumption is excessive (or exhaust smoke is blue) ................................................................ 20-716
S-9 Oil becomes contaminated quickly ................................................................................................... 20-717
S-10 Fuel consumption is excessive ......................................................................................................... 20-718
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down................................................ 20-719
S-12 Oil pressure monitor lights up (Drop in oil pressure)......................................................................... 20-720
S-13 Oil level rises (Coolant, fuel in oil) .................................................................................................... 20-721
S-14 Coolant temperature becomes too high (Overheating)..................................................................... 20-722
S-15 Abnormal noise is made ................................................................................................................... 20-723
S-16 Vibration is excessive ....................................................................................................................... 20-724
PC200/220(LC)-7 20-701
(11)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in [B] are items that can be
obtained from the user, depending on the user’s
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under [C] in the
chart on the right correspond to this.
The serviceman narrows down the causes from
information [A] that he has obtained from the user
and the results of [C] that he has obtained from his
own inspection.
[Troubleshooting] Causes
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been
marked as having the highest probability from infor-
mation gained from [Questions] and [Check
items].
(1) (2) (3)
(a)
Questions
[A] (b)
(c)
(d)
(e)
[B]
Check items
[C]
i
shooting
Trouble-
ii
iii
20-702 PC200/220(LC)-7
(5)
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and
mark the Cause column with E to use Causes
as reference for locating the cause of
)
tion
the failure. However, do not use this
injec
when making calculations to narrow
down the causes.
fuel
2. Use the E in the Cause column as ref-
sive
erence for [Degree of use (Operated for
le
xces
noz z
nce
long period)] in the [Questions] section
p (e
rfere
tion
g
as reference. As a rule, do not use it
t
me n
in
pum
im
injec
r
inte
nde
when calculating the points for locating
t
le
tion
ction
er e
ger,
, cyli
f uel
the cause, but it can be included if nec-
injec
lean
l inje
char
ring
essary to determine the order for trou-
ized
fuel
air c
r fue
bleshooting. urbo
ton
, se
ctive
n pis
ged
ged
rope
ed t
D ef e
Clog
Clog
Seiz
Wor
I mp
Confirm recent repair history
Degree of use Operatred for long period
PC200/220(LC)-7 20-703
(5)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel
Causes
d
hea
on)
)
ized
jecti
der
r se
el in
cylin
nge
e fu
e, va rger and
k, plu
essiv
eat
le
nozz
lve s
(rac
(exc
e
a
renc
boch
ump
tion
ming
ump
ent
terfe
r
en tu
injec
der
ce
r
on p
lem
uffle
valv
on ti
er, in
aran
tion
n
er e
etwe
, cyli
jecti
fuel
dm
ct of
jecti
injec
e cle
harg
lean
el in
ring
gge
d
air b
Defe r fuel in
conta
eize
Legend
rboc
fuel
lv
air c
, clo
e fu
n
r va
: Possible causes (judging from Questions and check items)
e of
s
to
ed tu
ctive
ctive
,
n pis
ectiv
: Most probable causes (judging from Questions and Check items)
shed
ged
ged
rope
rope
kag
: Possible causes due to length of use (used for a long period)
Defe
Clog
Clog
Seiz
Deff
Wor
Imp
Imp
Lea
Cru
: Items to confirm the cause.
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Blue under light load

Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after starting
Check items
engine, temperature of some cylinders is low

Match marks on fuel injection pump are out of alignment
Seal on fuel injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and cylinder head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Speed of some cylinders does not change when operating on
reduced cylinders
Troubleshooting
When check is made using delivery method, fuel injection timing

is found to be incorrect
Fuel injection pump test shows that fuel injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does not
return
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-704 PC200/220(LC)-7
(5)
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and cylinder head:
(3) Clogged, seized fuel injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting
area and carry out the troubleshooting item
marked . The Remedy is given as [Clean], so
carry out cleaning, and the exhaust gas color
should return to normal.
PC200/220(LC)-7 20-705
(5)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)
General causes why exhaust smoke comes out but engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel
(At ambient temperature of –10°C or below,
ASTM D975 No. 2 diesel fuel is used)
a Battery charging rate
Charging rate
Ambient 100 % 90 % 80 % 75 % 70 %
temperature
20°C 1.28 1.26 1.24 1.23 1.22
0°C 1.29 1.27 1.25 1.24 1.23
–10°C 1.30 1.28 1.26 1.25 1.24
• The specific gravity should exceed the value for the

charging rate of 70% in the above table.
• In cold areas the specific gravity must exceed the value
for the charging rate of 75% in the above table.
20-706 PC200/220(LC)-7
(5)
Replace
Replace
Replace
Replace
Adjust
Replace
PC200/220(LC)-7
Defe
tive
Correct Leak
injec
tion
age, pum
Clean clog p (ra
TROUBLESHOOTING
Clog ging ck, p

ged , air lung
Replace Defe
air b
reath
in fu
el pip
er s t
uck)
ctive er h
o ing
Replace fe ed p le in
Defe f
Causes
ctive u mp uel t
boos ank
t com
pens
ator
canc
el
(5)
20-707
S-1
TROUBLESHOOTING S-2
S-2 Engine does not start
(1) Engine does not turn
General causes why engine does not turn
• Internal parts of engine seized

a If internal parts of the engine are seized, car-
ry out troubleshooting for "Engine stops dur-
ing operations".
tion
n ec
it
• Failure in hydraulic pump system
tery
ircu
con
• Defective electrical system
t
ing c
d ba
inal
ch
otor
e
s t ar t
lay
t
t er m
swit
iora
lay
gm
ry re
ty re
g of
eter
ting
er y
ear
tartin
atte
wirin
s af e
or d
star
bat t
ing g
b
s
ctive
ctive
ctive
ctive
ctive
ctive
ctive
en r
D ef e
D ef e
Defe
Defe
Defe
D ef e
Defe
B r ok
Questions
Degree of use of machine Operated for long period

Condition of horn when Horn sounds
starting switch is turned ON
Horn volume is low
Speed of rotation is low
When starting switch is Makes grating noise
turned to START, pinion Soon disengages pinion again
moves out, but
Makes rattling noise and does not turn
When starting switch is turned to START, pinion does not
Check items
move out
When starting switch is turned to ON, there is no clicking

Troubleshooting of defective wiring in starting circuit
sound
Battery terminal is loose
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 4), turn the starting switch
OFF, connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are
Troubleshooting
connected, engine starts

2) When terminal B and terminal C of starting motor are
connected, engine starts
3) When terminal B and terminal C of safety relay are connected,
engine starts
4) There is no 24V between battery relay terminal b and terminal
E
When ring gear is inspected directly, tooth surface is found to be
chipped
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-708 PC200/220(LC)-7
(5)
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)
General causes why engine turns but no exhaust

smoke comes out
• Supply of fuel impossible

• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter) Causes
a Standards for use of fuel
d)
eize
er s
y
nk
lung
ft, ke
el t a
n
ck, p
sha
pisto
in fu
p (ra
er
g
drive
pipin
r
p
train
hole
aine
pum
pum
tank
ump
s
, str
fuel
her
e ed
d
pum
tion
on p
l us e
ilter
r eat
el in
king
en f
injec
air b
jecti
feed
nt f u
r f ue
, lea
f uel
br ok
ctive
en in
fficie
g ed
ged
ged
ope
ged
ed,
Defe
Clog
Clog
Clog
Impr
Clog
Brok
Seiz
I ns u
Questions

Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according to
Operation Manual
Fuel tank is found to be empty
There is leakage from fuel piping
Mud is stuck to fuel tank cap
When fuel filter is drained, fuel does not come out
Check items
When engine is cranked with starting motor,

1) No fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel spurts out even when injection pump piping sleeve
nut is loosened
Rust and water are found when fuel tank is drained
Inspect injection pump directly

When control rack is pushed, it is found to be heavy, or does
not return
Troubleshooting
Inspect feed pump directly

When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Repair
Repair
Remedy
Clean
Clean
Add
PC200/220(LC)-7 20-709
(5)
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
General causes why exhaust smoke comes out but Causes

engine does not start
• Lack of rotating force due to defective electrical
uc k )
system
er s t
ap
y
s pr a
nk c
lung
em
tive
el t a
syst
ck, p
er y
• Improper selection of fuel
ef ec
in fu
r
r line
batt
f uel
t
p (ra
er
men
le, d
r
er
rain
eat e
hole
t ed
nde
ir in
rain
pu m
le
noz z
p st
iora
er e
air h
g, a
, cyli
her
r, st
d
p um
tion
et er
us e
lean
reat
tion
ggin
e
ring
t ak e
ilt
injec
or d
f
injec
f eed
air b
f uel
air c
, clo
fuel
ton
in
ctive
ctive
ctive
oper
n pis
k age
ged
ged
ged
ged
ged
D ef e
Defe
D ef e
Clog
Clog
C l og
Clog
Clog
I m pr
W or
Lea
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from

around cylinder head
Non-specified fuel is being used
Operation Manual
Air cleaner clogging monitor lights up
Preheating monitor does not light up
Starting motor cranks engine slowly
When fuel dial is placed at FULL position, it does not contact stopper
When engine is cranked with starting motor,
Check items
1) Little fuel comes out even when injection pump piping

sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or
does not return
When fuel filter, strainer are inspected directly, they are
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found to

be clogged
When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
Speed does not change when operation of certain cylinders is stopped
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
Clean
20-710 PC200/220(LC)-7
(5)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (Follow-up is poor)
General causes why engine does not pick up Causes

smoothly

ap
r ay
eat
• Improper condition of fuel injction
nk c
e sp
l ve s
• Improper fuel used
el ta
nc e
v
d va
fecti
in fu
fere
e an
, de
inter
anc e
hole
ozzle
f valv
ger ,
lear
her
n
ac t o
tion
c har
r eat
ve c
c ont
injec
air b
ur bo
r v al
ctive
ge d
ope
ed t
g ed
Defe
Impr
Clog
Seiz
Clog
Questions
Operation Manual
Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idle speed under no load is normal, but speed
suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
When air cleaner element is inspected directly, it is found to

be clogged
found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
Troubleshooting
Speed does not change when operation of certain cylinders

is stopped
When control rack is pushed, it is found to be heavy, or does not return
When valve clearance is checked directly, it is found to be
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
Clean
Clean
Clean
Clean
PC200/220(LC)-7 20-711
(11)
TROUBLESHOOTING S-4
S-4 Engine stops during operations
General causes why engine stops during operations
• Seized parts inside engine

• Overheating
a If there is overheating and the engine stops,
carry out troubleshooting for overheating.
• Failure in hydraulic pump

a If the engine stops because of a failure in the
hydraulic pump, carry out troubleshooting for
H mode.
20-712 PC200/220(LC)-7
(5)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (Hunting)
General c auses why en gine does not rotate Causes

smoothly
• Air in fuel system

• Defective governor mechanism
• Defective governor motor mechanism
nk
a If hunting stops when governor spring is dis-
e l ta
rack
r nor
connected, carry out troubleshooting for E
nor
in fu
l
e
nt r o
ov er
r
gov
mode.
aine
r
aine
ole
ow
of co
of g
t of
p str
er h
tank
too l
, str
tmen
ation
tion
h
pum
filter
el in
reat
d is
per a
s
o per
adju
s pee
f eed
air b
nt f u
fuel
o
ctive
ctive
ctive
fficie
ge d
ged
ged
idle
Clog
D ef e
C l og
Clog
D ef e
Defe
I ns u
Low
Occurs at a certain speed range
Questions
Occurs at low idle

Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Replacement of filters has not been carried out according
to Operation Manual
Fuel tank is found to be empty
Rust, water are found when fuel tank is drained
Leakage from fuel piping
When feed pump is operated,
Check items
1) No response, light, return is quick

2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Seal on injection pump has come off
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
Troubleshooting
improperly adjusted
does not return
When feed pump strainer is inspected directly, it is
found to be clogged
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Remedy
Clean
Clean
Clean
Add
PC200/220(LC)-7 20-713
(11)
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output Causes

• Improper fuel used
(if non-specified fuel is used, output drops)
• Lack of output due to overtaking
nt
a If there is overheating and lack of output,
leme
carry out troubleshooting for overheating.
er e
lean
air c
ge d
Clog
Suddenly
Power was lost
Gradually
Questions

Replacement of filters has not been carried out according
to Operation Manual
Black
Check items
High idle speed under no load is normal, but speed

suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
High idle speed of engine is low
Leakage from fuel piping
When air cleaner element is inspected directly, it is found to be

clogged
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When fuel dial is placed at FULL position, lever does not contact stopper
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Remedy
Clean
Clean
Clean
Clean
20-714 PC200/220(LC)-7
(11)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (Incomplete combustion)
General causes why exhaust smoke is black Causes
)
ized
tion)
er s e
njec
t
y
sea
s pr a
ive i
lung
alve
tive
nc e
c es s
ck, p
nd v
ef ec
fere
x
nt
p (ra
l ve a
e
le, d
leme
(
inter
ance
der
r
p
g
uffle
m
pum
timin
of va
z
cylin
u
er e
noz
ger ,
lear
p
dm
tion
tion
ction
lean
tact
tion
char
ring,
lve c
gge
injec
injec
c on
injec
air c
r inje
, clo
urbo
r va
t on
ctive
ctive
ctive
n pis
s hed
ge d
rope
ged
r ope
ed t
D ef e
Defe
D ef e
Clog
Clog
Seiz
W or
Imp
Imp
Cru
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting
is stopped
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
does not return
Remedy
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
PC200/220(LC)-7 20-715
(5)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
a Do not run the engine at idle for more than 20 Causes

minutes continuously. (Both low and high idle)
r ger
oc ha
General causes why oil consumption is excessive
T ur b
• Abnormal combustion of oil
l
d
s ea
hea
e
• External leakage of oil
c
s t em
os e
a
ler
ken
r f
der
• Wear of lubrication system
al s u
coo
er h
, br o
e sy
cylin
plug
r oil
eat h
l, se
der
intak
ide)
d
nd
n or
n
er o
ing
a
r
rain
cylin
ine e
er e
or b
, gu
e
il pip
ar s
om
il pa
kage m oil filt
oil d
blow
ring
stem
r
b
ring,
in fr
oler
e
n re
t t ur
mo
o
t h
from
from
iston
br ea
il co
al at
lve (
k ed
r ok e
al a
t on
e fro
f r o
en o
n pis
en p
t suc
k age
n se
k age
n va
n se
g ed
n, b
k ag
B r ok
Clog
Brok
W or
W or
W or
W or
Wo r
D us
Lea
Lea
Lea
Lea
Oil consumption suddenly increased
Questions
Engine oil becomes contaminated quickly

Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine coolant
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in damper chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be
clogged with dirty oil
Troubleshooting
There is external leakage of oil from engine

Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be
dirty with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Remedy
Clean
20-716 PC200/220(LC)-7
(11)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated

quickly
• Entry of exhaust gas due to internal wear

• Clogging of lubrication passage
• Improper fuel
• Improper oil used
• Operation under excessive load
PC200/220(LC)-7 20-717
(5)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes
• Leakage of fuel

Operated for long period
Questions
Degree of use of machine

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items

Timing lock on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idle and high idle speeds are high
Injection pump measurement shows that injection amount is excessive

Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy, or does not return
Troubleshooting
When check is made using delivery method, injection timing is

found to be incorrect
Remove head cover and inspect directly
Remove feed pump and inspect directly
When engine speed is measured, low idle and high idle speeds
are found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-718 PC200/220(LC)-7
(11)
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down
General causes why oil is in coolant Causes
• Internal leakage in lubrication system

• Internal leakage in cooling system
t
as k e
k
bloc
ing
ad g
r
, O -r
oole
der
, he
tting
cylin
c or e
oil c
ead
i
by p
er h
ks in
oler
aulic
us ed
ylind
il co
crac
y d r
en o
en h
en c
s ca
nal
B r ok
B r ok
Hole
Brok
Inter
Questions
Suddenly increased
Oil level
Gradually increased
Hard water is being used as coolant
Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, spurts back

Hydraulic oil is cloudy white
When hydraulic oil is drained, water is found

shooting
Trouble-
Pressure-tightness test of cylinder head shows there is leakage

Remove oil pan and inspect directly
Replace
Replace
Replace
Replace
Replace
Remedy
PC200/220(LC)-7 20-719
(11)
S-12 Oil pressure monitor lights up (Drop in oil pressure)
General causes why oil pressure monitor lights up
• Leakage, clogging, wear of lubricating system

• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
a Standards for engine oil selection
20-720 PC200/220(LC)-7
(5)
S-13 Oil level rises (Coolant, fuel in oil)
a If there is oil in the coolant, carry out trouble- Causes

shooting for "Oil is in coolant".
General causes why oil level rises
v er
d co
eal
• Coolant in oil (milky white)
hea
nt s
ump
• Fuel in oil (diluted, and smells of diesel fuel)
k et
e
ipme
face
insid
gas
• Entry of oil from other component
on p
eve
-ring
l s ur
equ
ck
ea d
iping
er sle
c t i
r blo
e, O
s ea
je
ar y
d, h
in
p
ting
hold
li
linde
om
r c or
r ear
t
side
i
hea
osta
x
p au
y pit
el fr
ozzle
art in
e cy
coole
ged
her m
der
pu m
de b
of f u
in
am a
insid
n
p
l
t
y
n oil
s ma
ctive
ctive
ctive
ctive
en c
kage
n, d
cks
e
D ef e
D ef e
Defe
B r ok
D ef e
Hole
Brok
W or
Lea
Cra
Questions

There is oil in radiator coolant
Fuel must be added more frequently
Exhaust smoke is white
When engine is first started, drops of water come from
muffler
Leave radiator cap open. When engine is run at idle,
an abnormal number of bubbles appear, or water spurts back
Check items
Oil level goes down in damper chamber

Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Coolant temperature is low

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
Inspect rear seal directly

When pump auxiliary equipment is removed, seal is found to
be damaged
Remove injection pump and inspect directly
Defective contact with thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC200/220(LC)-7 20-721
(11)
S-14 Coolant temperature becomes too high (Overheating)
General causes why coolant temperature becomes Causes

too high
• Lack of cooling air (deformation, damage of fan)

• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in hydraulic pump system
a Carry out troubleshooting for H mode.
p
pum
ater
en w
B r ok
Suddenly overheated
Questions
Condition of overheating
Always tends to overheat
Coolant temperature Rises quickly
gauge Does not go down from red range
Radiator water level monitor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on coolant
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
There is play when fan pulley is rotated

Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Hydraulic oil temperature enters red range faster than
engine coolant temperature
Temperature difference between top and bottom radiator tanks

is excessive
Carry out troubleshooting for H mode.
Temperature difference between top and bottom radiator tanks

is slight
When water filler port is inspected, core is found to be clogged
Troubleshooting
When function test is carried out on thermostat, it does not

open even at cracking temperature
When coolant temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
20-722 PC200/220(LC)-7
(11)
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an exter- Causes

nal noise.
d)
General causes why abnormal noise is made
)
ction
eize
er s
je
e
• Abnormality due to defective parts
anc
ve in
lung
• Abnormal combustion
lear
e
r enc
essi
e
ck, p
r enc
zle
• Air sucked in from intake system
lve c
( ex c
erfe
noz
lash
p (ra
terfe
of v a
lt int
tion
bac k
mp
g
er, in
pum
in
n pu
c
n be
ent
us h
je
ain
ed in
harg
tion
stm
ectio
ed b
n, fa
ar tr
injec
adju
r boc
seiz
seiz
d fa
j
r ge
in
ctive
ctive
ed tu
ctive
,
rme
ope
g ed
ing,
Defe
D ef e
D ef o
Defe
Impr
Clog
Miss
Seiz
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
Troubleshooting
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC200/220(LC)-7 20-723
(5)
S-16 Vibration is excessive
a If there is abnormal noise together with the vibra- Causes

tion, carry out troubleshooting also for "Abnormal
noise is made".
tion)
d
ligne
n
injec
shio
General causes why vibration is excessive
misa
fuel
n cu
mp
sive
oke
• Defective parts (abnormal wear, breakage)
ing
p u
bea r
s , br
x c es
• Improper alignment
ulic
sh
• Abnormal combustion
bolt
ydra
p (e
main
per
ackla
ting
pum
d am
h
r od,
ai n b
and
oun
g
tion
side
in
cting
gine
ar t r
em
h
injec
s
art in
u
f en
ngin
nne
r ge
mb
ctive
en p
t er o
n co
n ca
r ope
se e
D ef e
B r ok
W or
Wo r
C en
Loo
Imp
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idle
Vibration occurs at mid-range speed
Check items
Vibration follows engine speed

Exhaust smoke is black

Remove side cover and inspect directly
Inspect directly for loose engine mounting bolts, broken cushion
Troubleshooting
Inspect inside damper directly

When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-724 PC200/220(LC)-7
(11)

Pc200 Trobleshooting

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TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202

TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE

POINTS TO REMEMBER WHEN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

1. Points to remember when handling electric

1) Handling wiring harnesses and connectors

Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

2) Removing, installing, and drying connectors

2) When removing from clips

3) Action to take after removing connectors

2) Fix the connector securely.

3) Correct any protrusion of the boot and any

4) If the connector clamp has been removed,

• Connecting connectors (DT type connector)

• Drying wiring harness

If water gets directly on the connector, do as fol-

2) Dry the inside of the connector with a dryer.

3) Carry out a continuity test on the connector.

3) Handling control box

3) Do not place objects on top of the control

6) Do not place the control box on oil, water, or

2. Points to remember when troubleshooting electric circuits

3. Points to remember when handling hydraulic

With the increase in pressure and precision of

1) Be careful of the operating environment.

2) Disassembly and maintenance work in the

4) Do not let any dirt or dust get in during refill-

5) Change hydraulic oil when the temperature

CHECKS BEFORE TROUBLESHOOTING

4. Check hydraulic oil strainer — Clean, drain

5. Check swing machinery oil level — Add oil

1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

1. Check for abnormal noise, smell — Repair

3. Check for discolored, burnt, exposed wiring — Replace

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Steps for troubleshooting

Failure-looking Phenomenon and Troubleshooting No.

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT

Connector No. Detailed information

Connector No. Detailed information

E06 X 1 Air conditioner compressor electromagnetic K-8

Connector No. Detailed information

CONNECTOR LOCATION STEREOGRAM

CONNECTOR LOCATION STEREOGRAM

Monitor Panel System Circuit Diagram (M Circuit)

Monitor Panel System Circuit Diagram (M Circuit)

Governor Control System Circuit Diagram (G Circuit) of GovernorPump Controller

Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controller

Pump Control System Circuit Diagram (P Circuit) of GovernorPump Controller

Pump Control System Circuit Diagram (P Circuit) of GovernorPump Controller

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

T-BRANCH BOX AND T-BRANCH ADAPTER TABLE

Governor Control System Circuit Diagram (G Circuit) of GovernorPump Controller

Pump Control System Circuit Diagram (P Circuit) of GovernorPump Controller

Pump Control System Circuit Diagram (P Circuit) of GovernorPump Controller