PC200-8M0 SM - Sen06109-00 PDF

SEN06109-00
HYDRAULIC PC200 -8M0

EXCAVATOR
PC200LC -8M0
PC220 -8M0
PC220LC -8M0
PC200- 400001
PC200LC- 400001
SERIAL NUMBERS and up
PC220- 100001
PC220LC- 100001
SEN06111-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
Machine model Serial number

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

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

100 Index
SEN06111-00 Composition of shop manual
Composition of shop manual 1

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

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

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

100 Standard service value table SEN06125-00
30 Testing and adjusting SEN06126-00

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

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

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

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

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

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

100 Index
Table of contents SEN06111-00
Center swivel joint ................................................................................................................... 10

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

100 Standard service value table SEN06125-00
Standard value table for engine related parts .......................................................................... 2
Standard value table for chassis related parts......................................................................... 4
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting ..................................................................... 3
Sketch of special tool............................................................................................................... 7
Testing engine speed............................................................................................................... 8
Testing intake air pressure (boost pressure) ........................................................................... 9
Testing exhaust gas color ........................................................................................................ 10
Adjusting valve clearance........................................................................................................ 11
Testing compression pressure................................................................................................. 13
Testing blowby pressure .......................................................................................................... 16
Testing engine oil pressure...................................................................................................... 17
Handling fuel system parts ...................................................................................................... 18
Releasing residual pressure from fuel system......................................................................... 18
Testing fuel pressure ............................................................................................................... 19
Handling reduced cylinder mode operation ............................................................................. 22
Handling no-injection cranking operation ................................................................................ 22
Testing fuel discharge, return and leak amount....................................................................... 23
Bleeding air from fuel circuit .................................................................................................... 26
Testing fuel circuit for leakage ................................................................................................. 27
Handling controller high voltage circuit.................................................................................... 28
Testing and adjusting air conditioner compressor belt tension ................................................ 29
Replacing alternator belt.......................................................................................................... 30
Testing swing circle bearing clearance .................................................................................... 31
Testing and adjusting track tension ......................................................................................... 32
Testing and adjusting oil pressure in work equipment, swing, and travel circuits .................... 34
Testing control circuit source pressure .................................................................................... 37
Testing and adjusting oil pressure in pump PC control circuit ................................................. 38
Testing and adjusting oil pressure in pump LS control circuit.................................................. 41
Testing solenoid valve output pressure ................................................................................... 46
Testing PPC valve output pressure ......................................................................................... 49
Adjusting play of work equipment and swing PPC valves ....................................................... 51
Testing parts which cause hydraulic drift of work equipment................................................... 52
PC200, 200LC, 220, 220LC-8M0 00-100 5

100 Index
Releasing remaining pressure from hydraulic circuit ............................................................... 54

Testing oil leakage ................................................................................................................... 55
Bleeding air from each part...................................................................................................... 58
Testing cab tipping stopper ...................................................................................................... 60
Adjusting mirrors...................................................................................................................... 61
Installation and adjustment of mirrors ...................................................................................... 62
Angle adjustment of rear view camera .................................................................................... 65
Special functions of machine monitor ...................................................................................... 2
Handling voltage circuit of engine controller ............................................................................ 2
Preparation work for troubleshooting of electrical system ....................................................... 3
Procedure for testing diodes.................................................................................................... 8
Pm Clinic service ..................................................................................................................... 9
40 Troubleshooting
100 Failure code table and fuse locations SEN06131-00
Failure codes table .................................................................................................................. 2
Fuse locations.......................................................................................................................... 9
200 General Information on troubleshooting SEN06132-00
Symptom and troubleshooting numbers .................................................................................. 2
Sequence of events in troubleshooting.................................................................................... 4
Checks before troubleshooting ................................................................................................ 6
Classification and procedures for troubleshooting................................................................... 8
Symptom and troubleshooting numbers .................................................................................. 10
Information in troubleshooting table......................................................................................... 12
Connector list and layout ......................................................................................................... 14
Connection table for connector pin numbers ........................................................................... 24
T- branch box and T- branch adapter table.............................................................................. 60
Troubleshooting method for open circuit in wiring harness of pressure sensor system .......... 63
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................... 3
Failure code [879AKB] A/C Inner Sensor Short Circuit ........................................................... 3
Failure code [879BKA] A/C Outer Sensor Open Circuit .......................................................... 3
Failure code [879BKB] A/C Outer Sensor Short Circuit........................................................... 3
Failure code [879CKA] Ventilating Sensor Open Circuit.......................................................... 3
Failure code [879CKB] Ventilating Sensor Short Circuit.......................................................... 4
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit............................................... 4
Failure code [879EMC] Ventilation Damper Abnormality......................................................... 4
Failure code [879FMC] Air Mix Damper Abnormality .............................................................. 4
Failure code [879GKX] Refrigerant Abnormality...................................................................... 4
Failure code [989L00] Engine Controller Lock Caution1 ......................................................... 5
Failure code [989M00] Engine Controller Lock Caution2 ........................................................ 6
Failure code [989N00] Engine Controller Lock Caution3......................................................... 7
Failure code [AA10NX] Air Cleaner Clogging .......................................................................... 8
Failure code [AB00KE] Charge Voltage Low ........................................................................... 10
Failure code [B@BAZG] Eng Oil Press Low............................................................................ 12
Failure code [B@BAZK] Engine Oil Level Low........................................................................ 13
Failure code [B@BCNS] Eng Water Overheat ........................................................................ 14
Failure code [B@BCZK] Radiator Coolant Level Low ............................................................. 16
Failure code [B@HANS] Hyd Oil Overheat ............................................................................. 18
Failure code [CA111] ECM Critical Internal Failure.................................................................. 19
Failure code [CA115] Eng Ne and Bkup Speed Sens Error..................................................... 19
Failure code [CA122] Chg Air Press Sensor High Error .......................................................... 20
Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 22
Failure code [CA131] Throttle Sensor High Error .................................................................... 24
Failure code [CA132] Throttle Sensor Low Error..................................................................... 26
00-100 6 PC200, 200LC, 220, 220LC-8M0

100 Index
Failure code [CA144] Coolant Temp Sens High Error ............................................................. 28

Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 30
Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 32
Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 34
Failure code [CA155] Chg Air Temp High Speed Derate......................................................... 36
Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 38
Failure code [CA221] Ambient Press Sens High Error............................................................ 40
Failure code [CA222] Ambient Press Sens Low Error............................................................. 42
Failure code [CA227] Sens 2 Supply Volt High Error .............................................................. 44
Failure code [CA234] Eng Overspeed..................................................................................... 44
Failure code [CA238] Ne Speed Sens Supply Volt Error......................................................... 45
Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 46
Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 48
Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................ 4
Failure code [CA342] Calibration Code Incompatibility ........................................................... 16
Failure code [CA351] Injectors Drive Circuit Error................................................................... 17
Failure code [CA352] Sens Supply 1 Volt Low Error ............................................................... 18
Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 20
Failure code [CA428] Water in Fuel Sensor High Error........................................................... 22
Failure code [CA429] Water in Fuel Sensor Low Error............................................................ 24
Failure code [CA435] Eng Oil Press Sw Error......................................................................... 26
Failure code [CA441] Battery Voltage Low Error ..................................................................... 28
Failure code [CA442] Battery Voltage High Error .................................................................... 30
Failure code [CA449] Rail Press Very High Error .................................................................... 31
Failure code [CA451] Rail Press Sensor High Error................................................................ 32
Failure code [CA452] Rail Press Sensor Low Error ................................................................ 34
Failure code [CA488] Chg Air Temp High Torque Derate........................................................ 36
Failure code [CA553] Rail Press High Error ............................................................................ 37
Failure code [CA559] Rail Press Low Error............................................................................. 38
Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 40
Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 42
Failure code [CA757] All Continuous Data Lost Error ............................................................. 43
Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 44
Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 48
Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 50
Failure code [CA2249] Rail Press Very Low Error................................................................... 51
Failure code [CA2311] lMV Solenoid Error .............................................................................. 51
Failure code [CA2555] Grid Htr Relay Open Circuit Error ....................................................... 52
Failure code [CA2556] Grid Htr Relay Short Circuit Error ....................................................... 54
Failure code [D110KB] Battery Relay Drive Short Circuit ........................................................ 4
Failure code [D19JKZ] Personal Code Relay Abnormality...................................................... 6
Failure code [D811MC] KOMTRAX Error ................................................................................ 8
Failure code [D862KA] GPS Antenna Open Circuit ................................................................ 9
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................... 10
Failure code [DA22KK] Pump Solenoid Power Low Error ....................................................... 12
Failure code [DA25KP] 5V Sensor 1 Power Abnormality ........................................................ 14
Failure code [DA26KP] 5V Sensor 2 Power Abnormality ........................................................ 16
Failure code [DA29KQ] Model Selection Abnormality ............................................................. 18
Failure code [DA2QKR] CAN2 Discon (Pump Con) ................................................................ 23
Failure code [DAF0MB] Monitor ROM Abnormality................................................................. 26
Failure code [DAF0MC] Monitor Error ..................................................................................... 27
PC200, 200LC, 220, 220LC-8M0 00-100 7

100 Index
Failure code [DAF8KB] Camera Power Supply Short Circuit .................................................. 28

Failure code [DAF9KQ] Model Selection Abnormality ............................................................. 30
Failure code [DAFGMC] GPS Module Error ............................................................................ 31
Failure code [DAFQKR] CAN2 Discon .................................................................................... 32
Failure code [DAZ9KQ] A/C Model Selection Abnormality ...................................................... 33
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) .............................................................. 34
Failure code [DB2QKR] CAN2 Discon (Engine Con) .............................................................. 36
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ............................................................. 40
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit............................................... 42
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................... 44
Failure code [DHPBMA] R Pump Press Sensor Abnormality .................................................. 46
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality......................................... 4
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ................................. 6
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ................................... 8
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality................................... 10
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality....................................... 12
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ....................................... 14
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ..................................... 16
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality................................. 18
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality ................................... 20
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality .................................. 22
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality................................... 24
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality ................................... 26
Failure code [DHX1MA] Overload Sensor Abnormality ........................................................... 28
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ......................................... 30
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ......................................... 32
Failure code [DV20KB] Travel Alarm Short Circuit .................................................................. 34
Failure code [DW43KA] Travel Speed Sol Open Circuit .......................................................... 36
Failure code [DW43KB] Travel Speed Sol Short Circuit .......................................................... 38
Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit ................................................ 40
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................... 42
Failure code [DW91KA] Travel Neutral Sol Open Circuit......................................................... 44
Failure code [DW91KB] Travel Neutral Sol Short Circuit......................................................... 46
Failure code [DWA2KA] Attachment Sol Open Circuit............................................................. 4
Failure code [DWA2KB] Attachment Sol Short Circuit............................................................. 6
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit ........................................................ 8
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit......................................................... 10
Failure code [DWK2KA] Variable Back Press Sol Open Circuit .............................................. 12
Failure code [DWK2KB] Variable Back Press Sol Short Circuit............................................... 14
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit ............................................................ 16
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit............................................................. 18
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ............................................................ 20
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ............................................................ 22
Failure code [DXE0KA] LS-EPC Sol Open Circuit................................................................... 24
Failure code [DXE0KB] LS-EPC Sol Short Circuit................................................................... 26
Failure code [DXE4KA] Attachment Flow EPC Open Circuit................................................... 28
Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................... 30
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit .................................................. 32
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .................................................. 34
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ..................................................... 36
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit...................................................... 38
Failure code [DY20KA] Wiper Working Abnormality................................................................ 40
Failure code [DY20MA] Wiper Parking Abnormality ................................................................ 42
Failure code [DY2CKB] Washer Drive Short Circuit ................................................................ 44
Failure code [DY2DKB] Wiper Drive (Fwd) Short .................................................................... 46
Failure code [DY2EKB] Wiper Drive (Rev) Short..................................................................... 48
00-100 8 PC200, 200LC, 220, 220LC-8M0

100 Index
400 Troubleshooting of electrical system (E-mode) SEN06138-00

Fuse locations ......................................................................................................................... 4
Information contained in troubleshooting table ........................................................................ 6
E-1 Engine does not start (Engine does not crank) ................................................................. 8
E-2 Preheater does not operate .............................................................................................. 13
E-3 When starting switch is turned to ON position, machine monitor displays nothing ........... 17
E-4 When starting switch is turned to ON position (with engine stopped),
basic check monitor lights up. ................................................................................... 20
E-5 Precaution monitor lights up while engine is running ........................................................ 21
E-6 Emergency stop monitor lights up while engine is running ............................................... 23
E-7 Fuel level gauge does not indicate properly ..................................................................... 24
E-8 Engine coolant temperature gauge does not indicate properly......................................... 26
E-9 Hydraulic oil temperature gauge does not indicate properly............................................. 27
E-10 Displays on machine monitor are different from those for actual machine ..................... 30
E-11 Some areas of machine monitor screen are not displayed ............................................. 31
E-12 Function switch does not operate ................................................................................... 31
E-13 Automatic warm-up system does not operate (in cold season) ...................................... 32
E-14 Auto-decelerator does not operate properly ................................................................... 33
E-15 Working mode does not change ..................................................................................... 34
E-16 Travel speed does not change........................................................................................ 35
E-17 Alarm buzzer cannot be canceled................................................................................... 36
E-18 When starting switch is turned OFF, service meter is not displayed ............................... 36
E-19 Service mode cannot be selected................................................................................... 36
E-20 Any of work equipment, swing and travel do not operate or cannot be locked............... 37
E-21 Swing holding brake does not operate properly.............................................................. 39
E-22 One-touch power maximizing function does not operate properly.................................. 42
E-23 Travel alarm does not sound or does not stop sounding ................................................ 45
E-24 Horn does not sound or does not stop............................................................................ 46
E-25 Windshield wiper and window washer do not operate .................................................... 48
E-26 BOOM DOWN indicator is not displayed properly with monitoring function ................... 50
E-27 ARM DUMP indicator is not displayed properly with monitoring function ....................... 50
E-28 ARM IN indicator is not displayed properly with monitoring function .............................. 50
E-29 BOOM RAISE indicator is not displayed properly with monitoring function .................... 51
E-30 BUCKET CURL indicator is not displayed properly with monitoring function ................. 51
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function................. 51
E-32 SWING indicator is not displayed properly with monitoring function............................... 52
E-33 TRAVEL indicator is not displayed properly with monitoring function ............................. 52
E-34 ATTACHMENT indicator is not displayed properly with monitoring function................... 53
E-35 Attachment hydraulic circuit cannot be changed ............................................................ 55
E-36 KOMTRAX system does not operate properly................................................................ 56
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN06139-00
System diagram of hydraulic and mechanical system............................................................. 4
Failure mode and cause table ................................................................................................. 6
Information in troubleshooting table ........................................................................................ 8
H-1 Speed or power of whole work equipment, swing, and travel is low................................. 9
H-2 Engine speed lowers significantly or engine stalls............................................................ 11
H-3 Work equipment, swing, and travel systems do not work ................................................. 12
H-4 Unusual noise comes out from around hydraulic pump.................................................... 13
H-5 Fine control performance or response is low.................................................................... 14
H-6 Speed or power of boom is low......................................................................................... 15
H-7 Speed or power of arm is low ........................................................................................... 16
H-8 Speed or power of bucket is low ....................................................................................... 17
H-9 Work equipment does not move in its single operation .................................................... 18
H-10 Hydraulic drift of work equipment is large ....................................................................... 19
H-11 Time lag of work equipment is large ............................................................................... 21
H-12 Other work equipment moves when one of work equipment is relieved......................... 22
H-13 One-touch power maximizing function does not work .................................................... 23
PC200, 200LC, 220, 220LC-8M0 00-100 9

100 Index
H-14 In combined operation of work equipment,

equipment having heavier load moves slower........................................................... 24
H-15 In combined operation of swing and boom RAISE, boom rising speed is low ................ 25
H-16 Travel speed drops largely in combined operation of swing and travel .......................... 26
H-17 Machine does not travel straight ..................................................................................... 27
H-18 Travel speed is low ......................................................................................................... 28
H-19 Machine is hard to steer or travel power is low............................................................... 29
H-20 Travel speed does not change or travel speed is low/high ............................................. 30
H-21 One of tracks does not run.............................................................................................. 31
H-22 Upper structure does not swing ...................................................................................... 32
H-23 Swing acceleration is poor or swing speed is low........................................................... 34
H-24 Upper structure overruns remarkably when it stops swinging ........................................ 36
H-25 Shock is large when upper structure stops swinging ...................................................... 37
H-26 Large sound is made when upper structure stops swinging ........................................... 38
H-27 Hydraulic drift of swing is large ....................................................................................... 39
H-28 Attachment circuit cannot be changed............................................................................ 40
H-29 Oil flow in attachment circuit cannot be controlled.......................................................... 41
600 Troubleshooting of engine (S-mode) SEN06140-00
Method of using troubleshooting chart..................................................................................... 2
S-1 Startability is poor .............................................................................................................. 6
S-2 Engine does not start ........................................................................................................ 7
S-3 Engine does not pick up smoothly .................................................................................... 10
S-4 Engine stops during operation .......................................................................................... 11
S-5 Engine runs rough or is unstable ...................................................................................... 12
S-6 Engine lacks power ........................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 15
S-9 Oil becomes contaminated early ....................................................................................... 16
S-10 Fuel consumption is excessive ....................................................................................... 17
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)....................................... 18
S-12 Oil pressure drops........................................................................................................... 19
S-13 Oil level rises (coolant or fuel in oil) ................................................................................ 20
S-14 Coolant temperature rises too high (overheating)........................................................... 21
S-15 Unusual noise is made.................................................................................................... 22
S-16 Vibration is excessive...................................................................................................... 23
50 Disassembly and assembly

100 General information on disassembly and assembly SEN06142-00
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tools list ....................................................................................................................... 7
Sketches of special tools ......................................................................................................... 12
Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of fuel injector assembly .................................................................. 6
Removal and installation of engine front oil seal ..................................................................... 13
Removal and installation of engine rear oil seal ...................................................................... 18
Removal and installation of cylinder head assembly ............................................................... 21
Removal and installation of radiator assembly ........................................................................ 36
Removal and installation of hydraulic oil cooler assembly....................................................... 38
Removal and installation of aftercooler assembly ................................................................... 40
Removal and installation of fuel cooler assembly.................................................................... 43
Removal and installation of engine and hydraulic pump assembly ......................................... 44
Removal and installation of final drive assembly ..................................................................... 2
Disassembly and assembly of final drive assembly................................................................. 4
Removal and installation of swing motor and swing machinery assembly .............................. 22
00-100 10 PC200, 200LC, 220, 220LC-8M0

100 Index
Disassembly and assembly of swing motor and swing machinery assembly.......................... 24

Removal and installation of swing circle assembly.................................................................. 34
Disassembly and assembly of carrier roller assembly............................................................. 2
Disassembly and assembly of track roller assembly ............................................................... 5
Removal and installation of idler and idler cushion assembly ................................................. 7
Disassembly and assembly of idler ......................................................................................... 8
Disassembly and assembly of idler cushion............................................................................ 11
Removal and installation of sprocket ....................................................................................... 13
Separation and connection of track shoe assembly ................................................................ 14
Removal and installation of revolving frame assembly............................................................ 18
Removal and installation of counterweight assembly .............................................................. 20
500 Hydraulic system SEN06146-00
Removal and installation of center swivel joint assembly ........................................................ 2
Disassembly and assembly of center swivel joint assembly ................................................... 4
Removal and installation of hydraulic tank assembly .............................................................. 5
Removal and installation of control valve assembly ................................................................ 9
Disassembly and assembly of control valve............................................................................ 14
Removal and installation of hydraulic pump assembly ............................................................ 19
Removal and installation of oil seal in hydraulic pump input shaft........................................... 23
Disassembly and assembly of work equipment PPC valve assembly..................................... 24
Disassembly and assembly of travel PPC valve ..................................................................... 26
Disassembly and assembly of work equipment cylinder ......................................................... 28
Removal and installation of work equipment assembly ........................................................... 2
700 Cab and its attachments SEN06148-00
Removal and installation of operator's cab assembly.............................................................. 2
Removal and installation of operator cab glass (stuck glass).................................................. 5
Removal and installation of front window assembly ................................................................ 15
Removal and installation of floor frame assembly ................................................................... 22
Removal and installation of air conditioner unit assembly ....................................................... 26
Removal and installation of machine monitor assembly.......................................................... 2
Removal and installation of engine controller assembly.......................................................... 4
Removal and installation of pump controller assembly ........................................................... 6
Removal and installation of KOMTRAX terminal assembly..................................................... 8
80 Appendix
100 Air conditioner SEN06151-00
Precautions for refrigerant........................................................................................................... 3
Air conditioner component .......................................................................................................... 4
Configuration and function of refrigeration cycle......................................................................... 6
Outline of refrigeration cycle ....................................................................................................... 7
Air conditioner unit ...................................................................................................................... 9
Air conditioner controller ............................................................................................................. 15
Compressor................................................................................................................................. 16
Condenser and Modulator........................................................................................................... 17
Sensor......................................................................................................................................... 18
Procedure for testing and troubleshooting .................................................................................. 20
Circuit diagram and arrangement of connector pins ................................................................... 22
System diagram .......................................................................................................................... 24
Parts and connectors layout........................................................................................................ 26
Testing air leakage (duct) ............................................................................................................ 29
Testing with self-diagnosis function............................................................................................. 31
Testing vent (mode) changeover................................................................................................. 33
Testing FRESH/RECIRC air changeover .................................................................................... 34
Testing sunlight sensor................................................................................................................ 35
PC200, 200LC, 220, 220LC-8M0 00-100 11

100 Index
Testing (dual) pressure switch for refrigerant .............................................................................. 36

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

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

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

SEN06111-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator

Form No. SEN06111-00
2012 KOMATSU
All Rights Reserved
Printed in Japan 07-12 (01)
00-100 14
SEN06112-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

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

SEN06112-00 Foreword, safety and general information
Foreword, safety and general information 1

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

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

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

Precautions for slinging work and making sig-

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

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

q When loosening the nuts fixing air conditioner

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

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

Fire prevention q When performing grinding or welding work

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

q Fire caused by piping Dispose of waste materials

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

How to read the shop manual SEN06112-00
How to read the shop manual 1
q Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
q Materials and specifications are subject to change without notice.
q The shop manuals are available for Machine part and Engine part. For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual

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

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

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

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

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

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

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

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

SEN06112-00 How to read the shop manual
q Revised edition mark

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

Explanation of terms for maintenance standard SEN06112-00
Explanation of terms for maintenance standard 1

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

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

SEN06112-00 Explanation of terms for maintenance standard
Repair limit and allowable value or allowable

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

Handling equipment of fuel system devices SEN06112-00
Handling equipment of fuel system devices 1

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

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

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

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

SEN06112-00 Handling of intake system parts
Handling of intake system parts 1

q The Komatsu Variable Geometry Turbocharger
(KVGT) consists of more precise parts (vari-
able mechanism) than the parts used in the
conventional turbocharger. If foreign material
enters this system, it may cause a failure. Use
special care to prevent entry of the foreign
material when servicing the air intake system.
Be careful of working environment

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

Handling of hydraulic equipment SEN06112-00
Handling of hydraulic equipment 1

q With the increase in pressure and precision of
the hydraulic components, the most common
cause of a failure is dirt (foreign material) in the
hydraulic circuit. Therefore, the special care
must be taken when adding hydraulic oil,or
wh en di s as s em bl in g or a s se mb li ng th e
hydraulic components.
Be careful of working environment

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

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

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

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

Method of disconnecting and connecting of push-pull type SEN06112-00
Method of disconnecting and connecting of push-pull type coupler 1

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

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

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

SEN06112-00 Handling of electrical equipment
Handling of electrical equipment 1

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

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

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

Handling of electrical equipment SEN06112-00
Oil, mud or dirt stuck to connector

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

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

a If the machine is left disassembled for

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

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

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

q For connectors fitted with the boot, correct Connection

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

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

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

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

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

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

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

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

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

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

Connection Example) Injection pressure control valve of

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

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

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

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

Turn-housing type (Round green connector) Handling controller

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

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

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

Precautions for troubleshooting electrical cir-

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

How to read electric wire code SEN06112-00
How to read electric wire code 1

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

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

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

SEN06112-00 How to read electric wire code
Dimension
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5

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

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

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

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

How to read electric wire code SEN06112-00
Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
a Remarks: In a color code consisting of two colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is Green and marking is White.
Types of circuits and color codes
Type of wire AVS, AV, CAVS AEX

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

SEN06112-00 Precautions when performing operation
Precautions when performing operation 1

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

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

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

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

Precautions when performing operation SEN06112-00
If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal No. Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
Precautions for installation work

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

SEN06112-00 Precautions when performing operation
3. Operate the hydraulic cylinder three to four times to the end of its stroke.
a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.
Precautions at the time of completing work

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

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

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

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

Practical use of KOMTRAX SEN06112-00
Practical use of KOMTRAX 1

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

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

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

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

SEN06112-00 Standard tightening torque table
Standard tightening torque table 1

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

Standard tightening torque table SEN06112-00
Table of tightening torque for split flanged bolts

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

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

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

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

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

SEN06112-00 Standard tightening torque table
Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a The table is applied to the threads coated with engine oil (wet threads)
Tightening torque (Nm {kgm}) Taper seal Face seal

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

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

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

Standard tightening torque table SEN06112-00
Tightening torque table for bolts and nuts on 102, 107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114
series engines to the torques shown in the following table.
Thread diameter Tightening torque

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

(mm) (Nm) (kgm)
6 82 0.81 0.20
8 10 2 1.02 0.20
10 12 2 1.22 0.20
12 24 4 2.45 0.41
14 36 5 3.67 0.51
Tightening torque table for tapered screws on 102, 107 and 114 series engines
a Unless otherwise specified, tighten the tapered inch thread screws used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Material In cast iron or steel In aluminum

Tightening torque Tightening torque
Thread diameter (inch)
(Nm) (kgm) (Nm) (kgm)
1/16 15 2 1.53 0.20 51 0.51 0.10
1/8 20 2 2.04 0.20 15 2 1.53 0.20
1/4 25 3 2.55 0.31 20 2 2.04 0.20
3/8 35 4 3.57 0.41 25 3 2.55 0.31
1/2 55 6 5.61 0.61 35 4 3.57 0.41
3/4 75 8 7.65 0.82 45 5 4.59 0.51
PC200, 200LC, 220, 220LC-8M0 00-200 39

SEN06112-00 List of abbreviation
List of abbreviation 1
q This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, com-
ponents, and functions whose meaning is not immediately clear. The spelling is given in full with an out-
line of the meaning.
q Abbreviations that are used in general society may not be included.
q Special abbreviations which appear infrequently are noted in the text(marked wit a).
q This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text
of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the shop manual

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

List of abbreviation SEN06112-00

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


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

List of abbreviation SEN06112-00

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

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

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

Abbreviation Actual word spelled out

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

Conversion table SEN06112-00
Conversion table 1
Method of using the conversion table
q The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches

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

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

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

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

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

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

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

SEN06112-00

2012 KOMATSU
All Rights Reserved
00-200 50
SEN06114-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

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

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

Working range diagram SEN06114-00
Working range diagram 1

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

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

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

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

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

Specifications SEN06114-00

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

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

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

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

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

Travel motor
Hydraulic
(with brake valve and parking brake)

motor
Hydraulic system
KMF125ABE-6, piston type: 1

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

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

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

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

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

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

Specifications SEN06114-00

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

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

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

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

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

Travel motor
Hydraulic
(with brake valve and parking brake)

motor
Hydraulic system
KMF125ABE-6, piston type: 1

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

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

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

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

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

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

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

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

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

SEN06114-00

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

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

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

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

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

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

SEN06116-00

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

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

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

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

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

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

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

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

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

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

200 Power train
Swing machinery SEN06117-00
1. Drain plug
2. Swing pinion (No. of teeth: 13)
4. No. 2 planetary gear
5. No. 2 sun gear
8. No. 1 sun gear
9. Swing motor
10. Oil level gauge
11. Ring gear
12. Case
Specifications
Reduction ratio: ((17 + 58)/17) x ((18 + 58)/18) = 18.627
Unit: mm
Backlash between swing motor Standard clearance Allowable clearance
13
shaft and No. 1 sun gear 0.18 to 0.28
Backlash between No. 1 sun
14 0.16 to 0.50 1.00
gear and No.1 planetary gear
15 0.18 to 0.59 1.10
16 0.39 to 0.71 1.20
17 0.16 to 0.50 0.90
Replace
18 0.18 to 0.59 1.00
19 0.07 to 0.23
tary carrier and swing pinion
Backlash between swing pinion
20 0.22 to 1.32 2.00
and swing circle
Clearance between plate and
21 0.66 to 1.14
No. 2 planetary carrier
Clearance between No. 2 sun
22 1.66 to 2.94
gear and plate
Standard dimension Repair limit Apply hard
Wear of swing pinion surface
23 chrome plating or
contacting with oil seal 125 (0/ 0.100) replace
PC200, 200LC, 220, 220LC-8M0 10-200 9

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

200 Power train
Swing machinery SEN06117-00
1. Drain plug
2. Swing pinion (No. of teeth: 13)
4. No. 2 sun gear
8. No. 1 sun gear
9. Swing motor
10. Oil level gauge
11. Ring gear
12. Case
Specifications
Reduction ratio: ((17 + 58)/17) x ((14 + 58)/14) = 22.689
Unit: mm
Backlash between swing motor Standard clearance Allowable clearance
13
shaft and No. 1 sun gear 0.18 to 0.28
14 0.16 to 0.50 1.00
15 0.18 to 0.59 1.10
16 0.35 to 0.64 1.20
17 0.12 to 0.44 0.90
Replace
18 0.16 to 0.56 1.00
19 0.08 to 0.23
tary carrier and swing pinion
Backlash between swing pinion
20 0.23 to 1.37 2.00
and swing circle
Clearance between plate and
21 0.58 to 1.62
No. 2 planetary carrier
Clearance between No. 2 sun
22 2.56 to 3.84
gear and plate
Standard dimension Repair limit Apply hard
Wear of swing pinion surface
23 chrome plating or
contacting with oil seal 125 (0/ 0.100) replace
PC200, 200LC, 220, 220LC-8M0 10-200 11

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

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

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

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

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

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

SEN06117-00

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

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

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

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

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

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

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

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

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

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

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

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

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

end.
*1. Triple grouser shoe

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

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

Unit: mm
Tightening torque (Nm {kgm}) Retightening angle (deg.)
Triple grouser 490 49
a. Regular 120 10
shoe {50 5}
link
Road liner 549 59
Shoe bolt Retighten
20 (Rubber pad type) {56 6}
Tightening torque Retightening angle Lower limit torque
b. Master (Nm {kgm}) (deg.) (Nm {kgm})
link

No. of shoes (each side) PC200-8M0: 45 PC200LC-8M0: 49
Standard dimen- Tolerance Standard
Interference between bushing sion Shaft Hole interference
21
and link
+0.434 +0.074
59 0.320 to 0.434
+0.394 0
Interference between regular +0.222 0.138
22 38 0.300 to 0.422
pin and link +0.162 0.200
Standard dimen- Tolerance Standard clear-
Clearance between regular pin sion Shaft Hole ance
23
and bushing
+0.222 +0.902
38 0.180 to 0.740 Adjust or replace
+0.162 +0.402
24 Interference between master sion Shaft Hole interference
(*) pin and link
+0.280 +0.062
37.8 0.188 to 0.280
+0.250 0
25 Clearance between master pin sion Shaft Hole clearance
(*) and bushing
0.150 +0.902
38 0.552 to 1.252
0.350 +0.402
* Dry type track link
10-300 10 PC200, 200LC, 220, 220LC-8M0

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

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

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

SEN06118-00

2012 KOMATSU
All Rights Reserved
10-300 14
SEN06119-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

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

SEN06119-00 Hydraulic equipment layout drawing
Hydraulic equipment layout

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

Hydraulic equipment layout drawing SEN06119-00
PC200, 200LC, 220, 220LC-8M0 10-401 3

SEN06119-00 Hydraulic tank and filter
Hydraulic tank and filter 1
1. Hydraulic tank Specifications

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

Hydraulic tank and filter SEN06119-00
PC200, 200LC, 220, 220LC-8M0 10-401 5

SEN06119-00 Hydraulic pump
Hydraulic pump 1
Model: HPV95+95
10-401 6 PC200, 200LC, 220, 220LC-8M0

Hydraulic pump SEN06119-00
Outline
q This pump consists of 2 variable capacity
swash plate piston pumps, PC valve, LS valve,
and EPC valve.
IMF : Front PC mode selector current

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

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

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

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

Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between
along cylindrical surface (B), so angle (a) volumes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
the ax ial di rec tio n of cy li nder b loc k (7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q (a) is named the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
q With center line (X) of rocker cam (4) at a

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

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

1. LS valve
PA : Pump port 1. Sleeve

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

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

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

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

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

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

2. PC valve
PA : Pump port 1. Plug

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

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

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

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

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

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

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

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

q The relationship between the average pump

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

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

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

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

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

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

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

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

SEN06119-00 Pilot oil filter
Pilot oil filter 1

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

Pilot oil filter SEN06119-00
PC200, 200LC, 220, 220LC-8M0 10-401 29

SEN06119-00

2012 KOMATSU
All Rights Reserved
10-401 30
SEN06120-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

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

SEN06120-00 Control valve
Control valve 1
a In this section, only the 7-spool valve (6-spool valve + service valve) is shown.
10-402 2 PC200, 200LC, 220, 220LC-8M0

Control valve SEN06120-00
A1: To bucket cylinder head PX1: From 2-stage relief solenoid valve
A2: To L.H. travel motor PX2: From 2-stage relief solenoid valve
A3: To boom cylinder bottom T: To hydraulic tank
A4: To swing motor T1: To hydraulic tank
A5: To R.H. travel motor TS: To hydraulic tank
A6: To arm cylinder head TSW: From swing motor
A-1: To attachment IS1: Pump merge-divider EPC valve (for main
ATT: From attachment spool) drive signal
B1: To bucket cylinder bottom IS2: Pump merge-divider EPC valve (for LS
B2: To L.H. travel motor spool) drive signal
B3: To boom cylinder head IS3: Variable back pressure solenoid valve drive
B4: To swing motor signal
B5: To R.H. travel motor 1. Variable back pressure valve
B6: To arm cylinder bottom 2. Variable back pressure solenoid valve
B-1: To attachment 3. Pump merge-divider EPC valve (for LS spool)
BP1: From LS select solenoid valve 4. Pump merge-divider EPC valve (for main
BP5: From attachment selector solenoid valve spool)
C: To oil cooler 5. Arm check valve
P1: From R.H. work equipment PPC valve 6. Boom hydraulic drift prevention valve
(bucket DUMP) 7. Service valve
P2: From R.H. work equipment PPC valve 8. Cover A
(bucket CURL) 9. 7-spool valve
P3: From travel PPC valve (L.H. travel 10. Arm quick return valve
REVERSE) 11. Cover B
P4: From travel PPC valve (L.H. travel FOR- 12. Merge-divider valve
WARD)
P5: From R.H. work equipment PPC valve
(boom RAISE)
P6: From R.H. work equipment PPC valve
(boom LOWER)
P7: From L.H. work equipment PPC valve
(swing RIGHT)
P8: From L.H. work equipment PPC valve
(swing LEFT)
P9: From travel PPC valve (R.H. travel
REVERSE)
P10: From travel PPC valve (R.H. travel FOR-
WARD)
P11: From L.H. work equipment PPC valve (arm
OUT)
P12: From L.H. work equipment PPC valve (arm
IN)
P-1: From R.H. attachment PPC valve
P-2: From R.H. attachment PPC valve
PLS1: To rear pump LS valve
PLS2: To front pump LS valve
PLSC: LS pressure pickup port
PP1: From rear pump
PP2: From front pump
PP1S: Front pump oil pressure sensor mounting
port
PPC: Pilot source pressure pickup port
PP2S: Rear pump oil pressure sensor mounting
port
PPS2: To front pump LS valve
PR: To solenoid valve, PPC valve, and EPC
valve
PST: From travel junction solenoid valve
PC200, 200LC, 220, 220LC-8M0 10-402 3

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

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

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

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

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

1. Unload valve R.H. travel valve

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

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

1. Return spring L.H. travel valve

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

1. LS shuttle valve Structure

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

CLSS SEN06120-00
CLSS 1
CLSS: Abbreviation for Closed center Load Sensing System
Structure of CLSS
CLSS: Abbreviation for Closed center Load Sensing System
Features Configuration
q Fine control not influenced by load q CLSS consists of variable capacity piston
q Control performance that allows digging even pump, control valve, and actuators.
when fine control operation is turned on q The main pump consists of pump itself, PC
q Ease of combined operation enabled by the valve and LS valve.
flow divider function that is determined by the
opening areas of spools during combined
operations
q Energy saving by variable pump control
PC200, 200LC, 220, 220LC-8M0 10-402 13

SEN06120-00 CLSS
Basic principle q If it becomes higher than the set pressure

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

operation.
q The pump swash plate angle shifts toward the

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

CLSS SEN06120-00
Pressure compensation control
q A pressure compensation valve is installed to the outlet port side of each control valve to balance the
load pressure.
q When actuators are operated in combination, the pressure difference (dP) between the upstream (inlet
port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of
the load (pressure).
q The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.
PC200, 200LC, 220, 220LC-8M0 10-402 15

SEN06120-00 CLSS
System diagram
a The illustration shows the state when actuator (7) is relieved at the stroke end in the merge mode.
1. Front pump 9. LS circuit

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

Functions and operation by valve SEN06120-00
Functions and operation by valve 1

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

SEN06120-00 Functions and operation by valve
1. Arm valve 33. Main relief valve (for arm, R.H. travel, and
2. R.H. travel valve swing circuits)
3. Swing valve Set pressure:
4. Boom valve 35.4 0.3 MPa {360.5 3 kg/cm2}
5. L.H. travel valve When one-touch power max. switch is set
6. Bucket valve to ON position:
7. Service valve 38.0 0.3 MPa {387 3 kg/cm2}
8. Spool (arm) 34. Unload valve (for boom, L.H. travel, bucket,
9. Spool (R.H. travel) and attachment circuits)
10. Spool (swing) Cracking pressure:
11. Spool (boom) 2.5 0.5 MPa {26 5 kg/cm2}
12. Spool (L.H. travel) 35. Unload valve (for arm, R.H. travel, and swing
13. Spool (bucket) circuits)
14. Spool (service) Cracking pressure:
15. Pressure compensation valve 2.5 0.5 MPa {26 5 kg/cm2}
16. Suction valve 36. Suction safety valve
17. Check valve (for boom regeneration circuit) Set pressure:
18. Check valve (for arm regeneration circuit) 24.5 0.5 MPa {250 5 kg/cm2}
19. Pump merge-divider EPC valve (for LS spool) 37. Suction safety valve
20. Pump merge-divider EPC valve (for main Set pressure:
spool) 38.9 0.5 MPa {397 5 kg/cm2}
21. LS shuttle valve 38. Suction safety valve
22. LS bypass plug Set pressure:
23. LS selector valve 31.4 0.5 MPa {320 5 kg/cm2}
24. Merge-divider valve 39. Suction 2-stage safety valve
25. Arm quick return valve 1st stage set pressure:
26. Self-pressure reducing valve 24.5 0.5 MPa {250 5 kg/cm2}
27. Travel junction valve 2nd stage set pressure:
28. Variable back pressure valve 20.6 0.5 MPa {210 5 kg/cm2}
29. Variable back pressure solenoid valve 40. Safety valve for hydraulic drift prevention valve
30. Cooler check valve Set pressure:
31. Boom hydraulic drift prevention valve 38.9 0.5 MPa {397 5 kg/cm2}
32. Main relief valve (for boom, L.H. travel, bucket,
and attachment circuits)
Set pressure:
35.4 0.3 MPa {360.5 3 kg/cm2}
When one-touch power max. switch is set
to ON position:
38.0 0.3 MPa {387 3 kg/cm2}
10-402 18 PC200, 200LC, 220, 220LC-8M0

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

Operation of relief valve

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

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

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

Pressure compensation valve

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

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

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

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

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

Shuttle valve in pressure compensation valve

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

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

Boom regeneration circuit

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

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

Arm regeneration circuit

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

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

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

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

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

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

LS selector valve Operation

LS: Abbreviation for Load Sensing When pilot pressure (BP) is shut off
q Since pilot pressure (BP) is shut off, piston (3)
is pressed to the left by force of spring (2).
q If the swing lever is moved, swing LS pressure
(P1) passing through swing spool (5) enters
port (A).
q Swing LS pressure (P1) presses valve (1) to
the left, and port (A) and port (B) are intercon-
nected.
q Swing LS pressure (P1) is transmitted from
port (A) to LS shuttle valve (8) through port (B).
When pilot pressure (BP) is supplied

q When pilot pressure (BP) is supplied, pilot
pressure (BP) moves piston (3) to the right
a The illustration shows the condition when the against the force of spring (2).
combined operation of swing and R.H. travel is q When piston (3) moves to the right, valve (1)
performed. [When pilot pressure (BP) is sup- disconnects ports (A) and (B).
plied] q Since ports (A) and (B) are disconnected,
1. Valve swing LS pressure (P1) is not transmitted to LS
2. Spring shuttle valve (8).
3. Piston q Swing LS pressure (P1) cannot affect other LS
4. Piston circuits, even if it rises.
5. Swing valve spool
6. R.H. travel valve spool
7. Arm valve spool
8. LS shuttle valve
9. LS circuit
Function
q This valve prevents the high LS pressure of the
swing valve from entering the LS circuits of
work equipment valves when the swing and
work equipment are in combined operation.
q This valve serves to improve operability of the
work equipment by blocking the high pressure
generated during swing operation.
PC200, 200LC, 220, 220LC-8M0 10-402 35

Self-pressure reducing valve

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

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

When abnormally high pressure is generated

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

Travel junction valve

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

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

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

Travel PPC shuttle valve

PPC: Abbreviation for Proportional Pressure Control
Function
q If boom RAISE, arm IN or OUT, bucket CURL or DUMP operation is performed when the machine is
traveling up a steep, the pilot pressure from the travel PPC valve serves to restrict the travel of respec-
tive spools of boom, arm and bucket valves so that the oil flow rates to respective cylinders are
restricted.
q To limit the travel of the boom, arm or bucket spool, the pilot pressure from the travel PPC valve passes
through the internal circuit of respective control valves and acts on the spool.
Operation
When travel levers are in NEUTRAL
q The oil in the stroke limiting signal chamber (a) passes through orifices (5) and (6) of respective pistons
(3) and (4) build in the travel spring case, and then is drained through the travel PPC valve.
q When boom RAISE (or arm IN or OUT, bucket CURL or DUMP) operation is performed, spool (1) moves
to the left until it contacts the end face of spring case (2) (st0).
10-402 42 PC200, 200LC, 220, 220LC-8M0

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

Boom hydraulic drift prevention valve

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

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

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

Safety valve for hydraulic drift prevention valve

Operation when abnormally high pressure is generated
q If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port
(B) opens check valve (1a) to actuate safety valve for hydraulic drift prevention valve (2).
q The pressurized oil of the boom cylinder bottom circuit pressure or arm cylinder head circuit pressure,
whichever has higher pressure, opens check valve (1a) or (1b) to actuate safety valve for hydraulic drift
prevention valve (2).
PC200, 200LC, 220, 220LC-8M0 10-402 47

Arm quick return valve
Function
q Large amount of oil is returned from the cylinder bottom when arm OUT operation is performed.
q The valve reduces this pressure loss.
Operation
In arm OUT operation
q In arm OUT operation, the pilot pressure from the PPC valve pushes pilot piston (1).
q The pressurized oil in chamber (b) inside the valve is drained through orifice (c).
q The pressurized oil of the arm cylinder bottom side flows from orifice (c) to drain port (T) through orifice
(a) and chamber (b).
q Chamber (b) and drain port (T) are interconnected, and the pressure of chamber (b) drops.
q If the pressure in chamber (b) drops lower than that of port (A), the force exerted on the pressure receiv-
ing surface of [Area (S2) of fd2 (surface of seat diameter)] on the port (A) side exceeds the combined
force of the force exerted on the pressure receiving surface [Area (S1) of fd1] on the chamber (b) side
of valve (2) and the spring force.
q The result is, (Force exerted on surface of fd2 > Force exerted on surface of fd1 + Force of spring).
q Valve (2) is pressed to the right and pressurized oil flows from port (A) to port (B).
q The pressurized oil of the arm cylinder bottom side is drained directly to the tank from port (B).
10-402 48 PC200, 200LC, 220, 220LC-8M0

In arm NEUTRAL operation
q When the arm is operated from arm OUT to NEUTRAL, the pilot pressure from PPC valve is shut off.
q The pressurized oil that flows in through orifice (a) in valve (2) and is drained, is stopped by pilot piston
(1).
q The holding pressure of the arm cylinder bottom side exerts a left-hand force on the right side of ring-
shaped surface, whose area is equal to the area of (S2 - S1) of valve (2).
q The combined force of the force exerted on the ring-shaped surface and the spring force of the spring
(3) moves valve (2) to the left and shuts off port (A) and port (B).
PC200, 200LC, 220, 220LC-8M0 10-402 49

Variable back pressure valve When engine is running (during swing or travel
operation)
Function q The pressurized oil (PR) from self-pressure
q This valve creates back pressure in the drain reducing valve (1) flows to variable back pres-
circuit to prevent cavitation caused by negative sure solenoid valve (3).
pressure in each actuator circuit (motors, cylin- q Since drive signal (IS3) of variable back pres-
ders, etc.). sure solenoid valve (3) is OFF, pressurized
q In order to reduce output loss, this valve oil (PR) is flown to spring chamber (C) of vari-
reduces the back pressure in the drain circuit able back pressure valve (4).
when any operation other than the travel and q Pressurized oil (PR) transmitted to spring
swing is performed. chamber (C) exerts a force on the left end face
of valve (6) (surface of fd), and it pushes valve
Operation (6) to the right as a combined force with the
When engine is stopped reaction force of spring (5).
q Pressurized oil is not supplied from the main q Pressure (PA) of drain circuit (A) of the control
pump to self-pressure reducing valve (1). valve acts on the right end face of valve (6)
q No oil pressure is transmitted from variable (surface of fd1) to push valve (6) to the left.
back pressure solenoid valve (3) to spring q Valve (6) balances at a position where it cre-
chamber (C), and valve (6) is pressed to the ates back pressure (PA) determined as fol-
right by the reaction force of spring (5). lows; PA = (Area of surface fd) x Pressure
q Drain circuit (A) of the control valve is intercon- (PR) + Reaction force of spring (5) / Area of
nected to port (T) through orifice (b) of valve surface fd1
(6). q Accordingly, the oil flow rate from drain circuit
(A) of the control valve to port (T) is limited. In
other words, the set pressure of variable back
pressure valve (4) is adjusted.
10-402 50 PC200, 200LC, 220, 220LC-8M0

When engine is running (other than swing or

travel operation)
q The pressurized oil from self-pressure reduc-
ing valve (1) flows to variable back pressure
solenoid valve (3).
q Since drive signal (IS3) of variable back pres-
sure solenoid valve (3) is ON, the pressur-
ized oil (PR) from self-pressure reducing valve
(1) flown to spring chamber (C) of variable
back pressure valve (4) is drained through
variable back pressure solenoid valve (3).
q Only the reaction force of spring (5) pushes
valve (6) to the right.
q Pressure (PA) of drain circuit (A) of the control
valve acts on the right end face of valve (6)
(surface of fd1) to push valve (6) to the left.
q Valve (6) balances at a position where it cre-
ates back pressure (PA) determined as fol-
lows; PA = Reaction force of spring (5) / Area
of surface fd1
q Accordingly, the oil flow rate from drain circuit
(A) of the control valve to port (T) is limited. In
other words, the set pressure of variable back
pressure valve (4) is adjusted.
PC200, 200LC, 220, 220LC-8M0 10-402 51

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

q The load at installed length of spring (1) is added with the force exerted by pilot pressure (P) applied to
the area of diameter (d1) of poppet (2), raising the set pressure to higher level.
10-402 52 PC200, 200LC, 220, 220LC-8M0

2-stage suction-safety valve

[Installed to port (B) of the service valve]
1. Spring
2. Piston
3. Spring
4. Holder
Function
q This valve has two settings for its set pressure.
q This valve is set to the low-pressure setting when the pilot pressure is applied to it from the attachment
circuit selector solenoid valve.
q ON/OFF of the pilot pressure changes the set pressure according to the type of the installed attachment
(breaker, crusher, etc.).
q The set pressure of this valve is determined by the load at installed length of spring (1). (High-pressure
side)
q The set pressure of the low-pressure setting is determined by the travel of the piston.
PC200, 200LC, 220, 220LC-8M0 10-402 53

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

When pilot pressure (P) is shut off (high pressure setting)
sure setting) q When pilot pressure (P) is supplied, the pilot
q Since pilot pressure (P) is shut off, piston (2) is pressure is transmitted to part (A) through pas-
pressed to the left by force of spring (3). [Load sage (B).
at installed length of spring (1) < Load at q The pilot pressure acts on the pressure receiv-
installed length of spring (3).] ing diameter at part (A) [(d1) (d2)] of piston
q The load at installed length of spring (1) (2).
becomes maximum, inducing high-pressure q Piston (2) compresses spring (3) by receiving
setting. pilot pressure and moves to the right until it
q Passage (B) is interconnected to the drain cir- contacts holder (4).
cuit via passage (C) and chamber (D). q Since spring (1) is expanded and reducing its
load at installed length, the set pressure is low-
ered.
q The amount of pressurized oil for stroke of pis-
ton (2) is drained from passage (C) via cham-
ber (D) .
10-402 54 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 10-402 55

SEN06120-00

2012 KOMATSU
All Rights Reserved
10-402 56
SEN06121-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

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

SEN06121-00 Swing motor
Swing motor 1
Model: KMF125ABE-6
B: From swing holding brake solenoid valve Specifications

MA: From control valve (swing RIGHT)
MB: From control valve (swing LEFT) Machine models PC200-8M0, PC220-8M0,
Item PC200LC-8M0 PC220LC-8M0
S: From control valve
T: To hydraulic tank Model KMF125ABE-6
1. Reverse prevention valve Theoretical displacement 125 cm3/rev

2. Safety valve Safety valve set pressure 28.4 MPa {290 kg/cm 2}
Rated engine speed 1,694 rpm 1,879 rpm
Brake release pressure 1.4 MPa {14 kg/cm2}
10-403 2 PC200, 200LC, 220, 220LC-8M0

Swing motor SEN06121-00
PC200, 200LC, 220, 220LC-8M0 10-403 3

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

{1.12 kg}
10-403 4 PC200, 200LC, 220, 220LC-8M0

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

MA: From control valve (swing RIGHT)
MB: From control valve (swing LEFT) Machine models PC200-8M0, PC220-8M0,
Item PC200LC-8M0 PC220LC-8M0
S: From control valve
T: To hydraulic tank Model KMF125AB-6
1. Safety valve Theoretical displacement 125 cm3/rev

Safety valve set pressure 28.4 MPa {290 kg/cm 2}
Rated engine speed 1,694 rpm 1,879 rpm
Brake release pressure 1.4 MPa {14 kg/cm 2}
PC200, 200LC, 220, 220LC-8M0 10-403 5

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

1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10. Cylinder block
11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Shuttle valve
Unit: mm
Load at Load at
Replace spring if
57.2 x 20.0 30.9
{0.35 kg} {0.27 kg} deformed
13.7 N 11.0 N
17 Shuttle valve spring 16.4 x 8.9 11.5
{1.4 kg}

{1.12 kg}
PC200, 200LC, 220, 220LC-8M0 10-403 7

Swing holding brake
1. When solenoid valve is de-energized 2. When solenoid valve is energized
Operation Operation
q As the swing holding brake is de-energized, q As the swing holding brake solenoid valve is
the pressurized oil from the self pressure energized, the valve is switched.
reducing valve is shut off. q The pressurized oil from the self pressure
q Port (B) is connected to tank circuit (T). reducing valve is conducted brake chamber (a)
q Brake piston (7) is pushed down by brake through port (B).
spring (1). q After entering chamber (a), the pressurized oil
q Disc (5) and plate (6) are pushed together, and compresses brake spring (1) and pushes
the brake is applied. brake piston (7) up.
q Disc (5) is separated from plate (6), releasing
the brake.
10-403 8 PC200, 200LC, 220, 220LC-8M0

Relief valve portion
Outline 2 When swing is stopped

q The relief valve portion consists of check q When the swing control lever is returned to
valves (2) and (3), shuttle valves (4) and (5), neutral, the supply of pressurized oil from the
and relief valve (1). pump to port (MA) is stopped.
q The pressurized oil from the motor outlet can't
Function return to the tank since the returning circuit to
q When the machine is in the swing holding the tank is closed from control valve (6). Thus,
mode, control valve (6) closes the motor outlet pressure on port (MB) increases.
circuit, but the motor rotation is continued by q Rotation resistance is generated on the motor
inertial force. and hence the brake starts working.
q The motor output, therefore, is abnormally q Shuttle valve (4) is pressed as pressure on
increased, resulting in damaging the motor. port (MB) goes above port (MA).
q In order to prevent the motor damages, the q The pressure on chamber (C) is increased to
relief valve relieves the abnormally high pres- the se t pr es sur e of r el ief va lv e ( 1) an d
sure to port (S) from the motor outlet side becomes the same as that of port (MB).
(high-pressure side) of the motor. q A high braking torque works on the motor,
thereby stopping the motor.
Operation q When relief valve (1) is being actuated, the
1 When starting swing relieved pressurized oil and the pressurized oil
q When the swing control lever is operated to the from port (S) are fed to port (MA) through
right- swing, the pressurized oil from the pump is check valve (3).
supplied to port (MA) through control valve (6). q Above prevents cavitation on port (MA).
q The pressure on port (MA) rises, the starting
torque is generated in the motor, and the motor
starts to rotate.
q The pressurized oil from the outlet port of the
motor passes from port (MB) through the con-
trol valve (6) and returns to the tank.
PC200, 200LC, 220, 220LC-8M0 10-403 9

SEN06121-00 Center swivel joint
Center swivel joint 1
A1 : To L.H. travel motor port (PB) 1. Cover

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

Center swivel joint SEN06121-00
Unit: mm
Standard dimension Standard clearance Allowable clearance
8 Clearance between rotor and shaft Replace
80 0.056 to 0.105 0.111
PC200, 200LC, 220, 220LC-8M0 10-403 11

SEN06121-00 Travel motor
Travel motor 1
L.H. travel motor

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

Travel motor SEN06121-00
PC200, 200LC, 220, 220LC-8M0 10-403 13

1. Regulator piston
2. Regulator valve
3. Motor case
5. Check valve
6. Rocker cam
7. Retainer guide
8. Output shaft
9. Pin
10. Retainer
11. Piston
12. Cylinder block
13. Valve plate
14. Counterbalance valve spool
15. Ring
16. Brake piston
17. Plate
18. Disc
19. Ball retainer
Unit: mm
Load at Load at
7.16 N 5.69 N
32.5 x 6.5 24.2
{0.73 kg} {0.58 kg} Replace spring if
{0.26 kg}

{0.21 kg} deformed
411 N 328 N
22 Spool return spring 58.4 x 30 42.6
{41.9 kg}

{33.5 kg}
54.9 N 43.9 N
23 Regulator valve spring 21.5 x 11.1 17.1
{5.6 kg}

{4.48 kg}
Specifications
Model HMV120
Min. 82
Theoretical discharge (cm3/rev)
Max. 106.2
2
Rated pressure: MPa {kg/cm } 37.3 {380}
Min. 2,689
Rated speed (rpm)
Max. 1,275
Brake release pressure (MPa {kg/cm2}) 1.18 {12}
2
Travel speed changeover pressure (MPa {kg/cm }) 0.78 {8.0}
10-403 14 PC200, 200LC, 220, 220LC-8M0

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

2) At high speed (motor swash plate angle at minimum)
q As the solenoid valve is energized, the pilot

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

Operation of parking brake
1) When starting travel
q As the travel lever is operated, pressurized oil

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

2) When travel is stopped
q As the travel lever is placed in neutral, counter-

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

Brake valve Operation when pressurized oil is supplied

q The brake valve consists of suction safety q Operating the travel lever conducts the pres-
valve (18A) and counterbalance valve (18). surized oil from the control valve to port (PA).
q Functions and operations of respective compo- q The pressurized oil push-opens suction safety
nents shall conform to the following. valve (18A) and then flows to motor outlet port
(MB) through motor inlet port (MA).
1) Counterbalance valve and check valve q The motor outlet side is closed by suction
safety valve (18B) and spool (19), so the pres-
Function sure at the supply side rises.
q When traveling downhill, the machine travel
speed tends to get faster than the motor
(engine) speed because of the downward force
generated from its own weight.
q If the machine travels with the engine at low
speed, the motor may rotate without load,
causing the machine to run away; resulting in a
very dangerous situation.
q These valves are used to prevent above by
controlling the machine to travel according to
the engine speed (pump discharge).
PC200, 200LC, 220, 220LC-8M0 10-403 19

q The pressurized oil on the supply side flows to Operation of brake during travelling downhill
chamber (S1) through orifice (E1) and orifice q If indication of the machine runaway is sensed
(E2) of the spool (19). while travelling downhill, the motor will be
q As the pressure in chamber (S1) goes above caused to rotate without load to decrease the
the spool selector pressure, spool (19) is inlet side oil pressure.
pushed toward right. q Pressure in chamber (S1) is released through
q Port (MB) and port (PB) are connected, open- orifices (E1) and (E2).
ing the motor outlet port side and starting the q As the pressure in chamber (S1) goes below
motor rotating. the spool selector pressure, spool (19) is
returned to the left by spring (20) and outlet
port (MB) is throttled.
q The pressure at the outlet port side rises, gen-
erating rotation resistance on the motor to pre-
vent the machine from running away.
q The spool moves to a position where the pres-
sure on outlet port (MB) can be balanced
against the machine's own weight and the inlet
port pressure.
q Oil flow from the outlet circuit is reduced to
ensure the travel speed corresponded to the
pump discharge.
10-403 20 PC200, 200LC, 220, 220LC-8M0

2) Safety valve q When the pressure rises above the set pressure
of the suction safety valve, poppet (1) opens.
Function q The pressurized oil passes through notch (A1)
of spool (19) into chamber (MA) of the circuit at
q As long as the machine travel is stopped (or it
the opposite side.
is travelling downhill), the counterbalance q At the time of counterclockwise rotation, it
valve closes the inlet and outlet circuits of the makes reverse operation of clockwise rotation.
motor.
q Since the motor is rotated by inertial force,
pressure in the motor outlet port side is abnor-
mally increased, potentially resulting in dam-
ages on the motor and piping.
q The safety valve releases this abnormal pres-
sure to the inlet port side of the motor in order
to prevent damages to the equipment.
Operation
(1) When travel is stopped
(or when travelling downhill) (Right swing)
q Reduction of the pressure at motor inlet (PA)
decreases the pressure in chamber (S1). (2) When starting travel
q When it drops beyond the spool switching (or when traveling at a constant speed)
pressure, spool (19) is returned to the left by
q As the travel lever is operated, the pressurized
spring (20), reducing the pressure at outlet
oil from the pump moves spool (19) toward right.
passage (B1).
q The passage to the suction safety valve func-
q The motor tries to continue rotation resorting to
tions as a circuit which passes through notch
inertial force, thus pressure on the outlet port
(B2) of spool (19), producing large differential
(MB) is increased.
pressure.
q The pump pressure rises, providing a large
tractional force to the valve.
PC200, 200LC, 220, 220LC-8M0 10-403 21

SEN06121-00 PPC valve
PPC valve 1
Work equipment and swing PPC valve 1
P: From self pressure reducing valve

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

PPC valve SEN06121-00
PC200, 200LC, 220, 220LC-8M0 10-403 23

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

Installed
Centering spring x Outside installed Free length installed
10 (for ports P3 and P4) diameter
length
length length
Replace spring if
17.7 N 14.1 N
42.5 x 15.5 34.0 damaged or
{1.80 kg} {1.44 kg}
deformed
Centering spring 29.4 N 23.5 N
11 (for ports P1 and P2)
44.5 x 15.5 34.0
{3.0 kg}

{2.40 kg}
16.7 N 13.3 N
12 Metering spring 26.5 x 8.15 24.9
{1.70 kg}

{1.36 kg}
10-403 24 PC200, 200LC, 220, 220LC-8M0

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

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

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

3. During fine control 4. At full stroke

(When control lever is returned) q Disc (5) pushes down piston (4), and retainer
q When disc (5) starts to be returned, spool (1) is (9) pushes down spool (1).
pushed up by the force of centering spring (3) q Fine control hole (f) is shut off from drain
and the pressure at port (P1). chamber (D), and is interconnected to pump
q Because of this, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D), and the pressur- q Therefore, the pilot pressure oil from the self
ized oil at port (P1) is released. pressure reducing valve passes through fine
q If the pressure of port (P1) is lowered exces- control hole (f) and flows to chamber (A) from
sively, spool (1) is pushed down by metering port (P1) to push the control valve spool.
spring (2). q The oil returning from chamber (B) passes
q Fine control hole (f) is shut off from drain from port (P2) through fine control hole (f') and
chamber (D), and it is almost simultaneously flows to drain chamber (D).
interconnected to pump pressure chamber
(PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the cham-
ber with pressurized oil.
10-403 26 PC200, 200LC, 220, 220LC-8M0

Travel PPC valve 1

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

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

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

Unit: mm

Installed
x Outside installed Free length installed
7 Centering spring
diameter
length
length length Replace spring if
damaged or
108 N 86.3 N deformed
48.6 x 15.5 32.5
{11.0 kg} {8.8 kg}
16.7 N 13.3 N
{1.7 kg}

{1.36 kg}
PC200, 200LC, 220, 220LC-8M0 10-403 29

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

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

3) During fine control 4) At full stroke

(When control lever is returned) q Lever (5) pushes down piston (4), and retainer
q When lever (5) starts to be returned, spool (1) (9) pushes down spool (1).
is pushed up by the force of centering spring q Fine control hole (f) is shut off from drain
(3) and pressure at port (P1). chamber (D), and is interconnected to pump
q Because of this, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D), and the pressur- q Therefore, the pilot pressure oil from the self
ized oil at port (P1) is released. pressure reducing valve passes through fine
q If the pressure of port (P1) is lowered exces- control hole (f) and flows to chamber (A) from
sively, spool (1) is pushed down by metering port (P1) to push the control valve spool.
spring (2). q The oil returning from chamber (B) passes
q Fine control hole (f) is shut off from drain cham- from port (P2) through fine control hole (f') and
ber (D), and it is almost simultaneously inter- flows to drain chamber (D).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the cham-
ber with pressurized oil.
PC200, 200LC, 220, 220LC-8M0 10-403 31

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


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

Load at Load at
8 Centering spring Outside diameter length
damaged or
33.9 x 15.3 28.4
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
{1.70 kg}

{1.36 kg}
PC200, 200LC, 220, 220LC-8M0 10-403 33

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

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

Load at Load at Replace PPC valve
Installed
Free length installed Free length installed assembly if spring
7 Return spring length
length length isdamaged or
deformed
3.1 N 2.5 N
9.5 8.4
{0.32 kg} {0.26 kg}
10-403 34 PC200, 200LC, 220, 220LC-8M0

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

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

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

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

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

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

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

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

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


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

Load at Load at
7 Centering spring Outside diameter length
damaged or
33.9 x 15.3 28.4
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
{1.70 kg}

{1.36 kg}
PC200, 200LC, 220, 220LC-8M0 10-403 41

SEN06121-00 Valve control
Valve control 1
10-403 42 PC200, 200LC, 220, 220LC-8M0

Valve control SEN06121-00
1. Travel PPC valve

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

SEN06121-00 Solenoid valve
Solenoid valve 1
PPC lock, travel junction, ATT selector, travel speed, swing brake, and 2-stage relief solenoid valves
10-403 44 PC200, 200LC, 220, 220LC-8M0

Solenoid valve SEN06121-00
1. PPC lock solenoid valve When solenoid is energized

2. 2-stage relief solenoid valve q As the signal current flows from the controller
3. Swing brake solenoid valve to solenoid (9), solenoid (9) is energized.
4. Travel speed solenoid valve Accordingly, spool (10) is pushed to the right.
5. Travel junction solenoid valve This operation flows the pressurized oil from
6. ATT selector solenoid valve the main pump, through port (P), via inside
7. Connector spool (10), to port (A), and eventually to the
8. Moving core actuator.
9. Coil At the same time, port (T) closes, the oil does
10. Spool not flow to the tank.
11. Block
12. Spring
T: To tank
A1: To PPC valve
A2: To main valve (2-stage relief valve)
A3: To swing motor
A4: To L.H. and R.H. travel motors
A5: To main valve (Travel junction valve)
A6: To ATT selector valve
P1: From main pump
ACC: To accumulator
Operation
When solenoid is de-energized
q Since the signal current does not flow from the
controller, solenoid (9) is de-energized.
For this reason, spool (10) is pushed to the left
by spring (12).
Since port (P) is closed to port (A), pressurized
oil from the main pump does not flow to the
actuator.
At this time, the oil from the actuator is drained
through ports (A) and (T) into the tank.
PC200, 200LC, 220, 220LC-8M0 10-403 45

SEN06121-00 PPC accumulator
PPC accumulator 1
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Gas capacity: 300 cc (for PPC)
10-403 46 PC200, 200LC, 220, 220LC-8M0

Return oil filter SEN06121-00
Return oil filter 1

For breaker
1. Drain plug Specifications

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

SEN06121-00 Attachment circuit selector valve
Attachment circuit selector valve 1
ACC: To accumulator
ATT: To attachment
P1: From attachment selector solenoid valve
TS: To hydraulic tank
V: To control valve
1. Spool
Unit: mm

Load at Load at
Free length x Installed Replace spring if
2 Spool return spring Outside diameter length
length length
damaged or
deformed
834 N 667 N
132 x 29 114.5
{85.0 kg} {68.0 kg}
10-403 48 PC200, 200LC, 220, 220LC-8M0

Attachment circuit selector valve SEN06121-00
Function 2. When breaker is installed

q When a breaker is installed, the return oil from q Pilot pressure from the attachment circuit
the breaker does not pass through the main selector solenoid valve contracts spring (2),
valve, but returns directly to the hydraulic tank. and spool (1) moves to the right to the stroke
q When other attachments (crusher, etc.) are end.
installed, the attachment and the main valve q Ports (ATT) and (V) are shut off and ports
are interconnected. (ATT) and (T) are interconnected.
q Pressurized oil returning from the breaker
Operation returns directly to the hydraulic tank through
port (T) without passing through the control
1. When attachment other than breaker valve.
is installed
q Spool (1) is pressed to the left by the force of
spring (2).
q Ports (ATT) and (V) are interconnected and
ports (ATT) and (T) are shut off. Attachment is
thus interconnected to the control valve.
PC200, 200LC, 220, 220LC-8M0 10-403 49

SEN06121-00 Hydraulic cylinder
Hydraulic cylinder 1
PC200-8M0 and PC200LC-8M0
Boom cylinder
Arm cylinder
Bucket cylinder
10-403 50 PC200, 200LC, 220, 220LC-8M0

Hydraulic cylinder SEN06121-00
Unit: mm
Standard Tolerance Standard Clearance

Cylinder
size Shaft Hole clearance limit
0.036 +0.222 0.083 to

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

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

Unit: mm
0.030 +0.190 0.100 to
Boom 80 1.0
0.060 +0.070 0.250
0.030 +0.190 0.100 to
0.076 +0.070 0.266
and bushing
0.030 +0.170 0.100 to
Bucket 70 1.0
0.060 +0.070 0.230 Replace pin and
0.030 +0.165 0.075 to bushing
Boom 70 1.0
0.060 +0.045 0.225
0.030 +0.190 0.100 to
0.076 +0.070 0.266
shaft and bushing
0.030 +0.165 0.075 to
Bucket 70 1.0
0.060 +0.045 0.225
PC200, 200LC, 220, 220LC-8M0 10-403 51

SEN06121-00 Hydraulic cylinder
PC220-8M0 and PC220LC-8M0

Boom cylinder
Arm cylinder
Bucket cylinder
10-403 52 PC200, 200LC, 220, 220LC-8M0

Hydraulic cylinder SEN06121-00
Unit: mm
Standard Tolerance Standard Clearance

Cylinder
size Shaft Hole clearance limit
0.036 +0.222 0.083 to

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

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

Unit: mm
0.030 +0.190 0.100 to
Boom 80 1.0
0.060 +0.070 0.250
0.030 +0.190 0.100 to
0.076 +0.070 0.266
and bushing
0.030 +0.175 0.100 to
Bucket 80 1.0
0.060 +0.075 0.246 Replace pin and
0.030 +0.190 0.075 to bushing
Boom 80 1.0
0.060 +0.070 0.225
0.030 +0.190 0.100 to
0.076 +0.070 0.266
shaft and bushing
0.030 +0.190 0.075 to
Bucket 80 1.0
0.060 +0.070 0.225
PC200, 200LC, 220, 220LC-8M0 10-403 53

SEN06121-00

2012 KOMATSU
All Rights Reserved
10-403 54
SEN06122-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

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

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

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

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

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

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

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

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

500 Work equipment
Shims for work equipment Plastic shim

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

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

500 Work equipment
Type B Shims to adjust play of bucket

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

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

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

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

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

SEN06122-00

2012 KOMATSU
All Rights Reserved
10-500 14
SEN06123-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

600 Electrical system
Engine control ...................................................................................................................................... 2
Electrical control system .................................................................................................................... 12
Machine monitor system .................................................................................................................... 35
Sensor................................................................................................................................................ 56
KOMTRAX system ............................................................................................................................. 60
PC200, 200LC, 220, 220LC-8M0 10-600 1

SEN06123-00 Engine control
Engine control 1
Operation of system 1
Starting engine
q When the starting switch is turned to the
START position, the starting signal flows to the
starting motor. Then, the starting motor turns to
start the engine.
When it happens, the engine controller checks

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

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

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

Engine control SEN06123-00
Component 1
Fuel control dial
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
PC200, 200LC, 220, 220LC-8M0 10-600 3

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

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

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

Input and output signals CN-CE01

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

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

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

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

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

SEN06123-00 Electrical control system
Electrical control system 1

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

Electrical control system SEN06123-00
PC200, 200LC, 220, 220LC-8M0 10-600 13

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

Function 1) Control method in each mode

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

B mode and L mode

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

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

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

3) Function to control when emergency pump

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

9. System component parts

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

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

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

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

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

Input and output signals

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

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

Machine monitor system SEN06123-00
Machine monitor system 1
1. Machine monitor Function

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

SEN06123-00 Machine monitor system
Machine monitor 1
Function q When the engine is started, the battery voltage

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

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


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

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

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

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

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

22. Air cleaner clogging monitor

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

Gauge
Gauge Display item Description Remarks

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

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

Caution monitor
Description
Symbol Display item Monitor display Remarks

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

Description

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

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

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

Description

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

Pilot monitor
Symbol Display item Description Remarks

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

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

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

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

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

Symbol Display item Description Remarks

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

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

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

Switches 1
No. Name Function Operation

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

No. Name Function Operation

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

Guidance icon and function switch

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

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

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

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

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

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

Selects the page right below the current page.

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

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

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

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

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

Switching the fuel

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

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

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

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

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

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

Operator mode function

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

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

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

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

Service mode function

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

SEN06123-00 Sensor
Sensor 1
q The signals from the sensors are input to the
monitor panel directly.
q Either side of a sensor of contact type is
always connected to the chassis ground.
Type of When When
Sensor name
sensor normal abnormal
ON OFF
Hydraulic oil level Contact
(Closed) (Open)
Resis-
Fuel level
tance
OFF ON
Air cleaner clogging Contact
(Closed) (Open)
ON OFF
Coolant level Contact
(Closed) (Open)
Hydraulic oil level sensor 1
1. Connector
2. Bracket
3. Float
4. Switch
10-600 56 PC200, 200LC, 220, 220LC-8M0

Sensor SEN06123-00
Fuel level sensor 1
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor 1
1. Adapter 3. Indicator
2. Hood 4. Connector
PC200, 200LC, 220, 220LC-8M0 10-600 57

SEN06123-00 Sensor
Coolant level sensor 1
1. Reserve tank
2. Float
3. Sensor
4. Connector
10-600 58 PC200, 200LC, 220, 220LC-8M0

Sensor SEN06123-00
PC200, 200LC, 220, 220LC-8M0 10-600 59

SEN06123-00 KOMTRAX system
KOMTRAX system 1
q The KOMTRAX system consists of the KOMTRAX terminal, communication antenna and GPS antenna.
q This system transmits various machine information by use of the radio communication. This system
allows the KOMTRAX operator to refer the information and provide various services to the customers.
q Information transmittable from the KOMTRAX system are as follows.
1. Operation map
2. Service meter reading
3. Location information
4. Abnormality record
a To provide the services, you need to make an arrangement for starting the KOMTRAX service sepa-
rately.
KOMTRAX terminal
Model: TC330
1. GPS antenna connection 3. Machine harness connection (070-12P)

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

KOMTRAX system SEN06123-00

070-18P[CN-CK01]

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

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

SEN06123-00 KOMTRAX system
Function
q This terminal uses the satellite communications technology.
q The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the com-
munication antenna.
q The status of the terminal can be checked by using the menu of KOMTRAX setting in the service
mode of the machine monitor .
q Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
q This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When changing the country where the system is used, you must give notice to Komatsu Ltd. the infor-
mation which country the system is used in advance.
10-600 62 PC200, 200LC, 220, 220LC-8M0

KOMTRAX system SEN06123-00
PC200, 200LC, 220, 220LC-8M0 10-600 63

SEN06123-00

2012 KOMATSU
All Rights Reserved
10-600 64
SEN06125-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

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

SEN06125-00 Standard value table for engine related parts
Standard value table for engine related parts 1

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

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

Coolant
Engine speed temperature: Within Low idle rpm 1,050 50 1,050 50
operating range
Rated speed rpm 2,000 2,000
Coolant temperature: Within

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

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

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

kPa Max. 0.98 1.96
Blow-by pressure operating range
{mmH2O} {Max. 100} {200}
Arm IN relief + power max.
SAE0W30E0S,
SAE5W40E0S, MPa Min. 0.29 0.25
High idle
SAE10W30DH, {kg/cm2} {Min. 3.0} {2.5}
SAE15W40DH,
Oil pressure
SAE30DH engine oil
Coolant MPa Min. 0.10 0.07
temperature: Within Low idle {kg/cm2} {Min. 1.0} {0.7}
operating range
Oil temperature Whole speed range (inside oil pan) C 80 to 110 120
Between fan pulley and alternator

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

Standard value table for engine related parts SEN06125-00
PC220, 220LC-8M0
Engine SAA6D107E-1

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

Coolant
Engine speed temperature: Within Low idle rpm 1,050 50 1,050 50
operating range
Rated speed rpm 2,000 2,000
Coolant temperature: operating

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

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

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

kPa Max. 0.98 1.96
Blow-by pressure operating range
{mmH2O} {Max. 100} {200}
Arm IN relief + power max.
SAE0W30E0S,
SAE5W40E0S, MPa Min. 0.29 0.25
High idle
SAE10W30DH, {kg/cm2} {Min. 3.0} {2.5}
SAE15W40DH,
Oil pressure
SAE30DH engine oil
Coolant MPa Min. 0.10 0.07
temperature: Within Low idle {kg/cm2} {Min. 1.0} {0.7}
operating range
Oil temperature Whole speed range (inside oil pan) C 80 to 110 120
Between fan pulley and alternator

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

SEN06125-00 Standard value table for chassis related parts
Standard value table for chassis related parts 1

PC200, 200LC-8M0

gory
machine
Engine coolant temperature: Within
operating range
Hydraulic oil temperature: Within
2 pumps at relief operating range rpm 1,800 100 1,800 100
Engine at high idle
Power mode (P)
Arm IN relief condition
Engine speed

operating range
At 2-pump relief +
operating range rpm 1,950 100 1,950 100
power max.
Engine at high idle
Working mode: P mode
Arm IN relief + Left knob switch ON
Engine at high idle
Speed when auto- Auto-deceleration switch in ON
deceleration is condition rpm 1,050 100 1,050 100
operated All control levers in NEUTRAL
condition
Raise mm 11.5 0.5 11.5 0.5

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

Spool stroke
Arm control valve Engine stopped

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

Travel of control levers
Control lever grip at center

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

Standard value table for chassis related parts SEN06125-00

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

N 15.7 3.9 Max. 24.5
Arm control lever
Hydraulic oil temperature: Within {kg} {1.6 0.4} {Max. 2.5}
operating range N 12.7 2.9 Max. 21.6
and pedal
Bucket control lever

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

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


gory
machine
operating range
Engine running at high idle
Working mode: P mode deg. Max. 100 Max. 130
Overswing
Swing circle misalignment amount (mm) () ()
when stopping after one turn
For measuring posture, see Swing
1
Hydraulic oil
temperature: Within
operating range
Engine running at 90 sec. 3.1 0.3 Max. 3.7
high idle
Working mode: P
Time required for mode
starting swing Time required for
passing points 90
and 180 from
starting point 180 sec. 4.4 0.4 Max. 5.5
For measuring
posture, see Swing
1
Swing
operating range
Time required to Working mode: P mode
sec. 24.2 2.5 Max. 30
complete turns Time required for 5 more turns after
making initial one turn
1
operating range
Engine stopped
Keeping upper structure transverse
on slope of 15
Swing drift on a slope Notching a mating mark on inner mm 0 0
and outer races of swing circle
Mating mark misalignment amount
during 5 minutes
2
operating range
Leakage from swing Engine running at high idle
l/min Max. 5 Max. 10
motor Swing lock switch: ON
Leakage amount for one minute
during swing relief
Hydraulic oil [PC200-8M0] [PC200-8M0]
temperature: Within 51.3 (+3.6/-6.7) 44.6 to 58.8
operating range Lo sec.
[PC200LC-8M0] [PC200LC-8M0]
Engine running at
55.9 (+3.9/-7.3) 48.6 to 63.8
high idle
Working mode: P [PC200-8M0] [PC200-8M0]
Travel
Travel speed mode 37.5 3.8 33.7 to 45.3

Mi sec.
(idle running) Time required to [PC200LC-8M0] [PC200LC-8M0]
make five idle turns 40.8 4.1 36.7 to 48.9
of track off ground
[PC200-8M0] [PC200-8M0]
after one idle turn
26.5 1.3 25.2 to 29.8
For measuring Hi sec.
posture, see Travel [PC200LC-8M0] [PC200LC-8M0]
1 28.8 1.5 27.3 to 32.3
20-100 6 PC200, 200LC, 220, 220LC-8M0


gory
machine
Hydraulic oil
temperature: Within
operating range Lo sec. 24 (+1.7/-3.1) 20.9 to 26.9
Engine running at
high idle
Working mode: P
Travel speed mode
Mi sec. 17 2.5 14.5 to 20.5
(actual running) Flat ground
Time required to
travel 20 m after
running up 10 m
For measuring Hi sec. 13 1.0 12.0 to 15.0
posture, see Travel
2
operating range
Engine at high idle
Travel
Travel speed: Lo
Travel deviation mm Max. 150 Max. 250
Solid and flat ground
Travel deviation (x) in travel of 20 m
after running up 10 m
For measuring posture, see Travel
2 and 3
operating range
Engine stopped
Machine drift on a Parking machine on slope of 12
mm 0 0
slope with sprocket facing upslope
Sliding distance for 5 minutes
4
operating range
Leakage from travel Engine at high idle
l/min 13.6 27.2
motor Traveling with sprocket locked
Leakage in 1 minute during travel
relief
Whole work operating range mm Max. 644 Max. 966
Hydraulic drift of work equipment
equipment Flat and level ground

Fill bucket with dirt or rated load
(0.8m 3: 1,440kg)
Work equipment
Boom cylinder Boom horizontal, arm fully retracted, mm Max. 19 Max. 29

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


gory
machine
Hydraulic oil
temperature: Within
operating range
Engine running at RAISE sec. 3.3 0.4 Max. 4.8
high idle
Working mode: P
mode
Boom
Time required from
RAISE stroke end till
bucket touches
ground LOWER sec. 2.4 0.3 Max. 3.7
For measuring
posture, see Work
equipment 2
Hydraulic oil
temperature: Within
operating range
Work equipment speed
IN sec. 3.5 0.4 Max. 4.5

Engine running at
Work equipment
high idle
Working mode: P
Arm mode
Time required from
OUT stroke end to
IN stroke end
For measuring OUT sec. 2.7 0.3 Max. 3.5
posture, see Work
equipment 3
Hydraulic oil
temperature: Within
operating range CURL sec. 2.4 0.3 Max. 3.3
Engine running at
high idle
Working mode: P
Bucket mode
Time required from
DUMP stroke end to
CURL stroke end
For measuring DUMP sec. 1.8 0.2 Max. 2.7
posture, see Work
equipment 4
20-100 8 PC200, 200LC, 220, 220LC-8M0


gory
machine
operating range
Engine running at low idle
Lower boom from RAISE stroke end
Boom sec. Max. 1.0 Max. 1.2
and measure time from when work
equipment touches the ground until
front side of machine rises
For measuring posture, see Work
equipment 5
operating range
Time lag
Move arm to IN from OUT stroke

Arm sec. Max. 2.0 Max. 2.8
end and measure time from when
Work equipment
arm stops momentarily until it starts

moving again
equipment 6
operating range
Move bucket to CURL from DUMP
Bucket sec. Max. 1.0 Max. 3.6
stroke end and measure time from
when bucket stops momentarily
until it starts moving again
equipment 7
Cylinders operating range cc/min 4.5 20
leakage
Internal

Center swivel with cylinder or travel to be cc/min 10 50
joint measured in relief condition
operating range
compound operation
Engine at high idle

Performance in
Travel deviation in Working mode: P mode

simultaneous Traveling speed: Lo
mm Max.200 Max.220
operation of work Travel deviation (x) in travel of 20 m
equipment and travel after running up 10 m on hard and
flat ground
2 and 3
operating range
Engine at high idle
PC flow control valve
Characteristics of
Rated load applied to bucket

(0.8m 3: 1,440kg)
Time required for
On hard and flat ground, set arm 4.2 0.4
turning from 0 to 90 sec.
vertically and lower back of bucket (Reference value)
with boom raised
to ground
Time required till passing spot of
90 starting from illustrated posture
and with boom raised
equipment 8
Discharge amount of
See performance of hydraulic pump (next page)
hydraulic pump
PC200, 200LC, 220, 220LC-8M0 20-100 9

Cate- Standard lower limit of

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

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

PC220, 220LC-8M0

gory
machine
operating range
2 pumps at relief operating range rpm 1,900 100 1,940 100
Engine at high idle
Power mode (P)
Arm IN relief condition
Engine speed

operating range
At 2-pump relief +
operating range rpm 1,950 100 1,950 100
power max.
Engine at high idle
Arm IN relief + Left knob switch ON
Engine at high idle
Speed when auto- Auto-deceleration switch in ON
deceleration is condition rpm 1,050 100 1,050 100
operated All control levers in NEUTRAL
condition
Raise mm 11.5 0.5 11.5 0.5

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

Spool stroke
Arm control valve Engine stopped

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

Travel of control levers
Control lever grip at center

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


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

N 15.7 3.9 Max. 24.5
Arm control lever
Hydraulic oil temperature: Within {kg} {1.6 0.4} {Max. 2.5}
operating range N 12.7 2.9 Max. 21.6
and pedal
Bucket control lever

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

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


gory
machine
operating range
Working mode: P mode deg. Max. 165 Max. 200
Overswing
Swing circle misalignment amount (mm) () ()
when stopping after one turn
1
Hydraulic oil
temperature: Within
operating range
Engine running at 90 sec. 3.0 0.3 Max. 3.5
high idle
Working mode: P
Time required for mode
starting swing Time required for
passing points 90
and 180 from
starting point 180 sec. 4.5 0.4 Max. 5.4
For measuring
posture, see Swing
1
Swing
operating range
Time required to Working mode: P mode
sec. 25.7 2.8 Max. 31
complete turns Time required for 5 more turns after
making initial one turn
1
operating range
Engine stopped
Keeping upper structure transverse
on slope of 15
Swing drift on a slope Notching a mating mark on inner mm 0 0
and outer races of swing circle
Mating mark misalignment amount
during 5 minutes
2
operating range
Leakage from swing Engine running at high idle
l/min Max. 5 Max. 10
motor Swing lock switch: ON
during swing relief
Hydraulic oil [PC220-8M0] [PC220-8M0]
temperature: Within 53.6 (+3.8/-7.0) 46.6 to 61.5
operating range Lo sec.
[PC220LC-8M0] [PC220LC-8M0]
Engine running at
58.1 (+4.1/-7.6) 50.5 to 66.3
high idle
Working mode: P [PC220-8M0] [PC220-8M0]
Travel
Travel speed mode 39.2 (+4.4/-3.6) 35.6 to 47.6

Mi sec.
(idle running) Time required to [PC220LC-8M0] [PC220LC-8M0]
make five idle turns 42.5 (+4.7/-3.9) 38.6 to 51.2
of track off ground
[PC220-8M0] [PC220-8M0]
after one idle turn
28.0 (+1.5/-1.3) 26.7 to 31.5
For measuring Hi sec.
posture, see Travel [PC220LC-8M0] [PC220LC-8M0]
1 30.3 (+1.6/-1.4) 28.9 to 33.9
PC200, 200LC, 220, 220LC-8M0 20-100 13


gory
machine
Hydraulic oil
temperature: Within
operating range Lo sec. 24 (+1.7/-3.1) 20.9 to 26.9
Engine running at
high idle
Working mode: P
Travel speed mode
Mi sec. 17 2.5 14.5 to 20.5
(actual running) Flat ground
Time required to
travel 20 m after
running up 10 m
For measuring Hi sec. 13 1.0 12.0 to 15.0
posture, see Travel
2
operating range
Engine at high idle
Travel
Travel speed: Lo
Travel deviation mm Max. 150 Max. 250
Solid and flat ground
Travel deviation (x) in travel of 20 m
after running up 10 m
2 and 3
operating range
Engine stopped
Machine drift on a Parking machine on slope of 12
mm 0 0
slopel with sprocket facing upslope
Sliding distance for 5 minutes
4
operating range
Leakage from travel Engine at high idle
l/min 13.6 27.2
motor Traveling with sprocket locked
Leakage in 1 minute during travel
relief
Whole work operating range mm Max. 600 Max. 900
Hydraulic drift of work equipment
equipment Flat and level ground

Fill bucket with dirt or rated load
(0.8m 3: 1,440kg)
Work equipment
Boom cylinder Boom horizontal, arm fully retracted, mm Max. 18 Max. 27

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


gory
machine
Hydraulic oil
temperature: Within
operating range
Engine running at RAISE sec. 3.4 (+0.5/-0.3) Max. 4.7
high idle
Working mode: P
mode
Boom
Time required from
RAISE stroke end till
bucket touches
ground LOWER sec. 2.7 0.3 Max. 4.4
For measuring
posture, see Work
equipment 2
Hydraulic oil
temperature: Within
operating range
Work equipment speed
IN sec. 4.1 0.4 Max. 4.6

Engine running at
Work equipment
high idle
Working mode: P
Arm mode
Time required from
OUT stroke end to
IN stroke end
For measuring OUT sec. 3.0 (+0.4/-0.2) Max. 3.5
posture, see Work
equipment 3
Hydraulic oil
temperature: Within
operating range CURL sec. 2.7 0.3 Max. 3.3
Engine running at
high idle
Working mode: P
Bucket mode
Time required from
DUMP stroke end to
CURL stroke end
For measuring DUMP sec. 2.1 0.2 Max. 2.7
posture, see Work
equipment 4
PC200, 200LC, 220, 220LC-8M0 20-100 15


gory
machine
operating range
Lower boom from RAISE stroke end
Boom sec. Max. 1.0 Max. 1.2
and measure time from when work
equipment touches the ground until
front side of machine rises
equipment 5
operating range
Time lag
Move arm to IN from OUT stroke

Arm sec. Max. 2.0 Max. 2.8
end and measure time from when
Work equipment
arm stops momentarily until it starts

moving again
equipment 6
operating range
Move bucket to CURL from DUMP
Bucket sec. Max. 1.0 Max. 3.6
stroke end and measure time from
when bucket stops momentarily
until it starts moving again
equipment 7
Cylinders operating range cc/min 4.5 20
leakage
Internal

Center swivel with cylinder or travel to be cc/min 10 50
joint measured in relief condition
operating range
compound operation
Engine at high idle

Performance in
Travel deviation in Working mode: P mode

simultaneous Traveling speed: Lo
mm Max.200 Max.220
operation of work Travel deviation (x) in travel of 20 m
equipment and travel after running up 10 m on hard and
flat ground
2 and 3
operating range
Engine at high idle
PC flow control valve
Characteristics of
Rated load applied to bucket

(0.8m 3: 1,440kg)
Time required for
On hard and flat ground, set arm 4.3 0.4
turning from 0 to 90 sec.
vertically and lower back of bucket (Reference value)
with boom raised
to ground
Time required till passing spot of
90 starting from illustrated posture
and with boom raised
equipment 8
Discharge amount of
See performance of hydraulic pump (next page)
hydraulic pump
20-100 16 PC200, 200LC, 220, 220LC-8M0

Cate- Standard lower limit of

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

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

For all models (Posture of machine for measur- Travel 1: Travel speed (idle running)
ing performance and measurement procedure)
Control valve: spool stroke
Travel 2: Travel speed (actual running), travel devi-

ation
Swing 1: Overswing, time required for starting

swing, time required to complete turns
Travel 3: Travel deviation
Swing 2: Swing drift on a slope
20-100 18 PC200, 200LC, 220, 220LC-8M0

Travel 4: Machine drift on a slope Work equipment 3: Arm speed
Work equipment 1: Hydraulic drift of work Work equipment 4: Bucket speed

equipment
Work equipment 5: Boom time lag

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

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

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

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

SEN06125-00

2012 KOMATSU
All Rights Reserved
20-100 22
SEN06127-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

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

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

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

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

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

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

Tools for testing, adjusting, and troubleshooting SEN06127-00
Sym-
Q'ty
bol
799-601-4101
or
799-601-4201
or T-adapter assembly 1
799-601-9000
or
799-601-9200
For ECONO
(Does not include 799-601-4201/
799-601-4350 799-601-9000 and 799-601-9200)
or Measurement box 1
799-601-9320 For ECONO
(Does not include 799-601-4101/
799-601-4201 and 799-601-9200)
799-601-9020 Adapter for DT 1 For DT2P
For DT3P
799-601-9030 Adapter for DT 1 (Does not include 799-601-4101 and
799-601-4201)
For DT4P
799-601-4260 Adapter for DT 1 (Does not include 799-601-9000 and
799-601-9200)
799-601-7000
or
Troubleshooting for 799-601-7100
chassis T or T-adapter assembly 1
Sensors/wiring harnesses 799-601-7400
or
799-601-8000
For ECONO
799-601-2600 Measurement box 1
(Does not include 799-601-7000)
799-601-7090 Adapter for M 1 For M2P
799-601-7140 Adapter for S 1 For S8P
For SW6P
799-601-7050 Adapter for SWP 1
For SW8P
799-601-7060 Adapter for SWP 1
For X1P
799-601-7010 Adapter for X 1 (Does not include 799-601-7000 and
799-601-7100)
799-601-7020 Adapter for X 1 For X2P
799-601-7360 Adapter for relay 1 For REL-5P
799-601-7310 Adapter for SWP 1 For SW12P
799-601-9890 Adapter for multiple 1 For DT-2, 3, 4/DTM-2
799-601-4280 Measurement box 1 For pump controller
Testing coolant tempera-
799-101-1502 Digital thermometer 1 99.9 to 1,299C
ture and oil temperature
Testing operating effort 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}

and depressing force 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
Testing stroke and Commercially
Ruler 1
hydraulic drift available
Testing work equipment Commercially
Stopwatch 1
speed available
Testing voltage and Commercially
Circuit tester 1
resistance available
Removal and installation
Commercially 3.26 mm torque wrench
of boost pressure and Hexlobe (TORX) wrench 1
available (KTC Q4T15 or equivalent)
temperature sensors
PC200, 200LC, 220, 220LC-8M0 30-101 5

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

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

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

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

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

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

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

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

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

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

a Checking tools for exhaust gas color
Symbol Part No. Part name
1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available

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

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

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

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

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

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

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

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

Testing compression pressure SEN06127-00
Testing compression pressure 1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SEN06127-00 Testing blowby pressure
Testing blowby pressure 1

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

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

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

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

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

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

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

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

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

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

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

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

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

Testing fuel pressure SEN06127-00
Testing fuel pressure 1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

left work equipment control lever to relieve
the arm circuit at the IN stroke end, and
measure the oil pressure.
2) Install nipples L2 and connect them to oil

pressure gauges [2].
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.
a Measuring condition and method of
judgment: If the pressures are in the
following ratio, the PC valve is nor-
mal.
Tested oil Operation of Ratio of oil
pressure lever pressures
Pump discharge
1
pressure
Arm IN relief
PC valve output Approx. 0.6
pressure (Approx. 3/5)
a If the PC valve or the servo piston is

abnormal, the PC valve output pres-
sure (servo piston inlet pressure) is
3) Start the engine and set the working mode
"the same as the pump discharge
in the power mode (P).
pressure" or "almost 0".
4) Run the engine at high idle and low idle,
set all the levers and pedals for work
equipment control, swing control, and
parts.
travel in neutral, and measure the oil pres-
sure at each speed.
2. Measuring PC-EPC valve output pressure
and remove oil pressure pickup plugs (5)
and (6).
(5): Front PC-EPC valve output pressure
pickup plug
(6): Rear PC-EPC valve output pressure
pickup plug
PC200, 200LC, 220, 220LC-8M0 30-101 39

SEN06127-00 Testing and adjusting oil pressure in pump PC control cir-
a Measuring condition and method of 1. Loosen locknut (9).

judgment: If the output pressures are a Before loosening the locknut, make coun-
the following values, the PC-EPC ter mark at the adjustment screw end so
valve is normal. that you can see the position of the lock-
nut before the adjustment (and you can
Operation of
Engine
lever
Output pressure return the locknut to its original position
after turning it in reverse).
All control Approx. 2.9 MPa
Low idle
levers and {Approx. 30 kg/cm2}
2. Turn adjustment screw (10) clockwise or coun-
pedals in 0 MPa
High idle neutral terclockwise to adjust.
{0 kg/cm2}
a Turn the adjustment screw
q Clockwise when the work equipment
speed is low (to in crease pu mp
absorption torque) and
parts.
q Counterclockwise when the engine
speed lowers (to decrease pump
Adjusting
absorption torque).
Adjusting pump PC valve
a If either of the following phenomena occurs 3. Tighten locknut (9).
and the PC valve seems to be defective, adjust 3 Locknut: 27 to 34 Nm {2.8 to 3.5 kgm}
PC valves (7) and (8) according to the proce-
dure shown below.
q As the working load increases, the engine
speed lowers remarkably.
q The engine speed is normal but the work
equipment speed is low.
q (7): Front pump PC valve
q (8): Rear pump PC valve
a The width across flats of the PC valve locknut
is 13 mm and that of the adjustment screw
(inside width) is 4 mm.
Do not turn any other locknuts or adjustment
screws since they affects the hydraulic pump
performance.
4. After finishing adjustment, check again that the

PC valve output pressure (servo piston inlet
pressure) is normal according to the above
described measurement procedure.
30-101 40 PC200, 200LC, 220, 220LC-8M0

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

in pump LS control circuit 1
in pump LS control circuit
1
M 2 799-401-2701 Differential pressure gauge
799-101-5220 Nipple (10 1.25 mm)
3
07002-11023 O-ring

lower the work equipment to the ground. 2) Install nipples M3 and nipples [1] of
Then, release the residual pressure from hydraulic tester M1 and connect them to
the hydraulic circuit. For details, see oil pressure gauges [2].
Releasing residual pressure from hydrau- a Connect the measuring part of plug
lic circuit. (3) by using joint (790-301-1271) and
elbow (790-301-1530) of hydraulic
Measuring tester M1 and nipple [1] so that it will
a Before measuring the oil pressure in the pump not interfere with the drain piping.
LS control circuit, check that the oil pressure in a Use the oil pressure gauge of 60 MPa
the work equipment, swing, and travel circuits {600 kg/cm2}.
and the control circuit source pressure are nor-
mal.
a Measure the oil pressure in the pump LS con-
trol circuit under the following condition.
range
1. Measurement of LS valve output pressure

(servo piston inlet pressure)
a Measure the LS valve output pressure
(servo piston inlet pressure) and pump
discharge pressure simultaneously to
compare them.
and remove oil pressure pickup plugs (1), 3) Start the engine and push up the track
(2), (3), and (4). shoe on the side to be measured with the
q (1): Front pump discharge pressure work equipment and prepare for running
pickup plug the track shoe idle.
q (2): Rear pump discharge pressure q When measuring front circuit: Right
pickup plug track shoe
q (3): Front LS valve output pressure q When measuring rear circuit: Left
pickup plug track shoe
q (4): Rear LS valve output pressure k Since the raised track will be run in
pickup plug the air during measurement, secure
a sufficient working area.
4) Set the working mode in the power mode
(P) and set the travel speed in the High
position.
PC200, 200LC, 220, 220LC-8M0 30-101 41

SEN06127-00 Testing and adjusting oil pressure in pump LS control cir-
5) Run the engine at high idle, set all the 2. Measurement of LS differential pressure
levers and pedals for work equipment con- a Measure the pump discharge pressure
trol, swing control, and travel control in and LS pressure (actuator load pressure)
neutral, and measure the oil pressure. simultaneously and calculate the differ-
Then, operate the travel lever to run the ence between them, to obtain the LS dif-
track in the air and measure the oil pres- ferential pressure.
sure. 1) Open the side cover of the pump room
k While taking extreme care for and remove oil pressure pickup plugs (1),
safety, run the raised track shoe. (2), (5), and (6).
a Do not operate the travel lever to its q (1): Front pump discharge pressure
stroke end (but stop it halfway). pickup plug
q (2): Rear pump discharge pressure
pickup plug
a Testing condition and judgment

method: When the hydraulic pres-
q (5): Front LS pressure pickup plug
sures are within ratio in the table, LS
q (6): Rear LS pressure pickup plug
valve is normal.
Position of levers and pedals
Travel lever
All levers and
move half-
pedals are at
way (Travel
neutral
without load)
Hydraulic pressure
1
to be measured
Pump discharge
(Actual value
pressure
is set as 1)
Almost same
pressure
Approx. 3/5 of
LS valve output
pressure
pressure
above

parts.
30-101 42 PC200, 200LC, 220, 220LC-8M0

2) Install nipples M3 and connect it to differ- 3) Run the engine, push up the track shoe on
ential pressure gauge M2 or the oil pres- the side to be measured with the work
sure gauge of hydraulic tester M1. equipment, and prepare for running track
a When using differential pressure gauge shoe idle.
M2: q When measuring front circuit: Right
Connect the pump discharge pres- track shoe
sure to the high pressure side (back q When measuring rear circuit: Left
side) and connect the LS pressure to track shoe
the low pressure side (lower side). k Since the raised track shoe will be
Since the differential pressure gauge run idle during measurement,
needs a 12V power source, connect it secure a sufficient working area.
to a battery. 4) Set the working mode in the power mode
a When using oil pressure gauge (in M1): (P) and set the travel speed in the High
Use the oil pressure gauge of 60 MPa position.
{600 kg/cm 2 } having the unit of 1.0 5) Run the engine at high idle, set all the
MPa {10 kg/cm2}. Since the differen- levers and pedals for work equipment con-
tial pressure is approximately 4.0 trol, swing control, and travel in neutral,
MPa {40 kg/cm2} at maximum, mea- and measure the oil pressure at each
sure it by installing the same gauge to speed. Then, operate the travel lever to
the pickup plugs alternately. run the track shoe idle and measure the oil
q The figure shows the pump discharge pressure.
pressure side. k While taking extreme care for
safety, run the raised track shoe.
a Do not operate the travel lever to its
stroke end (but stop it halfway).
q The figure shows the LS pressure side.

judgment: If the pressures are in the
following value, the LS valve is nor-
mal.
LS differential
Operation of levers
pressure
All control levers and pedals Specified LS dif-
in neutral ferential pressure
Travel lever moved halfway (See standard
(Track running in the air) values table)

parts.
PC200, 200LC, 220, 220LC-8M0 30-101 43

SEN06127-00 Testing and adjusting oil pressure in pump LS control cir-
3. Measurement of LS-EPC valve output pres-

sure
and remove oil pressure pickup plug (7).

parts.
2) Install nipple M3 and connect them to oil
pressure gauge [2].
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.
3) Start the engine.

4) Run the engine at high idle, operate the
travel speed selector switch and travel
lever, and measure the output pressure in
each case.
judgment: If the output pressures are
the following value, the LS-EPC valve
is normal.
Travel Operation of
Output pressure
speed lever
Travel lever Approx. 2.9 MPa
Lo
in neutral {Approx. 30 kg/cm2}
Travel lever
0 MPa
Hi operated a
{0 kg/cm2}
little (Note)
Note: Move the travel lever to a degree

that the PPC oil pressure switch is
turned ON (before the track starts
moving).
30-101 44 PC200, 200LC, 220, 220LC-8M0

Adjusting
Adjusting LS valve
a If the LS differential pressure is abnormal,
adjust the LS valve according to the following
procedure.
q (8): Front pump LS valve
q (9): Rear pump LS valve
1. While fixing adjustment screw (10), loosen

locknut (11).
2. Turn adjustment screw (10) to adjust the differ-

ential pressure.
a If the adjustment screw is
q Turned to the right, the differential
pressure is increased.
q Turned to the left, the differential
pressure is decreased.
a Quantity of adjustment (LS differential
pressure) per turn of adjustment screw:
Approx. 1.1 MPa {Approx. 10.8 kg/cm2}
3. While fixing adjustment screw (10), tighten

locknut (11).
3 Locknut: 49 to 68.6 Nm {5 to 7 kgm}
4. After finishing adjustment, check again that the

LS differential pressure is normal according to
the above described measurement procedure.
PC200, 200LC, 220, 220LC-8M0 30-101 45

SEN06127-00 Testing solenoid valve output pressure
Testing solenoid valve output a When measuring with hoses (2) (6),
pressure 1 remove the undercover of the control
valve.
a Measuring tools for solenoid valve output pres-
sure
1
N 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (Size 02)

hydraulic circuit.
a Before measuring the solenoid valve output
pressure, check that the control circuit source 2. Install adapter N2 and connect the discon-
pressure is normal. nected hose again.
a Measure the solenoid valve output pressure
under the following condition. 3. Fit nipple [1] of hydraulic tester N1 and then
q Hydraulic oil temperature: Within operating connect it to oil pressure gauge [2].
range a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.
1. Disconnect outlet hoses (1) (6) of the sole- a The figure shows the measuring tools con-
noid valves to be measured. nected to outlet hose (1) of the PPC lock
solenoid valve.
No. Solenoid valve to be measured
1 PPC lock solenoid valve
2 2-stage relief solenoid valve
3 Swing holding brake solenoid valve
4 Travel speed selector solenoid valve
5 Travel junction solenoid valve
ATT return selector solenoid valve
6
(Attachment installation specification)
a When measuring with hose (1), remove

the undercover (rear side) of the opera-
tor's cab.
4. Start the engine.
5. Run the engine at high idle, operate the control

levers and switches to turn the solenoid valve
ON or OFF, and measure the oil pressure.
a For the conditions for turning the solenoid
valve ON and OFF, see the operation
table of each solenoid valve.
a The operating condition of the solenoid
valve can be checked with the monitoring
function of the machine monitor (For
details, see Special functions of machine
monitor).
q Monitoring code: 02300 Solenoid 1
q Monitoring code: 02301 Solenoid 2
30-101 46 PC200, 200LC, 220, 220LC-8M0

Testing solenoid valve output pressure SEN06127-00
a If the output pressure is as follows, the

solenoid valve is normal.
Solenoid valve Output pressure
OFF
0 MPa {0 kg/cm2}
(Demagnetization)
ON (Excitation) 2.9 MPa {30 kg/cm2}

PC200, 200LC, 220, 220LC-8M0 30-101 47

SEN06127-00 Testing solenoid valve output pressure
Operation table of PPC lock solenoid valve

Operating condition Operation
Lock OFF
Lock lever
Free ON
Operation table of 2-stage relief solenoid valve

Overheat 1st setting is ON
Overheat 2nd setting is ON OFF
All of work equipment, swing, and travel signals are OFF
Swing lock switch is ON
Travel signal is ON
L mode is selected ON
Boom LOWER signal is ON
P/E mode is Signals other than swing single signal are ON
Left knob switch is ON
selected Swing single signal is ON
OFF
Other than above condition
Operation table of swing holding brake solenoid valve

Work equipment, swing, and All are OFF OFF
travel signals Any one is ON ON
Operation table of travel speed selector solenoid valve

Overheat 2nd setting signal is ON
Fuel control dial is at 1,500 rpm or below
Travel speed switch is at Lo/Mi (PC200-8M0)
OFF
Travel speed switch is at Lo (PC220-8M0)
Travel speed switch is at Hi (PC200- Travel signal is OFF
8M0)
F or R pump pressure is 24.5 MPa {250 kg/cm2}
Travel speed switch is at Mi/Hi (PC220- Travel signal is
8M0) ON F or R pump pressure is 15.3 MPa {150 kg/cm2}
ON
Other than above condition
Operation table of travel junction solenoid valve

Travel steering signal is ON
ON
Travel steering Travel lever is operated independently F or R pump pressure is 24.5 MPa {250 kg/cm2}
signal is OFF Other than above condition OFF
Operation table of ATT return selector solenoid valve (Machine with provision for attachment)
Working mode: Other than B OFF
Working mode: B ON
30-101 48 PC200, 200LC, 220, 220LC-8M0

Testing PPC valve output pressure SEN06127-00
Testing PPC valve output pressure 1

Connecting points of PPC piping
a The above figure shows the connecting points

of the PPC piping on the control valve of 1
attachment installation specification. The col-
ors in ( ) are the colors of the bands installed
for distinction of the pipes.
PC200, 200LC, 220, 220LC-8M0 30-101 49

SEN06127-00 Testing PPC valve output pressure
a Measuring tools for PPC valve output pressure

1
P
2 799-401-3100 Adapter (Size 02)
3 799-401-3200 Adapter (Size 03)

hydraulic circuit.
a If the output pressure is as follows, the
a Before measuring the PPC valve output pres-
PPC valve is normal.
sure, check that the control circuit source pres-
sure is normal. Operation of lever Output pressure
a Measure the solenoid valve output pressure Neutral 0 MPa {0 kg/cm2}
under the following condition.
Almost same as control
q Hydraulic oil temperature: Within operating Stroke end circuit basic pressure (See
range standard values table)
1. Disconnect the hose of the PPC circuit to be

measured. 6. After finishing measurement, remove the mea-
a For the hose to be disconnected, see suring tools and return the removed parts.
Connecting points of PPC piping.
2. Install adapter P2 and connect the discon-

nected hoses again.
3. Install nipple [1] of hydraulic tester P1 and con-

nect it to oil pressure gauge [2].
a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.
a The figure shows the measuring tools con-
nected to the hose of the bucket dump
PPC circuit.
4. Start the engine and set the working mode in

the power mode (P).
5. Run the engine at high idle and measure the

oil pressure with the control lever in neutral
and moved to its stroke end.
30-101 50 PC200, 200LC, 220, 220LC-8M0

Adjusting play of work equipment and swing PPC valves SEN06127-00
Adjusting play of work equipment

and swing PPC valves 1
a If the right and left work equipment levers have
large play, adjust them according to the follow-
ing procedure.
a The play of the lever terminal must be 0.5 3
mm at a position of 200 mm from the center of
lever rotation.
1. Remove the work equipment and swing PPC

valve assembly.
2. Remove bellows (1).
3. Loosen locknut (2) and tighten disc (3) until it

touches the heads of 4 pistons (4).
a Do not move the piston at this time.
4. Fix disc (3) and tighten locknut (2) to the speci-

fied torque.
3 Locknut: 69 to 88 Nm {7 to 9 kgm}
5. Install bellows (1).
6. Install the work equipment and swing PPC

valve assembly.
PC200, 200LC, 220, 220LC-8M0 30-101 51

SEN06127-00 Testing parts which cause hydraulic drift of work equipment
Testing parts which cause 2. Inspection of arm cylinder

hydraulic drift of work equipment 1) Stop the arm cylinder approximately 100
mm before the IN stroke end and stop the
a If the work equipment (cylinder) drifts hydrauli- engine.
cally, check to see if the causal part is the cyl-
inder packing or control valve side according to
the following procedure.
1. Measurement of boom and bucket cylin-

ders
1) Set the machine in the posture for mea-
suring hydraulic drift and stop the engine.
a Fill the bucket with a rated load or
with dirt and sand.
2) Operate the arm control lever in the IN

position.
q If the lowering speed is increased at
this time, the cylinder packing is
defective.
q If the lowering speed does not
change at this time, the control valve
is defective.
a Operate the control lever while the
starting switch is in the ON position.
2) When checking the boom cylinder, set the a If the pressure in the accumulator is
boom control lever to the RAISE position. lost, run the engine for approximately
When checking the bucket cylinder, set 5 seconds to increase the pressure in
the bucket control lever to the CURL posi- the accumulator.
tion. [Reference]
q If the lowering speed is increased at Reason why the lowering speed is increased
this time, the cylinder packing is by the above operation when the cylinder
defective. packing is the cause of the hydraulic drift:
q If the lowering speed does not 1) If the machine is set in the above posture
change at this time, the control valve (where the holding pressure is applied to
is defective. the bottom side), the oil leaks from the
a Operate the control lever while the bottom side to the head side. Since the
starting switch is in the ON position. volume on the head side is less than that
a If the pressure in the accumulator is on the bottom side by the volume of the
lost, run the engine for approximately rod, the pressure in the head side is
5 seconds to increase the pressure in increased by the oil flowing in from the
the accumulator. bottom side.
2) As the pressure in the head side is
increased, it is balanced at a certain level
(which depends on the leakage), and then
the lowering speed is lowered.
3) If the circuit on the head side is opened to
the drain circuit by the above operation of
the lever (the bottom side is closed by the
check valve at this time), the oil on the
head side flows in the drain circuit. As a
result, the pressure is unbalanced and the
lowering speed is increased.
30-101 52 PC200, 200LC, 220, 220LC-8M0

Testing parts which cause hydraulic drift of work equipment SEN06127-00
3. Checking PPC valve

While the pressure in the accumulator is high,
set the lock lever to the LOCK/FREE position
and measure the lowering distance.
a Operate the control lever while the starting
switch is in the ON position.
a If the pressure in the accumulator is lost,
run the engine for approximately 5 sec-
onds to increase the pressure in the accu-
mulator.
a If there is a difference in the lowering dis-
tance between the LOCK position and
FREE position, the PPC valve is defective
(it has an internal defect).
PC200, 200LC, 220, 220LC-8M0 30-101 53

SEN06127-00 Releasing remaining pressure from hydraulic circuit
Releasing remaining pressure 4) Repeat steps 2) and 3) above 2 3 times,

from hydraulic circuit 1 and the residual pressure in the piping is
released completely.
1. Releasing remaining pressure from hydrau-
lic tank 3. Release of remaining pressure from swing
k Since the hydraulic tank is enclosed motor circuit
and pressurized, release the residual The remaining pressure in the swing motor cir-
pressure from it when removing a hose cuit can be released by performing the opera-
or a plug connected to it. tion for Releasing remaining pressure from
1) Lower the work equipment to the ground hydraulic cylinder circuit (Operate the lever to
in a stable posture and stop the engine. SWING only, however).
2) Loosen oil filler cap (1) of the hydraulic
tank gradually to release the air in the 4. Release of remaining pressure from travel
tank. motor circuit
Since the control valve spool of the travel
motor circuit is connected to the drain circuit,
the pressure in this circuit can be released by
performing Releasing remaining pressure
from hydraulic tank.
2. Release of remaining pressure from

hydraulic cylinder circuit
k When disconnecting a pipe between a
hydraulic cylinder and the control
valve, release the remaining pressure
from the piping according to the follow-
ing procedure.
1) Lower the work equipment to the ground
and release the residual pressure from the
hydraulic tank. For details, see Releasing
remaining pressure from hydraulic tank.
a Keep the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch to ON position
and set the lock lever to the FREE posi-
tion, and then operate the right and left
work equipment control levers forward,
backward, to the right, and to the left.
a The control valve is operated by the
pressure in the accumulator. The
pressure in the accumulator is used
up, however, after the control valve is
operated 2 3 times.
3) Run the engine at low idle for 5 seconds to
increase the pressure in the accumulator.
a The engine does not start until the
lock lever is set to the LOCK position
once.
30-101 54 PC200, 200LC, 220, 220LC-8M0

Testing oil leakage SEN06127-00
Testing oil leakage 1 2. Measuring oil leakage from arm cylinder

1) Move the arm cylinder to the IN stroke end
a Measuring tools for oil leakage and stop the engine.
Symbol Part No. Part name k Release the residual pressure from
the piping on the arm cylinder
Commercially
Q Measuring cylinder head side. For details, see Releas-
available
ing residual pressure from hydrau-
a Measure the oil leakage under the following lic circuit (Operate the lever to arm
condition. IN only, however).
q Hydraulic oil temperature: Within operat- 2) Disconnect hose (2) on the cylinder head
ing range side and block the hose side with a flange.
k Take care not to disconnect the
1. Measuring oil leakage from boom cylinder hose on the cylinder bottom side.
1) Move the boom cylinder to the RAISE a Use the following part to block the
stroke end and stop the engine. hose side.
k Release the residual pressure from
07379-00640 (Flange #06)
the piping on the boom cylinder
head side. For details, see Releas-
lic circuit (Operate the lever in the
boom RAISE direction only, how-
ever).
2) Disconnect hose (1) on the cylinder head
side and block the hose side with a flange.
hose on the cylinder bottom side.
a Use the following part to block the
hose side.
07379-00640 (Flange #06)
3) Run the engine at high idle and relieve the
arm circuit by moving the arm IN.
k Take care not to "move the arm
OUT".
4) Start measuring the oil leakage 30 sec-
onds after relieving is started and mea-
sure for 1 minute.
5) After finishing measurement, return the
removed parts.

boom circuit by raising the boom.
k Take care not to "lower the boom".
sure for 1 minute.
removed parts.
PC200, 200LC, 220, 220LC-8M0 30-101 55

SEN06127-00 Testing oil leakage
3. Measuring oil leakage from bucket cylinder 4. Measuring oil leakage from swing motor
1) Move the bucket cylinder to the CURL 1) Disconnect 2 drain hoses (4) and block
stroke end and stop the engine. the hose side with plugs.
k Release the residual pressure from a Use the following part to block the
the piping on the bucket cylinder hose side.
head side. For details, see Releas- 07376-70522 (Plug #05)
lic circuit (Operate the lever in the
bucket CURL direction only, how-
ever).
2) Disconnect hose (3) on the cylinder head
side and block the hose side with a flange.
hose on the cylinder bottom side.
hose side.
07379-00640 (Flange #06)
2) Turn the swing lock switch ON.

swing circuit by swinging.
a Start measuring the oil leakage 30
seconds after relieving is started and
measure for 1 minute.
a After measuring 1 time, swing 180,
and then measure again.
removed parts.

bucket circuit by curling the bucket.
k Take care not to dump the bucket.
sure for 1 minute.
removed parts.
30-101 56 PC200, 200LC, 220, 220LC-8M0

Testing oil leakage SEN06127-00
5. Measuring oil leakage from travel motor 5) After finishing measurement, return the
1) Remove the travel motor cover. removed parts.
2) Run the engine, lock the sprocket, and
stop the engine.
k Put pin [1] between the sprocket
and track frame to lock the travel
mechanism securely.
3) Disconnect drain hose (5) of the travel

motor and block the hose side with a plug.
hose side.
07376-70422 (Plug #04)
4) Run the engine at high idle, relieve the

travel circuit, and measure the oil leakage.
k Before operating the travel lever,
check the position and locking
direction of the locked sprocket
again.
k Wrong operation of the lever can
cause an accident. Accordingly,
make signals and checks securely.
a Start measuring the oil leakage 30
seconds after relieving is started and
measure for 1 minute.
a Measure several times, moving the
motor a little (changing the position of
the valve plate and cylinder and that
of the cylinder and piston) each time.
PC200, 200LC, 220, 220LC-8M0 30-101 57

SEN06127-00 Bleeding air from each part
Bleeding air from each part 1

q: Execution of work
o: Go to next procedure
Air bleeding item Air bleeding procedure
1 2 3 4 5 6
Bleeding air Checking oil
Bleeding air Bleeding air
from Starting Bleeding air level and
from swing from travel
hydraulic engine from cylinder starting
Contents of work motor motor
pump operation
Replacing hydraulic oil q q
q q q q
Cleaning strainer (See note) (See note)
Replacing return filter element q o o o q
Replacing and repairing hydraulic pump

q q q o o q
Removing suction piping
Replacing and repairing control valve
q q o o q
Removing control valve piping
Replacing and repairing cylinder
q q o o q
Removing cylinder piping
Replacing and repairing swing motor
q o q o q
Removing swing motor piping
Replacing and repairing travel motor
q o o q q
Removing travel motor piping
Replacing and repairing swivel joint
q o o o q
Removing swivel joint piping
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
1. Bleeding air from hydraulic pump 2. Starting engine

1) Loosen air bleeder (1) and check that oil When running the engine after performing step
oozes out through the air bleeder. 1, keep its speed at low idle for 10 minutes.
2) After the oil oozes out, tighten air bleeder a If the engine coolant temperature is low
(1). and the automatic warm-up operation is
3 Air bleeder: started, stop the engine temporarily and
7.8 to 9.8 Nm {0.8 to 1.0 kgm} reset the automatic warm-up operation
a Do not use an impact wrench to with the fuel control dial (Set the starting
tighten the air bleeder. switch to the ON position and hold the fuel
control dial in the MAX position for 3 sec-
onds, and the automatic warm-up opera-
tion is reset).
3. Bleeding air from cylinder

a If a cylinder is replaced, bleed air from it
before installing it to the work equipment.
In particular, the boom cylinder does not
move to the lowering stroke end, if it is
installed to the work equipment.
1) Run the engine at low idle for approxi-
mately 5 minutes.
2) While running the engine at low idle, raise
and lower the boom 4 to 5 times.
a Stop the piston rod approximately 100
mm before each stroke end. Do not
relieve the oil.
30-101 58 PC200, 200LC, 220, 220LC-8M0

Bleeding air from each part SEN06127-00
3) While running the engine at high idle, per- 2) Check the oil level by sight gauge (3) on
form step 2). the rear side of the hydraulic tank.
4) While running the engine at low idle, move a If the oil level is below line L, it is
the piston rod to the stroke end and insufficient. Add oil.
relieve the oil. a The oil level changes according to the
5) Bleed air from the arm cylinder and bucket oil temperature. Add oil when the oil
cylinder according to steps 2) to 4). level is out of the following standard
ranges.
4. Bleeding air from swing motor q When oil temperature is 10 to 30C:
1) Run the engine at low idle. Between line H and line L
2) Swing slowly to bleed air. q When oil temperature is 50 to 80C:
Near line H
5. Bleeding air from travel motor
1) Run the engine at low idle.
2) Loosen air bleeder (2) and check that oil
oozes out through the air bleeder.
3) After the oil oozes out, tighten air bleeder
(2).
3 Air bleeder:
27.5 to 35.3 Nm {2.8 to 3.6 kgm}
6. Checking oil level and starting work

1) Run the engine, retract the arm cylinder
and bucket cylinder fully, lower the work
equipment to the ground, and stop the
engine.
PC200, 200LC, 220, 220LC-8M0 30-101 59

SEN06127-00 Testing cab tipping stopper
Testing cab tipping stopper 1
a Check the cab tipping stopper according to the

following procedure.
1. Remove the additional under cover at the rear

of the operator's cab. (Only for the machine
equipped with the reinforced type under cover)
2. Check the tightening torque of the mounting

bolt (2) of the lock plate (1).
3 Bolt (2):
98 to 123 Nm {10 to 12.5 kgm}
[Reference]
q The tightening torque of mounting bolt (4) of
cab tipping stopper (3) is different from that of
a common bolt 30 mm in diameter. Take care.
3 Bolt (4): 245 to 309 Nm {25 to 31.5 kgm}
30-101 60 PC200, 200LC, 220, 220LC-8M0

Adjusting mirrors SEN06127-00
Adjusting mirrors 1
PC200, 200LC, 220, 220LC-8M0 30-101 61

SEN06127-00 Installation and adjustment of mirrors
Installation and adjustment of 4) Retract the mirror into position (C) when
mirrors 1 transporting the machine.
1. Installation of retractable mirrors 5) Retractable mirror (b1): Install at 15 mm

Install retractable mirrors (a1) and (b1) as (from the top of the stay). Install mirror
shown in the figure. stay (4) so that the mirror will be fixed at
1) Retractable mirror (a1): Install at 20 mm (A) of the 3 stopping positions where the
(from the bottom of the intermediate stay). mirror is extracted most and fixed angle (f)
Install mirror stay (1) so that the mirror will to be at an angle of approximately 26 deg.
be fixed at (A) of the 3 stopping positions to the side of the machine body.
where the mirror is extracted most and a If the mirrors are not installed to the cor-
fixed angle (e) to be at an angle of approx- rect positions, they may interfere with the
imately 94 deg. to the intermediate stay. exterior parts.
a If the mirrors are not installed to the cor-
rect positions, they may interfere with the
exterior parts.
6) Tighten bolts (5) of mirror.

3 Bolt: 6.0 to 7.0 Nm {0.61 to 0.71 kgm}
7) Tightening torque of mirror stay bolt (6).
3 Bolt: 15 to 19.6 Nm {1.5 to 2 kgm}
2) Tighten bolts (2) of mirror.
3 Bolt: 6.0 to 7.0 Nm {0.61 to 0.71 kgm} a If the tightening torque is low, the bolts
3) Tightening torque of mirror stay bolt (3). may be dragged. If the former is too high,
3 Bolt: 15 to 19.6 Nm {1.5 to 2 kgm}
the body may be broken.
a If the tightening torque is low, the bolts
may be dragged. If the former is too high,
the body may be broken.
8) Retract the mirror into position (C) when

transporting the machine.
30-101 62 PC200, 200LC, 220, 220LC-8M0

Installation and adjustment of mirrors SEN06127-00
2. Adjustment of retractable mirrors

1) Adjust the retractable mirrors at position
(A).
2) With retractable mirrors (a1) and (b1)
open, loosen mirror bolts (1) and (2) and
stay mounting bolts (3) and (4) and adjust
the mirrors so that the operator can see
the right and left rear views best which are
blind corners from the operators seat.
a Adjust the mirror so that the operator can
see persons (or things 1 m high and
approximately 30 cm in diameter) at the
right and left rear ends of the machine.
a Take care not to tighten stay mounting
bolts (3) and (4) (If they are tightened too
strongly, the stay may be broken since it is
made by die-casting).
PC200, 200LC, 220, 220LC-8M0 30-101 63

SEN06127-00 Installation and adjustment of mirrors
3) Tighten the stay mounting bolts so that the

clearance to the stay mating face will be
even.
3. Adjustment of unretractableble mirrors

1) See the "Adjusting mirrors" page, adjust
mirrors (c1) and (d1) so that the operator
can see persons at 1 m arou nd the
machine (hatched area) from the opera-
tors seat.
a If the mirror is hard to adjust, loosen mirror
screw (1).
2) Tighten screw (1) of mirror.
3 Screw:
3.0 to 3.5 Nm {0.31 to 0.35 kgm}
a When adjusting mirror, secure clearance
(g) so that mirror stay does not interfere
with mirror.
30-101 64 PC200, 200LC, 220, 220LC-8M0

Angle adjustment of rear view camera SEN06127-00
Angle adjustment of rear view 1. Remove cover (2) by inserting flat-head screw-
camera 1 driver [1] in the hole in cover (3) and pressing
the internal pawl.
Adjust the camera so that persons in area (w) at 1
meter around the machine is displayed on the
machine monitor in the operator cab.
a Claw of cover (2) is made of plastic, it is

easily damaged while removing, therefore
take special care at work.
If the image displayed on the monitor is out of posi-
tion, remove cover (2) of camera (1) and adjust the
installation angle (A) of the rear view camera.
2. Remove two bolts (4).
3. Remove cover (2).
PC200, 200LC, 220, 220LC-8M0 30-101 65

SEN06127-00 Angle adjustment of rear view camera
4. Loosen mounting bolts (5) of camera (1) and

adjust installation (A) of camera so that the
side line of camera is matched with the corner
(B) of the bracket.
Angle (A): 48(+2/0)
a A part of the machine is displayed on the

monitor screen.
Adjust the camera so that the image of the
counterweight occupy approximately 10 to
15% of the monitor screen.
5. After adjusting, tighten bolts (5).

3 Camera mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6. Install covers (2) and (3).
30-101 66 PC200, 200LC, 220, 220LC-8M0

Angle adjustment of rear view camera SEN06127-00
PC200, 200LC, 220, 220LC-8M0 30-101 67

SEN06127-00

2012 KOMATSU
All Rights Reserved
30-101 68
SEN06128-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

Special functions of machine monitor ............................................................................................................. 2
PC200, 200LC, 220, 220LC-8M0 30-102 1

SEN06128-00 Special functions of machine monitor
Special functions of machine monitor 1
30-102 2 PC200, 200LC, 220, 220LC-8M0

Special functions of machine monitor SEN06128-00
Upper part of machine monitor (display portion)

(a): Multi-information display
a When the engine is started, the battery voltage may drop suddenly, depending on the ambient tempera-
ture and the condition of the battery.
In this case, the screen display of the machine monitor may go off for a moment. This phenomenon is
not a failure, however.
Upper part of machine monitor (switch portion)

[F1]: F1 Function switch
a The function of each function switch is indicated by the icon which is displayed just above the function
switch on the screen of the multi-information display panel (a).
a If the icon for a function switch is not displayed, that function switch is not working.
Lower part of machine monitor (switch portion)

[1]: Numeral 1 input switch/Auto-deceleration switch
[2]: Numeral 2 input switch/Working mode selector switch
[3]: Numeral 3 input switch/Travel speed selector switch
[4]: Numeral 4 input switch/Alarm buzzer stop switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Window washer switch
[7]: Numeral 7 input switch/Air conditioner switch
Switch having no numerals : Air conditioner switch
a Each switch has the function indicated by the icon on it and the function of inputting a numeral.
a The machine monitor automatically judges which function of each switch is currently enabled according
to the screen display of the multi-information display panel (a).
PC200, 200LC, 220, 220LC-8M0 30-102 3

Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary functions and special functions and displays information of various
types on the multi-information display panel.
Some information are displayed automatically according to the configuration of the machine monitor and the
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The information items in this mode are displayed ordinarily. The operator can display and set them by
operating the switches (Display and setting of some items need special operations of the switches).
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting.
30-102 4 PC200, 200LC, 220, 220LC-8M0

Operator mode (outline) Service mode

A Display of KOMATSU logo Monitoring / Pre-defined
A Display of inputting password Monitoring / Custom
A Display of check of breaker mode Abnormality Record (Mechanical Systems)
A Display of check before starting Abnormality Record (Electrical Systems)
A Display of warning after check before starting Maintenance record
A Display of ending of maintenance interval Maintenance Mode Setting
A Display of check of working mode and travel speed Phone Number Entry
A Display of standard screen Default (Key-On Mode)
A Display of end screen Default (Unit)
O (Special operation)
B Selection of auto-deceleration Default (With/Without Attachment)
B Selection of working mode Default (Camera)
B Selection of travel speed Diagnostic Tests (Cylinder Cut-out)
B Operation to stop alarm buzzer Adjustment (Pump Absorption Torque (F))
B Operation of windshield wiper Adjustment (Pump Absorption Torque (R))
B Operation of window washer Adjustment (Low Speed)
B Operation of air conditioner/heater Adjustment (Attachment Flow Adjustment)
Operation to display camera mode No Injection
B
(if camera is installed)
KOMTRAX Settings (Terminal Status)
B Operation to display clock and service meter
KOMTRAX Settings (GPS and Communication Status)
B Check of maintenance information
KOMTRAX Settings (Modem Information)
Setting and display of user mode (including
B Service Message
KOMTRAX messages for user)
C Display of ECO guidance
C Display of caution monitor
C Display of action level and failure code
Function of checking display of LCD
D
(Liquid Crystal Display)
D Function of checking service meter
Function of usage limitation setting/maintenance
D
password
a Group of screens or functions in operator mode

A: Display or function from turning ON of starting switch to switching to the standard screen is over, and
display after starting switch is turned OFF
B: Display or function when the machine monitor switches are operated
C: Display or function when certain conditions are met
D: Display or function when operation of special switches is required
PC200, 200LC, 220, 220LC-8M0 30-102 5

Operator mode (Outline) a Display sequence in operator mode

a Only outline of the operator mode is described The contents of display from the time when
in this section. starting switch is turned ON to time when
For details of contents and operations of each screen changes to standard screen depends
function and display, see Structure and func- on the setting and condition of the machine.
tion, or the Operation and Maintenance Man- A : When the engine start lock is set effective
ual. B : When the engine start lock is set ineffective
a The following are the screens or functions of C : When working mode at start is set to
the operator mode explained in this section breaker mode (B)
(including some items which need special D : When there is abnormal item in check-
operations). before-starting items
E : When an overdue maintenance item is dis-
Display pattern covered
A B C D E
Display of KOMATSU logo 1 1 1 1 1
Display of inputting password 2
Display of check of breaker mode 2
Display of check before starting 3 2 3 2 2
Display of warning after check
3
before starting
Display of ending of maintenance
3
interval
Display of check of working mode
4 3 4 4 4
and travel speed
Display of standard screen 5 4 5 5 5
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of window washer
Operation of air conditioner/heater
Operation to display camera mode (if camera is
installed)
Operation to display clock and service meter
Check of maintenance information
Setting and display of user mode (including
KOMTRAX messages for user)
Display of ECO guidance
Display of caution monitor
Display of action level and failure code
Function of checking display of LCD (Liquid Crystal
Display)
Function of checking service meter
Function of usage limitation setting/maintenance
password
30-102 6 PC200, 200LC, 220, 220LC-8M0

Display of KOMATSU logo

When starting switch is turned to ON position,
KOMATSU logo is displayed for 2 seconds.
a After the KOMATSU logo screen is displayed
for 2 seconds, the screen changes to Pass-
word input screen, or Check before starting
screen.
Display of check of breaker mode

When the starting switch is turned ON, if the work-
ing mode is set to the breaker mode [B], a message
to inform the operator of starting in the breaker
mode is displayed on the screen.
k If an attachment other than the breaker is
used while the working mode is set to the
Display of inputting password breaker mode [B], the machine may move
After the KOMATSU logo screen is displayed, the unexpectedly or may not operate normally
screen to input the engine start lock password is or the hydraulic components may be dam-
displayed. aged.
a This screen is displayed only when the engine a After operation to check of the breaker mode is
start lock function is enabled. finished, the screen changes to Display of
a If correct password is input, the screen check before starting.
changes to Check before starting screen. If [No] is selected: Working mode is set to
a The machine monitor has some password pro- economy mode [E]
tect functions other than the engine start lock. If [Yes] is selected: Working mode is set to
Those functions are independent from one breaker mode [B]
another.
a The following screen may be displayed instead

of the above Password input screen.
a If this screen is displayed, call the person
responsible for the operation of KOMTRAX in
your Komatsu distributor and ask for remedy.
PC200, 200LC, 220, 220LC-8M0 30-102 7

Display of check before starting Display of maintenance due time over

When the screen changes to the check before If the check before starting detected a maintenance
starting screen, the check before starting is per- item that is near or overdue the set interval, the
formed for 2 seconds. maintenance monitor is displayed for 30 seconds to
a If any abnormalities are detected in the check urge the operator to perform maintenance.
before starting, the screen changes to Warning a This screen is displayed only when the mainte-
after the check before starting screen or Over- nance reminder function is enabled. If the
due Maintenance screen. remaining time of any item is set time hours or
a If no abnormalities were detected in the check less, the yellow icon is displayed. If the remain-
before starting, display changes to Working ing time of any item is 0 hour or less, the red
Mode and Travel Speed Check screen. icon is displayed.
a The monitors (6 monitors) on the screen shows a The maintenance reminder function is enabled
the items currently subjected to the check before or disabled by using the machine monitor in
starting. the service mode.
Display of check of working mode and travel

Display of warning after check before starting speed
If any abnormalities are detected in the check If the check before starting is finished normally, the
before starting, the alarm monitor is displayed on screen for checking the working mode and travel
the screen. speed is displayed for 2 seconds.
a The figure shows how air cleaner clogging a After the Working mode and travel speed
monitor (a) warns of clogging on air cleaner. check screen is finished, the screen changes
to the Standard screen.
30-102 8 PC200, 200LC, 220, 220LC-8M0

Display of standard screen a If the auto-deceleration is set to OFF, auto-

If the machine monitor starts normally, the standard deceleration monitor (b) goes off.
screen is displayed.
a Service meter (a) or clock is displayed in the
top center area of the screen (use [F4] to
switch the display of the service meter and
clock).
a Right end of the screen displays ECO gauge
(b) (turn on or off the display in the operator
mode).
Selection of working mode

Select desired working mode according to the fol-
lowing procedure.
1. While the standard screen is displayed, press
the working mode selector switch, and the
working mode selection screen is displayed.
a Following figure shows the working mode
selection screen when with attachment is
Display of end screen set. (If with attachment is not set in ser-
When starting switch is turned to OFF position, the vice mode, attachment mode ATT/P,
end screen is displayed for 5 seconds. ATT/E are not displayed.)
a Another message may be displayed on the
end screen due to the message display func-
tion of KOMTRAX.
2. Operate the function switches or working mode

selector switch to select the desired working
mode and enter the selection.
Selection of auto-deceleration Function switch
While the ordinary screen is displayed, if the auto- q [F3]: Moves to lower item
deceleration switch is pressed, large auto-deceler- q [F4]: Moves to upper item
ation monitor (a) is displayed for 2 seconds and the q [F5]: Cancels selection and returns to
setting of the auto-deceleration is changed. standard screen
a Each time the auto-deceleration switch is q [F6]: Enters selection and returns to stan-
pressed, the auto-deceleration is changed in dard screen
the order of [ON] o [OFF] o [ON]. Working mode selector switch
a If the auto-deceleration is set to ON, large q Pressed : Moves to lower item
monitor (a) and auto-deceleration monitor (b) q Kept pressed : Enters selection and
are displayed simultaneously. returns to standard screen
PC200, 200LC, 220, 220LC-8M0 30-102 9

a If you do not touch any of the function If No is selected: Screen returns to work-
switches and working mode selector ing mode selecting screen
switch for 5 seconds, the selection is If [Yes] is selected: Working mode is set to
determined and the screen changes to the breaker mode [B]
standard screen.
Selection of travel speed

3. When the ordinary screen is displayed again, While the standard screen is displayed, if the travel
large working mode monitor (a) is displayed for speed selector switch is pressed, large travel
2 seconds, and then the setting of the working speed monitor (a) is displayed for two seconds and
mode is changed to the selected mode. the setting of the travel speed is changed.
a When large monitor (a) is displayed, the a Travel speed setting sequentially changes
display of working mode monitor (b) is between [Lo] o [Mi] o [Hi] o [Lo] in this order
changed, too. every time the switch is pressed.
a When large monitor (a) is displayed, the dis-
play of travel speed monitor (b) is changed,
too.
<Precautions for selecting breaker mode [B]>

q If breaker mode [B] is selected, both of the
control of the hydraulic pump and the set-
ting of the hydraulic circuit are changed. Operation to stop alarm buzzer
q If an attachment other than the breaker is While the alarm buzzer is sounding, if the alarm
used, the machine may move unexpect- buzzer cancel switch is pressed, the alarm buzzer
edly or may not operate normally or the stops.
hydraulic components may be damaged. a Even if the alarm buzzer cancel switch is
q After the breaker mode is selected, the pressed, the screen display does not change.
screen to confirm the selection of the
breaker mode is displayed (The buzzer
sounds intermittently while this screen is
displayed).
q If the setting is confirmed on this screen,
the screen changes to the standard
screen.
30-102 10 PC200, 200LC, 220, 220LC-8M0

Operation of windshield wiper Operation to display camera mode (if camera is

While the ordinary screen is displayed, if the wiper installed)
switch is pressed, large wiper monitor (a) is dis- If [F3] is pressed, the multi-display changes to the
played for 2 seconds and the wiper starts or stops. camera image (Set the connection of the camera in
a The window washer does not operate if the the service mode).
window limit switch is ON.
a The wiper setting changes sequentially
between [INT] o [ON] o [OFF] o [INT] every
time you press the switch.
a When the wiper is set to INT or ON, large mon-
itor (a) is displayed and the display of wiper
monitor (b) is changed at the same time.
a If the wiper is set to OFF, large monitor (a) is
not displayed and the wiper monitor disap-
pears.
a Up to two cameras can be connected. When

the camera mode is selected, however, only
the image of camera 1 is always displayed at
first.
Operation of window washer

While the ordinary screen is displayed, if the win-
dow washer switch is pressed, the washer fluid is
splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen display does not change.
Operation of air conditioner/heater

While the standard screen is displayed, if the air a If any caution is issued with the display panel
conditioner switch is pressed, Air-conditioner Set- in the camera mode, the corresponding cau-
ting screen is displayed. tion monitor is displayed at the left top of the
a While Air-conditioner Setting screen is dis- screen (excluding the low hydraulic oil temper-
played, if you do not touch any switch for 5 ature caution monitor).
seconds, the screen changes to the standard
screen.
PC200, 200LC, 220, 220LC-8M0 30-102 11

a If no control lever is operated for 10 seconds Check of maintenance information

while a failure enough to display an action level You can check the maintenance information on the
is occurring with the display panel in the cam- maintenance screen by pressing [F6] while the
era mode, the screen returns to the standard maintenance monitor is displayed.
screen and displays information about that fail- When the maintenance monitor does not appear,
ure. press [F6] and then press [F1] or [F2]. Then make
a When two or more cameras are connected, the sure the display is switched to the maintenance
image of one of them or the images of two of screen.
them can be displayed.
a When 2-camera image display [F4] is selected,
images of cameras 1 and 2 are displayed on
the right and left side of the screen.
You can specify which of image of cameras 1
and 2 to appear on the right side and which on
the left side from Camera in the service
mode.
Operation to display clock and service meter

While the standard screen is displayed, if [F4] is
pressed, the service meter and the clock are dis-
played alternately in section (a).
a When selecting the clock display, perform the
time adjustment, 12-hour or 24-hour display
a To reset the remaining time after finishing
setting, and summer time setting by using the
maintenance, more operations are necessary.
user mode functions.
30-102 12 PC200, 200LC, 220, 220LC-8M0

Setting and display of user mode (including Display of ECO guidance

KOMTRAX messages for user) When the machine is set in a certain operating con-
To enter the user mode, press [F6] to display the dition, the ECO Guidance screen is displayed auto-
User Menu screen while the standard screen is matically to urge the operator to perform the
displayed. energy-saving operation.
a ECO Guidance screen is displayed when the
following conditions are met while this display
function is set to enabled in operator mode.
a Conditions for display:
q Idle stop guidance
If no lever is operated for a period of at least 5
minutes and the engine keeps running at idle
speed during this period, the guidance on idle
stop is displayed on the monitor. This function
helps reduce unnecessary fuel consumption
by alerting the operator to stop the engine
while waiting for the next operation, or during a
break.
a The lamp for the idle stop guidance goes
out automatically when the lever operation
a The User Menu has following menus. is resumed, or if the function switch [F5] is
pressed.
ECO Guidance
Machine setting
Maintenance
Monitor setting
Check mail
[KOMTRAX message]
q There are two types of KOMTRAX message;
one is for the user and the other is for the tech-
nician.
q For user: It denotes the messages transmitted
from the KOMTRAX base station to users.
Upon receiving a message, the message mon-
itor is displayed on the standard screen. Oper- Guidance on deterrence of hydraulic relief
ate this Check mail when viewing contents of If relieving lasts for 3 or more seconds during oper-
a message. ation, guidance on deterrence of hydraulic relief is
q For technician: It refers to the messages trans- displayed on the monitor.
mitted to the technicians from the KOMTRAX a The lamp for the guidance on deterrence of
base station. When a message is received, the hydraulic relief goes out automatically after 10
standard screen does not display any informa- seconds has passed since it appeared, or if the
tion relevant to the message received. To view function switch [F5] is pressed.
contents of a message, operate Display ser-
vice message of the service menu in the ser-
vice mode.
PC200, 200LC, 220, 220LC-8M0 30-102 13

q E-mode recommendation guidance q Low fuel level guidance

If light-load work continues for 10 or more min- If the amount of time the machine can be oper-
utes in P- or ATT/P-mode, E-mode recommen- ated that is projected from the remaining fuel
dation guidance is displayed. This function level and the latest average fuel consumption
helps reduce unnecessary fuel consumption drops to less than 8 hours, the low oil level
by alerting the operator to turn on E-mode. guidance is displayed.
a The lamp for the E-mode recommendation a The lamp for the low oil level guidance
guidance goes out automatically after 10 goes out automatically after 10 seconds
seconds has passed since it appeared, or has passed since it appeared, or if the
if the function switch [F5] is pressed. function switch [F5] is pressed.
q Travel partial recommendation guidance Display of caution monitor

If machine travel in the travel mode Hi and the If an error that is serious enough to display Action
fuel control dial at MAX continues for 2 or more Level L01 alarm monitor on the standard screen
minutes, the travel partial recommendation or camera mode screen occurs, a large alarm mon-
guidance is displayed. When traveling the itor is displayed on the screen once and is continu-
machine for a long period of time, moving the ously shown in window (a).
fuel control dial from MAX to a lower position a On the camera mode screen, the alarm moni-
helps reduce fuel consumption. tor flashes at the left upper of the screen when
a The lamp for the travel partial recommen- a caution is issued.
dation guidance goes out automatically
after 10 seconds has passed since it
appeared, or if the function switch [F5] is
pressed.
30-102 14 PC200, 200LC, 220, 220LC-8M0

If an error serious enough to display a alarm moni- a The telephone No. is displayed only when the
tor of Action Level [L02], [L03] or [L04] occurs, the telephone number is registered in the service
alarm monitor is displayed at the center of the mon- mode.
itor screen until the error is eliminated. a If multiple problems occur simultaneously, all
the codes are displayed repeatedly in order.
a Because the information of the displayed fail-
ure code is logged in the abnormality record in
the service mode, check the details in the ser-
vice mode.
a The Error list automatically returns to the
standard screen after 30 seconds.
a Since Error list cannot be displayed from the
screen on which the camera mode is dis-
played, move to Error list from the standard
screen side.
Display of action level and failure code

If an abnormality that displays an action level and a
failure code occurs on the standard screen or cam-
era mode screen, the alarm monitor lights up.
If the alarm monitor lights up, press function switch

[F5] to display the Error list.
q [F1]: Moves to next page (screen) (if dis-
played)
q [F2]: Moves to previous page (screen) (if dis-
played)
q [F5]: To return to standard screen
On the Error list screen, the following information
is displayed.
(a): Alarm monitor
(b): Action level (3 digits)
(c): Failure code (5 or 6 digits)
(d): Failure code name
(e): Message
(f): Telephone No. (if registered)
a This screen display appears only when a prob-
lem (failure code) for which an action level is
set occurs.
PC200, 200LC, 220, 220LC-8M0 30-102 15

a Actions to take given by action levels to opera- a To return to the former screen, press any one
tor (Excerpt from the Operation and Mainte- of the function switches.
nance Manual) Reference: An LCD panel, as one of its characteris-
tics, sometimes shows black spots (spots that
Degree remain unlit) and bright spots (spots that do not go
Action Alarm off).
of emer- Buzzer Remedy
level monitor If the number of the bright points and black points
gency
Stop immediately does not exceed 10, the LCD panel is not faulty or
and perform defective.
Q checking and
(Con- maintenance.
High L04 Q
tinu- Ask your Komatsu
ous) distributor for test-
ing and repair ser-
vices.
Stop work, move
machine to safe
place, stop it, and
Q perform checking
L03 (Inter- Q and maintenance.
mittent) Ask your Komatsu
distributor for test-
ing and repair ser-
vices.
I Stop work, and Function of checking service meter

then run the When checking the service meter with the starting
engine at medium switch in the OFF position, operate the numeral
speed with no input switches as follows to display only the service
Q load, or stop it. If
meter section.
L02 (Inter- Q the condition does
q Switch operations (simultaneous): [4] + [1]
mittent) not improve, ask
your Komatsu dis- a There is some time lag in start of the LCD, so
tributor for testing hold down the switches until the service meter
and repair ser- is displayed.
vices. a If you release one of the switches, the monitor
Some functions goes off.
are restricted, but Reference: After the machine monitor is used con-
the machine can tinuously over a long period of time, blue points
work. After finish- (points that remain lit) may appear on this screen. It
L01 ing work, perform does not indicate that the LCD panel is faulty or
(For 2 checking and defective.
Low Q
seconds maintenance.
only) Ask your Komatsu
distributor to per-
form testing or
repairs as neces-
sary.
Function of checking display of LCD (Liquid

Crystal Display)
While the standard screen is displayed, if the
numeral input switches or function switches are
operated in the following manner, the entire LCD
screen turns white.
q Switch operations (simultaneous): [4] + [F2]
a When finishing the operation of the switches,
release [F2] first.
a If there is a display error in the LCD, only that
part is indicated in black.
30-102 16 PC200, 200LC, 220, 220LC-8M0

Function of usage limitation setting/mainte- 3. After the Usage Limitation Setting screen is
nance password displayed, select a setting using the function
Selecting the Usage Limitation Setting displays the switch.
password input screen when you proceed to setting q [F3]: Moves to lower item
of the breaker or attachment, or maintenance reset- q [F4]: Moves to upper item
ting Observe the following procedure when using q [F5]: Cancels the selection and return the
the Usage Limitation Setting. display to the preceding screen
1. While the standard screen is displayed, per- q [F6]: Validates the selection
form the following operation with the numeral
input switches.
q Operation of switches (While pressing [4],
press the switches in order):
[4]+[5]o[5]o[5]
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned to ON position.
Selection of Usage limitation ON/OFF

After the Usage Limitation ON/OFF screen is
displayed, select a desired one using the func-
tion switch.
q Disable Password input screen is not dis-
played
q Enable: The password input screen for
setting of the breaker or attachment, or
2. After the Usage Limitation password screen is maintenance resetting appears.
displayed, input the current password using q [F3]: Moves to lower item
the numeral input switches and validate it q [F4]: Moves to upper item
using the function switch. q [F5]: Cancels the selection and return the
display to the preceding screen
q [F5]: Deletes the entered numbers/ q [F6]: Validates the selection
Restores the standard screen
q [F6]: Validates the entered password
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to request inputting the password
again is displayed.
a The password for the Usage Limitation and the

engine start lock password are not identical.
PC200, 200LC, 220, 220LC-8M0 30-102 17

4. Changing a password If the screen to notify completion of setting is

After the Usage Limitation New Password displayed and then the standard screen is dis-
Input screen is displayed, input a new pass- played, the password has been changed suc-
word with the numeral input switches and vali- cessfully
date it with the function switch.
q [F5]: Deletes the entered numbers/
Returns the display to the preceding
screen
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to request inputting the password
again is displayed.
a Set a new password in 4 to 6 digits (a
password of 3 or less digits or 7 or more
digits is not accepted).
After the Usage Limitation New Password

Input screen is displayed again, input the new
pa ssword again with the numeral inpu t
switches and validate it with the function
switch.
q [F5]: Deletes the entered numbers/
Restores the standard screen
a If the input password is different from the
entered in the first time, the message to
request reentry is displayed.
30-102 18 PC200, 200LC, 220, 220LC-8M0

Service mode
To change the mode of the machine monitor to the
service mode from the operator mode, perform the
following operation.
This operation is always required when you use the
service mode.
1. Check of screen display and operation of

switches
While the standard screen is displayed, per-
form the following operation by using the
numeral input switches.
q Operation of switches (While pressing [4],
press the switches in order):
[4] + [1] o [ 2 ] o [ 3 ] a The menu items which can be selected in
a This operation of the switches is accepted the service menu are as follows (including
only while the standard screen is dis- some items which need special opera-
played. tions).
01 Monitoring / Pre-defined
02 Monitoring / Custom
Abnormality Record (Mechanical Systems)
03
Abnormality Record (Electrical Systems)
04 Maintenance record
05 Maintenance Mode Setting
06 Phone Number Entry
Default (Key-On Mode)
Default (Unit)
07
Default (With/Without Attachment)
Default (Camera)
2. Selection of service menu 08 Diagnostic Tests (Cylinder Cut-out)
When the Service Menu screen is displayed, Adjustment (Pump Absorption Torque (F))
the service mode is selected. Select the
Adjustment (Pump Absorption Torque (R))
desired service menu by using the function 09
switches or numeral input switches. Adjustment (Low Speed)
q [F3]: Moves to lower item Adjustment (Attachment Flow Adjustment)
q [F4]: Moves to upper item 10 No Injection
q [F5]: Returns the display to the standard
KOMTRAX Settings (Terminal Status)
screen (operator mode)
q [F6]: Validates the selection KOMTRAX Settings (GPS and Communication
11
a If you input a 2-digit code by using the Status)
numeral input switches, the corresponding KOMTRAX Settings (Modem Information)
menu is directly selected. This will allow 12 Service Message
you to validate the selection using [F6].
PC200, 200LC, 220, 220LC-8M0 30-102 19

Monitoring / Pre-defined a If the working mode is changed to breaker

The machine monitor can monitor the condition of mode [B], the screen to confirm the change of
the machine in real time by receiving signals from the setting is displayed as in changing the
various switches, sensors, and actuators installed working mode on the standard screen.
to many parts of the machine and the information
from the controllers which control them.
In the monitoring / pre-defined, monitoring items
that are used frequently in daily work are selected
beforehand.
1. Selecting the menu

Select Monitoring / Pre-defined on the Ser-
vice Menu screen.
2. Check of monitoring / pre-defined information

After the Monitoring / Pre-defined screen is
displayed, you can check the items displayed
in the troubleshooting support by using the
function switches.
q [F1]: Moves to the next page (screen)
q [F2]: Moves to the previous page (screen)
q [F4]: Selects hold or its releasing
(If hold is selected, a diagonal line is dis-
played on the HOLD portion)
q [F5]: Returns to service menu screen
a You can select and check any items not
displayed in Monitoring / Pre-defined
from the Monitoring items.
30-102 20 PC200, 200LC, 220, 220LC-8M0

List of monitoring / pre-defined items (SI unit indicates the default values)
Support screen (1/7) Fuel injection

Applicable equip-
No. ID Item name Unit (SI)
ment
1 01002 Engine speed r/min ENG
2 04107 Coolant temperature C ENG
3 04501 Engine oil level MON
4 04401 Hydr. oil temperature C PUMP
5 03203 Battery power supply V ENG
Support screen (2/7) Fuel injection

Applicable equip-
ment
2 04107 Coolant temperature C ENG
3 36400 Rail pressure MPa ENG
4 36200 Rail pressure command MPa ENG
5 18500 Boost temperature C ENG
6 37400 Ambient pressure kPa ENG
Support screen (3/7) F & R pumps basic items

Applicable equip-
ment
2 01100 F pump pressure MPa PUMP
3 01101 R pump pressure MPa PUMP
4 01300 PC-EPC sol current (F) mA PUMP
5 01302 PC-EPC sol current (R) mA PUMP
Support screen (4/7) F & R pumps application items

Applicable equip-
ment
2 01100 F pump pressure MPa PUMP
3 01101 R pump pressure MPa PUMP
4 01300 PC-EPC sol current (F) mA PUMP
5 01302 PC-EPC sol current (R) mA PUMP
6 01500 LS-EPC sol current mA PUMP
PC200, 200LC, 220, 220LC-8M0 30-102 21

Support screen (5/7) PPC pressure

Applicable equip-
ment
2 07400 Boom Raise PPC pressure MPa PUMP
3 07500 Boom Lower PPC pressure MPa PUMP
4 07200 Arm In PPC pressure MPa PUMP
5 07600 Arm Out PPC pressure MPa PUMP

Applicable equip-
ment
2 09002 Swing Right PPC pressure MPa PUMP
3 09001 Swing Left PPC pressure MPa PUMP
4 07300 Bucket Curl PPC pressure MPa PUMP
5 07301 Bucket Dump PPC pressure MPa PUMP

Applicable equip-
ment
2 07102 Travel Fwd LH PPC pressure MPa PUMP
3 07103 Travel Fwd RH PPC pressure MPa PUMP
4 07104 Travel Rev LH PPC pressure MPa PUMP
5 07105 Travel Rev RH PPC pressure MPa PUMP
6 04401 Hydr. oil temperature AaC PUMP
30-102 22 PC200, 200LC, 220, 220LC-8M0

Monitoring / Custom a You can select up to six monitoring codes

The machine monitor can monitor the condition of at the same time. Note, however, that six
the machine in real time by receiving signals from items may not be available depending on
various switches, sensors, and actuators installed how they are displayed on the screen.
to many parts of the machine and the information
from the controllers which control them.
The monitoring function allows you to select a
desired monitoring item.
Select Monitoring on the Service Menu
screen.
3. Getting machine monitor ready for monitoring

After selecting monitoring items, set the
machine monitor ready for monitoring by using
the function switch or numeral input switch.
a Execution by use of function switches:
Double-click [F6] or hold it down (for
approximately 2 seconds).
2. Selecting monitoring item a Execution using numeral input switch:
After the Monitoring selection menu screen [99999] and press [F6].
for monitoring item selection is displayed, a When monitoring only two items, for
select the item to be monitored by using the example, select them and enter them by
function switches or numeral input switches. using [F6]. If [F6] is pressed once more at
q [F1]: Moves to left item this time, the machine monitor is set ready
q [F2]: Moves to right item for monitoring.
q [F3]: Moves to lower item a If monitoring items are selected up to the
q [F4]: Moves to upper item limit number, the machine monitor is auto-
q [F5]: Deletes the entered numbers/ matically set ready for monitoring.
Returns the display to the service menu
q [F6]: Validates the selection
a In setting of the monitoring, each time
function switch [F2] is pressed, sequential
switching among [ENG] o [PUMP] o
[MON] o [ENG] takes place in this order.
(Pressing [F1] induces the sequential
switching in the reverse order.)
a Selection with function switches: Select an
applicable equipment using [F1] or [F2],
and select an item using [F3] or [F4] and
determine it using [F6].
a Selection with numeral input switch:
Select a desired item by entering the cor-
responding 5-digit code and then validate
it using [F6].
a If the color of the selection cursor changes
from yellow to red, selection of the item is
entered.
PC200, 200LC, 220, 220LC-8M0 30-102 23

4. Performing monitoring 6. Changing machine setting mode during moni-

After the Monitoring screen for execution is toring
displayed, perform the necessary operation of To change the setting of the working mode,
the machine and check the monitoring informa- travel speed, or auto-deceleration during moni-
tion. toring, operate the corresponding switch under
a Monitoring information is indicated by the current condition to turn on the applicable
value, ON/OFF, or special display. mode.
a The unit of display can be selected in SI a If the setting is changed during monitoring,
unit, metric unit, or inch unit with the the new setting is held even after the
Default function in the service mode. screen returns to the standard screen
after monitoring is finished.
5. Holding monitoring information

The monitoring information can be held and a If the working mode is changed to breaker
released with the function switches. mode [B], the screen to confirm the change of
q [F4]: Selects hold or its releasing the setting is displayed as in changing the
(If hold is selected, a diagonal line is dis- working mode on the standard screen.
played on the HOLD portion)
q [F5]: Returns the display to monitoring
selection menu screen
30-102 24 PC200, 200LC, 220, 220LC-8M0

7. Saving monitoring item

A function switch lets you save and delete the
selected item.
q [F1]: MEMORY
q [F2]: CLEAR
a When you saved a monitoring item,

selecting Monitoring again displays the
screen that confirms whether you want to
display the once saved item.
a When you saved an item, you can display
it as may times as you want until it is
deleted.
a If you save an item when another item is
saved already, the currently saved item is
overwritten by the last one.
a In addition to [F2], using [F6] in the follow-
ing screen allows deleting a saved moni-
toring item.
q KOMTRAX terminal screen
q With/Without Attachment screen
q Functional specification screen
q Air conditioner setting screen
PC200, 200LC, 220, 220LC-8M0 30-102 25

Monitoring items table
Unit (Default: SI) Equipment

Code No. Monitoring item (Displayed on screen) Remarks
SI Metric Imperial in charge
01002 Engine speed r/min rpm rpm ENG
04107 Coolant temperature C C F ENG
03203 Battery power supply V V V ENG
2
36400 Rail pressure MPa kg/cm psi ENG
2
37400 Ambient pressure kPa kg/cm psi ENG
18500 Charge temperature C C F ENG
Display in
absolute
value
36500 Charge pressure-A kPa kg/cm2 psi ENG
(including
ambient
pressure)
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Throttle position sensor volt V V V ENG
04105 Coolant temp sensor volt V V V ENG
37401 Ambient pressure sensor volt V V V ENG
18501 Charge temp sensor volt V V V ENG
36501 Charge pressure sensor volt V V V ENG
17500 Engine power mode - ENG
31701 Throttle Position % % % ENG
31706 Final throttle position % % % ENG
18600 Inject fueling command mg/st mg/st mg/st ENG
2
36200 Rail pressure command MPa kg/cm psi ENG
36300 Injection Timing command CA CA CA ENG
37300 Fuel rate (Note 1) l/h l/h gal/h ENG
WIF: Water
18800 Water in fuel ONOFF ENG
In Fuel
20216 ECM build version ENG
20217 Calibration data version ENG
18900 ECM internal temp C C F ENG
20400 ECM S/N ENG
2
47000 KDPF outlet pressure kPa kg/cm psi KDPF
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
2
01100 F pump pressure MPa kg/cm psi PUMP
2
01101 R pump pressure MPa kg/cm psi PUMP
2
07400 Boom Raise PPC pressure MPa kg/cm psi PUMP
2
07500 Boom Lower PPC pressure MPa kg/cm psi PUMP
2
07200 Arm In PPC pressure MPa kg/cm psi PUMP
2
07600 Arm Out PPC pressure MPa kg/cm psi PUMP
07300 Bucket Curl PPC pressure MPa kg/cm2 psi PUMP
07301 Bucket Dump PPC pressure MPa kg/cm2 psi PUMP
09001 Swing Left PPC pressure MPa kg/cm2 psi PUMP
30-102 26 PC200, 200LC, 220, 220LC-8M0


09002 Swing Right PPC pressure MPa kg/cm2 psi PUMP
07102 Travel Fwd LH PPC pressure MPa kg/cm2 psi PUMP
2
07103 Travel Fwd RH PPC pressure MPa kg/cm psi PUMP
2
07104 Travel Rev LH PPC pressure MPa kg/cm psi PUMP
2
07105 Travel Rev RH PPC pressure MPa kg/cm psi PUMP
04401 Hydr. oil temperature C C F PUMP
01300 PC-EPC sol current (F) mA mA mA PUMP
01302 PC-EPC sol current (R) mA mA mA PUMP
01500 LS-EPC sol current mA mA mA PUMP
08000 Merge-divide sol current main mA mA mA PUMP
08001 Merge-divide sol current LS mA mA mA PUMP
01700 Attachment sol current mA mA mA PUMP
03200 Battery voltage V V V PUMP
03701 Controller Output 2 PUMP
04402 Hydr. temp. sensor volt V V V PUMP
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
2
15900 Boom Bottom Pressure MPa kg/cm psi PUMP
Swing ONOFF PUMP
Travel ONOFF PUMP
Boom Lower ONOFF PUMP
01900 Pressure Switch 1 Boom Raise ONOFF PUMP
Arm In (Curl) ONOFF PUMP
Arm Out
ONOFF PUMP
(Dump)
Bucket Curl ONOFF PUMP
Bucket Dump ONOFF PUMP
01901 Pressure Switch 2
Service ONOFF PUMP
Travel steering ONOFF PUMP
Travel Junc-
ONOFF PUMP
tion
Swing holding
ONOFF PUMP
02300 Solenoid valve 1 brake
Merge-divider ONOFF PUMP
2-stage Relief ONOFF PUMP
Travel Speed ONOFF PUMP
Service Return ONOFF PUMP
02301 Solenoid valve 2 Variable back
ONOFF PUMP
press
Lever Sw. ONOFF PUMP
Swing
ONOFF PUMP
02200 Switch Input 1 Release SW.
Swing holding
ONOFF PUMP
brake SW.
PC200, 200LC, 220, 220LC-8M0 30-102 27


Model select 1 ONOFF PUMP
02201 Switch Input 2 Model select 4 ONOFF PUMP
Overload
ONOFF PUMP
Alarm
Key
02202 Switch Input 3 ONOFF PUMP
switch(ACC)
02203 Switch Input 4 PUMP
Window Limit
ONOFF PUMP
SW.
02204 Switch Input 5
P Limit SW. ONOFF PUMP
W Limit SW. ONOFF PUMP
Pump controller Ass'y
20229 PUMP
P/N
20403 Pump controller Serial No. PUMP
20230 Pump controller prog. P/N PUMP
20212 PUMP
04300 Battery charge volt V V V MON
04200 Fuel level sensor volt V V V MON
Key switch ONOFF MON
Start ONOFF MON
Preheating ONOFF MON
04500 Monitor Input 1
Light ONOFF MON
Radiator cool-
ONOFF MON
ant level
Aircleaner ONOFF MON
Eng. oil level ONOFF MON
04501 Monitor Input 2
Battery charge
ONOFF MON
volt
Swing brake
04502 Monitor Input 3 ONOFF MON
Sw.
F1 ONOFF MON
F2 ONOFF MON
F3 ONOFF MON
04503 Monitor Function Switches
F4 ONOFF MON
F5 ONOFF MON
F6 ONOFF MON
SW1 ONOFF MON
SW2 ONOFF MON
Monitor 1st & 2nd Row SW3 ONOFF MON
04504
Switches SW4 ONOFF MON
SW5 ONOFF MON
SW6 ONOFF MON
30-102 28 PC200, 200LC, 220, 220LC-8M0


SW7 ONOFF MON
SW8 ONOFF MON
Monitor 3rd & 4th Row SW9 ONOFF MON
04505
Switches SW10 ONOFF MON
SW11 ONOFF MON
SW12 ONOFF MON
SW13 ONOFF MON
04506 Monitor 5th Row Switches SW14 ONOFF MON
SW15 ONOFF MON
20227 Monitor Ass'y P/N MON
20402 Monitor serial No. MON
20228 Monitor prog. P/N MON
20200 Monitor prog. version MON
55300 Aircon compressor status ONOFF MON
55000 Aircon outside temp. code MON
55100 Aircon inside temp. code MON
55200 Aircon mode data(mon) MON
Aircon mode data(aircon
55201 MON
ECU)
Only when
20260 KOMTRAX Assy P/N MON KOMTRAX
is used
Only when
20418 KOMTRAX Serial No MON KOMTRAX
is used
Only when
20261 KOMTRAX Prog. P/N MON KOMTRAX
is used
a Listing order of monitoring items in table

The monitoring items are listed in the order of display on the Monitoring selection menu screen for mon-
itoring item selection.
a Unit
The display unit can be set to SI, meter, or inch as required (select a desired unit from Unit of
Default).
mg/st in the display unit is an abbreviation for milligram/stroke.
a Equipment in charge
ENG: The engine controller detects monitoring information.
PUMP: The pump controller detects monitoring information.
MON: The machine monitor detects monitoring information.
Note 1: Fuel Rate (Code No. : 37300) is theoretical fuel consumption ratio. (Since it is a theoretical value,
there is some differences between the actual fuel consumption ratio).
PC200, 200LC, 220, 220LC-8M0 30-102 29

Abnormality Record (Mechanical Systems) 3. Information displayed on abnormality record

The machine monitor classifies and logs the fail- screen
ures which occurred in the past or which are occur- On the Mechanical Systems abnormality
ring at present into the mechanical system record screen, the following information is dis-
abnormality, and electrical system abnormality. played.
To check the mechanical system abnormality (a): Occurrence order of abnormalities from
record, perform the following procedures. latest one/Total number of abnormalities in
a For the failure code list, see 40 Failure codes the log
table. (b): Failure codes
(c): Detail of failure
1. Selecting the menu (d): Number of occurrences (displayable
Select Abnormality Record on the Service range: 0 to 65,535 times)
Menu Screen. (e): Service meter reading at first occurrence
(f): Service meter reading at last occurrence
played)
q [F2]: Moves to previous page (screen) (if
displayed)
q [F5]: Returns to the Abnormality Record
screen
a If no failure is logged, the message of No
Error is displayed.
a In the mechanical systems abnormality
record screen, up to 50 cases currently
stored are displayed.
a If the number of occurrences is one (first
occurrence), the service meter reading at
the first occurrence and that at the last
2. Selecting sub menu occurrence are the same.
After the Abnormality Record screen is dis- When the latest service meter reading is
played, select Mechanical Systems by using recovered, the value at the recovery time
the function switches or numeral input is displayed, thus the above readings may
switches. not be the same.
q [F3]: Moves to lower item a If [E] is displayed on the left of a failure
q [F4]: Moves to upper item code, the abnormality is still occurring or
q [F5]: Returns the display to the service restoration of it has not been confirmed.
menu screen a For all the failure codes that the machine
q [F6]: Validates the selection monitor can record, see the Failure codes
a You may enter a 2-digit code by using the table.
numeral input switches to select the item
of that code and enter it by using [F6].
4. Clearing abnormality record

A contents of the mechanical system abnor-
mality record cannot be cleared.
30-102 30 PC200, 200LC, 220, 220LC-8M0

Abnormality Record (Electrical Systems) 3. Information displayed on abnormality record

The machine monitor classifies and logs the fail- screen
ures which occurred in the past or which are occur- On the Electrical Systems abnormality record
ring at present into the mechanical system screen, the following information is displayed.
abnormality, and electrical system abnormality. (a): Occurrence order of abnormalities from
To check the electrical system abnormality record, latest one/Total number of abnormalities in
perform the following procedures. the log
a For the failure code list, see 40 Failure codes (b): Failure codes
table. (c): Detail of failure
(d): Number of occurrences (displayable
1. Selecting the menu range: 0 to 65,535 times)
Select Abnormality Record on the Service (e): Service meter reading at first occurrence
Menu Screen. (f): Service meter reading at last occurrence
played)
q [F2]: Moves to previous page (screen) (if
displayed)
q [F3]: Moves to lower item
q [F4]: Moves to upper item
q [F5]: Returns to the Abnormality Record
screen
a If no failure is logged, the message of No
Error is displayed.
a In the electrical systems abnormality
record screen, up to 20 cases currently
stored are displayed.
If the number of the cases reaches 21, the
code that occurred most recently is dis-
2. Selecting sub menu played and the oldest code is deleted.
After the Abnormality Record screen is dis- a If the number of occurrences is one (first
played, select Electrical Systems by using occurrence), the service meter reading at
the function switches or numeral input the first occurrence and that at the last
switches. occurrence are the same.
q [F3]: Moves to lower item a If [E] is displayed on the left of a failure
q [F4]: Moves to upper item code, the abnormality is still occurring or
q [F5]: Returns the display to the service restoration of it has not been confirmed.
menu screen a For all the failure codes that the machine
q [F6]: Validates the selection monitor can record, see the Failure codes
a You may enter a 2-digit code by using the table.
PC200, 200LC, 220, 220LC-8M0 30-102 31

4. Clearing abnormality record 3) After the Electrical Sys. Error Reset

1) While the Electrical Systems abnormality screen is displayed, press the function
record screen is displayed, press the switches.
numeral input switches as follows. q [F5]: Returns to Electrical Systems
q Operation of switches (While pressing Abnormality Record screen (delete
[4], press the switches in order): mode)
[4] + [1] o [ 2 ] o [ 3 ] q [F6]: Performs deletion
a The following figure shows the screen
displayed when the items are cleared
one by one (which is a little different
from the screen displayed when all
the items are cleared together).
2) Check that the screen is set in the clear

mode, and then clear the items one by
one or together by using the function
switches.
a If the screen is set in the clear mode,
icon [CLEAR] is indicated above [F2]. 4) If the screen to notify completion of clear-
q [F2]: Deletes all items ing is displayed and then the Electrical
q [F3]: Moves to lower item Systems (clear mode) screen is dis-
q [F4]: Moves to upper item played, the clearing of the abnormality
q [F5]: Returns to the Abnormality record is completed.
Record screen a After a while, the screen returns to
q [F6]: Deletes items one by one the Electrical Systems screen of
a To clear items one by one: Select the abnormality record.
item to be cleared by using [F3] or
[F4] and press [F6].
a To clear all items together: Press
[F2], and all the items are cleared,
regardless of selection of the items.
a If [E] is displayed on the left of a fail-
ure code, the clearing operation is
accepted but the information is not
cleared.
30-102 32 PC200, 200LC, 220, 220LC-8M0

Maintenance record a The following items can be selected on

The machine monitor records the maintenance Maintenance Record screen.
information of the filters, oils, etc., which are dis-
played and checked by the following operations. 49 Cleaning and replacement of cleaner
When maintenance is performed, if the remaining
01 Engine Oil Change
time is reset in the operator mode, the number of
maintenance times is recorded in this record. 02 Engine Oil Filter Change
1. Selecting the menu 03 Fuel Main Filter Change
Select Maintenance Record on the Service 41 Fuel Pre Filter Change
Menu screen.
04 Hyd Oil Filter Change
05 H/Tank Breather Change
07 Damper Case Service
08 Final Drive Oil Change Interval
09 S/Machinery Oil Change
10 Hydraulic Oil Change
3. Items displayed on Maintenance Record

screen
The following information is displayed on the
screen.
(a): Maintenance items
(b): Replacement time elapsed up to present
2. Selecting maintenance item (c): Service meter reading (SMR) at previous
After the Maintenance Record screen is dis- replacement
played, select a maintenance item to be
checked by using the function switches or
numeral input switches.
q [F5]: Returns the display to the service
menu screen
a You may enter a 2-digit code by using the
of that code.
PC200, 200LC, 220, 220LC-8M0 30-102 33

Maintenance Mode Setting a The following items can be selected on the

The actuating condition of the maintenance Maintenance Mode Setting screen.
reminder function in the operation mode can be set
and changed by using this menu. 00 Maintenance Mode Change
q To enable or disable the function
49 Air Cleaner cleaning / Change Interval
q To change set replacement interval (by item)
q To initialize all set replacement intervals 01 Engine Oil Change Interval
02 Eng Oil Filter Change Interval
1. Selecting the menu 03 Fuel Main Filter Change Interval
Select Maintenance Mode Setting on the
41 Fuel Pre Filter Change Interval
Service Menu screen.
04 Hyd. oil filter change interval
05 H/tank breather change interval
07 Damper Case Service Interval
08 Final Drive Oil Change Interval
09 S/Machinery oil change interval
10 Hydraulic Oil Change Interval
99 All Default Value
3. Contents of Maintenance Mode Change

After selecting Maintenance Mode Change
and the screen is displayed, select the desired
setting with the function switches.
q ON: Functions of all maintenance items
2. Selecting sub menu
are set effective in operator mode
After the Maintenance Mode Setting screen is
q OFF: Maintenance reminder functions of
displayed, select an item to change the setting
all maintenance items are disabled in
with the function switches or the numeral input
operator mode
switches.
q [F5]: Cancels selection and return to the
Maintenance Mode Change screen
q [F6]: Enters selection and return to the
menu screen
a Even if ON/OFF of each item has been
q [F6]: Validates the selection
set, if the above setting is changed, it
a You may enter a 2-digit code by using the
overrides the individual setting.
30-102 34 PC200, 200LC, 220, 220LC-8M0

4. Contents of Maintenance Notice Time Setting 5. Setting of each maintenance item

After selecting Maintenance Notice Time Set- After selecting each maintenance item to dis-
ting, if the screen is displayed, select the play its setting screen, perform the setting by
desired setting with the function switches. using the function switches.
q ON: Function of each maintenance item
selected is enabled in the operator mode
q OFF: Function of each maintenance item
selected is disabled in the operator mode
q [F3]: Moves to lower set value
q [F4]: Moves to upper set value
q [F5]: Cancels selection and returns to the
q [F6]: Enters selection and returns to the
a Even if ON/OFF of each item has been
set, if the above setting is changed, it
overrides the individual setting.
q Default value: Maintenance Notice Time

set in machine monitor (Recommended by
the manufacturer and not changeable).
q Set value code: Maintenance interval that
can be freely set. Maintenance reminder
function works according to this set time in
operator mode (which is set in increments
of 10 hours).
q [F3]: Decreases set value
q [F4]: Increases set value
q [F5]: Cancels setting before enter and
return to the Maintenance Mode Change
screen.
q [F6]: Enters selection and returns to the 6. Contents of setting of set value of each mainte-
Maintenance Mode Setting screen nance item
After selecting the set value of each mainte-
nance item, if the screen is displayed, perform
the setting for the item with the function
switches.
PC200, 200LC, 220, 220LC-8M0 30-102 35

q Default value: Maintenance Notice Time 7. Function of All Default Value

set in machine monitor (Recommended by After selecting 99 All Default Value and the
the manufacturer and not changeable). screen is displayed, set with the function
q Set value code: Maintenance interval that switches.
can be freely set. Maintenance reminder
function works according to this set time in
operator mode (which is set in increments
of 25 hours).
q [F5]: Cancels setting before enter and
returns to the Maintenance Mode
Change screen.
q [F6]: Enters setting and returns to Main-
tenance Mode Change screen
a After entering the selection with the [F6]
key, return to the Maintenance Mode Set-
ting screen by pressing [F5], and the set-
ting will be made.
q If this function is executed, the set values
a If the set value of an item of which mainte-
of all the maintenance items are initialized.
nance reminder function is set to ON is
q [F5]: Returns to Maintenance Mode Set-
changed after one operating hours or
ting screen
more from the setup, the change is recog-
q [F6]: Enters initialization
nized as a reset of the remaining time.
a A while after [F6] is pressed, the initializa-
tion completion screen is displayed. Then,
if the Maintenance Mode Setting screen
is displayed, initialization is completed.
30-102 36 PC200, 200LC, 220, 220LC-8M0

Phone Number Entry q If [F6] is pressed without inputting a digit,

The telephone number, which is displayed together there is not information of phone number.
with the Occurred error list in the operator mode, Accordingly, no phone number is dis-
can be input and changed according to the follow- played in the operator mode.
ing procedure.
If a telephone number is not input by using this
function, no telephone number is displayed in the
operator mode.

Select Phone Number Entry on the Service
Menu screen.
Default (Key-On Mode)

Use the menu of Default to check or change vari-
ous settings of the machine monitor and machine.
Use the sub menu of Key-on Mode to set the
working mode selected and displayed on the
machine monitor when the starting switch is turned
to ON position.
2. Registering and changing phone number 1. Selecting the menu

After the Phone Number Entry screen is dis- Select Default on the Service Menu screen.
played, register or change the phone number
q [F2]: Deletes all input No.
q [F3]: Moves to left position (if not blank)
q [F4]: Moves to right position (if not blank)
q [F5]: Resets input digit/Returns the dis-
play to the service menu screen
q [F6]: Confirms input
q Up to 14 digits can be input from the left.

Input nothing in the surplus positions.
q If one of the input digits is wrong, move to
that digit (its background changes to
orange) and overwrite it to correct.
PC200, 200LC, 220, 220LC-8M0 30-102 37

2. Selecting sub menu selected, turning on the starting switch

After the Default screen is displayed, select displays Power mode [P] when [ATT/P] is
Key-on Mode by using the function switches selected and displays economy mode [E]
or numeral input switches. when [ATT/E] is selected.
a Select this sub menu as in the case of a If the engine is stopped with the working
selecting a menu on the Service Menu mode set to breaker mode [B] in the oper-
screen. ator mode, Breaker Mode [B] is always
displayed when the starting switch is
turned to ON position, regardless of the
above setting.
3. Selecting mode
After the Key-on Mode screen is displayed,
select the mode to be set by using the function
switches. Default (Unit)
q Power mode: [P] is displayed when the Use the menu of Default to check or change vari-
starting switch is set to the ON position ous settings of the machine monitor and machine.
q Economy mode: [E] is displayed when the Use the sub menu of Unit to select the unit of the
starting switch is set to the ON position. data displayed for monitoring, etc.
q Lifting mode: [L] is displayed when the
starting switch is set to the ON position. 1. Selecting the menu
q Breaker mode: [B] is displayed when the Select Default on the Service Menu screen.
starting switch is set to the ON position.
q Attachment mode/P-mode: [ATT/P] is dis-
played when the starting switch is set to
the ON position.
q Attachment mode/E-mode: [ATT/E] is dis-
played when the starting switch is set to
the ON position.
q Mode at previous key-off: The mode
selected the last time is displayed when
the starting switch is set to the ON posi-
tion.
q [F5]: Cancels the selection and returns
the display to the default screen
q [F6]: Validates the selection and returns
a Factory default is Mode at Previous Key-
off.
a If With Attachment is not selected, selec-
tion of the Attachment /P-Mode and
Attachment/E-mode is disabled.
a If you change the setting to Without
attachment when Attachment/P-mode
[ATT/P] or Attachment/E-mode [ATT/E] is
30-102 38 PC200, 200LC, 220, 220LC-8M0

2. Selecting sub menu Default (With/Without Attachment)

After the Default screen is displayed, select Use the menu of Default to check or change vari-
Unit by using the function switches or ous settings of the machine monitor and machine.
numeral input switches. Use the sub menu of With/Without Attachment to
a Select this sub menu as in the case of configure attachment setting when the attachment
selecting a menu on the Service Menu is installed or removed.
screen.
Select Default on the Service Menu screen.
3. Selecting unit
After the Unit screen is displayed, select the
unit to be set by using the function switches. 2. Selecting sub menu
q [F3]: Moves to lower item After the Default screen is displayed, select
q [F4]: Moves to upper item With/Without Attachment by using the func-
q [F5]: Cancels the selection and returns tion switches or numeral input switches.
the display to the default screen a Select this sub menu as in the case of
q [F6]: Validates the selection and returns selecting a menu on the Service Menu
the display to the default screen screen.
a Factory default is SI Unit.
3. Selecting With/Without
After the With/Without Attachment screen is
displayed, select the setting by using the func-
tion switches.
q Without Attachment: When attachment is
not installed
q With Attachment: For machines with pro-
vision for attachment
q [F5]: Cancels the selection and returns
PC200, 200LC, 220, 220LC-8M0 30-102 39

q [F6]: Validates the selection and returns 2. Selecting sub menu

the display to the default screen After the Default screen is displayed, select
a When an attachment is installed, if this Camera using the function switch or numeral
setting is not configured correctly, the set- input switches.
ting of attachment in the operator mode a Select this sub menu as in the case of
cannot be performed. As a result, the selecting a menu on the Service Menu
attachment may not work normally or the screen.
hydraulic components may be damaged.
3. Selection of camera setting

Default (Camera) After the Camera screen for setting is dis-
Use the menu of Default to check or change vari- played, select the setting by using the function
ous settings of the machine monitor and machine. switches.
Use the sub menu of Camera to configure camera q Without Attachment: Camera is not
setting when the camera is installed or removed. selected.
q With Attachment: Image of connected
1. Selecting the menu camera is displayed in original position (as
Select Default on the Service Menu screen. in mirror, used for back monitor)
q [ ]: Image of connected camera is dis-
played in reverse position (as seen
directly, when used as front or side moni-
tor)
q [R]: Image of connected camera is dis-
played in original position (as in mirror,
used for back monitor)
q [F5]: Cancels the setting before validation
and returns the display to the Default
screen
q [F6]: Validates the selection made in each
step
a Camera 1 does not provide switching
between [ ] and [R] .
a After entering the setting of each column
by using [F6], return to the Default
screen by using [F5], and the setting is
effective.
a If a camera is connected but not config-
ured normally by using this function, the
icon of camera is not displayed above [F3]
in the operator mode. Accordingly, the
image of the camera cannot be seen.
30-102 40 PC200, 200LC, 220, 220LC-8M0

a If the camera is installed, check that the a The simultaneous display function of two
right and left portions of the displayed images becomes effective when camera 1
image are correct. and camera 2 are configured.
a If two or more cameras are connected, be

sure to configure them from camera 1 in
order.
PC200, 200LC, 220, 220LC-8M0 30-102 41

Diagnostic Tests (Cylinder Cut-out) 3. Selecting cylinder to be cut out

The operator can perform Cylinder Cut-out mode After the Cylinder Cut-out screen is dis-
operation with the machine monitor. played, select a cylinder to be Cut out by using
Cylinder Cut-out mode operation means to run the the function switches.
engine with 1 or more fuel injectors disabled electri- q [F1]: Moves to left item
cally to reduce the number of effective cylinders. q [F2]: Moves to right item
This operation is used to identify a cylinder that q [F4]: Selects hold or release
does not output power normally (combustion in it is (If hold is selected, a diagonal line is dis-
abnormal). played on the HOLD portion)
q [F5]: Returns to the testing screen
1. Selecting the menu q [F6]: Validates the selection
Select Testing on the Service Menu screen. a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes white,
the cylinder is cut out.
a If the machine monitor cuts out a cylinder
but the engine controller cannot cut out
that cylinder, the background (a) of the
cylinder No. becomes yellow.
a One or more cylinders can be cut-out.
a During the Cylinder Cut-out operation, the
auto-deceleration function can be
enabled. If the auto-deceleration is set to
ON, auto-deceleration monitor (b) is dis-
played.

After the Testing screen is displayed, select
Cylinder Cut-out by using the function
switches or numeral input switches.
a Select this sub menu as in the case of
selecting a menu on the Service Menu
screen.
4. Resetting cutout cylinder

When changing a cylinder to be cut out or
when Cylinder Cut-out operation is finished,
select a cut-out cylinder to be reset with the
function switches.
a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes blue,
the cylinder is reset.
a If the machine monitor resets a Cut-out
cylinder but the engine controller cannot
reset that Cut-out cylinder, the back-
ground (a) of the cylinder No. becomes
red.
30-102 42 PC200, 200LC, 220, 220LC-8M0

a The cut-out cylinder is not automatically reset Adjustment (Pump Absorption Torque (F))
even after returning to the operator mode. The machine monitor allows for adjustment of vari-
Accordingly, be sure to perform the resetting ous items related to the machine with the machine
operation after the Cylinder Cut-out operation monitor.
is finished. The sub menu of Pump Absorption Torque (F) is
used to finely adjust the absorption torque of the
5. Holding displayed data front hydraulic pump.
Each time [F4] is pressed during the Cylinder
Cut-out operation, the displayed data is newly 1. Selecting the menu
held (c) (the real-time data is kept displayed on Select Adjustment on the Service Menu
the left side). screen.
While the data is held, if [F4] is pressed, the
data holding function is reset.
a The holding function is available for a cyl-
inder, regardless of whether it is cut out or
not.

After the Adjustment screen is displayed,
select Pump Absorption Torque (F) using the
function switches or numeral input switches.
[Reference] selecting a menu on the Service Menu
q If a normally operating cylinder is dis- screen.
abled, the following phenomena occur.
1) The engine speed lowers.
2) The value (quantity) of final injection com-
mand increases.
q If the engine is running near the full speed,
however, the engine speed may not lower
for the reason of engine control.
q In this case, lower the engine speed by
using the fuel control dial and judge by
increase of the injection rate command.
PC200, 200LC, 220, 220LC-8M0 30-102 43

3. Selecting pump absorption torque setting Adjustment (Pump Absorption Torque (R))
After the Pump Absorption Torque (F) screen The machine monitor allows for adjustment of vari-
is displayed, select a set value in the right col- ous items related to the machine with the machine
umn by using the function switches. monitor.
q Set value code: For actual torque adjust- The sub menu of Pump Absorption Torque (R) is
ment value, see the table shown below. used to finely adjust the absorption torque of the
q [F3]: Increases set value rear hydraulic pump.
q [F6]: Confirms setting and returns to the 1. Selecting the menu
adjustment menu screen Select Adjustment on the Service Menu
a The 3-digit number in the left column do screen.
not change since it is the code of this func-
tion.

a Relationship between set value code and select Pump Absorption Torque (R) using the
torque offset value function switches or numeral input switches.
Set value selecting a menu on the Service Menu
Code Torque offset value screen.
code
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm}
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}
3. Selecting pump absorption torque setting

After the Pump Absorption Torque (R) screen
is displayed, select a set value in the right col-
umn by using the function switches.
q Set value code: For actual torque adjust-
ment value, see the table shown below.
q [F6]: Confirms setting and returns to the
adjustment menu screen
30-102 44 PC200, 200LC, 220, 220LC-8M0

a The 3-digit number in the left column do Adjustment (Low Speed)

not change since it is the code of this func- The machine monitor allows for adjustment of vari-
tion. ous items related to the machine with the machine
monitor.
The sub menu of Low Speed is used to finely adjust
the travel speed at Low setting.

Select Adjustment on the Service Menu
screen.
a Relationship between set value code and

torque offset value
Set value
Code Torque offset value
code
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm} After the Adjustment screen is displayed,
003 +9.8 Nm {+1 kgm} select Low speed using the function switches
022 004 0 Nm {0 kgm} or numeral input switches.
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm} screen.
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}
PC200, 200LC, 220, 220LC-8M0 30-102 45

3. Selecting low speed Adjustment (Attachment Flow Adjustment)

After the Low Speed screen for setting is dis- The machine monitor allows for adjustment of vari-
played, select a set value in the right column ous items related to the machine with the machine
by using the function switches. monitor.
q Set value code: For the actual travel The sub menu of Attachment Flow Adjustment
speed at Low setting, see the table shown allows for fine adjustment of the oil flow to the
below. attachment during combined operation.
q [F4]: Decreases set value 1. Selecting the menu
q [F6]: Confirms setting and returns to the Select Adjustment on the Service Menu
adjustment menu screen screen.
a The 3-digit number in the left column do
not change since it is the code of this func-
tion.

select Attachment Flow Adjustment by using
a Relationship between set value and travel the function switches or numeral input
speed at Low setting switches.
Set value selecting a menu on the Service Menu
Code Travel speed at Low screen.
code
000 3.0 km/h
001 2.8 km/h
020
002 3.2 km/h
003 3.4 km/h
3. Selecting set value code for oil flow distribution

After the screen of Attachment Flow Adjust-
ment is displayed, select a set value in the
right column by using the function switches.
q Set value code: For actual distribution of
oil flow, see the table shown below
q [F6]: Confirms setting and returns to the
adjustment menu screen
30-102 46 PC200, 200LC, 220, 220LC-8M0

a The 3-digit number in the left column do 2. Confirmation screen

not change since it is the code of this func- When "No Injection" screen is displayed, the
tion. monitor system checks whether the communi-
cation with the engine controller is available.
The following screen is displayed during the
communication.
a Relationship between set value and distribu-

tion of oil flow to attachment
After checking the communication, the mes-
Set value Distribution of flow sage to ask if no injection cranking should be
Code performed appears. Select the answer by
code to attachment
using the function switch.
000 50%
001 70% 3. Starting no injection cranking
044
002 100% If no injection cranking (fuel injection in no cyl-
003 40% inders) becomes effective, No Injection. is
displayed on the screen. Under this condition,
crank the engine by using the starting motor.
No Injection q While the screen is changing to the follow-
If the engine is operated after long storage of the ing screen, the screen of Getting Ready.
machine, it may be worn or damaged because of is displayed.
insufficient lubrication with oil. To prevent this, the q Limit the duration of cranking to 20 sec-
machine monitor allows for cranking the engine onds to protect the starting motor.
without injecting fuel to lubricate the engine before
starting it.
Set the no injection cranking while the engine is
stopped.

Select No Injection on the Service Menu
screen.
4. Finishing no injection cranking

After cranking is finished, turn the key to the
OFF position.
a Switching from the above screen to
another is not available.
5. Prohibiting no injection cranking

Even if the operator tries to perform the no
injection cranking while the engine is running,
PC200, 200LC, 220, 220LC-8M0 30-102 47

the message "The engine is operating. Please KOMTRAX Settings (Terminal Status)
turn the key off once." is displayed and the no The setting and operating status of KOMTRAX can
injection cranking does not become effective. be checked by using the menu of KOMTRAX Set-
tings.
KOMTRAX Settings is used to check the setting
condition of the KOMTRAX terminal.

Select KOMTRAX Settings on the Service
Menu screen.
And the Confirmation screen appears to dis-

able the attempted no injection cranking in the
following cases.
q Communication between the monitor and
engine controller is not normal.
q Engine was started before the message
N o i nj e c t i o n c ra n k i n g i s a v a i l a ble
appears on the screen. 2. Selecting submenu
After the KOMTRAX Settings screen is dis-
played, select Terminal Status with the func-
tion switches or numeral input switches.
a Select this submenu as in the case of
screen.
30-102 48 PC200, 200LC, 220, 220LC-8M0

3. Contents displayed on the terminal status 2. Selecting sub menu

screen After the KOMTRAX Settings screen is dis-
On the Terminal Status screen, the following played, select GPS & Communication Status
information is displayed. with the function switches or numeral input
q Terminal Type: Model name of the switches.
KOMTRAX communication modem a Select this sub menu as in the case of
q KOMTRAX Communication : Status of selecting a menu on the Service Menu
sign-up test underway screen.
q GMT time: Greenwich Mean Time (add 9
hours to it for Japan time)
q [F5]: Returns the display to the KOMTRAX
settings screen
3. Contents displayed on GPS & Communication

Status screen
On the GPS & Communication Status screen,
the following items are displayed.
KOMTRAX Settings (GPS and Communication q Positioning: GPS positioning status
Status) q Communication: Communication environ-
The setting and operating status of KOMTRAX can ment and connection status of the com-
be checked by using the menu of KOMTRAX Set- munication modem
tings. q Number of message not yet sent: Number
GPS & Communication Status is used to check of mails that are saved on the machine
the positioning and communication status of the monitor and have not yet been transmitted
KOMTRAX terminal. q [F5]: Returns the display to the
KOMTRAX settings screen
Select KOMTRAX Settings on the Service
Menu screen.
PC200, 200LC, 220, 220LC-8M0 30-102 49

KOMTRAX Settings (Modem Information) 3. Modem status displayed

The setting and operating status of KOMTRAX can IP addresses (2 addresses) of the modem are
be checked by using the menu of KOMTRAX Set- displayed.
tings. q [F5]: Returns the display to the KOMTRAX
Modem status is used to check the IP address of settings screen
the KOMTRAX communication modem. a An IP address is a unique number
assigned to each modem that is used
1. Selecting the menu when communication between the modem
Select KOMTRAX Settings on the Service and server is turned on.
Menu screen.
Service Message
2. Selecting sub menu Special messages for the technician sent from the
After the KOMTRAX Settings screen is dis- KOMTRAX base station (a distributor, etc.) can be
played, select Modem Status with the func- checked by using this function.
tion switches or numeral input switches. If a received message has return mail setting, a
a Select this sub menu as in the case of return mail can be sent by using the numeral input
selecting a menu on the Service Menu switches.
screen.
1. Selecting menu
Select Service Message on the Service Menu
screen.
30-102 50 PC200, 200LC, 220, 220LC-8M0

2. Displaying message (read-only)

If a message is received, the content is dis-
played. If there is no message, No message
is displayed.
menu screen
a This message is different from that sent
for the operator with the machine monitor
in the operator mode.
a Since this message is special for the tech-
nician, the message monitor is not dis-
played when it is received with the
machine monitor in the operator mode.
3. Displaying message (message with return mail

function)
If a message provides the Numeric Input line
under the text, input a proper number by using
the numeral input switches and enter it by
using the function switch, and the information
is returned to the KOMTRAX base station.
q [F5]: Returns the display to the KOMTRAX
settings screen
q [F6]: Validates and returns the input value.
a This message is different from that sent
for the operator with the machine monitor
in the operator mode.
a Since this message is special for the tech-
nician, the message monitor is not dis-
played when it is received with the
machine monitor in the operator mode.
PC200, 200LC, 220, 220LC-8M0 30-102 51

SEN06128-00

2012 KOMATSU
All Rights Reserved
30-102 52
SEN06129-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

Handling voltage circuit of engine controller ................................................................................................... 2
Preparation work for troubleshooting of electrical system .............................................................................. 3
Procedure for testing diodes ........................................................................................................................... 8
Pm Clinic service ............................................................................................................................................ 9
PC200, 200LC, 220, 220LC-8M0 30-103 1

SEN06129-00 Handling voltage circuit of engine controller
Handling voltage circuit of engine

controller 1
1. Before disconnecting or connecting a connec-
tor between the engine controller and engine,
be sure to turn the starting switch OFF.
2. If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
30-103 2 PC200, 200LC, 220, 220LC-8M0

Preparation work for troubleshooting of electrical system SEN06129-00
Preparation work for

troubleshooting of electrical
system
a When carrying out troubleshooting of an elec-
tric circuit related to the machine monitor,
engine controller, pump contoller, or
KOMTRAX communication MODEM, expose
the related connectors according to the follow-
ing procedure.
a Disconnect and connect the connectors having
special locking mechanisms according to the
procedure shown below.
1. Machine monitor
1) Remove the screws (three pcs.) mounting
cover (1).
a One of the three screws is covered
with cap (2).
a Disconnect connector P31 of the sun-
light sensor and remove cover (1).
4) Insert or connect troubleshooting T-adapt-

ers in or to connectors CM01, CM02, and
CM04 on machine monitor (7).
2) Remove a mounting bolt and duct (6).

3) Insert a flat-head screwdriver in slit (3)
and pull it up around projection (4) to
remove cover (5).
PC200, 200LC, 220, 220LC-8M0 30-103 3

SEN06129-00 Preparation work for troubleshooting of electrical system
2. Engine controller 3. Pump controller

1) Open the engine hood. 1) Slide the operator's seat and seat stand to
a The engine controller is mounted on the forward end.
the engine (on the counterweight 2) Remove the 5 mounting bolts and cool &
side). hot box (6).
2) Insert or connect troubleshooting T-adapt- a While removing the cool & hot box,
ers in or to connectors CE01, CE02, and disconnect the drain hose.
CE03 of engine controller (5). 3) Remove the 2 mounting bolts, 1 fastener,
a Connectors CE01 and CE02 are fixed and magazine box (7).
with screws. When disconnecting 4) Remove the 3 mounting bolts and cover
them, loosen the screws. (8).
a When returning connectors CE01 and 5) Remove fuse box cover (9) and cover
CE02, tighten the screws to the spec- (10).
ified torque. a Since the underside of cover (10) is
3 Screw: 3 1 Nm {0.3 0.1 kgm} clamped, pull it up.
6) Remove the 7 mounting bolts and cover
(11).
7) Connect the troubleshooting adapters to

connectors C01 and C02 of pump control-
ler (12).
a Install the adapters to only the wiring
harness side.
30-103 4 PC200, 200LC, 220, 220LC-8M0

a The connectors of the pump control- 6) Connect troubleshooting T-adapters to

ler have a special locking mecha- connectors CK01 and CK02 of
nism. Disconnect them according to KOMTRAX communication module (15).
steps (a) to (c) and connect them
according to steps (d) to (f) as shown
below.
Disconnection: (a) Unlock (b)
Slide lever (c) Disconnect connec-
tor.
Connection: (d) Position connector
(e) Slide lever (f) Lock.
5. Atmospheric pressure sensor (AMBAIR

PRESSURE)
Engine Ne speed sensor (CRANK SENSOR)
Engine Bkup speed sensor (CAM SENSOR)
Engine oil pressure switch (OIL PRESSURE
SWITCH)
a Disconnection and connection of con-
nector
4. KOMTRAX communication module
The connectors of the atmospheric pres-
1) Slide the operator's seat and seat
sure sensor, engine Ne speed sensor,
stand to the forward end.
engine Bkup speed sensor, engine oil
2) Remove the five mounting bolts and cool
pressure switch have a special locking
& hot box (9).
mechanism. Disconnect them according
a While removing the cool and hot box,
to steps (a) to (c) and connect them
disconnect the drain hose.
according to steps (d) to (f) as shown
3) Remove the two mounting bolts, one fas-
below.
tener, and magazine box (10).
Disconnection: (a) Slide lever (b)
4) Remove the three mounting bolts and
Unlock (c) Disconnect connector.
cover (11).
Connection: (d) Connect connector (e)
5) Remove the seven mounting bolts and
Lock (f) Slide lever.
cover (14).
PC200, 200LC, 220, 220LC-8M0 30-103 5

SEN06129-00 Preparation work for troubleshooting of electrical system
a Removal and installation of sensor 7. Supply pump IMV solenoid (FUEL REGU-
A deep socket is necessary for removal LATOR)
and installation of the engine oil pressure a Disconnection and connection of con-
switch. See "Tools for testing, adjusting, nector
and troubleshooting". The connector of the supply pump IMV
solenoid has a special locking mecha-
6. Boost pressure and temperature sensor nism. Disconnect it according to steps (a)
(BOOST PRESS & IMT) to (b) and connect it according to steps (c)
a Disconnection and connection of con- to (d) as shown below.
nector Disconnection: (a) Unlock (b) Discon-
The connector of the boost pressure and nect connector.
temperature sensor has a special locking Connection: (c) Connect connector (d)
mechanism. Disconnect it according to Lock.
steps (a) to (b) and connect it according to
steps (c) to (d) as shown below.
Disconnection: (a) Unlock (b) Discon-
nect connector.
Connection: (c) Connect connector (d)
Lock.
8. Common rail pressure sensor (FUEL RAIL

PRESS)
a Disconnection and connection of con-
nector
The connector of the common rail pres-
sure sensor has a special locking mecha-
nism. Disconnect it according to steps (a)
a Removal and installation of sensor to (b) and connect it according to steps (c)
A torque wrench is necessary for removal to (d) as shown below.
and installation of the boost pressure and Disconnection: (a) Unlock (b) Discon-
temperature sensor. See "Tools for test- nect connector.
ing, adjusting, and troubleshooting". Connection: (c) Connect connector (d)
Lock.
30-103 6 PC200, 200LC, 220, 220LC-8M0

a Precautions for disconnecting connector 9. Engine coolant temperature sensor (COOL-

The direction of the lock of the connector ANT TEMP)
varies with the position of the sensor is a Disconnection and connection of con-
screwed in and the lock may face a direc- nector
tion in which it is difficult to unlock (on the The connector of the engine coolant tem-
underside or engine side). perature sensor has a special locking
In this case, pinch the lock in direction (a) mechanism. Disconnect it according to
with bent-nose nippers [1] (commercially steps (a) to (b) and connect it according to
available), and the lock is reset. steps (c) to (d) as shown below.
Since the lock clicks when it is unlocked, Disconnection: (a) Unlock (b) Discon-
disconnect the connector after a click is nect connector.
heard. Connection: (c) Connect connector (d)
Lock.
a Precautions for connecting connector

Take care not to connect the connector
reversely. a Removal and installation of sensor
Engage lock (e) on the wiring harness side A deep socket is necessary for removal
with triangular notch (f) on the sensor side and installation of the engine coolant tem-
(Do not engage lock (e) with square guide perature sensor. See "Tools for testing,
(g) on the opposite side of triangular notch adjusting, and troubleshooting".
(f)).
PC200, 200LC, 220, 220LC-8M0 30-103 7

SEN06129-00 Procedure for testing diodes
Procedure for testing diodes 1

a Test the assembled-type diode (8-pin) and the
single diode (2-pin) according to the following
procedure.
a The conductive directions of the assembled-
type diode are as follows.
2. When using analog circuit tester

1) Set the tester in the resistance range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
i) Apply the red (+) lead of the tester to
the anode (P) side of the diode and
a The conductive direction of the single diode is apply the black () lead to the cath-
indicated on the surface of the diode. ode (N) side.
ii) Apply the red (+) lead of the tester to
the cathode (N) side of the diode and
apply the black () lead to the anode
(P) side.
3) Judge the condition of the diode by the
movement of the pointer.
q The pointer does not move in i) but
moves in ii): The diode is normal (The
moving range (resistance) depends
on the type and selected range of the
tester, however).
q The pointer moves in both i) and ii):
The diode is defective (Internal short
circuit).
1. When using digital circuit tester q The pointer moves in neither of i) and
1) Set the tester in the diode range and read ii): The diode is defective (Internal
the indicated value. disconnection).
a When an ordinary circuit tester is
used, the voltage of the internal bat-
tery is indicated.
2) Apply the red (+) lead of the tester to the
anode (P) side of the diode and apply the
black () lead to the cathode (N) side and
check the indicated value.
3) Judge the condition of the diode by the
indicated value.
q The indicated value does not change:
The diode does not have continuity
(Defective).
q The indicated value changes:
The diode has continuity (Normal).
Note: In the case of a silicon diode, a
value in the range from 460 to 600 is indi-
cated.
30-103 8 PC200, 200LC, 220, 220LC-8M0

Pm Clinic service SEN06129-00
Pm Clinic service 1
Model name Serial No. Service meter
T PC200-8M0 T PC220-8M0
h
T PC200LC-8M0 T PC220LC-8M0
User's name Date of execution Inspector
/ /
Specifications
Main components Attachments Shoe width
Boom T Standard T ( ) T Breaker T 600 mm
Arm T Standard T ( ) T( ) T 700 mm
Bucket T Standard T ( ) T( ) T( )
Check of oil/coolant level
T Radiator coolant When necessary
T Machinery case oil
T Engine oil T Damper case oil
T( )
T Hydraulic oil T Final drive case oil
Ambient temperature Altitude
C m
Operator's opinion
Result of visual inspection
Mechanical equipment system fault history Electrical equipment system fault history
989EKX times/1st time h/last h times/1st time h/last h
AA10NX times/1st time h/last h times/1st time h/last h
AB00KE times/1st time h/last h times/1st time h/last h
B@BAZG times/1st time h/last h times/1st time h/last h
B@BAZK times/1st time h/last h times/1st time h/last h
B@BCNS times/1st time h/last h times/1st time h/last h
B@BCZK times/1st time h/last h times/1st time h/last h
B@HANS times/1st time h/last h times/1st time h/last h
CA234 times/1st time h/last h times/1st time h/last h
Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge
PC200, 200LC, 220, 220LC-8M0 30-103 9

SEN06129-00 Pm Clinic service
Items related to engine
30-103 10 PC200, 200LC, 220, 220LC-8M0

Items related to oil pressure
PC200, 200LC, 220, 220LC-8M0 30-103 11

Check sheet (PC200/200LC-8M0)

Model Serial No. Service meter User's name Date of execution Inspector
/ /
1. Engine
Condition for check
Standard Mea-
Good
Bad
No. Check item Fuel Work- Auto- Operation of Unit value for new Repair limit sured
Left knob
control ing decel- work machine value
switch
dial mode eration equipment
1,990 to 1,990 to
1 Engine speed rpm
All levers in 2,130 2,130
MAX
Engine oil neutral MPa Min. 0.29 0.25
2
pressure {kg/cm2} {Min. 3.0} {2.5}
OFF
1,000 to 1,000 to
3 Engine speed rpm
MIN OFF
4 P
1,850 to 1,850 to
5 Engine speed rpm
2,050 2,050
ON Arm IN relief
Blow-by kPa Max. 0.98 1.96
6 MAX
pressure {mmH2O} {Max. 100} {200}
All levers in
7 Engine speed ON OFF rpm 950 to 1,050 950 to 1,050
neutral
2. Work equipment speed

Condition for check
Standard Mea-
Good
Bad
No. Check item Fuel Work- Unit value for new Repair limit sured
control ing Checking posture, etc. machine value
dial mode
1 Boom RAISE Work equipment extended fully sec 2.9 to 3.7 Max. 4.7
P
sec 3.1 to 3.9 Max. 4.5
2 Arm IN E sec 3.2 to 4.0 Max. 4.5
Boom top horizontal
L sec 6.0 to 7.4 Max. 7.7
3 Arm OUT sec 2.4 to 3.0 Max. 3.5
Boom top horizontal
4 Bucket CURL sec 2.1 to 2.7 Max. 3.1
Arm cylinder retracted fully
MAX Work equipment extended fully
5 Swing (5 turns) sec 21.7 to 26.7 Max. 30
Swing right and left
P STD 44.6 to 54.9 44.6 to 58.8

LO sec
LC 48.6 to 59.8 48.6 to 63.8
Oneside of track STD 33.7 to 41.3 33.7 to 45.3
Travel
6 pushed up and turned MI sec
(5 idle turns) LC 36.7 to 44.9 36.7 to 48.9
forward and backward
STD 25.2 to 27.8 25.2 to 29.8
HI sec
LC 27.3 to 30.3 27.3 to 32.3
30-103 12 PC200, 200LC, 220, 220LC-8M0

3. Hydraulic drift of work equipment

Condition for check
Standard Mea-
Good
Bad
dial mode
Boom top horizontal
Hydraulic drift of mm/
1 Engine stopped Arm cylinder retracted fully Max. 600 Max. 900
bucket tip 15 min
Bucket loaded
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Condition for check
600K 600K 600K 600K 60K
Good
Bad
No. Checked part
Fuel Work-
Left knob Operation of work F pump R pump F pump R pump
control ing Control
switch equipment main main LS LS
dial mode
Self pressure A
1 All lever in neutral
reducing valve
OFF
Main relief valve B B B B
2
(Low pressure)
Arm out relief
Main relief valve C C C C
3 ON
(Low pressure)
D1 D1 D2 D2
4 Unload valve All levers in neutral
Right track driven idle E1 E2

Lever moved halfway
5 LS valve
Left track driven idle E1 E2

Lever moved halfway
MAX P
Swing lock F F

Swing motor Right swing relief
6
safety valve Swing lock F F
OFF
Left swing relief
Right travel lock G

Right forward relief
Main relief valve Right travel lock G
Travel motor
Right reverse relief
7 Safety valve
Travel junction Left travel lock G

valve Left forward relief
Left travel lock G

Left reverse relief
Testing oil pressure Unit Standard value for new machine Repair limit
A (Control circuit source pressure) 2.93 to 3.43 {30 to 35} 2.74 to 3.43 {28 to 35}
B (Work equipment relief pressure,
33.6 to 36.3 {343 to 370} 33.1 to 37.2 {338 to 380}
Standard value
low)
C (Work equipment relief pressure,
MPa 36.1 to 38.7 {368 to 395} 36.1 to 39.7 {368 to 405}
high)
{kg/cm2}
D (Unload pressure) D1 to D2 = 2.5 to 4.5 {26 to 46} D1 to D2 = 2.5 to 4.5 {26 to 46}
E (LS differential pressure) E1 to E2 = 1.7 to 1.9 {17 to 19} E1 to E2 = 1.7 to 1.9 {17 to 19}
F (Swing relief pressure) 28.8 to 31.8 {295 to 325} 28.4 to 32.3 {290 to 330}
G (Travel relief pressure) 36.7 to 39.7 {375 to 405} 36.8 to 40.2 {375 to 410}
PC200, 200LC, 220, 220LC-8M0 30-103 13

* Gauge changing work: Change hoses of gauges [3] and [4].

[1] [2] [3a] [4a] [5]
Condition for check
600K 600K 600K 600K 60K
Good
Bad
No. Check item
Fuel Work-
control ing Control
switch equipment main main servo servo
dial mode
H1 H1 H2 H2
8 Servo piston MAX P OFF Arm out relief
Standard value
Checked oil pressure Unit Standard value for new machine Repair limit
H1 : H2 = 1 : 0.6
H (Servo control pressure)
(Oil pressure ratio)
* Gauge changing work: Change gauges [3] and [4] to 60K and change hose conditions of [3], [4],
and [5].
[1] [2] [3b] [4b] [5a]
Condition for check
600K 600K 60K 60K 60K
Good
Bad
No. Check item
Fuel Work-
control ing LS-EPC
switch equipment main main (F) (R)
dial mode
J1 J1
MIN
P
J2 J2

PC-EPC (F)
valve J3 J3
9 E All levers in neutral
PC-EPC (R)
valve
J4 J4
L
OFF J5 J5
B
MAX
Travel speed: Lo K1

travel lever in neutral
Travel speed: Mi K2
10 LS-EPC valve P Travel lever oper-
ated
Travel speed: Hi K3
Travel lever oper-
ated
J1
Approx. 2.9 {Approx. 30}
(PC-EPC valve output pressure 1)
J2
J3
Standard value

J4
Approx. 1.7 {Approx. 17.5}
(PC-EPC valve output pressure 4) MPa
J5 {kg/cm2}
K1
(LS-EPC valve output pressure 1)
K2
K3
0 {0}
30-103 14 PC200, 200LC, 220, 220LC-8M0

Check sheet (PC220/220LC-8M0)

Model Serial No. Service meter User's name Date of execution Inspector
/ /
1. Engine
Condition for check
Standard Mea-
Good
Bad
No. Check item Fuel Work- Auto- Operation of Unit value for new Repair limit sured
Left knob
control ing decel- work machine value
switch
dial mode eration equipment
2,090 to 2,090 to
1 Engine speed rpm
MAX
2
OFF
1,000 to 1,000 to
3 Engine speed rpm
MIN OFF
4 P
1,850 to 1,850 to
5 Engine speed rpm
2,050 2,050
ON Arm IN relief
Blow-by kPa Max. 0.98 1.96
6 MAX
pressure {mmH2O} {Max. 100} {200}
All levers in
7 Engine speed ON OFF rpm 950 to 1,150 950 to 1,150
neutral
2. Work equipment speed

Condition for check
Standard Mea-
Good
Bad
dial mode
1 Boom RAISE Work equipment extended fully sec 3.1 to 3.9 Max. 4.9
P
sec 3.7 to 4.5 Max. 4.8
2 Arm IN E sec 3.8 to 4.6 Max. 4.9
Boom top horizontal
L sec 7.0 to 8.6 Max. 9.0
3 Arm OUT sec 2.8 to 3.4 Max. 3.5
Boom top horizontal
4 Bucket CURL sec 2.4 to 3.0 Max. 3.3
Arm cylinder retracted fully
MAX Work equipment extended fully
5 Swing (5 turns) sec 22.9 to 28.5 Max. 31
Swing right and left
P STD 46.6 to 57.4 46.6 to 61.5

LO sec
LC 50.5 to 62.3 50.5 to 66.3
Oneside of track STD 35.6 to 43.6 35.6 to 47.6
Travel
6 pushed up and turned MI sec
(5 idle turns) LC 38.6 to 46.2 38.6 to 51.2
forward and backward
STD 26.7 to 29.5 26.7 to 31.5
HI sec
LC 28.9 to 31.9 28.9 to 33.9
PC200, 200LC, 220, 220LC-8M0 30-103 15

3. Hydraulic drift of work equipment

Condition for check
Standard Mea-
Good
Bad
dial mode
Boom top horizontal
Hydraulic drift of mm/
1 Engine stopped Arm cylinder retracted fully Max. 600 Max. 900
bucket tip 15 min
Bucket loaded
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Condition for check
600K 600K 600K 600K 60K
Good
Bad
No. Checked part
Fuel Work-
control ing Control
switch equipment main main LS LS
dial mode
Self pressure A
1 All lever in neutral
reducing valve
OFF
Main relief valve B B B B
2
(Low pressure)
Arm out relief
Main relief valve C C C C
3 ON
(Low pressure)
D1 D1 D2 D2
4 Unload valve All levers in neutral
Right track driven idle E1 E2

Lever moved halfway
5 LS valve
Left track driven idle E1 E2

Lever moved halfway
MAX P
Swing lock F F

Swing motor Right swing relief
6
safety valve Swing lock F F
OFF
Left swing relief
Right travel lock G

Right forward relief
Main relief valve Right travel lock G
Travel motor
Right reverse relief
7 Safety valve
Travel junction Left travel lock G

valve Left forward relief
Left travel lock G

Left reverse relief
A (Control circuit source pressure) 2.93 to 3.43 {30 to 35} 2.75 to 3.43 {28 to 35}
B (Work equipment relief pressure,
33.6 to 36.3 {343 to 370} 33.1 to 37.2 {338 to 380}
Standard value
low)
C (Work equipment relief pressure,
MPa 36.1 to 38.8 {368 to 395} 36.1 to 39.7 {368 to 405}
high)
{kg/cm2}
D (Unload pressure) D1 to D2 = 2.5 to 4.5 {26 to 46} D1 to D2 = 2.5 to 4.5 {26 to 46}
E (LS differential pressure) E1 to E2 = 1.7 to 1.9 {17 to 19} E1 to E2 = 1.7 to 1.9 {17 to 19}
F (Swing relief pressure) 28.8 to 31.8 {295 to 325} 28.4 to 32.3 {290 to 330}
G (Travel relief pressure) 36.7 to 39.7 {375 to 405} 36.8 to 40.2 {375 to 410}
30-103 16 PC200, 200LC, 220, 220LC-8M0

* Gauge changing work: Change hoses of gauges [3] and [4].

[1] [2] [3a] [4a] [5]
Condition for check
600K 600K 600K 600K 60K
Good
Bad
No. Check item
Fuel Work-
control ing Control
switch equipment main main servo servo
dial mode
H1 H1 H2 H2
8 Servo piston MAX P OFF Arm out relief
Standard value
Checked oil pressure Unit Standard value for new machine Repair limit
H1 : H2 = 1 : 0.6
H (Servo control pressure)
(Oil pressure ratio)
* Gauge changing work: Change gauges [3] and [4] to 60K and change hose conditions of [3], [4],
and [5].
[1] [2] [3b] [4b] [5a]
Condition for check
600K 600K 60K 60K 60K
Good
Bad
No. Check item
Fuel Work-
control ing LS-EPC
switch equipment main main (F) (R)
dial mode
J1 J1
MIN
P
J2 J2

PC-EPC (F)
valve J3 J3
9 E All levers in neutral
PC-EPC (R)
valve
J4 J4
L
OFF J5 J5
B
MAX
Travel speed: Lo K1

travel lever in neutral
Travel speed: Mi K2
10 LS-EPC valve P Travel lever oper-
ated
Travel speed: Hi K3
Travel lever oper-
ated
J1
J2
J3
Standard value

J4
(PC-EPC valve output pressure 4) MPa
J5 {kg/cm2}
K1
K2
K3
0 {0}
PC200, 200LC, 220, 220LC-8M0 30-103 17

SEN06129-00

2012 KOMATSU
All Rights Reserved
30-103 18
SEN06131-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting 1
100 Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Fuse locations................................................................................................................................................. 9
PC200, 200LC, 220, 220LC-8M0 40-100 1

SEN06131-00 Failure codes table
Failure codes table 1

Failure Component Action Category Reference
Trouble (Displayed on screen)
code in charge level of record documents No.
Electrical
879AKA A/C Inner Sensor Open Circuit MON
system
Electrical
879AKB A/C Inner Sensor Short Circuit MON
system
Electrical
879BKA A/C Outer Sensor Open Circuit MON
system
Electrical
879BKB A/C Outer Sensor Short Circuit MON
system
Electrical
879CKA Ventilating Sensor Open Circuit MON
system See section 80,
Electrical Appendix
879CKB Ventilating Sensor Short Circuit MON
system
Electrical
879DKZ Sunlight Sensor Open Or Short Circuit MON
system
Electrical
879EMC Ventilating Damper Abnormality MON L01
system
Electrical
879FMC Air Mix Damper Abnormality MON L01
system
Electrical
879GKX Refrigerant Abnormality MON L01
system
Electrical
989L00 Engine Controller Lock Caution1 MON
system
Electrical
989M00 Engine Controller Lock Caution2 MON
system Troubleshooting
Electrical by failure code,
989N00 Engine Controller Lock Caution3 MON
system Part 1
Mechanical SEN06133-**
AA10NX Air Cleaner Clogging MON L01
system
Mechanical
AB00KE Charge Voltage Low MON L03
system
Mechanical
B@BAZG Eng Oil Press Low ENG L03
system
Mechanical
B@BAZK Engine Oil Level Low MON L01
system
Mechanical
B@BCNS Eng Water Overheat ENG L02
system
Mechanical
B@BCZK Radiator Coolant Level Low MON L01
system
Mechanical
B@HANS Hyd Oil Overheat PUMP L02
system
Electrical
CA111 ECM Critical Internal Failure ENG L04
system
Electrical
CA115 Eng Ne and Bkup Speed Sens Error ENG L04
system
Electrical
CA122 Chg Air Press Sensor High Error ENG L03
system
Electrical
CA123 Chg Air Press Sensor Low Error ENG L03
system
Electrical
CA131 Throttle Sensor High Error ENG L03
system
40-100 2 PC200, 200LC, 220, 220LC-8M0

Failure codes table SEN06131-00

Electrical
CA132 Throttle Sensor Low Error ENG L03
system
Electrical
CA144 Coolant Temp Sens High Error ENG L01
system
Electrical
CA145 Coolant Temp Sens Low Error ENG L01
system
Electrical
CA153 Chg Air Temp Sensor High Error ENG L03
system
Electrical
CA154 Chg Air Temp Sensor Low Error ENG L03
system
Electrical
CA155 Chg Air Temp High Speed Derate ENG L03
system
Electrical Troubleshooting
CA187 Sens Supply 2 Volt Low Error ENG L03
system by failure code,
Electrical Part 1
CA221 Ambient Press Sens High Error ENG L03 SEN06133-**
system
Electrical
CA222 Ambient Press Sens Low Error ENG L03
system
Electrical
CA227 Sens 2 Supply Volt High Error ENG L03
system
Electrical
CA234 Eng Overspeed ENG
system
Electrical
CA238 Ne Speed Sens Supply Volt Error ENG L01
system
Electrical
CA271 IMV/PCV1 Short Error ENG L03
system
Electrical
CA272 IMV/PCV1 Open Error ENG L03
system
Electrical
CA322 Inj #1(L#1) Open/Short Error ENG L03
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system Part 2
Electrical SEN06134-**
CA342 Calibration Code Incompatibility ENG L04
system
Electrical
CA351 Injectors Drive Circuit Error ENG L03
system
Electrical
CA352 Sens Supply 1 Volt Low Error ENG L03
system
Electrical
CA386 Sens Supply 1 Volt High Error ENG L03
system
Electrical
CA428 Water in Fuel Sensor High Error ENG L01
system
PC200, 200LC, 220, 220LC-8M0 40-100 3


Electrical
CA429 Water in Fuel Sensor Low Error ENG L01
system
Electrical
CA435 Eng Oil Press Sw Error ENG L01
system
Electrical
CA441 Battery Voltage Low Error ENG L04
system
Electrical
CA442 Battery Voltage High Error ENG L04
system
Electrical
CA449 Rail Press Very High Error ENG L03
system
Electrical
CA451 Rail Press Sensor High Error ENG L03
system
Electrical
CA452 Rail Press Sensor Low Error ENG L03
system
Electrical
CA488 Chg Air Temp High Torque Derate ENG L03
system
Electrical
CA553 Rail Press High Error ENG L01
system
CA559 Rail Press Low Error ENG L01
Electrical Part 2
CA689 Eng Ne Speed Sensor Error ENG L01 SEN06134-**
system
Electrical
CA731 Eng Bkup Speed Sens Phase Error ENG L01
system
Electrical
CA757 All Continuous Data Lost Error ENG L04
system
Electrical
CA778 Eng Bkup Speed Sensor Error ENG L01
system
Electrical
CA2185 Throt Sens Sup Volt High Error ENG L03
system
Electrical
CA2186 Throt Sens Sup Volt Low Error ENG L03
system
Electrical
CA2249 Rail Press Very Low Error ENG L03
system
Electrical
CA2311 lMV Solenoid Error ENG L03
system
Electrical
CA2555 Grid Htr Relay Open Circuit Error ENG L01
system
Electrical
CA2556 Grid Htr Relay Short Circuit Error ENG L01
system
40-100 4 PC200, 200LC, 220, 220LC-8M0


Electrical
D110KB Battery Relay Drive Short Circuit PUMP L01
system
Electrical
D19JKZ Personal Code Relay Abnormality MON L03
system
Electrical
D811MC KOMTRAX Error KOMTRAX
system
Electrical
D862KA GPS Antenna Open Circuit KOMTRAX
system
Electrical
D8AQKR CAN2 Discon (KOMTRAX) MON
system
Electrical
DA22KK Pump Solenoid Power Low Error PUMP L03
system
Electrical
DA25KP 5V Sensor 1 Power Abnormality PUMP
system
Electrical
DA26KP 5V Sensor 2 Power Abnormality PUMP
system
Electrical
DA29KQ Model Selection Abnormality PUMP L01
system
Electrical
DA2QKR CAN2 Discon (Pump Con) MON L03
system
Electrical
DAF0MB Monitor ROM Abnormality MON
DAF0MC Monitor Error MON
system Part 3
DAF8KB Camera Power Supply Short Circuit MON L03
system
Electrical
DAF9KQ Model Selection Abnormality MON L03
system
Electrical
DAFGMC GPS Module Error KOMTRAX
system
Electrical
DAFQKR CAN2 Discon (Monitor) KOMTRAX
system
Electrical
DAZ9KQ A/C Model Selection Abnormality MON
system
Electrical
DAZQKR CAN2 Discon (Aircon ECU) MON L01
system
Electrical
DB2QKR CAN2 Discon (Engine Con) MON L03
system
Electrical
DGH2KB Hyd Oil Sensor Short Circuit PUMP L01
system
Electrical
DHA4KA Air Cleaner Clog Sensor Open Circuit MON L01
system
Electrical
DHPAMA F Pump Press Sensor Abnormality PUMP L01
system
Electrical
DHPBMA R Pump Press Sensor Abnormality PUMP L01
system
PC200, 200LC, 220, 220LC-8M0 40-100 5


Electrical
DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP L01
system
Bucket CURL PPC Press Sensor Electrical
DHS4MA PUMP L01
Abnormality system
Electrical
DHS8MA Boom Raise PPC Press Sensor Abnormality PUMP L01
system
Boom Lower PPC Press Sensor Electrical
DHS9MA PUMP L01
Abnormality system
Electrical
DHSAMA Swing RH PPC Press Sensor Abnormality PUMP L01
system
Electrical
DHSBMA Swing LH PPC Press Sensor Abnormality PUMP L01
system
Electrical
DHSCMA Arm Dump PPC Press Sensor Abnormality PUMP L01
system
Bucket Dump PPC Press Sensor Electrical
DHSDMA PUMP L01
Abnormality system
Electrical
DHSFMA Travel FW L PPC Press Sensor Abnormality PUMP L01
system
Electrical
DHSGMA Travel FW R PPC Press Sensor Abnormality PUMP L01
system
DHSHMA Travel BW L PPC Press Sensor Abnormality PUMP L01
Travel BW R PPC Press Sensor Electrical Part 4
DHSJMA PUMP L01 SEN06136-**
Abnormality system
Electrical
DHX1MA Overload Sensor Abnormality PUMP L04
system
Electrical
DR21KX Camera 2 Picture Rev. Drive Abnormality MON L01
system
Electrical
DR31KX Camera 3 Picture Rev. Drive Abnormality MON L01
system
Electrical
DV20KB Travel Alarm Short Circuit PUMP L01
system
Electrical
DW43KA Travel Speed Sol Open Circuit PUMP L01
system
Electrical
DW43KB Travel Speed Sol Short Circuit PUMP L01
system
Electrical
DW45KA Swing brake Sol. Valve Open Circuit PUMP L01
system
Electrical
DW45KB Swing Brake Sol Short Circuit PUMP L01
system
Electrical
DW91KA Travel Neutral Sol Open Circuit PUMP L01
system
Electrical
DW91KB Travel Neutral Sol Short Circuit PUMP L01
system
40-100 6 PC200, 200LC, 220, 220LC-8M0


Electrical
DWA2KA Attachment Sol Open Circuit PUMP L03
system
Electrical
DWA2KB Attachment Sol Short Circuit PUMP L03
system
Electrical
DWK0KA 2-stage Relief Sol Open Circuit PUMP L01
system
Electrical
DWK0KB 2-stage Relief Sol Short Circuit PUMP L01
system
Electrical
DWK2KA Variable Back Press Sol Open Circuit PUMP L01
system
Electrical
DWK2KB Variable Back Press Sol Short Circuit PUMP L01
system
Electrical
DXA8KA PC-EPC (F) Sol Open Circuit PUMP L03
system
Electrical
DXA8KB PC-EPC (F) Sol Short Circuit PUMP L03
system
Electrical
DXA9KA PC-EPC (R) Sol Open Circuit PUMP L03
system
Electrical
DXA9KB PC-EPC (R) Sol Short Circuit PUMP L03
system
Electrical
DXE0KA LS-EPC Sol Open Circuit PUMP L01
DXE0KB LS-EPC Sol Short Circuit PUMP L01
system Part 5
DXE4KA Attachment Flow EPC Open Circuit PUMP
system
Electrical
DXE4KB Attachment Flow EPC Short Circuit PUMP
system
Electrical
DXE5KA Merge-divide Main Sol Open Circuit PUMP L01
system
Electrical
DXE5KB Merge-divide Main Sol Short Circuit PUMP L01
system
Electrical
DXE6KA Merge-divide LS Sol Open Circuit PUMP L01
system
Electrical
DXE6KB Merge-divide LS Sol Short Circuit PUMP L01
system
Electrical
DY20KA Wiper Working Abnormality PUMP
system
Electrical
DY20MA Wiper Parking Abnormality PUMP
system
Electrical
DY2CKB Washer Drive Short Circuit PUMP
system
Electrical
DY2DKB Wiper Drive (For) Short PUMP
system
Electrical
DY2EKB Wiper Drive (Rev) Short PUMP
system
PC200, 200LC, 220, 220LC-8M0 40-100 7

a In this table, failure codes are arranged in the order of characters from numeric to alphabetic character.
a A component in charge means a controller or the machine monitor that is in charge of the system check.
MON: Machine monitor
ENG: Engine controller
PUMP: Pump controller
KOMTRAX: KOMTRAX terminal
a The failure codes that do not have numbers in the action level columns are not displayed on the stan-
dard screen even when a failure related to them occurs. They are simply recorded in the abnormality
record (electrical system and mechanical system) of the service menu.
a The "Category of record" shows the abnormality record into which the failure is classified, the electrical
system or mechanical system, when it is recorded in the abnormality record of the service menu.
For details, see "Troubleshooting by failure code (Display of code)".
40-100 8 PC200, 200LC, 220, 220LC-8M0

Fuse locations SEN06131-00
Fuse locations 1
Connection table of fuse box
a This connection table shows the devices to which power supply from each fuse of the fuse box supplies
power (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power while the starting switch is in the
OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
Type of
Fuse
power Fusible link Fuse No. Destination of power
capacity
supply
Lamp relay, rear lamp relay, cab lamp relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve
1 10 A [When pump drive switch is operated in emergency]
Swing holding brake solenoid valve
[When swing holding brake release switch is operated]
2 30 A Pump controller (Solenoid power supply)
Switch power F04
supply (60 A) PPC oil pressure lock solenoid valve
3 10 A Starting motor cut-out relay (PPC lock)
Starting motor cut-out relay (Personal code)
Cigarette lighter
4 10 A
Windshield washer motor
5 10 A Horn relay, horn
6 10 A Electrical intake air heater relay
7 10 A Rotary lamp
Switch power F04 8 20 A Right headlamp, working lamp (boom), working lamp (rear)
supply (60 A) Radio
9 10 A
Left knob switch (pump controller input)
10 5A Air conditioner controller supply
Air conditioner unit
11 20 A
Air conditioner compressor electromagnetic clutch
Switch power F04 12 10 A (Spare)
supply (60 A) 13 10 A Headlamp
14 10 A Optional power supply (1)
Radio (backup power supply)
16 10 A
Room lamp
Starting switch
Constant F05
17 20 A Machine monitor
power supply (30 A)
Pump controller
18 5A Air conditioner controller backup
19 30 A Engine controller
Switch power Starting switch
20 5A Engine controller (ACC signal)
supply ACC
PC200, 200LC, 220, 220LC-8M0 40-100 9

SEN06131-00 Fuse locations
Locations of fusible links
Location of fuse box and fuse Nos.
40-100 10 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-100 11

SEN06131-00

2012 KOMATSU
All Rights Reserved
40-100 12
SEN06132-00
SEN05984-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
200 General Information on troubleshooting
Symptom and troubleshooting numbers ..................................................................................................... 2

Sequence of events in troubleshooting ....................................................................................................... 4
Checks before troubleshooting ................................................................................................................... 6
Classification and procedures for troubleshooting ...................................................................................... 8
Symptom and troubleshooting numbers ..................................................................................................... 10
Information in troubleshooting table ............................................................................................................ 12
Connector list and layout ............................................................................................................................ 14
Connection table for connector pin numbers .............................................................................................. 24
T- branch box and T- branch adapter table ................................................................................................. 60
Troubleshooting method for open circuit in wiring harness of pressure sensor system.............................. 63
PC200, 200LC, 220, 220LC-8M0 40-200 1

SEN06132-00 Symptom and troubleshooting numbers
Symptom and troubleshooting numbers

(Rev. 2011/09)
k Park the machine on a level surface, lower the work equipment to the ground so that it is stable,
and stop the engine.
k When performing the operation with two or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the cable from the negative () terminal of the bat-
tery first.
k When removing the plug or cap from a component which is under pressure of oil, water, or air, al-
ways release the internal pressure first. When installing measuring equipment, be sure to connect
it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to perform repairs swiftly, and to pre-
vent reoccurrence of the failure. When performing troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When performing troubleshooting, do not hurry 2) Perform checks on items listed in "Checks
to disassemble the components. before starting".
If components are disassembled immediately af- 3) Perform checks on other checking items.
ter any failure occurs: 4) Check other maintenance matters which can
q Parts that have no connection with the failure be checked appearance and are considered
or other unnecessary parts will be disassem- to be necessary.
bled.
q It will become impossible to find the cause of 4. Checking failure symptom
the failure. Check the extent of the failure by yourself, and
It will also cause a waste of manhours, parts, or judge whether it is a real failure or a problem with
oil or grease, and at the same time, will also lose the method of operation, etc.
the confidence of the user or operator. a When operating the machine to reproduce
For this reason, when performing troubleshoot- the failure symptom, do not perform any in-
ing, it is necessary to perform thorough prior inspection or measurement that may make the
vestigation and to perform troubleshooting in problem worse.
accordance with the fixed procedure.
5. Troubleshooting
2. Points to ask the user or operator Use the results of the investigation and inspec-
1) Have any other problems occurred apart tion in Items 2 to 4 to narrow down the probable
from the problem that has been reported? causes of the failure, then use the trouble-
2) Was there anything strange about the ma- shooting flowchart to locate the failure exactly.
chine before the failure occurred? a The basic procedure for troubleshooting is as
3) Did the failure occur suddenly, or were there follows.
problems with the machine condition before 1] Start from the simple points.
the failure? 2] Start from the most likely points.
4) Under what conditions did the failure occur? 3] Investigate other related parts or informa-
5) Had any repairs been performed before the tion.
failure? When were these repairs per-
formed? 6. Measures to remove root cause of failure
6) Has the same kind of failure occurred be- Even if the immediate failure is removed, the
fore? same failure may occur again, unless the root
cause of the failure is repaired. To prevent this,
3. Check before troubleshooting always investigate why the cause of the failure
1) Check the machine for other symptoms of occurred. Then, remove the root cause.
failure.
40-200 2 PC200, 200LC, 220, 220LC-8M0

Symptom and troubleshooting numbers SEN06132-00
PC200, 200LC, 220, 220LC-8M0 40-200 3

SEN06132-00 Sequence of events in troubleshooting
Sequence of events in troubleshooting

(Rev. 2011. 7)
40-200 4 PC200, 200LC, 220, 220LC-8M0

Sequence of events in troubleshooting SEN06132-00
PC200, 200LC, 220, 220LC-8M0 40-200 5

SEN06132-00 Checks before troubleshooting
Checks before troubleshooting

No. Item Criterion Remedy
1 Check for unusual sounds and smells Repair
2 Check for dirt around engine Remove
3 Check for water leakage around engine Repair
4 Check for oil leakage around engine Repair

a: Engine, lubricating oil and coolant
5 Check for leakage from fuel line Repair
6 Check of radiator for clogging Remove
7 Check of level and type of fuel Refilling
8 Check for foreign matter in fuel Clean and drain
9 Check of fuel pre-filter Replace
10 Check of fuel main filter Replace
Between H
11 Check of level (in oil pan) and type of engine oil Refilling
L
Between H
12 Check of coolant level (in sub tank) Refill with coolant
L
Dust indi-
cator does
13 Check of air cleaner for clogging Clean or replace
not show
red piston.
1 Check for unusual sounds and smells Repair
2 Check for oil leakage Repair

b: Hydraulic and mechanical equipment
Between H
3 Check of hydraulic oil level Refilling
L
4 Check of hydraulic oil strainer Clean and drain
5 Check of hydraulic oil filter Replace
Between H
6 Check of swing machinery case oil level Refilling
L
Between H
7 Check of damper case oil level Refilling
L
8 Check of final drive case oil level Refilling
9 Air bleeding Air bleeding
40-200 6 PC200, 200LC, 220, 220LC-8M0

Checks before troubleshooting SEN06132-00
No. Item Criterion Remedy
1 Check of battery terminal for looseness and corrosion Retighten or replace
2 Check of alternator terminal for looseness and corrosion Retighten or replace
3 Check of starting motor terminal for looseness and corrosion Retighten or replace
4 Check of battery voltage (with engine stopped) 20 to 30 V Charge or replace
Between H
5 Check of battery electrolyte level Add or replace
and L
6 Check of wiring harness for discoloration, burnt areas and cover peeling Repair or replace
7 Check for removal of wiring harness clamp and sagging of wiring harness Repair
c: Electrical equipment
8 Check of grounding Repair
9 Check for loose connector and damaged lock Repair or replace
10 Check of connector pin for corrosion, bends and deformation Repair or replace
11 Check for water and foreign matter in connector Dry, clean or replace
12 Check of wiring harness for open and short circuit Repair or replace
13 Check of fuse for blowing out and corrosion Replace

After sev-
eral min-
utes
14 Check of alternator voltage (when engine speed is medium or higher) Replace
operation:
27.5 29.5
V
Check of battery relay operation sound (when starting switch is turned to
15 Replace
ON or OFF position)
16 Check and cleaning of rear view camera Clean or repair

e: Interior parts d: Exterior parts
1 Check of undercarriage Repair
2 Check of handrails and steps Repair
3 Check of mirrors Clean or repair
1 Check of gauges and monitors Clean or replace
2 Check of seat belt Repair
PC200, 200LC, 220, 220LC-8M0 40-200 7

SEN06132-00 Classification and procedures for troubleshooting
Classification and procedures for troubleshooting
Classification of troubleshooting
Mode Content
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon which appears to be connected with machine trouble occurs on the machine, select a proper
troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting
section.
1. Procedure for troubleshooting to be taken when user code and failure code are displayed on
machine monitor:
If a user code and a failure code are displayed on the standard screen of the machine monitor, perform
the troubleshooting for the corresponding "Display of code" according to the displayed failure code.
a If multiple failures occur simultaneously, all the failure codes are displayed repeatedly in order. Note
down all the codes.
2. Procedure for troubleshooting when a user code and a failure code are not displayed on machine
monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1].)
1) If a code is recorded, carry out troubleshooting for the "Display of code" corresponding to the recorded
code.
a If an electrical system failure code is recorded, delete all the codes once, follow the procedure to
reproduce the failure code, and then see if the failure is still detected. (See [*2].)
a A failure code of the mechanical system cannot be deleted.
2) If no failure code is found in the abnormality record, a trouble that the machine cannot find out by itself
may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which appears to be connected with machine trouble again and
select the same phenomenon from the list on the next page, and then perform troubleshooting corre-
sponding to that phenomenon in the "E-mode", "H-mode", or "S-mode" troubleshooting.
3. Action to take after failure is eliminated

Clear all the failure codes in the electrical system abnormality record, referring to the next page.
40-200 8 PC200, 200LC, 220, 220LC-8M0

Classification and procedures for troubleshooting SEN06132-00
[*1], [*2] 5. Press the [F3] switch (R) on the panel switch to
1. While pressing numerical key [4] on the panel see if the next failure code is displayed and note
switch on the standard screen, press [1], [2] and down all of the failure codes.
[3] in order. a A failure code of the mechanical system can-
not be deleted.
6. Press [F5] switch (RETURN) on the panel switch
to return to the "Abnormality Record" screen.
7. Enter the "Electrical System Abnormality
Record" screen similarly to steps 2 and 3.
2. On the service menu screen, press switch [F3]

(R) twice in the panel switch section, and select
"03 Abnormality Record".
3. Press [F6] switch ( ) on the panel switch to
enter the selection and go to "Abnormality 8. Press the [F3] switch (R) on the panel switch to
Record" screen. see if the next failure code is displayed and note
down all of the failure codes.
a "E" on the left of a failure code indicates that
the failure is "active" (the failure remains or
restoration to normal has not been con-
firmed). A failure code having no "E" on its
left is a "non-active" one. Since it disappears
at the following clear step, be sure to note it
down.
9. While pressing numerical key [4] on the panel
switch, press [1], [2] and [3] in this order to enter
the "Clear mode". (Same as 1)
10. Press [F2] switch(CLEAR) on the panel switch.
4. Press [F6] switch ( ) on the panel switch to

enter the selection and go to "Mechanical
System Abnormality Record" screen.
11. Press [F6] switch ( ) on the panel switch to clear

all the failure codes.
to return to "Electrical System Abnormality
Record" screen. See if any failure code is still
displayed and note down the displayed ones.
to return to the "Abnormality Record" screen.
PC200, 200LC, 220, 220LC-8M0 40-200 9

SEN06132-00 Symptom and troubleshooting numbers
Symptom and troubleshooting numbers

Symptom and troubleshooting number
Troubleshooting
No. Symptom of failure Display
E-mode H-mode S-mode
of code
User code and failure code
1 User code and failure code are displayed on machine monitor
The failure code is displayed on the mechanical system abnormality Follow the troubleshooting procedure for
2
record screen the failure code.
The failure code is displayed on the electrical system abnormality
3
record screen
The failure code is displayed on the air conditioner or heater abnor- "Inspection by self-diagnosis function" in
4
mality record screen Chapter 80
Check items related to engine
5 Startability is poor S-1
6 Engine does not start E-1 S-2
7 Engine does not pick up smoothly S-3
8 Engine stops during operation H-2 S-4
9 Engine runs rough or is unstable (hunts) S-5
10 Engine lacks power S-6
11 Exhaust smoke is black (incomplete combustion) S-7
12 Oil consumption is too much (or exhaust smoke is blue) S-8
13 Oil becomes contaminated early S-9
14 Fuel consumption is excessive S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
16 Oil pressure drops S-12
17 Oil level rises (coolant or fuel in oil) S-13
18 Coolant temperature rises too high (overheating) S-14
19 Unusual noise is heard S-15
20 Vibration is excessive S-16
21 Preheater does not operate E-2
22 Automatic warm-up system does not operate (in cold season) E-13
23 Auto-decelerator does not operate normally E-14
Symptom related to work equipment, swing and travel
All of work equipment, swing, and travel does not work or can not
24 E-20 H-3
swing lock
25 All of work equipment, swing and travel work slow or lack power H-1
26 Engine speed lowers significantly or engine stalls H-2 S-6
27 Working mode does not change E-15
28 Unusual sound is heard from around hydraulic pump H-4
29 Fine control performance or response is poor H-5
Symptom related to work equipment
30 Speed or power of boom is low H-6
31 Speed or power of arm is low H-7
32 Speed or power of bucket is low H-8
33 Work equipment does not move in single operation H-9
34 Hydraulic drift of work equipment is large H-10
35 Time lag of work equipment operation is large H-11
36 Other wok equipment moves when one of work equipment is relieved H-12
37 One-touch power maximizing function does not work. E-22 H-13
38 Attachment circuit can not be changed E-35 H-28
40-200 10 PC200, 200LC, 220, 220LC-8M0

Symptom and troubleshooting numbers SEN06132-00
Troubleshooting
No. Symptom of failure Display
E-mode H-mode S-mode
of code
39 Oil flow in attachment circuit cannot be changed H-29
Symptom related to combined operation

In combined operation of work equipment, equipment having heavier
40 H-14
load moves slower
In combined operations of swing and boom RAISE, boom rising speed
41 H-15
is low
42 Travel speed drops largely in combined operation of swing and travel H-16
Symptom related to travel
43 Machine does not travel straight H-17
44 Travel speed is low H-18
45 Machine is hard to steer or travel power is low H-19
46 Travel speed does not change or travel speed is too low or high E-16 H-20
47 One of tracks does not run H-21
48 Travel alarm does not sound or does not stop sounding E-23
Symptom related to swing
49 Upper structure does not swing H-22
50 Swing acceleration is poor or swing speed is low H-23
51 Upper structure overruns excessively when it stops swinging H-24
52 Shock is larger when upper structure stops swinging H-25
53 Large sound is made when upper structure stops swinging H-26
Swing brake does not operate properly
54 E-21 H-27
Swing drift on a slope is large
Symptom is related to machine monitor
When starting switch is turned to ON position, machine monitor dis-
55 E-3
plays nothing.
When starting switch is turned ON (before starting engine), basic
56 E-4
check monitor lights up
57 Precaution monitor lights up while engine is running E-5
58 Emergency stop monitor lights up while engine is running E-6
59 Engine coolant temperature gauge does not indicate correctly E-8
60 Hydraulic oil temperature gauge does not indicate correctly E-9
61 Fuel level gauge does not indicate correctly E-7
Contents of display on machine monitor is different from that of actual
62 E-10
machine
63 Some areas of machine monitor are not displayed E-11
64 Function switch does not work E-12
65 Alarm buzzer cannot be stopped E-17
66 While starting switch is in OFF position, service meter is not displayed E-18
67 Service mode can not be selected E-19
68 Horn does not sound or does not stop E-24
69 Windshield wiper and window washer do not operate E-25
Air conditioner does not operate normally (including air conditioner "Testing and troubleshooting procedure" in
70
fault record) Chapter 80
71 Monitoring function does not display lever control signal normally E-2634
Others
72 KOMTRAX system does not operate properly. E-36
PC200, 200LC, 220, 220LC-8M0 40-200 11

SEN06132-00 Information in troubleshooting table
Information in troubleshooting table

(Rev. 2011/12)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action level Failure code
Display on Failure name displayed on the Abnormality Record screen of the
Display on Failure
machine machine monitor
machine monitor
monitor
Detail of
Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by the machine
controller monitor or controller
Problem on A problem that appears as a failure on the machine as a result of an action (above) that is performed by
machine the machine monitor or controller.
Related
Information on occurred failure or troubleshooting
information
Cause Procedure, measuring location, criteria and remarks
<Contents of description>
q Procedure
q Measuring location
1 Defective - a "Between A and B" denotes measuring values such as voltage and resistance
between A and B.
a "Between A and ground" means the measurement of voltage, resistance or
others between terminal A and the place which has a continuity with chassis
frame such as unpainted hexagonal head bolt or bolt hole which has no rust,
Open or short circuit in wir- etc.
2 q Criteria to judge probable causes (standard value), remarks
ing harness
<How to use troubleshooting sheet>
q Perform troubleshooting procedures in numerical order.
q If the check result does not meet the criteria, the probable cause described on the
left column is the actual cause of the failure.
Open circuit in wiring har-
q If the check result shows no failure, and unless otherwise specified, proceed to the
ness
3 next step (next cause item).
(wire breakage or defective
q If a defect is found and repaired, check that the defect has been corrected.
contact of connector)
<Failures in wiring harness>
q Open circuit in wiring
Connection of connector is defective or wiring harness is broken.
Ground fault in wiring har- q Ground fault
4 ness A harness not to be connected to the ground (earth) circuit comes into contact with
(contact with ground circuit) the ground (earth) circuit or chassis accidentally.
q Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into contact with
the power (24 V) circuit accidentally.
q Short circuit
Hot short circuit An independent wire in the harness erroneously comes into contact with another
5
(contact with 24 V circuit) independent wire.
(poor insulation at connector and others)
<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapter as follows unless otherwise spec-
Short circuit in wiring har- ified.
6
ness q When "male" or "female" is not indicated with a connector number, disconnect
the connector, and insert T-adapter between the male and female connectors.
q When "male" or "female" is indicated with a connector number, disconnect the
connector, and connect T-adapter only to either male or female connector.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads as shown be-
7 Defective controller low unless otherwise specified.
q Connect the positive (+) lead to pin or wire indicated first.
q Connect the negative (-) lead to a pin or wire indicated second.
40-200 12 PC200, 200LC, 220, 220LC-8M0

Information in troubleshooting table SEN06132-00
Circuit diagram related to troubleshooting
This is the excerpted circuit diagram related to trouble-

shooting
q The circuit diagram contains the connector Nos., pin
Nos., and connector colors related to the failure.
q The / in a connector number is either:
1) An abbreviation (of more than three letters)
Example: T/C (Torque Converter)
2) Different connector number at male and female sides
Example: BREAK OUT/E24
q The circuit diagram contains the destination or source of
the branch line in a wiring harness.
q The arrow (io) indicates a rough installation position
on the given machine.
q NO: Normally Open
q NC: Normally Closed
q Signal names such as GND and 24 V are included in ad-
dition to connector numbers at junctions, etc. in circuit di-
agrams.
q Except for GND and 24 V, a signal name indicated at a
junction, etc. shows that the wire is connected to another
junction or controller at where the same signal name is
indicated.
PC200, 200LC, 220, 220LC-8M0 40-200 13

SEN06132-00 Connector list and layout
Connector list and layout
Num-
Address of
Connector No. Model ber of Component name
stereogram
pins
A13 DT 2 Intermediate connector H-1
A15 DT 2 Intermediate connector K-9
A40 DT 4 Intermediate connector S-1
A41 DT 4 Camera 2 S-1
AB Terminal 1 Alternator (Terminal B) AG-9
AC01 10 Air conditioner unit X-5
AC02 4 Air conditioner unit W-9
AC03 X 1 Air conditioner compressor electromagnetic clutch AF-4
AMB AIR
FRAMATOME 3 Ambient pressure sensor AE-2
PRESSURE
BOOST PRESS.
SUMITOMO 4 Boost pressure/temperature sensor intake manifold AG-5
&IMT
CAM SENSOR FRAMATOME 3 Engine Bkup speed sensor AF-1
C01 AMP 80 Pump controller V-9
C02 AMP 40 Pump controller W-9
CE01 DRC 60 Engine controller AG-1
CE02 DRC 50 Engine controller AF-1
CE03 DTP 4 Engine controller AG-1
CK01 070 18 KOMTRAX communication module X-7
CK02 070 12 KOMTRAX communication module X-7
CM01 070 18 Machine monitor O-5
COOLANT TEMP PACKARD 2 Engine coolant temperature sensor AE-3
CP3 PUMP
80SCH 2 Pump regulator valve AJ-2
REGULATOR
CRANK SENSOR FRAMATOME 3 Engine Ne speed sensor AF-1
D01 SWP 8 Diode N-9
D02 SWP 8 Diode N-9
D03 SWP 8 Diode N-9
D10 M 2 Diode
D11 M 2 Diode
E01 Terminal 1 Electrical intake air heater AG-5
E06 DT 2 Intermediate connector AI-1
E08 X 1 Intermediate connector AG-9
E10 D 1 Intermediate connector AE-6
E12 3 Alternator (Terminals IG and L) AH-8
F01 Terminal 20 Fuse box T-9
F04 L 2 Fusible link (65A) B-9
F05 M 2 Fusible link (30A) C-8
FUEL RAIL
BOSCH 3 Common rail pressure sensor AI-5
PRESS
H09 M 8 Intermediate connector X-4
H15 090 22 Intermediate connector V-1
40-200 14 PC200, 200LC, 220, 220LC-8M0

Connector list and layout SEN06132-00
Num-
Address of
stereogram
pins
H16 S 12 Intermediate connector X-3
INJECTOR #1 DT 2 Injector #1 AE-4
INJECTOR #2 DT 2 Injector #2 AF-4
INJECTOR #3 DT 2 Injector #3 AF-5
INJECTOR #4 DT 2 Injector #4 AG-5
INJECTOR #5 DT 2 Injector #5 AH-5
INJECTOR #6 DT 2 Injector #6 AH-6
INJECTOR CYL.
DT 4 Intermediate connector AE-1
1&2
INJECTOR CYL.
DT 4 Intermediate connector AG-5
3&4
INJECTOR CYL.
DT 4 Intermediate connector AI-6
5&6
J01 20 Junction connector (Black) W-3
J02 20 Junction connector (Black) W-2
J03 20 Junction connector (Green) V-2
J04 20 Junction connector (Green) X-3
K01 M 2 Pump (PC) resistor O-8
K02 DT 3 CAN terminal resistance AH-1
L01 DT 2 Working lamp (Boom) E-8
L02 DT 2 Right headlamp F-9
L03 M 2 Room lamp T-9
L05 SWP 2 Intermediate connector AC-8
L09 DT 2 Rear working lamp [Rear working lamp specification]
L15 DT 2 Rotary lamp [Rotary lamp specification] AB-8
M01 PA 10 Radio U-1
M02 M 2 Speaker (Left) AC-8
M03 M 2 Speaker (Right) AB-9
M04 2 Cigarette lighter S-9
M05 M 6 Wiper motor O-4
M06 YAZAKI 2 Window washer tank L-2
M07 090 2 Horn (High tone) G-1
M08 090 2 Intermediate connector G-1
M09 M 2 Optional power supply connector (1) M-1
M10 M 2 Intermediate connector N-1
M14 DT 2 Travel alarm I-1
M40 X 2 Headlamp [Headlamp specification] AB-1
M41 X 2 Headlamp [Headlamp specification] Y-8
N08 DT 12 Service connector T-9
OIL PRESSURE
FRAMATOME 2 Engine oil pressure switch AI-1
SWICH
P01 AMP 3 Bucket curl PPC pressure sensor K-9
P02 AMP 3 Boom lower PPC pressure switch K-9
P03 AMP 3 Swing left PPC pressure sensor L-6
PC200, 200LC, 220, 220LC-8M0 40-200 15

Num-
Address of
stereogram
pins
P04 AMP 3 Arm curl PPC pressure sensor L-8
P05 AMP 3 Bucket dump PPC pressure sensor L-7
P06 AMP 3 Boom raise PPC pressure sensor L-7
P07 AMP 3 Swing right PPC pressure sensor L-8
P08 AMP 3 Arm dump PPC pressure switch L-5
P09 AMP 3 L.H. travel FORWARD PPC pressure sensor P-1
P10 AMP 3 L.H. travel REVERSE PPC pressure sensor Q-1
P11 AMP 3 R.H. travel FORWARD PPC pressure sensor O-2
P12 AMP 3 R.H. travel REVERSE PPC pressure sensor P-1
P13 X 2 Intermediate connector O-3
Attachment pedal front PPC pressure switch
P14 X 2 O-3
[Attachment specification]
Attachment pedal rear PPC pressure switch
P15 X 2 O-2
P17 S090 2 Air conditioner high/low pressure switch S-9
P18 090 2 Outside air temperature sensor L-5
P20 M 3 Fuel control dial P-8
P21 X 2 Fuel level sensor G-9
P22 D 2 Hydraulic oil temperature sensor I-9
P23 DT 2 Air cleaner clogging switch L-4
P24 X 2 Radiator coolant level switch L-3
P25 AMP 3 F pump pressure sensor J-9
P26 AMP 3 R pump pressure sensor J-9
P31 2 Air conditioner daylight sensor O-6
P44 DT 2 Engine oil level sensor AH-8
P47 DT 2 Water-in-fuel sensor H-9
R01 Terminal 1 Battery relay (Terminal E) C-8
R02 Terminal 1 Battery relay (Terminal BR) C-8
R03 Terminal 1 Battery relay (Terminal M) B-7
R04 Terminal 1 Battery relay (Terminal B) C-9
R05 Relay 5 Light relay T-9
R06 Relay 5 Starting motor cutout relay (PPC lock) N-9
R07 Relay 5 Starting motor cutout relay (Personal code) N-9
R08 Relay 5 Horn relay U-9
R10 Relay 5 Rear light relay [Rear light specification] T-9
R12 Relay 5 Cab light relay [Cab light specification] T-9
R15 Terminal 1 Electrical intake air heater relay (Coil circuit) A-8
R16A Terminal 1 Electrical intake air heater relay (Switch circuit) A-8
R16B Terminal 1 Electrical intake air heater relay (Switch circuit) A-9
R17 X 1 Intermediate connector B-7
R18 Relay 5 Automatic preheater relay V-9
R21 Relay 5 Air conditioner compressor relay W-9
R23 Relay 5 Engine controller relay (1) U-9
R24 Relay 5 Engine controller relay (2) V-9
R28 Terminal 1 Starting safety relay (terminal C) B-9
40-200 16 PC200, 200LC, 220, 220LC-8M0

Num-
Address of
stereogram
pins
S01 Terminal 6 Starting switch P-7
S02 SWP 6 Light switch P-8
S04 SWP 6 Swing lock switch Q-8
S07 SWP 6 Rotary lamp switch [Rotary lamp specification] Q-8
S10 Y090 2 Right knob switch R-1
S11 Y090 2 Left knob switch U-1
S14 M 3 PPC oil pressure lock switch U-1
S21 Terminal 12 Emergency pump drive switch O-9
S22 Terminal 6 Swing holding brake release switch O-9
S25 090 16 Intermediate connector O-8
S30 S 8 Model selection connector U-9
SB Terminal 1 Starting motor (Terminal B) AE-7
SC Terminal 1 Starting motor (Terminal C) AE-7
T01 Terminal 2 Floor frame ground W-2
T02 Terminal 1 Cab ground AD-2
T03 M 1 Radio body ground U-1
T04 Terminal 1 Revolving frame ground S-1
T05 Terminal 1 Revolving frame ground S-1
T06 Terminal 1 Revolving frame ground T-1
T08 Terminal 1 Ground B-8
T12 Terminal 1 Engine cylinder block ground AH-1
TOOL PORT DT 3 Communication connector AE-2
V01 DT 2 PPC lock solenoid valve J-1
V02 DT 2 2-stage relief solenoid valve I-1
V03 DT 2 Swing holding brake solenoid valve J-1
V04 DT 2 Travel speed shifting solenoid valve G-9
V05 DT 2 Travel junction solenoid valve K-1
Attachment return selector solenoid valve
V06 DT 2 H-9
V11 DT 2 F-PC-EPC valve I-9
V12 D 2 R-PC-EPC valve J-9
V19 D 2 LS-EPC valve I-9
V23 D 2 Merge-divider EPC valve (Main) I-9
V24 D 2 Merge-divider EPC valve (LS) H-9
V25 DT 2 Variable back pressure solenoid valve K-1
Attachment flow regulator EPC valve
V30 DT 2 O-3
W03 X 2 Window rear limit switch AB-9
PC200, 200LC, 220, 220LC-8M0 40-200 17

Layout of connector (1/6)
40-200 18 PC200, 200LC, 220, 220LC-8M0

(2/6)
PC200, 200LC, 220, 220LC-8M0 40-200 19

(3/6)
40-200 20 PC200, 200LC, 220, 220LC-8M0

(4/6)
PC200, 200LC, 220, 220LC-8M0 40-200 21

(5/6)
40-200 22 PC200, 200LC, 220, 220LC-8M0

(6/6)
PC200, 200LC, 220, 220LC-8M0 40-200 23

SEN06132-00 Connection table for connector pin numbers
Connection table for connector pin numbers

(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
40-200 24 PC200, 200LC, 220, 220LC-8M0

Connection table for connector pin numbers SEN06132-00
PC200, 200LC, 220, 220LC-8M0 40-200 25

40-200 26 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 27

40-200 28 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 29

40-200 30 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 31

40-200 32 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 33

40-200 34 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 35

40-200 36 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 37

40-200 38 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 39

40-200 40 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 41

40-200 42 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 43

40-200 44 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 45

40-200 46 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 47

40-200 48 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 49

40-200 50 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 51

40-200 52 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 53

40-200 54 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 55

40-200 56 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 57

40-200 58 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-200 59

SEN06132-00 T- branch box and T- branch adapter table
T- branch box and T- branch adapter table

(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal col-
umn indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identifi-
Part No. Part name cati-on
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO 2P q q
ECONO
799-601-2790 Adapter for ECONO 12
12P
q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
ECONO
799-601-2840 Extension cable (ECONO type) 12
12P
q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799 -601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 - q q
799 -601-7090 Adapter for M 2 M2P q q q q
799-601-7110 Adapter for M 3 M3P q q q q
799-601-7340 Adapter for M 8 M8P q
40-200 60 PC200, 200LC, 220, 220LC-8M0

T- branch box and T- branch adapter table SEN06132-00
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identifi-
symbol
799-601-7140 Adapter for M 8 S8P q q q q

799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601- 9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430*
Socket for engine(CRI-T3) PCV
2 P q q
PC200, 200LC, 220, 220LC-8M0 40-200 61

SEN06132-00 T- branch box and T- branch adapter table
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identifi-
symbol
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q

795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine(CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140
Ambient pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190*
Common rail pressure
3 1, 2, 3 L q q
799-601-4230*
Air intake pressure/temperature
4 1, 2, 3, 4 C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1, 2, 3 A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1, 2, 3 B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1, 2, 3, G q q
799-601-4340*
Pump actuator
2 2, PA q q
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
4 1, 2, 3, 4T q
799 -601-4260 Adapter for controller (ENG) 4 DTP4 q q
799 -601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 q
799-601-4280* Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2 to 4 and DTM2 3, q
4
* Shows not T-adapter but socket.
40-200 62 PC200, 200LC, 220, 220LC-8M0

Troubleshooting method for open circuit in wiring harness of pressure sensor system SEN06132-00
Troubleshooting method for open circuit in wiring harness of pressure

sensor system
a Since pressure sensors consisting not only of resistor but also electronic circuit components such as am-
plifiers have variation in measured value and its own polarities. So troubleshooting must be performed
carefully.
Failure codes applicable to this diagnosis

q CA123: Charge air pressure sensor low error
q CA451: Common rail pressure sensor high error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector.
2) Measure resistances R1 and R2 between pins.
a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore,
when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor
connector so that their polarities match these of the sensor.
a If measured value is infinite, take measurements by applying the probes of opposite polarities and
record the finite value obtained as a measured value.
a Since measured values may be dispersed, take several measurements.
Cause of this dispersion appears to be a charge in a sensor. Repeat steps 1 and 2 several times.
Consider this dispersion when judging whether the wiring harness is open in step 3.
2. Measure and record resistance with the wiring harness between the pressure sensor and engine controller
connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) With the pressure sensor to measure connected, disconnect connector (3) on engine controller side,
and connect T-adapter (4) to the harness side connector.
3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins.
3. Judging open circuit

If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is open".
a "Apparent difference" means a difference of 10 or more times.
PC200, 200LC, 220, 220LC-8M0 40-200 63

SEN06132-00 Troubleshooting method for open circuit in wiring harness of pressure sensor system
List of pressure sensor measuring locations and reference values

Measuring location at sen-
Sensor Measured internal resis- Remarks
sor pin
tance of sensor (reference)
Charge pressure sen- R2: between (2) and (4) Approx. 100 z Sensor is common to engine models
sor R1: between (1) and (4) Approx. 200 z 107 and 114
Sensor is common to engine models
R2: Between (3) and (1) Approx. 23 kz
Common rail pressure 107 and 114
sensor R1: Between (1) (+) and If polarities are inverted, resistance is
Approx. 10 Mz
(2) (-) infinite
*: In addition to the above, when measuring R2', disconnect the following: (See circuit diagram related to each
failure code)
q When measuring R2' of charge pressure sensor (CA123):
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water sepa-
rator)
q When measuring R2' of common rail pressure sensor (CA451):
Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator)
Measurement record (For measuring locations, see circuit diagram related to each failure code.)
Sensor + Wiring harness
Sensor unit
(Measuring location on wir-
Sensor (Measuring location on sen- Measured value Measured value
ing harness side connector
sor pin side connetor)
of engine controller)
R2': Between (37) and (47)
Charge pressure sen- R2: between (2) and (4)
(*)
sor
R1: between (1) and (4) R1': Between (44) and (47)
R2': Between (37) and (47)
R2: Between (3) and (1)
Common rail pressure (*)
sensor R1: Between (1) (+) and R1': between (47)(+) and
(2) (-) (25)(-)
40-200 64 PC200, 200LC, 220, 220LC-8M0

Troubleshooting method for open circuit in wiring harness of pressure sensor system SEN06132-00
PC200, 200LC, 220, 220LC-8M0 40-200 65

SEN06132-00
2012 KOMATSU
All Rights Reserved
40-200 66
SEN06133-00
SEN05985-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
301 Troubleshooting by failure code, Part 1
Failure code [879AKA] A/C Inner Sensor Open Circuit .............................................................................. 3

Failure code [879AKB] A/C Inner Sensor Short Circuit............................................................................... 3
Failure code [879BKA] A/C Outer Sensor Open Circuit.............................................................................. 3
Failure code [879BKB] A/C Outer Sensor Short Circuit.............................................................................. 3
Failure code [879CKA] Ventilating Sensor Open Circuit............................................................................. 3
Failure code [879CKB] Ventilating Sensor Short Circuit ............................................................................. 4
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit .................................................................. 4
Failure code [879EMC] Ventilation Damper Abnormality............................................................................ 4
Failure code [879FMC] Air Mix Damper Abnormality.................................................................................. 4
Failure code [879GKX] Refrigerant Abnormality......................................................................................... 4
Failure code [989L00] Engine Controller Lock Caution1 ............................................................................ 5
Failure code [989M00] Engine Controller Lock Caution2 ........................................................................... 6
Failure code [989N00] Engine Controller Lock Caution3............................................................................ 7
Failure code [AA10NX] Air Cleaner Clogging ............................................................................................. 8
Failure code [AB00KE] Charge Voltage Low .............................................................................................. 10
Failure code [B@BAZG] Eng Oil Press Low............................................................................................... 12
Failure code [B@BAZK] Engine Oil Level Low ........................................................................................... 13
Failure code [B@BCNS] Eng Water Overheat............................................................................................ 14
Failure code [B@BCZK] Radiator Coolant Level Low ................................................................................ 16
Failure code [B@HANS] Hyd Oil Overheat................................................................................................. 18
PC200, 200LC, 220, 220LC-8M0 40-301 1

SEN06133-00
Failure code [CA111] ECM Critical Internal Failure ..................................................................................... 19

Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................ 19
Failure code [CA122] Chg Air Press Sensor High Error ............................................................................. 20
Failure code [CA123] Chg Air Press Sensor Low Error .............................................................................. 22
Failure code [CA131] Throttle Sensor High Error ....................................................................................... 24
Failure code [CA132] Throttle Sensor Low Error ........................................................................................ 26
Failure code [CA144] Coolant Temp Sens High Error................................................................................. 28
Failure code [CA145] Coolant Temp Sens Low Error ................................................................................. 30
Failure code [CA153] Chg Air Temp Sensor High Error.............................................................................. 32
Failure code [CA154] Chg Air Temp Sensor Low Error............................................................................... 34
Failure code [CA155] Chg Air Temp High Speed Derate ............................................................................ 36
Failure code [CA187] Sens Supply 2 Volt Low Error................................................................................... 38
Failure code [CA221] Ambient Press Sens High Error ............................................................................... 40
Failure code [CA222] Ambient Press Sens Low Error ................................................................................ 42
Failure code [CA227] Sens 2 Supply Volt High Error.................................................................................. 44
Failure code [CA234] Eng Overspeed ........................................................................................................ 44
Failure code [CA238] Ne Speed Sens Supply Volt Error ............................................................................ 45
Failure code [CA271] IMV/PCV1 Short Error .............................................................................................. 46
Failure code [CA272] IMV/PCV1 Open Error.............................................................................................. 48
40-301 2 PC200, 200LC, 220, 220LC-8M0

Failure code [879AKA] A/C Inner Sensor Open Circuit SEN06133-00
Failure code [879AKA] A/C Inner Sensor Open Circuit

See "Failure code [879AKA] A/C Inner Sensor Open Circuit" in chapter 80 "Others".
a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the
machine, the air conditioner controller or air conditioner unit must be replaced.
Failure code [879AKB] A/C Inner Sensor Short Circuit

See chapter 80 Others "Failure code [879AKB] A/C Inner Sensor Short Circuit".
a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the
machine, the air conditioner controller or air conditioner unit must be replaced.
Failure code [879BKA] A/C Outer Sensor Open Circuit

See chapter 80 Others "Failure code [879BKA] A/C Outer Sensor Open Circuit".
Failure code [879BKB] A/C Outer Sensor Short Circuit

See chapter 80 Others "Failure code [879BKB] A/C Outer Sensor Short Circuit".
Failure code [879CKA] Ventilating Sensor Open Circuit

See "Failure code [879CKA] Ventilating Sensor Open Circuit" in chapter 80 "Others".
a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor in-
stalled on the machine, the air conditioner controller or air conditioner unit must be replaced.
PC200, 200LC, 220, 220LC-8M0 40-301 3

SEN06133-00 Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit

See chapter 80 Others "Failure code [879CKB] Ventilating Sensor Short Circuit".
a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor in-
stalled on the machine, the air conditioner controller or air conditioner unit must be replaced.
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit

See chapter 80 Others "Failure code [879DKZ] Sunlight Sensor Open or Short Circuit".
Failure code [879EMC] Ventilation Damper Abnormality

See chapter 80 Others "Failure code [879EMC] Ventilation Damper Abnormality".
a Since the vent select servo motor cannot be disconnected on the machine, the air conditioner controller
or air conditioner unit must be replaced.
Failure code [879FMC] Air Mix Damper Abnormality

See chapter 80 Others "Failure code [879FMC] Air Mix Damper Abnormality".
a Since the air mix servo motor connector cannot be disconnected on the machine, the air conditioner con-
troller or air conditioner unit must be replaced.
Failure code [879GKX] Refrigerant Abnormality

See chapter 80 Others "Failure code [879GKX] Refrigerant Abnormality".
40-301 4 PC200, 200LC, 220, 220LC-8M0

Failure code [989L00] Engine Controller Lock Caution1 SEN06133-00
Failure code [989L00] Engine Controller Lock Caution1

Action
Failure code Engine controller lock caution1
level Failure
(Machine monitor system)
989L00
Detail of
q Engine controller lock up is detected (Factor 1).
failure
Action of q None in particular
controller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Engine cannot be started.
machine
q If this failure code is generated after machine monitor is replaced, user password must be changed
Related
to one before replacement.
information
q Method of reproducing failure code: Turn starting switch to ON position.

1 Replacement of machine monitor This problem may be caused by replacement of machine monitor.
PC200, 200LC, 220, 220LC-8M0 40-301 5

SEN06133-00 Failure code [989M00] Engine Controller Lock Caution2
Failure code [989M00] Engine Controller Lock Caution2

Action
level Failure
989M00
Detail of
q Engine controller lock up is detected (Factor 2).
failure
Action of q None in particular
Problem on
machine
q If this failure code is generated after machine monitor is replaced, user password must be changed
Related
to one before replacement.
information

1 Replacement of machine monitor This problem may be caused by replacement of machine monitor.
If this failure code is displayed while machine monitor is not replaced, machine
2 Defective machine monitor monitor may be defective. (Since this is an internal defect, troubleshooting
cannot be performed.)
40-301 6 PC200, 200LC, 220, 220LC-8M0

Failure code [989N00] Engine Controller Lock Caution3 SEN06133-00
Failure code [989N00] Engine Controller Lock Caution3

Action
level Failure
989N00
Detail of failure q Engine controller lock up is detected (Factor 3).
Action of con- q Tries automatic recovery.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
machine
Related infor- q Method of reproducing failure code: Failure code cannot be reproduced since machine recovers
mation when cause of failure disappears.

If this failure code is generated repeatedly, engine controller may be defective.
1 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0 40-301 7

SEN06133-00 Failure code [AA10NX] Air Cleaner Clogging
Failure code [AA10NX] Air Cleaner Clogging

Action
Failure code Air cleaner clogging
level Failure
L01 AA10NX
q Air cleaner clogging switch signal voltage is not 1 V or less while engine is running, and machine
Detail of failure
monitor detects clogging of air cleaner (open of sensor contacts).
Action of con-
q Displays air cleaner clogging monitor in yellow on machine monitor.
troller
Problem on
q If machine is operated as it is, engine may be damaged.
machine
q Input state (ON/OFF) from air cleaner clogging switch can be checked by using monitoring func-
Related infor- tion.
mation (Code 04501: Monitor Input 2)
q Method of reproducing failure code: Start engine.

Clogged air cleaner Air cleaner may be clogged, Check it for clogging and then clean or replace if
1
(when system is normal) clogged.
1. Turn starting switch to OFF position.
2. Disconnect connector P23 and connect T-adapter to male side.
3. Start engine.
Defective air cleaner clogging
2 When air cleaner
switch (internal open circuit) Resistance Max. 1 z
Between P23 (male) (1) works properly *1
and (2) When air cleaner
Resistance Min. 1 Mz
is clogged *2
2. Disconnect connectors CM02 and P23, and connect T-adapters to each
Open circuit in wiring harness
female side.
3 (wire breakage or defective con-
tact of connector) Between CM02 (female) (4) and P23 (female) (1) Resistance Max. 1 z
Between P23 (female) (2) and ground Resistance Max. 1 z
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine.
4 Defective machine monitor When air cleaner
Voltage Max. 1 V
Between CM02 (4) and works properly
CM01 (3) When air cleaner
Voltage 7 11 V
is clogged
q Air cleaner suction resistance

*1: -3,430 Pa Max. {-350 mmH2O}
*2: -7,470 490 Pa {-762 50 mmH2O}
40-301 8 PC200, 200LC, 220, 220LC-8M0

Failure code [AA10NX] Air Cleaner Clogging SEN06133-00
Circuit diagram related to air cleaner clogging
PC200, 200LC, 220, 220LC-8M0 40-301 9

SEN06133-00 Failure code [AB00KE] Charge Voltage Low
Failure code [AB00KE] Charge Voltage Low

Action
Failure code Charging voltage low
level Failure
L03 AB00KE
q While engine is running, voltage from alternator drops, and machine monitor detects that battery
Detail of failure
charge voltage is low (below 7.8 V).
Action of q Displays charge level monitor red on machine monitor.
machine moni- q Even if cause of failure disappears, machine does not become normal until starting switch is turned
tor to OFF position.
Problem on
q If machine is operated as it is, battery may not be charged.
machine
q Signal voltage from alternator can be checked with monitoring function.
Related infor-
(Code: 04300 Charge voltage)
mation

Loose alternator terminal or open 1. Turn starting switch to OFF position.
1
circuit at terminal 2. Check terminal.
2. Insert T-adapters into connector E12.
Defective generation by alternator
2 3. Start engine.
(when system is normal)
Between E12 (1) and Engine speed: Medium
Voltage 27.5 to 29.5 V
ground or higher
2. Disconnect diode D01 and connect T-adapter to male side.
a Check the continuity in diode range.
3 Defective diode
Between D01 (male) (2) (+) and (6) (-) No continuity
Between D01 (male) (6) (+) and (2) (-) Continuity
Defective wiring harness or 2. Insert T-adapter into connector CM01.
4 3. Start engine.
machine monitor
Between CM01 (16) and ground Voltage 20 to 30 V
a If no failure is found in checks on cause 2, this check is not required.
Open circuit in wiring harness 1. Turn starting switch to OFF position.
5 (wire breakage or defective con- 2. Disconnect connectors CM01 and E12, and connect T-adapters to each
tact of connector) female side.
Between C0M1 (female) (16) and E12 (female) (1) Resistance Max. 1 z
Ground fault in wiring harness 2. Disconnect connectors CM01 and E12, and connect T-adapter to either
6
(contact with ground circuit) female side.
Between CM01 (female) (16) or E12 (female) (1)
and ground
If no failure is found by above checks, machine monitor is defective.
7 Defective machine monitor
40-301 10 PC200, 200LC, 220, 220LC-8M0

Failure code [AB00KE] Charge Voltage Low SEN06133-00
Electrical diagram related to charging cricuit
PC200, 200LC, 220, 220LC-8M0 40-301 11

SEN06133-00 Failure code [B@BAZG] Eng Oil Press Low
Failure code [B@BAZG] Eng Oil Press Low

Action
Failure code Engine Oil Pressure Low
level Failure
(Engine controller system)
L03 B@BAZG
q While engine is running, engine controller detects engine oil pressure drop (sensor contact is
Detail of failure
closed) from signal voltage of engine oil pressure switch.
Action of con- q Displays engine oil pressure monitor red on machine monitor.
Problem on
q If machine is operated as it is, engine may be damaged.
machine
q Signal from engine oil pressure switch is input to engine controller. If engine oil pressure switch is
Related infor- determined to be closed (ON) while engine is running, engine controller transmitts this signal to
mation machine monitor to display this failure code.

Dropped engine oil pres-
1 sure (when system works Engine oil pressure may be low. Check it and remove cause if it is low.
properly)
If no failure is found by check on cause 1, engine oil pressure monitoring system may
Defective engine oil pres-
2 be defective. Perform troubleshooting for "E-6 Emergency stop monitor lights up while
sure monitoring system
engine is running".
40-301 12 PC200, 200LC, 220, 220LC-8M0

Failure code [B@BAZK] Engine Oil Level Low SEN06133-00
Failure code [B@BAZK] Engine Oil Level Low

Action
Failure code Engine Oil Level Low
level Failure
L01 B@BAZK
q While engine is running, signal voltage from engine oil level switch does not remain below 1 V, so
Detail of failure
machine monitor determines that engine oil level is low (oil level switch is open).
Action of con-
q Displays engine oil level monitor yellow on machine monitor.
troller
Problem on
q If machine is operated as it is, engine may seize up.
machine
q Input (ON/OFF) from engine oil level switch can be checked with monitoring function.
Related infor-
(Code: 04501 Monitor input 2)
mation
q Method of reproducing failure code: Start engine

Engine oil level low
1 Check engine oil level. If it is low, remove cause.
(when system works properly)
Defective engine oil level switch 2. Disconnect connector P44.
2 3. Turn starting switch to ON position.
(internal defect)
Between P44 (male) (1) and ground Resistance Max. 1 z
Open circuit in wiring harness 2. Disconnect connectors CM02 and P44, and connect T-adapters to each
3 (wire breakage or defective con- female side.
tact of connector)
Between CM02 (female) (2) and P44 (female) (1) Resistance Max. 1 z
q Reference
4 Defective machine monitor 2. Insert T-adapters into connectors CM01 and CM02.
3. Turn starting switch to ON position.
Between CM02 (2) and CM01 (3) Voltage Min. 10 V
Circuit diagram related to engine oil level switch
PC200, 200LC, 220, 220LC-8M0 40-301 13

SEN06133-00 Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCNS] Eng Water Overheat

Action
Failure code Engine water overheat
level Failure
L02 B@BCNS
q While engine is running, voltage from engine coolant temperature sensor drops, and engine con-
Detail of failure
troller detects engine coolant overheated.
Action of con-
q Displays engine coolant temperature monitor in red on machine monitor.
troller
Problem on
q If machine is operated as it is, engine may seize up.
machine
q Signal voltage of engine coolant temperature sensor is input to engine controller that transmits in-
formation to machine monitor through CAN communication system.
Related infor-
q Engine coolant temperature can be checked with monitoring function
mation
(Code: 04107 Engine coolant temperature)

Overheating of engine coolant
1 Engine coolant may overheat. Check it and remove cause if it overheats.
(when system is normal)
If no failure is found by checks on cause 1, engine coolant temperature sensor
Defective engine coolant tempera-
2 system may be defective. Perform troubleshooting for failure codes [CA144]
ture sensor system
and [CA145].
40-301 14 PC200, 200LC, 220, 220LC-8M0

Failure code [B@BCNS] Eng Water Overheat SEN06133-00
PC200, 200LC, 220, 220LC-8M0 40-301 15

SEN06133-00 Failure code [B@BCZK] Radiator Coolant Level Low
Failure code [B@BCZK] Radiator Coolant Level Low

Action
Failure code Radiator Coolant Level Low
level Failure
L01 B@BCZK
q While starting switch is at ON position (with engine stopped) or engine is running, radiator coolant
Detail of failure level switch signal voltage does not remain below 1 V, so machine monitor determines that radiator
coolant level is low (sensor contact is open).
Action of con-
q Displays radiator coolant level monitor yellow on machine monitor.
troller
Problem on
q If machine is operated as it is, engine may overheat.
machine
q Input (ON/OFF) from radiator coolant level switch can be checked with monitoring function.
Related infor-
mation

Lowered radiator coolant level Check radiator sub tank for lowering of coolant level. If coolant level is low, add
1
(when system works properly) coolant.
2. Disconnect connector P24 and connect T-adapters to male side.
Defective coolant level switch Between
2 FULL and Resistance Max. 1 z
(internal defect)
Between P24 (male) (1) and (2) LOW lines
Below LOW
line
Open circuit in wiring harness 2. Disconnect connectors CM02 and P24, and connect T-adapters to each
3 (Wire breakage or defective con- female side.
tact) a Add coolant.
Between CM02 (female) (3) and P24 (female) (1) Resistance Max. 1 z
q Reference
2. Insert T-adapters into connector CM02.
4 Defective machine monitor Between
FULL and Voltage Max. 1 V
Between CM02 (3) and CM01 (3) LOW lines
Below LOW
Voltage 7 11 V
line
40-301 16 PC200, 200LC, 220, 220LC-8M0

Failure code [B@BCZK] Radiator Coolant Level Low SEN06133-00
Circuit diagram related to radiator coolant level switch
PC200, 200LC, 220, 220LC-8M0 40-301 17

SEN06133-00 Failure code [B@HANS] Hyd Oil Overheat
Failure code [B@HANS] Hyd Oil Overheat

Action
Failure code Hydraulic oil overheat
level Failure
(Pump controller system)
L02 B@HANS
Detail of q While engine is running, overheating of hydraulic oil (above approx. 102 C) is detected from signal
failure voltage of hydraulic oil temperature sensor.
Action of q Displays hydraulic oil temperature monitor red on machine monitor.
Problem on
q If machine is operated as it is, hydraulic components may be damaged.
machine
q Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmit-
ted to machine monitor through CAN communication system.
Related q Hydraulic oil temperature can be checked with monitoring function
information (Code: 04401 Hydraulic oil temperature)
q See E-mode troubleshooting E-9 in Hydraulic oil temperature gauge does not indicate properly

Overheating of hydraulic oil
1 Hydraulic oil may overheat. Check it and remove cause if it overheats
Defective hydraulic oil tempera- If no failure is found by check on cause 1, hydraulic oil temperature monitoring
2
ture gauge system system may be defective. Perform troubleshooting for failure code [DGH2KB].
40-301 18 PC200, 200LC, 220, 220LC-8M0

Failure code [CA111] ECM Critical Internal Failure SEN06133-00
Failure code [CA111] ECM Critical Internal Failure

Action
Failure code Engine Controller Module Critical Internal Failure
level Failure
L04 CA111
Detail of failure q Memory or power supply circuit in engine controller is defective.
Action of con-
q None in particular
troller
Problem on
q Engine may stop during operation or may not be able to start.
machine
q Power supply voltage to engine controller can be checked with monitoring function.
Related infor-
(Code: 03203 Battery voltage)
mation
1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
2 Perform troubleshooting for failure code [CA441].
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

Action
Failure code Engine Ne and Bkup speed sensor Error
level Failure
L04 CA115
Detail of failure q Signals from both engine Ne and Bkup speed sensors are abnormal.
Action of con-
troller
Problem on q Engine stops.
machine q Engine does not start
Related infor-
mation

Defective connection of sensor Connectors of Ne speed sensor and Bkup speed sensor may be connected
1
connector defectively (wrong connection). Check them.
Perform troubleshooting for troubleshooting Nos. 1 to 10 of failure code
2 Defective Ne speed sensor system
[CA689].
Defective Bkup speed sensor sys-
tem
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0 40-301 19

SEN06133-00 Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA122] Chg Air Press Sensor High Error

Action
Failure code Charge Air Press Sensor High Error
level Failure
L03 CA122
Detail of failure q High voltage appears in signal circuit of charge (boost) pressure & temperature sensor.
Action of con-
q Takes boost pressure to be at fixed value and allows engine to run.
troller
Problem on
q Engine output lowers.
machine
q Input voltage from boost pressure sensor can be checked with monitoring function.
(Code: 36501 (V))
q Boost pressure sensed by boost pressure sensor can be checked with function.
Related infor-
(Code: 36500 (kPa))
mation
q If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in normal con-
dition.

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them.
Defective sensor power supply 2
2 If failure code [CA227] is also displayed, perform troubleshooting for it first.
line
2. Disconnect connector BOOST PRESS & IMT.
If failure code changes from [CA122] to [CA123] ,boost pressure sensor is
defective.
a Failure code [CA153] for temperature sensor is displayed at the same time.
Ignore this failure code since it appears because of disconnection of
Defective boost pressure & tem-
3 sensor.
perature sensor
q Reference
2. Insert T-adapters to connector ECM.
Sensor out-
Between ECM (44) and (47) Voltage 0.3 to 4.7 V
put

2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect
4 Short circuit in wiring harness T-adapter to female side of ECM.
Between ECM (female) (37) and (44) Resistance Min. 100 kz
2. Disconnect connector BOOST PRESS & IMT, and connect T-adapter to
Hot short circuit in wiring harness connector ECM.
5 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT
(Contact with 24 V circuit)
disconnected).
Between ECM (44) and (47) Voltage Max. 1 V
40-301 20 PC200, 200LC, 220, 220LC-8M0

Failure code [CA122] Chg Air Press Sensor High Error SEN06133-00
Circuit diagram related to charge pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-301 21

SEN06133-00 Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA123] Chg Air Press Sensor Low Error

Action
Failure code Charge Air Pressure Sensor Low Error
level Failure
L03 CA123
Detail of failure q Low voltage appears in pressure signal circuit of charge (boost) pressure & temperature sensor.
Action of con-
q Takes boost pressure to be at fixed value and allows engine to run.
troller
Problem on
machine
q Input voltage from boost pressure sensor can be checked with monitoring function.
(Code: 36501 (V))
q Boost pressure sensed by boost pressure sensor can be checked with function.
(Code: 36500 (kPa))
Related infor-
mation
q Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for
checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).
q If sensor connector is disconnected, this failure code is displayed.

tor
Defective power supply system of
If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it
2 charge pressure sensor (boost
first.
pressure sensor)
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST
PRESS & IMT and ECM.
3 Short circuit in wiring harness 3. Connect T-adapters to female side of ECM.
Ground fault in wiring harness 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect
4 T-adapter to female side of ECM.
(contact with ground circuit)
Between ECM (female) (44) and ground Resistance Min. 100 kz
If no failure is found by above checks, there may be open circuit in wiring har-
5 Open circuit in wiring harness
ness. (*)
a If no failure is found by checks on causes 1 to 5 and check result on cause
6 is abnormal, sensor is defective.
Defective boost pressure & tem-
perature sensor
6 2. Insert T-adapters to connector ECM.
(improper input voltage to engine
controller)
Sensor out-
put
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General in-
formation on troubleshooting".
40-301 22 PC200, 200LC, 220, 220LC-8M0

Failure code [CA123] Chg Air Press Sensor Low Error SEN06133-00
Circuit diagram related to charge pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-301 23

SEN06133-00 Failure code [CA131] Throttle Sensor High Error
Failure code [CA131] Throttle Sensor High Error

Action
Failure code Throttle Sensor High Error
level Failure
L03 CA131
Detail of failure q High voltage appears in fuel control dial circuit.
q Uses throttle value obtained before failure detection to run engine if failure is detected with starting
Action of con-
switch at ON position.
troller
q Uses full throttle value to run engine if starting switch is set to ON position after failure detection.
Problem on
q Engine speed cannot be controlled by using fuel control dial.
machine
q Signal voltage from fuel control dial can be checked with monitoring function.
Related infor-
(Code: 03000 Fuel control dial voltage)
mation

See descriptions of wiring harness and connectors in "c: Electrical equip-
1 ment"of "Checks before troubleshooting" in "General information on trouble-
tor
shooting", and check them.
Defective throttle sensor power
supply system
Defective fuel control dial (throttle Between P20 (male) (1) and (3) Resistance 4.0 to 6.0 kz
3
sensor)
Between P20 (male) (2) and (3) Resistance 0.25 to 5.0 kz
2. Disconnect connector CE02, and connect T-adapters to female side.
Open or short circuit in wiring har-
4
ness Between CE02 (famale) (22) and (23) Resistance 4.0 to 6.0 kz
Between CE02 (famale) (9) and (23) Resistance 0.25 to 5.0 kz
2. Disconnect connectors CE02 and P20, and connect T-adapters to either
5 Short circuit in wiring harness female side.
Between CE02 (female) (9) and (22), or between
P20 (female) (1) and (2)
Hot short circuit in wiring harness 2. Disconnect connector P20 and connect T-adapters to female side.
(contact with 24 V circuit)
Between P20 (female) (2) and ground Voltage Max. 1 V
q Reference
2. Insert T-adapters into connector CE02.
7 Defective engine controller 3. Turn starting switch to ON position.
4. Operate fuel control dial and perform troubleshooting.
Power sup-
Between CE02 (22) and (23) Voltage 4.75 to 5.25V
ply
Sensor out-
Between CE02 (9) and (23) Voltage 0.5 to 4.5 V
put
40-301 24 PC200, 200LC, 220, 220LC-8M0

Failure code [CA131] Throttle Sensor High Error SEN06133-00
Circuit diagram related to throttle sensor
PC200, 200LC, 220, 220LC-8M0 40-301 25

SEN06133-00 Failure code [CA132] Throttle Sensor Low Error
Failure code [CA132] Throttle Sensor Low Error

Action
Failure code Throttle Sensor Low Error
level Failure
L03 CA132
Detail of failure q Low voltage appears in fuel control dial circuit.
q Uses throttle value obtained before failure detection to run engine if failure is detected with starting
Action of con-
switch at ON position.
troller
q Uses full throttle value to run engine if starting switch is set to ON position after failure detection.
Problem on
q Engine speed cannot be controlled by using fuel control dial.
machine
q Signal voltage from fuel control dial can be checked with monitoring function.
Related infor-
(Code: 03000 Fuel control dial votage)
mation

See descriptions of wiring harness and connectors in "c: Electrical equip-
1 ment"of "Checks before troubleshooting" in "General information on trouble-
tor
shooting", and check them.
Defective throttle sensor power
supply system
Defective fuel control dial (throttle Between P20 (male) (1) and (3) Resistance 4.0 to 6.0 kz
3
sensor)
2. Disconnect connector CE02, and connect T-adapters to female side.
4
ness Between CE02 (famale) (22) and (23) Resistance 4.0 to 6.0 kz
Between CE02 (famale) (9) and (23) Resistance 0.25 to 5.0 kz
2. Disconnect connectors CE02 and P20, and connect T-adapters to each
female side .
Between CE02 (female) (22) and P20
5 (wire breakage or defective con- Resistance Max. 1 z
(female) (1)
tact of connector)
Between CE02 (female) (9) and P20 (female)
Resistance Max. 1 z
(2)
Between CE02 (female) (23) and P20
Resistance Max. 1 z
(female) (3)
6 Short circuit in wiring harness female side.
Between CE02 (female) (9) and (23), or
between P20 (female) (2) and (3) Resistance Min. 1 Mz

Ground fault of wiring harness female side.
7
Between CE02 (female) (9) or P20 (female)
(2) and ground
40-301 26 PC200, 200LC, 220, 220LC-8M0

Failure code [CA132] Throttle Sensor Low Error SEN06133-00

q Reference
4. Operate fuel control dial and perform troubleshooting.
Between CE02 (22) and (23) Power supply Voltage 4.75 to 5.25V
Between CE02 (9) and (23) Sensor output Voltage 0.5 to 4.5 V
PC200, 200LC, 220, 220LC-8M0 40-301 27

SEN06133-00 Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA144] Coolant Temp Sens High Error

Action
Failure code Coolant Temperature Sensor High Error
level Failure
L01 CA144
Detail of failure q High voltage appears in signal circuit of coolant temperature sensor .
Action of con-
q Takes coolant temperature to be at fixed value and allows engine to run.
troller
Problem on q Engine does not start easily at low temperature.
machine q Overheat prevention function does not work.
q Input voltage from engine coolant temperature sensor can be checked with monitoring function.
(Code: 04105 (V))
q Temperature sensed by engine coolant temperature sensor can be checked with monitoring func-
tion.
Related infor- (Code: 04107 (C))
mation q Method of reproducing failure code: Turn starting switch to ON position.
q This failure code is displayed if temperature sensor connector is disconnected.
q Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit
(not designed as a T-adapter).

tor
2. Disconnect connector COOLANT TEMP, and connect socket to male side.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant
temperature above 0 C, regard coolant temperature sensor as normal.
0 C Resistance 30 to 37 kz
Defective coolant temperature
2 Between COOLANT
sensor 25 C Resistance 9.3 to 10.7 kz
TEMP (male) (A) and (B)
a Coolant temperature 50 C Resistance 3.2 to 3.8 kz
-Resistaure charac-
80 C Resistance 1.0 to 1.3 kz
teristics
95 C Resistance 700 to 800 z
2. Disconnect connector ECM and connect T-adapters to female side.
Open or short circuit in wiring har- Between ECM (female) (15) and (38) (Coolant tem-
3 perature: Min. 0C)
ness Resis-
a Use "Coolant temperature-Resistance charac- 700 z to 37 kz
tance
teristics" table shown above as resistance crite-
ria.
40-301 28 PC200, 200LC, 220, 220LC-8M0

Failure code [CA144] Coolant Temp Sens High Error SEN06133-00
Circuit diagram related to coolant temperature sensor
PC200, 200LC, 220, 220LC-8M0 40-301 29

SEN06133-00 Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA145] Coolant Temp Sens Low Error

Action
Failure code Coolant Temperature Sensor Low Error
level Failure
L01 CA145
Detail of failure q Low voltage appears in signal circuit of coolant temperature sensor .
Action of con-
q Takes coolant temperature to be at fixed value and allows engine to run.
troller
Problem on q Engine does not start easily at low temperature.
machine q Overheat prevention function does not work.
q Input voltage from engine coolant temperature sensor can be checked with monitoring function.
(Code: 04105 (V))
q Temperature sensed by engine coolant temperature sensor can be checked with monitoring func-
Related infor- tion.
mation (Code: 04107(C) )
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA144] for "High Error" is displayed.

tor
2. Disconnect connector COOLANT TEMP, and connect socket to male side.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant
temperature above 0 C, regard coolant temperature sensor as normal.
0 C Resistance 30 to 37 kz
Between COOLANT
Defective coolant temperature 25 C Resistance 9.3 to 10.7 kz
2 TEMP (male) (A) and (B)
sensor a Coolant temperature 50 C Resistance 3.2 to 3.8 kz
-Resistaure charac-
teristics
Whole cool-
Between (B) and ground ant temper- Resistance Min. 100 kz
ature range
Between ECM (female) (15) and (38) (Coolant tem-
3 Short circuit in wiring harness perature: Min. 0 C)
Resis-
a Use "Coolant temperature-Resistance charac- 700 z to 37 kz
tance
teristics" table shown above as resistance crite-
ria.
2. Disconnect connectors ECM and COOLANT TEMP, and connect
Ground fault in wiring harness
Resis-
Between ECM (female) (15) and ground Min. 100 kz
tance
40-301 30 PC200, 200LC, 220, 220LC-8M0

Failure code [CA145] Coolant Temp Sens Low Error SEN06133-00
Circuit diagram related to coolant temperature sensor
PC200, 200LC, 220, 220LC-8M0 40-301 31

SEN06133-00 Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA153] Chg Air Temp Sensor High Error

Action
Failure code Charge Air Temperature Sensor High Error
level Failure
L03 CA153
q High voltage appears in temperature signal circuit of charge (boost) pressure & temperature sen-
Detail of failure
sor.
Action of con-
q Takes boost temperature to be at fixed value and allows engine to run.
troller
Problem on
q Engine protection function based on boost temperature does not work.
machine
q Input voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
q Temperature sensed by boost temperature sensor can be checked with monitoring function.
(Code: 18500(C))
Related infor-
mation
q Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit
q This failure code is displayed if temperature sensor connector is disconnected.

tor
2. Disconnect connector BOOST PRESS & IMT, and connect socket to male
side.
-40 C Resistance 41 to 48 kz
Between BOOST
Defective charge temperature sen-
2 PRESS & IMT (male) (3) 0 C Resistance 5.4 to 6.1 kz
sor
and (4)
a Boost tempera-
ture-Resistance cha- 60 C Resistance 560 to 600 z
riacteristic
3 Between ECM (female) (23) and (47)
ness Resis-
a Use "Boost temperature-Resistance character- 80 z to 48 kz
tance
istics" table shown above as resistance criteria.
40-301 32 PC200, 200LC, 220, 220LC-8M0

Failure code [CA153] Chg Air Temp Sensor High Error SEN06133-00
Circuit diagram related to charge temperature sensor
PC200, 200LC, 220, 220LC-8M0 40-301 33

SEN06133-00 Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA154] Chg Air Temp Sensor Low Error

Action
Failure code Charge Air Temperature Sensor Low Error
level Failure
L03 CA154
Detail of failure q Low voltage appears in temperature signal circuit of charge (boost) pressure & temperature sensor.
Action of con-
q Takes boost temperature to be at fixed value and allows engine to run.
troller
Problem on
q Engine protection function based on boost temperature does not work.
machine
q Input voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
Related infor-
(Code: 18500(C))
mation
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA153] for "High Error" is displayed.

tor
2. Disconnect connector BOOST PRESS & IMT, and connect socket to male
side.
Defective charge temperature sen- Between BOOST
2
sor PRESS & IMT (male) (3) 0 C Resistance 5.4 to 6.1 kz
and (4)
a Boost tempera-
ture-Resistance cha- 60 C Resistance 560 to 600 z
riacteristic
3 Short circuit in wiring harness Between ECM (female) (23) and (47)
Resis-
a Use "Boost temperature-Resistance character- 80 z to 48 kz
tance
istics" table shown above as resistance criteria.
Ground fault in wiring harness 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect
4
(contact with ground circuit) T-adapter to female side of ECM.
Resis-
Between ECM (female) (23) and ground Min. 100 kz
tance
40-301 34 PC200, 200LC, 220, 220LC-8M0

Failure code [CA154] Chg Air Temp Sensor Low Error SEN06133-00
Circuit diagram related to charge temperature sensor
PC200, 200LC, 220, 220LC-8M0 40-301 35

SEN06133-00 Failure code [CA155] Chg Air Temp High Speed Derate
Failure code [CA155] Chg Air Temp High Speed Derate

Action
Failure code Charge Air Temperature High Speed Derate
level Failure
L03 CA155
q Boost temperature sensed by charge (boost) pressure & temperature sensor exceeds upper limit
Detail of failure
of temperature control.
Action of con-
q Restricts engine output and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine stops.
q Boost temperature can be checked with monitoring function.
Related infor-
(Code: 18500 Boost temperature)
mation

Aftercooler cooling performance may degrade. Check it for following points:
Lowered cooling performance of q Looseness and damage of fan belt
1
aftercooler q Insufficient cooling air
q Clogging of aftercooler fins
Abnormal rise of turbocharger out- Outlet temperature of turbocharger may be abnormally high. Check related
2
let temperature parts.
Defective boost temperature sen- If no failure is found by above checks, boost temperature sensor system may
3
sor be defective. Perform troubleshooting for failure codes [CA153] and [CA154].
40-301 36 PC200, 200LC, 220, 220LC-8M0

Failure code [CA155] Chg Air Temp High Speed Derate SEN06133-00
PC200, 200LC, 220, 220LC-8M0 40-301 37

SEN06133-00 Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error

Action
Failure code Sensor power Supply 2 Voltage Low Error
level Failure
L03 CA187
Detail of failure q Low voltage appears in sensor power supply 2 circuit.
Action of con- q Takes charge (boost) pressure & temperature to be at fixed values and allows engine to run.
troller q Restricts engine output and allows engine to run.

machine q Engine starting performance becomes deteriorated.
Related infor-
mation

tor
2. Disconnect following connectors sequentially one by one and turn starting
switch to ON position each time.
3. After each troubleshooting, return to 1.
If this failure code is not displayed when a connector is disconnected, that sen-
sor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because of disconnection of
2 Defective sensor or wiring harness connector. Ignore failure codes other than [CA187].
Sensor or harness Connector
Boost pressure/temperature sensor BOOST PRESS & IMT
Common rail pressure sensor FUEL RAIL PRESS
Bkup sensor CAM SENSOR
Engine wiring harness ECM
2. Disconnect connector ECM and connect T-adapters to male side.
3 Defective engine controller 3. Turn starting switch to ON position with connector ECM disconnected.
Between ECM (male) (37) and (47) Voltage 4.75 to 5.25V
40-301 38 PC200, 200LC, 220, 220LC-8M0

Failure code [CA187] Sens Supply 2 Volt Low Error SEN06133-00
Circuit diagram related to sensor power supply 2
PC200, 200LC, 220, 220LC-8M0 40-301 39

SEN06133-00 Failure code [CA221] Ambient Press Sens High Error
Failure code [CA221] Ambient Press Sens High Error

Action
Failure code Ambient Pressure Sensor High Error
level Failure
L03 CA221
Detail of failure q High voltage appears in signal circuit of ambient pressure sensor.
Action of con-
q Takes ambient pressure to be at fixed value and allows engine to run.
troller
q Input voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related infor-
q Ambient pressure sensed by ambient pressure sensor can be checked with monitoring function.
mation
(Code: 37400 (kPa))

tor
Defective sensor power supply 1 If failure code [CA352] or [CA386] is displayed simultaneously, perform trou-
2
system bleshooting for it first.
2. Disconnect connector AMB. AIR PRESSURE.
If failure code changes from [CA221] to [CA222], sensor is defective.
3 Defective ambient pressure sensor q Reference
Sensor out-
put
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect
4 Short circuit in wiring harness T-adapters to either female side.
Between ECM (female) (33) and (3), or between
Resistance Min. 100 kz
AMB. AIR PRESSURE (female) (1) and (3)
2. Disconnect connector AMB. AIR PRESSURE.
3. Connect T-adapter to female side of connector AMB. AIR PRESSURE or
Hot short circuit in wiring harness insert T-adapter in connector ECM.
5 4. Turn starting switch to ON position (with connector AMB. AIR PRESSURE
disconnected).
Between ECM (3) and (38), or between AMB. AIR
Voltage Max. 1 V
PRESSURE (female) (3) and (2)
40-301 40 PC200, 200LC, 220, 220LC-8M0

Failure code [CA221] Ambient Press Sens High Error SEN06133-00
Circuit diagram related to ambient pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-301 41

SEN06133-00 Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA222] Ambient Press Sens Low Error

Action
Failure code Ambient Pressure Sensor Low Error
level Failure
L03 CA222
Detail of failure q Low voltage appears in signal circuit of ambient pressure sensor.
Action of con-
troller
q Input voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related infor- q Ambient pressure sensed by ambient pressure sensor can be checked with monitoring function.
mation (Code: 37400 (kPa))
q If sensor connector is disconnected, this failure code is displayed.

tor
If failure code [CA352] or [CA386] is also displayed, perform troubleshooting
for it first.
Defective power supply system of 2. Disconnect connector AMB. AIR PRESSURE and connect T-adapter to
2
ambient pressure sensor female side.
Between AMB. AIR PRESSURE Power sup- 4.75 to
Voltage
(female) (1) and (2) ply input 5.25 V
2. Disconnect connectors AMB. AIR PRESSURE and ECM, and connect
T-adapters to each female side.
a If power supply input in checks on cause 2 is nor-
mal, this check is not required.
Resistance Max. 10 z
Short circuit in wiring harness Between ECM (female) (33) and AMB. AIR
3 (wire breakage or defective con- PRESSURE (female) (1)
tact of connector) a If power supply input in checks on cause 2 is nor-
mal, this check is not required.
Between ECM (female) (38) and AMB. AIR
PRESSURE (female) (2)
Between ECM (female) (3) and AMB. AIR PRES-
SURE (female) (3) (sensor output)
Ground fault in wiring harness T-adapters to either female side.
4
Between ECM (female) (3) and ground, or between
AMB. AIR PRESSURE (female) (3) and ground
5 Short circuit in wiring harness T-adapters to either female side.
Between ECM (female) (3) and (38), or between
AMB. AIR PRESSURE (female) (2) and (3)
40-301 42 PC200, 200LC, 220, 220LC-8M0

Failure code [CA222] Ambient Press Sens Low Error SEN06133-00

a If no failure is found by checks on causes 1 to 5 and check result of cause
Defective ambient pressure sensor 1. Turn starting switch to OFF position.
6 (improper input voltage to engine 2. Insert T-adapters to connector ECM.
controller) 3. Turn starting switch to ON position.
Sensor out-
put
Circuit diagram related to ambient pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-301 43

SEN06133-00 Failure code [CA227] Sens 2 Supply Volt High Error
Failure code [CA227] Sens 2 Supply Volt High Error

Action
Failure code Sensor 2 Power Supply Voltage High Error
level Failure
L03 CA227
Detail of failure q High voltage appears in sensor power supply 2 circuit.
Action of con- q Takes boost pressure and boost temperature to be at fixed values and allows engine to run.
troller q Restricts engine output and allows engine to run.

Related infor-
mation
Perform troubleshooting for failure code [CA187].
Failure code [CA234] Eng Overspeed

Action
Failure code Engine Overspeed
level Failure
CA234
Detail of failure q Engine speed exceeds upper limit of speed control.
Action of con-
q Stops injection until engine speed lowers to normal level.
troller
Problem on
q Engine speed fluctuates.
machine
q Engine speed can be checked with monitoring function.
Related infor-
(Code: 01002 Engine speed)
mation
q Method of reproducing failure code: Start engine and keep it running at high idle.

1 Use of improper fuel Fuel used may be improper. Check it.
Method of using machine may be improper, so instruct operator on how to use
2 Usage is improper
machine properly.
If no failure is found by checks on causes 1 and 2, engine controller may be
3 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot be per-
formed.)
40-301 44 PC200, 200LC, 220, 220LC-8M0

Failure code [CA238] Ne Speed Sens Supply Volt Error SEN06133-00
Failure code [CA238] Ne Speed Sens Supply Volt Error

Action
Failure code Ne Speed Sensor Supply Voltage Error
level Failure
L01 CA238
Detail of failure q Low voltage appears in power supply circuit of engine Ne speed sensor.
Action of con-
q Controls engine with signal from engine Bkup speed sensor.
troller
q Running engine stops (when Bkup speed sensor is also defective).
Problem on q Stopped engine cannot be started (when Bkup speed sensor is also defective).
machine q Starting performance is poor.
q Engine hunts.
Related infor-
mation

tor
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After each troubleshooting, return to step 1.
If this failure code is not displayed when a sensor is disconnected, sensor or
engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are also displayed. This is because of disconnection of
connector. Ignore failure codes other than [CA238].
Ne speed sensor CRANK SENSOR
3. Turn starting switch to ON position with engine wiring harness discon-
3 Defective engine controller nected.
4.75 to
Between ECM (male) (16) and (48) Voltage
5.25 V
Circuit diagram related to Ne speed sensor
PC200, 200LC, 220, 220LC-8M0 40-301 45

SEN06133-00 Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA271] IMV/PCV1 Short Error

Action
Failure code IMV/PCV1 Short circuit Error
level Failure
L03 CA271
Detail of failure q Short circuit is detected in drive circuit of supply pump actuator.
Action of con-
troller
q Engine speed does not increase from low idle.
Problem on
machine
q Common rail fuel pressure rises above command value.
Related infor-
mation

tor
2. Disconnect connector CP3 PUMP REGULATOR.
2 Defective supply pump actuator 3. Turn starting switch to ON position.
If failure code changes from [CA271] to [CA272] , supply pump actuator is
defective.
Short circuit or ground fault in wir-
3
ing harness Between ECM (female) (2) and (32) Resistance 1 to 5 z
4 Short circuit in wiring harness 2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect
T-adapter to female side of ECM.
Ground fault in wiring harness 2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect
5
(contact with ground circuit) T-adapter to female side of ECM.
40-301 46 PC200, 200LC, 220, 220LC-8M0

Failure code [CA271] IMV/PCV1 Short Error SEN06133-00
Circuit diagram related to IMV/PCV1
PC200, 200LC, 220, 220LC-8M0 40-301 47

SEN06133-00 Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA272] IMV/PCV1 Open Error

Action
Failure code IMV/PCV1 Open circuit Error
level Failure
L03 CA272
Detail of failure q Open circuit is detected in drive circuit of supply pump actuator.
Action of con-
troller
Problem on q Engine runs but its speed does not stabilize.
machine q Common rail fuel pressure rises above command value.
Related infor- q Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
mation able to female connector of sensor wiring harness, and thus not usable for checking open circuit

tor
2. Disconnect connector CP3 PUMP REGULATOR.
2 Defective supply pump actuator
Between CP3 PUMP REGULATOR (male) (1) and
Resistance Max. 5 z
(2)
Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapters to female side.
3
ness
Between ECM (female) (2) and (32) Resistance Max. 5 z
1.Turn starting switch to OFF position.

2.Disconnect connector CP3 PUMP REGULATOR.
3.Insert T-adapters to connector ECM.
Hot short circuit in wiring harness 4.Turn starting switch to ON position and perform troubleshooting after one
4
(contact with 24 V circuit) minute or longer (with connector CP3 PUMP REGULATOR disconnected).
a Average voltage is displayed because of PWM.
Between ECM (2) and (32) Voltage Max. 3 V

this is internal defect, troubleshooting cannot be performed.)
40-301 48 PC200, 200LC, 220, 220LC-8M0

Failure code [CA272] IMV/PCV1 Open Error SEN06133-00
Circuit diagram related to IMV/PCV1
PC200, 200LC, 220, 220LC-8M0 40-301 49

SEN06133-00
2012 KOMATSU
All Rights Reserved
40-301 50
SEN06134-00
SEN05986-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
Failure code [CA322] Inj #1(L#1) Open/Short Error.................................................................................... 4

Failure code [CA342] Calibration Code Incompatibility............................................................................... 16
Failure code [CA351] Injectors Drive Circuit Error ...................................................................................... 17
Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................................. 18
Failure code [CA386] Sens Supply 1 Volt High Error.................................................................................. 20
Failure code [CA428] Water in Fuel Sensor High Error .............................................................................. 22
Failure code [CA429] Water in Fuel Sensor Low Error ............................................................................... 24
Failure code [CA435] Eng Oil Press Sw Error ............................................................................................ 26
Failure code [CA441] Battery Voltage Low Error ........................................................................................ 28
Failure code [CA442] Battery Voltage High Error ....................................................................................... 30
Failure code [CA449] Rail Press Very High Error ....................................................................................... 31
Failure code [CA451] Rail Press Sensor High Error ................................................................................... 32
Failure code [CA452] Rail Press Sensor Low Error.................................................................................... 34
Failure code [CA488] Chg Air Temp High Torque Derate ........................................................................... 36
Failure code [CA553] Rail Press High Error ............................................................................................... 37
PC200, 200LC, 220, 220LC-8M0 40-302 1

SEN06134-00
Failure code [CA559] Rail Press Low Error ................................................................................................ 38

Failure code [CA689] Eng Ne Speed Sensor Error..................................................................................... 40
Failure code [CA731] Eng Bkup Speed Sens Phase Error ......................................................................... 42
Failure code [CA757] All Continuous Data Lost Error................................................................................. 43
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................. 44
Failure code [CA2185] Throt Sens Sup Volt High Error .............................................................................. 48
Failure code [CA2186] Throt Sens Sup Volt Low Error............................................................................... 50
Failure code [CA2249] Rail Press Very Low Error ...................................................................................... 51
Failure code [CA2311] lMV Solenoid Error ................................................................................................. 51
Failure code [CA2555] Grid Htr Relay Open Circuit Error........................................................................... 52
Failure code [CA2556] Grid Htr Relay Short Circuit Error........................................................................... 54
40-302 2 PC200, 200LC, 220, 220LC-8M0

SEN06134-00
PC200, 200LC, 220, 220LC-8M0 40-302 3

SEN06134-00 Failure code [CA322] Inj #1(L#1) Open/Short Error
Failure code [CA322] Inj #1(L#1) Open/Short Error

Action
Failure code Injector #1 (L#1) Open or Short Circuit Error
level Failure
L03 CA322
Detail of failure q Open or short circuit is detected in drive circuit of No. 1 injector.
Action of con-
troller
Problem on q Poor combustions or hunting occurs.
machine q Engine output lowers.
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

tor
2. Disconnect connector INJECTOR CYL 1&2 and connect T-adapter to male
side.
2 Defective No. 1 injector
Between INJECTOR CYL 1&2 (male) (C) and (D) Resistance Max. 2 z
Between INJECTOR CYL 1&2 (male) (C) and
ground
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (45) and (53) Resistance Max. 2 z
2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
Between ECM (female) (45) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
1&2 (female) (C)
Resistance Max. 2 z
1&2 (female) (D)
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
5 T-adapter to female side of either one.
Between ECM (female) (45) or INJECTOR CYL
1&2 (female) (C) and ground
a Check with multimeter in continuity mode.
6 Short circuit in wiring harness
Between ECM (female) (45) and each pin other No continuity (no sound
than (45) is heard.)
Defective other cylinder injectors If different failure codes are displayed, perform troubleshootings for them on
7
or wiring harness ahead.
If no failure is found by checks on causes 1 to 7, engine controller is defective.
40-302 4 PC200, 200LC, 220, 220LC-8M0

Failure code [CA322] Inj #1(L#1) Open/Short Error SEN06134-00
Circuit diagram related to injector #1
PC200, 200LC, 220, 220LC-8M0 40-302 5


Action
Failure code Injector #5(L#5) Open or Short Circuit Error
level Failure
L03 CA323
Action of con-
troller
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

tor
side.
ground
3
5&6 (female) (C)
Resistance Max. 2 z
5&6 (female) (D)
5 T-adapters to either female side.
7
40-302 6 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-302 7


Action
level Failure
L03 CA324
Action of con-
troller
Related infor-
q While engine is running normally, approximately 65 V of pulse voltage is supplied to injector (+)
mation
side. But it is pulse voltage and cannot be measured with multimeter.

tor
side.
ground
3
3&4 (female) (C)
Resistance Max. 2 z
3&4 (female) (D)
7
40-302 8 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-302 9


Action
Failure code Injector #6(L#6) Open or Short Circuit Error
level Failure
L03 CA325
Action of con-
troller
Related infor-
q While engine is running normally, pulse voltage of apporx. 65 V is supplied to injector (+) side but
mation
cannot be measured with multimeter because it cannot measure pulse voltages.

tor
side.
Between INJECTOR CYL 5&6 (male) (A) and (B) Resistance Max. 2 z
Between INJECTOR CYL 5&6 (male) (A) and
ground
3
2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect
tact of connector) Between ECM (female) (57) and INJECTOR CYL
Resistance Max. 2 z
5&6 (female) (A)
Resistance Max. 2 z
5&6 (female) (B)
5&6 (female) (A) and ground
7
40-302 10 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-302 11


Action
level Failure
L03 CA322
Action of con-
troller
Related infor-
mation

tor
side.
Between INJECTOR CYL 1&2 (male) (B) and
ground
3
1&2 (female) (B)
Resistance Max. 2 z
1&2 (female) (A)
1&2 (female) (B) and ground
7
40-302 12 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-302 13


Action
level Failure
L03 CA332
Action of con-
troller
Related infor-
mation

tor
side.
Between INJECTOR CYL 3&4 (male) (B) and
ground
3
3&4 (female) (B)
Resistance Max. 2 z
3&4 (female) (A)
3&4 (female) (B) and ground
7
40-302 14 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 40-302 15

SEN06134-00 Failure code [CA342] Calibration Code Incompatibility
Failure code [CA342] Calibration Code Incompatibility

Action
Failure code Calibration Code Incompatibility
level Failure
L04 CA342
Detail of failure q Matching error occurs in engine controller data.
Action of con-
troller
Problem on
q Engine may run normally, or engine is stopped and cannot be restarted.
machine
Related infor-
mation
(Code: 03203 (V))
Defective power supply voltage

system
40-302 16 PC200, 200LC, 220, 220LC-8M0

Failure code [CA351] Injectors Drive Circuit Error SEN06134-00
Failure code [CA351] Injectors Drive Circuit Error

Action
Failure code Injectors Drive Circuit Error
level Failure
L03 CA351
Detail of failure q There is error in drive power circuit of injector.
Action of con-
troller
q Exhaust gas becomes black.
Problem on q Combustion becomes irregular.
Related infor-
mation
(Code: 03203 (V))
Defective power supply voltage

system
PC200, 200LC, 220, 220LC-8M0 40-302 17

SEN06134-00 Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA352] Sens Supply 1 Volt Low Error

Action
Failure code Sensor Power supply 1 Voltage Low Error
level Failure
L03 CA352
Detail of failure q Low voltage appears in sensor power supply 1 circuit.
Action of con-
troller
Related infor-
mation

tor
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After each troubleshooting, return to step 1.
If this failure code is not displayed when a sensor is disconnected, sensor or
engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed as well. This is because of disconnection
of connector. Ignore all failure codes other than [CA352].
Ambient pressure sensor AMB. AIR PRESSURE
3 Defective engine controller 3. Turn starting switch to ON position with connector ECM disconnected.
Between ECM (male) (33) and (38) Voltage 4.75 to 5.25V
40-302 18 PC200, 200LC, 220, 220LC-8M0

Failure code [CA352] Sens Supply 1 Volt Low Error SEN06134-00
Circuit diagram related to sensor power supply 1
PC200, 200LC, 220, 220LC-8M0 40-302 19

SEN06134-00 Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA386] Sens Supply 1 Volt High Error

Action
Failure code Sensor Power Supply 1 Voltage High Error
level Failure
L03 CA386
Detail of failure q High voltage appears in sensor power supply 1 circuit.
Action of con-
troller
Related infor-
mation

Perform troubleshooting for failure code [CA352]
40-302 20 PC200, 200LC, 220, 220LC-8M0

Failure code [CA386] Sens Supply 1 Volt High Error SEN06134-00
PC200, 200LC, 220, 220LC-8M0 40-302 21

SEN06134-00 Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA428] Water in Fuel Sensor High Error

Action
Failure code Water-in-fuel Sensor High Error
level Failure
L01 CA428
Detail of failure q High voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
Action of con-
troller
Problem on
q Water separator monitor is not displayed correctly.
machine
q Signal (ON/OFF) from water-in-fuel sensor can be checked with monitoring function.
Related infor-
(Code: 18800)
mation

tor
Defective water-in-fuel sensor 2. Disconnect connector P47, and connect T-adapters to female side.
2 a If water is in water separator, drain it.
installed to fuel pre-filter
Between P47 (female) (1) and (2) Resistance Min. 100 kz
3
ness Between ECM (female) (14) and (47)
(Resistance of water-in-fuel sensor)
Open circuit in wiring harness 2. Disconnect connectors ECM and P47, and connect T-adapters to each
tact of connector) Between ECM (female) (14) and P47 (female) (1) Resistance Max. 10 z
Between ECM (female) (47) and P47 (female) (2) Resistance Max. 10 z
2. Disconnect connectors ECM and P47, and connect T-adapters to female
side of ECM.
40-302 22 PC200, 200LC, 220, 220LC-8M0

Failure code [CA428] Water in Fuel Sensor High Error SEN06134-00
Circuit diagram related to water-in-fuel sensor
PC200, 200LC, 220, 220LC-8M0 40-302 23

SEN06134-00 Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA429] Water in Fuel Sensor Low Error

Action
Failure code Water-in-fuel Sensor Low Error
level Failure
L01 CA429
Detail of failure q Low voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
Action of con-
troller
Problem on
q Water separator monitor is not displayed correctly.
machine
q Signal (ON/OFF) from water-in-fuel sensor can be checked with monitoring function.
Related infor-
(Code: 18800)
mation

tor
2. Disconnect connector P47, and connect T-adapters to female side.
Defective water-in-fuel sensor a If water is in water separator, drain it.
2
installed to fuel pre-filter Between P47 (female) (1) and (2) Resistance Min. 100 kz
Between P47 (female) (1) and ground Resistance Min. 100 kz
3 Between ECM (female) (14) and (47)
ing harness Resistance Min. 100 kz
(Resistance of water-in-fuel sensor)
2. Disconnect connectors ECM and P47, and connect T-adapters to female
side of ECM.
Ground fault in wiring harness 2. Disconnect connectors ECM and P47, and connect T-adapters to either
5
Between ECM (female) (14) or P47 (female) (1) and
ground
40-302 24 PC200, 200LC, 220, 220LC-8M0

Failure code [CA429] Water in Fuel Sensor Low Error SEN06134-00
Circuit diagram related to water-in-fuel sensor
PC200, 200LC, 220, 220LC-8M0 40-302 25

SEN06134-00 Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA435] Eng Oil Press Sw Error

Action
Failure code Engine Oil Pressure Switch Error
level Failure
L01 CA435
Detail of failure q Failure occurs in engine oil pressure switch signal circuit.
Action of con-
troller
Problem on q Protection function by engine oil pressure does not operate.
machine q Engine oil pressure monitor is not displayed normally.
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q Engine oil pressure switch is in CLOSED (ON) when oil pressure is low (when engine is stopped),
Related infor- but is in OPEN (OFF) when oil pressure is high (when engine is running).
mation q To display this failure code, engine controller checks if engine oil pressure switch is in CLOSED
(ON), that is, if signal voltage is zero or not, only when engine is stopped.
q Failure of engine oil pressure switch with engine running is shown by failure code [B@BAZG].

tor
2. Disconnect connector OIL PRESSURE SWITCH and connect T-adapter to
Defective engine oil pressure
2 male side of connector.
switch
Between OIL PRESSURE SWITCH (male) (1) and
ground
3
ness
Between ECM (female) (17) and ground Resistance Max. 10 z
Circuit diagram related to engine oil pressure switch
40-302 26 PC200, 200LC, 220, 220LC-8M0

Failure code [CA435] Eng Oil Press Sw Error SEN06134-00
PC200, 200LC, 220, 220LC-8M0 40-302 27

SEN06134-00 Failure code [CA441] Battery Voltage Low Error
Failure code [CA441] Battery Voltage Low Error

Action
Failure code Battery Voltage Low Error
level Failure
L04 CA441
Detail of failure q Low voltage appears in controller power supply circuit.
Action of con-
troller
Problem on q Engine stops.
machine q Starting performance is poor.
Related infor-
mation
(Code: 03203 (V))

1 Loose or corroded battery terminal Battery cable terminal may be loose or corroded. Check it directly.
Loose terminal or partial open cir- 1. Turn starting switch to OFF position.
2
cuit at terminal Check terminals of alternator, battery relay, ground terminal (T12), etc.
tor
2. Perform troubleshooting with starting switch at OFF position and at engine
4 Improper battery voltage cranking.
Between battery terminals (+) and (-). Voltage 20 to 30 V
5 Defective alternator 3. Start engine (Engine speed: Middle or faster).
Between E12 (1) and ground Voltage 27.5 to 29.5 V
q Reference
1. Turn starting switch to OFF position and disconnect battery ground cable.
3. Connect battery ground cable.
4. Measure voltage with starting switch at ON position and when starting
engine.
Between CE03 (3) and
Starting switch: ON Voltage 20 to 30 V
(1)
Between CE03 (3) and
Starting switch: START Voltage Min. 12 V
(1)
40-302 28 PC200, 200LC, 220, 220LC-8M0

Failure code [CA441] Battery Voltage Low Error SEN06134-00
Circuit diagram related to engine controller power supply
PC200, 200LC, 220, 220LC-8M0 40-302 29

SEN06134-00 Failure code [CA442] Battery Voltage High Error
Failure code [CA442] Battery Voltage High Error

Action
Failure code Battery Voltage High Error
level Failure
L04 CA442
Detail of failure q High voltage (36 V or higher) appears in controller power supply circuit.
Action of con-
troller
Problem on q Engine continues to run normally, but it may stop during running or may not be able to start if it is
machine stopped.
Related infor-
mation
(Code: 03203 (V))

Perform troubleshooting for failure code [CA441].
40-302 30 PC200, 200LC, 220, 220LC-8M0

Failure code [CA449] Rail Press Very High Error SEN06134-00
Failure code [CA449] Rail Press Very High Error

Action
Failure code Common Rail Pressure Very High Error
level Failure
L03 CA449
Detail of failure q High pressure error (2) occurs in common rail circuit.
Action of con-
troller
Problem on q Engine sound becomes large when no or light load is applied.
q Common rail pressure can be checked with monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
Air may be in low-pressure circuit. Check it directly according to following pro-

cedure.
2 Air in low pressure circuit 1. Remove fuel pressure pickup port plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel pre-filter.
3. Check fuel and air from pressure pickup plug for leakage level.
a For check of pressure in fuel return circuit, see Testing and adjusting, "Test-
ing fuel pressure".
3 Defect in fuel return circuit parts Max. 0.02 MPa
Fuel return circuit pres- Engine at low idle or
sure cranking {Max. 0.19 kg/cm2}
Defective common rail pressure
4 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system
a For check of leakage from pressure limiter, see "Checking fuel return rate
and leakage" in Testing and adjusting.
5 Defective pressure limiter
Leakage from pressure
At low idle 0 cc (no leakage)
limiter
6 Defective supply pump If no failure is found by above checks, supply pump may be defective.
PC200, 200LC, 220, 220LC-8M0 40-302 31

SEN06134-00 Failure code [CA451] Rail Press Sensor High Error
Failure code [CA451] Rail Press Sensor High Error

Action
Failure code Common Rail Pressure Sensor High Error
level Failure
L03 CA451
Detail of failure q High voltage appears in signal circuit of common rail pressure sensor.
Action of con-
troller
Problem on q Engine speed or output lowers.
q Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure sensor volt)
Related infor-
q This failure code is displayed if common rail pressure sensor connector is disconnected.
mation
q Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for
checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).

tor
Defective common rail pressure If failure code [CA227] or [CA187] is also displayed, perform troubleshooting
2
sensor power supply system for it first.
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST
3 Short circuit in wiring harness PRESS & IMT and ECM.
3. Connect T-adapters to female side of ECM.
2. Disconnect connector FUEL RAIL PRESS, and connect T-adapter to
connector ECM.
Hot short circuit in wiring harness 3. Turn starting switch to ON position (with connector FUEL RAIL PRESS
4
(contact with 24 V circuit) disconnected).
a Pin (25) of ECM is connected to 5V line via resistor inside engine controller.
Between ECM (25) and (47) Voltage Approx. 5 V
If no failure is found by above checks, there may be open circuit in wiring har-
ness. (*)
a If no failure is found by checks on causes 1 to 5 and check result of cause
sensor
6 2. Insert T-adapters to connector ECM.
(improper input voltage to engine
controller)
Sensor out-
put
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General in-
formation on troubleshooting".
40-302 32 PC200, 200LC, 220, 220LC-8M0

Failure code [CA451] Rail Press Sensor High Error SEN06134-00
Circuit diagram related to common rail pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-302 33

SEN06134-00 Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA452] Rail Press Sensor Low Error

Action
Failure code Common Rail Pressure Sensor Low Error
level Failure
L03 CA452
Detail of failure q Low voltage appears in signal circuit of common rail pressure sensor.
Action of con-
troller
Problem on q Engine speed or output lowers.
q Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure sensor volt)
Related infor-
mation
q If sensor connector is disconnected even in normal condition, failure code [CA451] for "High Error"
is displayed.

tor
Defective common rail pressure If failure code [CA187] (ground fault in sensor power supply system) or
2
sensor power supply system [CA227] is displayed, perform troubleshooting for it first.
a Check that failure code [CA187] (Ground fault in sensor power supply sys-
tem) is not displayed.
2. Disconnect connector FUEL RAIL PRESS.
Defective common rail pressure If failure code [CA452] changes to [CA451] , sensor is defective.
3
sensor q Reference
Sensor out-
put
Ground fault in wiring harness 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect
2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect
5 Short circuit in wiring harness T-adapter to female side of ECM.
40-302 34 PC200, 200LC, 220, 220LC-8M0

Failure code [CA452] Rail Press Sensor Low Error SEN06134-00
Circuit diagram related to common rail pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-302 35

SEN06134-00 Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA488] Chg Air Temp High Torque Derate

Action
Failure code Charge air temperature high torque derate
level Failure
L03 CA488
q Temperature signal from boost pressure & temperature sensor exceeds upper limit of temperature
Detail of failure
control.
Action of con-
troller
Problem on
machine
q Boost temperature can be checked with monitoring function.
Related infor-
(Code 18500: Boost temperature)
mation

Cooling performance of aftercooler may degrade. Check following points:
Lowered cooling performance of q Looseness and damage of fan belt
1
aftercooler q Insufficient cooling air
q Clogging of aftercooler fins
Abnormal rise of turbocharger out- Outlet temperature of turbocharger may be abnormally high. Check related
2
let temperature parts.
Defective boost temperature sen-
3 Perform troubleshooting for failure codes [CA153] and [CA154].
sor
40-302 36 PC200, 200LC, 220, 220LC-8M0

Failure code [CA553] Rail Press High Error SEN06134-00
Failure code [CA553] Rail Press High Error

Action
Failure code Rail Press High Error
level Failure
L01 CA553
Detail of failure q Excessively high pressure trouble (1) has occurred in the common rail circuit.
Action of con-
troller
Problem on q Engine noise becomes louder at no or light load.
Related infor-
(Code 36400: Common rail pressure)
mation
Connection of ground terminals may be defective. Check the following termi-

nals.
Defective connection of ground q Ground terminal of machine (() terminal of battery)
2
terminal q Ground terminal of engine
q Ground terminal of engine controller
q Ground terminal of starting motor
3 Perform troubleshooting for failure code [CA451], [CA452]
sensor system
PC200, 200LC, 220, 220LC-8M0 40-302 37

SEN06134-00 Failure code [CA559] Rail Press Low Error
Failure code [CA559] Rail Press Low Error

Action
Failure code Common Rail Pressure Low Error
level Failure
L01 CA559
Detail of failure q Low pressure error (1) is detected in common rail circuit.
Action of con-
troller
q Engine does not start at all or does not start easily.
Problem on
machine
Related infor-
(Code: 36400 Common rail pressure)
mation

1 Use of improper fuel Check fuel used as it may be improper one.
Fuel may leak to outside. Check it (Check visually while running engine at low
2 Fuel leakage to outside
idle).
a For more information on troubleshooting, see Note 1.
a For check of fuel pressure in low-pressure circuit, see Testing and adjust-
ing, "Testing fuel pressure".
Negative pressure at fuel
At high idle Max. -50.7 MPa
supply pump inlet (outlet
(if engine can be started) {Max. -380 mmHg}
3 Defect in low-pressure circuit parts side of fuel pre-filter)
During cranking 0.3 to 1.1 MPa
(if engine cannot be
Inlet pressure of fuel started) {3.1 to 11.3 kg/cm2}
main filter 0.5 to 1.3 MPa
At low idle
(if engine can be started) {5.1 to 13.3 kg/cm2}
a For check of leakage from pressure limiter, see Testing and adjusting,
Checking fuel return rate and leakage.
4 Defective pressure limiter
Leakage from pressure
At low idle 0 cc (no leakage)
limiter
a For check of return rate from injector, see Testing and adjusting, Checking
fuel return rate and leakage.
Defective injector During cranking
5 (including high-pressure piping in (if engine cannot be Max. 90 cc/min
cylinder head) Return rate from injector started)
At low idle
Max. 180 cc/min
(if engine can be started)
a For check of return rate from supply pump, see Testing and adjusting,
Checking fuel return rate and leakage.
During cranking
6 Defective supply pump (if engine cannot be Max. 140 cc/min
Return rate from supply started)
pump
At low idle
Max. 1,000 cc/min
(if engine can be started)
7 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system
Note 1: Check the low-pressure line parts for the following.
1) Fuel level
2) Clogging of fuel tank breather
3) Leakage or clogging of low-pressure fuel piping
4) Clogging of fuel pre-filter
5) Clogging of fuel main filter
6) Replace the fuel filter when the problem is not removed even if it is found to be not clogged.
40-302 38 PC200, 200LC, 220, 220LC-8M0

Failure code [CA559] Rail Press Low Error SEN06134-00
PC200, 200LC, 220, 220LC-8M0 40-302 39

SEN06134-00 Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA689] Eng Ne Speed Sensor Error

Action
Failure code Engine Ne Speed Sensor Error
level Failure
L01 CA689
Detail of failure q Signal from engine Ne speed sensor is abnormal.
Action of con-
q Continues to control engine by using signal from engine Bkup speed sensor.
troller
q Engine hunts.
Problem on
q Starting performance is poor.
machine
q Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
sensor cannot be determined to be normal by measuring its resistance with multimeter.
Related infor-
q Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be measured by
mation
using multimeter.
q Speed sensor senses passing slotted hole in speed sensing wheel that is installed on inside of
crankshaft vibration damper and rotated by crankshaft.

tor
Defective Ne speed sensor power
supply system
Breakage or improper installation
Engine Ne speed sensor may be broken or may have improper installation
3 (looseness) of engine Ne speed
(looseness). Check it directly.
sensor
2. Disconnect connector CRANK SENSOR and connect T-adapter to female
Defective Ne speed sensor power side.
4
supply input 3. Turn starting switch to ON position.
Between CRANK SENSOR (female) Power sup-
Voltage 4.75 to 5.25V
(1) and (2) ply input
2. Disconnect connectors ECM and CRANK SENSOR.
a If no failure is found in checks on cause 4, this
check is not required. Resis-
Max. 10 z
Open circuit in wiring harness Between ECM (female) (16) and CRANK tance
5 (wire breakage or defective con- SENSOR (female) (1)
tact of connector) a If no failure is found in checks on cause 4, this
check is not required. Resis-
Max. 10 z
Between ECM (female) (48) and CRANK tance
SENSOR (female) (2)
Between ECM (female) (27) and CRANK SENSOR Resis-
Max. 10 z
(female) (3) tance
2. Disconnect connectors ECM and CRANK SENSOR.
Between ECM (female) (16) and (27) or CRANK Resis-
6 Short circuit in wiring harness Min. 100 kz
SENSOR (female) (1) and (3) tance
Between ECM (female) (27) and (48) or CRANK Resis-
Min. 100 kz
SENSOR (female) (2) and (3) tance
Ground fault in wiring harness 2. Disconnect connectors ECM and CRANK SENSOR.
7
(contact with ground circuit) Between ECM (female) (27) or CRANK SENSOR Resis-
Min. 100 kz
(female) (3) and ground tance
40-302 40 PC200, 200LC, 220, 220LC-8M0

Failure code [CA689] Eng Ne Speed Sensor Error SEN06134-00

Hot short circuit in wiring harness 2. Disconnect connector CRANK SENSOR.
Between CRANK SENSOR (female) (3) and ground Voltage Max. 1 V
Damage or loose mounting of
9 Check speed sensing wheel directly.
speed sensing wheel
If no failure is found by above checks, Ne speed sensor is defective. (Since
10 Defective Ne speed sensor
Circuit diagram related to engine Ne speed sensor
PC200, 200LC, 220, 220LC-8M0 40-302 41

SEN06134-00 Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Action
Failure code Engine Bkup Speed Sensor Phase Error
level Failure
L01 CA731
q Phase error is detected between signals from engine Ne speed sensor and engine Bkup speed
Detail of failure
sensor
Action of con-
q Continues to control engine by using signal from engine Ne speed sensor.
troller
q Engine does not start at all or does not start easily.
Problem on
q Idle speed is unstable.
machine
Related infor-
mation

Breakage of engine Ne speed sen-
1 Engine Ne speed sensor may be broken. Check it.
sor
Breakage of engine Bkup speed
2 Engine Bkup speed sensor may be broken. Check it.
sensor
Speed sensing wheel on crankshaft side may be installed defectively or bro-
ken. Check it according to following procedure.
Defective installation or breakage 1. Align paint mark (M1) on damper with Ne speed sensor top (M2).
3 of speed sensing wheel on crank- a Do not align with mark of No. 1 cylinder compression top dead center
shaft side (approimately 80 deg. before compression top dead center).
2. If center of oblong hole (WS) of speed sensing wheel aligns with Ne speed
sensor top (M2), installation is correct.
Speed sensing ring on camshaft may be installed defectively or broken. Check
it according to the following procedure.
Defective installation or breakage
1. Set No. 1 cylinder to compression TDC (align with mark).
4 of speed sensing ring on camshaft
2. Remove Bkup speed sensor.
side
3. If you can see double-slot part (with one crest) (B) on speed sensing ring
through sensor mounting hole (H), speed sensing ring is installed correctly.
Defective timing of crankshaft and

5 Timing of crankshaft and camshaft may be defective. Check it.
camshaft
Connection of ground terminal may be defective. Check following terminals.
q Ground terminal of machine ((-) terminal of battery)
Defective connection of ground
6 q Ground terminal of engine
terminal
q Ground terminal of engine controller
q Ground terminal of starting motor
40-302 42 PC200, 200LC, 220, 220LC-8M0

Failure code [CA757] All Continuous Data Lost Error SEN06134-00
Failure code [CA757] All Continuous Data Lost Error

Action
Failure code All Continuous Data Lost Error
level Failure
L04 CA757
Detail of failure q All data in engine controller are lost.
Action of con-
troller
Problem on q Engine may stop and may not be started again.
machine q Monitoring function of machine monitor (engine controller system) may not work normally.
Related infor-
mation
PC200, 200LC, 220, 220LC-8M0 40-302 43

SEN06134-00 Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA778] Eng Bkup Speed Sensor Error

Action
Failure code Engine Bkup Speed Sensor Error
level Failure
L01 CA778
Detail of failure q Singal from engine Bkup speed (cam) sensor is abnormal.
Action of con-
q Continues to control engine by using signal from engine Ne speed sensor.
troller
Problem on q Starting performance is poor.
q Since inside of speed sensor is not coil but Hall sensor and electronic circuit, speed sensor cannot
Related infor- be determined to be normal by measuring its resistance with multimeter.
mation q Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured by
using multimeter.
q Speed sensor scans rotating slot of speed sensing ring mounted on camshaft.

tor
Defective sensor power supply 2
2 If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
system
Damage or incorrect (loose) instal-
Engine Bkup speed (CAM) sensor may be damaged or incorrectly (loosely)
3 lation of engine Bkup speed (CAM)
installed. Check it.
sensor
2. Disconnect connector CAM SENSOR , and connect T-adapter to female
Defective power input to engine side.
4
Bkup speed sensor 3. Turn starting switch to ON position.
Between CAM SENSOR (female) (1) Power sup-
Voltage 4.75 to 5.25V
and (2) ply
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapters
to each female side.
Open circuit in wiring harness Between ECM (female) (37) and CAM SENSOR Resis-
Max. 10 z
5 (wire breakage or defective con- (female) (1) tance
tact of connector) Between ECM (female) (47) and CAM SENSOR Resis-
Max. 10 z
(female) (2) tance
Between ECM (female) (26) and CAM SENSOR Resis-
Max. 10 z
(female) (3) tance
to either female side.
6 Short circuit in wiring harness Between ECM (female) (26) and (37) or CAM SEN- Resis-
Min. 100 kz
SOR (female) (1) and (3) tance
Between ECM (female) (26) and (47) or CAM SEN- Resis-
Min. 100 kz
SOR (female) (2) and (3) tance
Ground fault in wiring harness to either female side.
7
Between ECM (female) (26) or CAM SENSOR Resis-
Min. 100 kz
(female) (3) and ground tance
2. Disconnect connector CAM SENSOR, and connect T-adapter to female
Hot short circuit in wiring harness side.
8
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Between CAM SENSOR (female) (3) and ground Voltage Max. 1 V
40-302 44 PC200, 200LC, 220, 220LC-8M0

Failure code [CA778] Eng Bkup Speed Sensor Error SEN06134-00

Remove engine Bkup speed (CAM) sensor, and check ring through hole (H).
9 Loose speed sensing ring a If speed sensing ring (B) is loosely installed, follow instructions given in the
"Reference" column.
If no failure is found by above checks, engine Bkup speed (CAM) sensor is
Defective engine Bkup speed
10 defective. (Since this is an internal defect, troubleshooting cannot be per-
(CAM) sensor
formed.)
Circuit diagram related to engine Bkup speed sensor
PC200, 200LC, 220, 220LC-8M0 40-302 45

SEN06134-00 Failure code [CA778] Eng Bkup Speed Sensor Error
Reference for troubleshooting of CA778 (107 se- 5. Check mounting bolt (4) of camshaft ring (5) for
ries engine) looseness.
Checking camshaft ring for loose installation 3 Mounting bolt (4):
Remove the front cover and check the camshaft ring 10 2 Nm
for looseness. (DP): Dowel pin
a See "Removal and installation of front seal" in
Disassembly and assembly.
a Keep the front seal, liquid gasket LG-7 and front
seal tool (795-799-6400) on hand.
Removal
1. Remove the fan and fan belt. For details, see
"Removal and installation of front seal" in Disas-
sembly and assembly.
2. Remove damper assembly (1).
(DP): Dowel pin
Installation
a See the figures in "Removal" for installation.
1. Install front cover (2).
3 Front cover:
Liquid gasket (LG-7)
2. Install the front seal according to the following
procedure. For details, see "Removal and instal-
lation of front seal" in Disassembly and
assembly.
1) Install front seal (3).
3. Remove front cover (2). 2) Install the damper assembly with the dowel
4. Remove front seal (3). pin (DP).
(RING): Ring 3) Install fan belt, and install the fan.
4) Install the cooling system assembly.
40-302 46 PC200, 200LC, 220, 220LC-8M0

Failure code [CA778] Eng Bkup Speed Sensor Error SEN06134-00
PC200, 200LC, 220, 220LC-8M0 40-302 47

SEN06134-00 Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2185] Throt Sens Sup Volt High Error

Action
Failure code Throttle Sensor Power Supply Voltage High Error
level Failure
L03 CA2185
Detail of failure q High voltage (5.25 V or higher) appears in throttle sensor power supply circuit.
Action of con-
q Sets throttle position by using signal other than throttle sensor signal and allows engine to run.
troller
Problem on
q Engine speed cannot be controlled by fuel control dial.
machine
Related infor-
mation

tor
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor (fuel con-
2 If this failure code is not displayed, throttle sensor is defective.
trol dial)
a Other failure codes are displayed, too. This is because connector is discon-
nected. Ignore failure codes other than [CA2185].
2. Disconnect connectors CE02, CE03 and P20, and connect T-adapters to
each female side of CE02 and CE03.
3 Short circuit in wiring harness Between CE02 (female) (22) and each pin other Resis-
Min. 1 Mz
than (22) tance
Resis-
Between CE02 (female) (22) and CE03 (female) (3) Min. 1 Mz
tance
Hot short circuit in wiring harness 2. Disconnect connector P20 and connect T-adapters to female side.
Between P20 (female) (1) and ground Voltage 4.75 to 5.25V
2. Disconnect connector CE02, and connect T-adapters to male side.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness disconnected.
Between CE02 (male) (22) and (23) Voltage 4.75 to 5.25V
40-302 48 PC200, 200LC, 220, 220LC-8M0

Failure code [CA2185] Throt Sens Sup Volt High Error SEN06134-00
Circuit diagram related to engine controller power supply
PC200, 200LC, 220, 220LC-8M0 40-302 49

SEN06134-00 Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2186] Throt Sens Sup Volt Low Error

Action
Failure code Throttle Sensor Power Supply Voltage Low Error
level Failure
L03 CA2186
Detail of failure q Low voltage appears in throttle sensor power supply circuit.
Action of con-
q Sets throttle position by using signal other than throttle sensor signal and allows engine to run.
troller
Problem on
q Engine speed cannot be controlled by fuel control dial.
machine
Related infor-
mation

1 of "Checks before troubleshooting" in "General information on troubleshoot-
tor
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor (fuel con-
2 If this failure code is not displayed, throttle sensor is defective.
trol dial)
a Other failure code is displayed too. This is because connector is discon-
nected. Ignore failure codes other than [CA2186].
3 female side.
Between CE02 (female) (22) or P20 (female) (1) Resis-
Min. 1 Mz
and ground tance
2. Disconnect connectors CE02 and P20, and connect T-adapters to female
side of CE02.
4 Short circuit in wiring harness 3. Turn starting switch to ON position.
Between CE02 (female) (22) and each pin other Resis-
Min. 1 Mz
than (22) tance
2. Disconnect connector CE02, and connect T-adapters to male side.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness disconnected.
Between CE02 (male) (22) and (23) Voltage 4.75 to 5.25V
40-302 50 PC200, 200LC, 220, 220LC-8M0

Failure code [CA2249] Rail Press Very Low Error SEN06134-00
Failure code [CA2249] Rail Press Very Low Error

Action
Failure code Rail Press Very Low Error
level Failure
L03 CA2249
Detail of failure q No-pressure feed error (level 2) in supply pump was detected.
Action of con-
troller
Problem on
machine
q Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36401 (V)).
Related infor-
q Common rail pressure sensed by common rail pressure sensor can be checked by using monitor-
mation
ing function. (Code: 36400 (MPa))

1 Supply pump no pressure error Perform troubleshooting for failure code [CA559] .
Failure code [CA2311] lMV Solenoid Error

Action
Failure code IMV solenoid error
level Failure
L03 CA2311
Detail of failure q Resistance value of supply pump actuator circuit is unusually high or low.
Action of con-
troller
Problem on
machine
Related infor-
mation

1 IMV solenoid error Perform troubleshooting for failure codes [CA271] and [CA272].
PC200, 200LC, 220, 220LC-8M0 40-302 51

SEN06134-00 Failure code [CA2555] Grid Htr Relay Open Circuit Error
Failure code [CA2555] Grid Htr Relay Open Circuit Error

Action
Failure code Intake air Heater Relay Open Circuit Error
level Failure
L01 CA2555
Detail of failure q Open circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
troller
Problem on q Intake air heater does not work in auto preheating (degraded starting performance at low temper-
machine ature and emission of white smokes)
(Code: 18500)
q Method of reproducing failure code: Turn starting switch to ON position (when boost temperature
Related infor- is below -4 C)
mation q Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
side of preheater relay R18.
q For troubleshooting related to heater relay and secondary side of preheater relay R18, see E-2 in
E-mode.

tor
2. Disconnect relay R18, and connect T-adapters to male side.
200 to
Between R18 (male) (1) and (2) Resistance
400 z
2 Defective preheater relay R18
2. Replace relay R18 with another one.
If this failure code disappears, original preheater relay R18 is defective.
Open or short circuit in wiring har- 2. Disconnect connector CE02, and connect T-adapters to female side.
3
ness Between CE02 (female) (40) and (42) 200 to
Resistance
a Preheater relay R18 coil resistance 400 z
a If no failure is found by check on cause 3, this check is not required.
2. Disconnect connector CE02 and relay R18, and connect T-adapters to
4 Open circuit in wiring harness each female side.
Between CE02 (female) (40) and R18 (female) (1) Resistance Max. 1 z
Between R18 (female) (2) and CE02 (42) Resistance Max. 1 z
female side of CE02.
5 Short circuit in wiring harness a Check with multimeter in continuity mode.
Between CE02 (female) (40) and each pin other No continuity
than (40) (No sound is heard)
40-302 52 PC200, 200LC, 220, 220LC-8M0

Failure code [CA2555] Grid Htr Relay Open Circuit Error SEN06134-00
Circuit diagram related to intake air heater relay
PC200, 200LC, 220, 220LC-8M0 40-302 53

SEN06134-00 Failure code [CA2556] Grid Htr Relay Short Circuit Error
Failure code [CA2556] Grid Htr Relay Short Circuit Error

Action
Failure code Intake air Heater Relay Short Circuit
level Failure
L01 CA2556
Detail of failure q Short circuit is detected in drive circuit (primary circuit) of preheater relay.
Action of con-
troller
Problem on q Intake air heater does not work in auto preheating (degraded starting performance at low temper-
machine ature and emission of white smokes)
(Code: 18500 )
q Method of reproducing failure code: Turn starting switch to ON position (when boost temperature
Related infor- is below -4 C)
mation q Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
side of preheater relay R18.
q For troubleshooting related to heater relay and secondary side of preheater relay R18, see E-2 in
E-mode.

tor
200 to
Between R18 (male) (1) and (2) Resistance
400 z
2 Defective preheater relay R18
If this failure code disappears, original preheater relay R18 is defective.
3 Ground fault in wiring harness either female side.
Between CE02 (female) (40) or R18 (female) (1)
and ground
female side of CE02.
4 Short circuit in wiring harness a Check with multimeter in continuity mode.
Between CE02 (female) (40) and each pin other No continuity
than (40) (No sound is heard)
40-302 54 PC200, 200LC, 220, 220LC-8M0

Failure code [CA2556] Grid Htr Relay Short Circuit Error SEN06134-00
Circuit diagram related to intake air heater relay
PC200, 200LC, 220, 220LC-8M0 40-302 55

SEN06134-00
2012 KOMATSU
All Rights Reserved
40-302 56
SEN06135-00
SEN05987-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
Failure code [D110KB] Battery Relay Drive Short Circuit ........................................................................... 4

Failure code [D19JKZ] Personal Code Relay Abnormality ......................................................................... 6
Failure code [D811MC] KOMTRAX Error ................................................................................................... 8
Failure code [D862KA] GPS Antenna Open Circuit.................................................................................... 9
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)................................................................................... 10
Failure code [DA22KK] Pump Solenoid Power Low Error .......................................................................... 12
Failure code [DA25KP] 5V Sensor 1 Power Abnormality ........................................................................... 14
Failure code [DA26KP] 5V Sensor 2 Power Abnormality ........................................................................... 16
Failure code [DA29KQ] Model Selection Abnormality ................................................................................ 18
Failure code [DA2QKR] CAN2 Discon (Pump Con) ................................................................................... 23
Failure code [DAF0MB] Monitor ROM Abnormality .................................................................................... 26
Failure code [DAF0MC] Monitor Error ........................................................................................................ 27
Failure code [DAF8KB] Camera Power Supply Short Circuit ..................................................................... 28
Failure code [DAF9KQ] Model Selection Abnormality ................................................................................ 30
Failure code [DAFGMC] GPS Module Error ............................................................................................... 31
Failure code [DAFQKR] CAN2 Discon........................................................................................................ 32
Failure code [DAZ9KQ] A/C Model Selection Abnormality ......................................................................... 33
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ................................................................................. 34
Failure code [DB2QKR] CAN2 Discon (Engine Con).................................................................................. 36
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ................................................................................ 40
PC200, 200LC, 220, 220LC-8M0 40-303 1

SEN06135-00
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit .................................................................. 42
Failure code [DHPAMA] F Pump Press Sensor Abnormality ...................................................................... 44
Failure code [DHPBMA] R Pump Press Sensor Abnormality ..................................................................... 46
40-303 2 PC200, 200LC, 220, 220LC-8M0

SEN06135-00
PC200, 200LC, 220, 220LC-8M0 40-303 3

SEN06135-00 Failure code [D110KB] Battery Relay Drive Short Circuit
Failure code [D110KB] Battery Relay Drive Short Circuit

Action
Failure code Battery Relay Drive Short Circuit
level Failure
L01 D110KB
Detail of failure q Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
q Stops 24 V output to battery relay primary circuit (coil side).
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Each controller may fail in writing of data into its ROM (non-volatile memory).
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.
Related infor-
q Output state (ON/OFF) to battery relay can be checked with monitoring function.
mation
(Code: 03700 Controller output 1)
q Method of reproducing failure code: Turn starting switch to ON position, then turn it to OFF position.
Defective battery relay 1. Turn starting switch to OFF position.

1
(Internal short circuit) Between terminal R01 and terminal BR Continuity
2. Disconnect negative battery cable (in order not to make short circuit).
3. Disconnect connector R01, terminal R02, and connectors D01, H15 and
C02.
2 Between terminal R02 (BR) and ground Resistance Min. 1 Mz
Between any of terminal R02 (harness side), C02
(female) (108), D01 (female) (1) or (2) and ground
Between D01 (female) (5) and ground Resistance Min. 1 Mz
If no failure is found by above checks, pump controller is defective.
q Reference
2. Insert T-adapters into connector D01.
3 Defective pump controller 3. Turn starting switch to ON position.
4. Measure voltage during 4 to 7seconds after turning starting switch from ON
to OFF position
Between D01 (5) and ground Voltage 20 to 30 V
40-303 4 PC200, 200LC, 220, 220LC-8M0

Failure code [D110KB] Battery Relay Drive Short Circuit SEN06135-00
Circuit diagram related to battery relay
PC200, 200LC, 220, 220LC-8M0 40-303 5

SEN06135-00 Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D19JKZ] Personal Code Relay Abnormality

Action
Failure code Personal Code Relay Abnormality
level Failure
(KOMTRAX system in machine monitor)
L03 D19JKZ
Detail of failure q Open circuit or short circuit is detected in primary (coil) circuit of personal code relay.
q None in particular (for open circuit)
Action of q Stops output to personal code relay (for short circuit).
machine moni- q If cause of failure disappears, machine becomes normal by itself (for open circuit).
tor q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position (when short circuit is detected).
Problem on q When circuit is open, you can start the engine if engine start lock is enabled.
machine q When circuit has ground fault, you cannot start the engine.
q This failure code is displayed only when engine lock function is enabled.
q Method of reproducing failure code: Turn starting switch to ON position (open circuit). Failure code
Related infor-
cannot be reproduced (short circuit).
mation
q Troubleshooting for this failure code covers circuit starting from No. 3 of fuse F01, through primary
(coil) circuit of personal code relay R07, to machine monitor.

1 Blown fuse No. 3 of fuse box F01 When fuse is blown, ground fault may have probably occurred in circuit.
Between R07 (male) (1) and (2) Resistance 100 to 500 z
2 Defective personal code relay R07 1. Turn starting switch to OFF position.
If this failure code disappears, original personal code relay R07 is defective.
2. Remove fuse No. 3 of fuse box F01.
Open circuit or short circuit or 3. Disconnect connector CM01 and connect T-adapter to female side.
3
ground fault in wiring harness Between F01-3 and CM01 (female) (6) Resistance 100 to 500 z
Between F01-3 or CM01 (female) (6) and ground Resistance Min. 1 Mz
4 Open circuit in wiring harness 3. Disconnect connector CM01 and relay R07, and connect T-adapters to
each female side.
Between F01-3 and R07 (female) (1) Resistance Max. 1 z
Between R07 (female) (2) and CM01 (female) (6) Resistance Max. 1 z
3. Disconnect connector CM01 and relay R07, and connect T-adapters to
5 Ground fault in wiring harness either female side.
Between F01-3 or R07 (female) (1) and ground Resistance Min. 1 Mz
Between R07 (female) (2) and ground, or between
CM01 (female) (6) and ground
3. Disconnect connectors CM01 and relay R07, and connect T-adapters to
6 Short circuit in wiring harness female side of connector CM01.
Between CM01 (female) (6) and each pin other No continuity
than pin (6) (No sound is heard)
If no failure is found by above checks, machine monitor (KOMTRAX portion) is
Defective machine monitor
7 defective. (Since this is an internal defect, troubleshooting cannot be per-
(KOMTRAX section)
formed.)
40-303 6 PC200, 200LC, 220, 220LC-8M0

Failure code [D19JKZ] Personal Code Relay Abnormality SEN06135-00
Circuit diagram related to personal code relay
PC200, 200LC, 220, 220LC-8M0 40-303 7

SEN06135-00 Failure code [D811MC] KOMTRAX Error
Failure code [D811MC] KOMTRAX Error

Action
Failure code KOMTRAX error
level Failure
(KOMTRAX system)
D811MC
Detail of failure q KOMTRAX malfunctions.
Action of con-
troller
Problem on
q KOMTRAX system does not operate properly.
machine
Related infor-
mation

KOMTRAX is defective.
1 Malfunction of KOMTRAX
40-303 8 PC200, 200LC, 220, 220LC-8M0

Failure code [D862KA] GPS Antenna Open Circuit SEN06135-00
Failure code [D862KA] GPS Antenna Open Circuit

Action
Failure code GPS Antenna Open Circuit
level Failure
(KOMTRAX system)
D862KA
Detail of failure q Open circuit is detected in GPS antenna circuit.
Action of
machine moni-
q If cause of failure disappears, machine becomes normal by itself.
tor
Problem on
q GPS positioning cannot work.
machine
Related infor-
mation

Defective GPS antenna or Probable causes are defective GPS antenna, open circuit or short circuit in
1
antenna cable antenna GPS cable, and defective connection of antenna cable connector (A).
Structural illustration
PC200, 200LC, 220, 220LC-8M0 40-303 9

SEN06135-00 Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)

Action
Failure code CAN 2 Disconnection (KOMTRAX)
level Failure
(Detected by machine monitor) (Machine monitor system)
D8AQKR
q Machine monitor cannot recognize pump controller through CAN communication 2 line (KOM-
Detail of failure
NET/c).
Action of
machine moni- q None
tor
Problem on
q None
machine
Method of reproducing failure code: Turn starting switch to ON position.
q
Start of CAN communication is recognized by each controller when ACC signal of starting switch
q
is received.
q Machine monitor indicates a CAN communication error in CAN2 with failure code [DA2QKR],
[DB2QKR], [D8AQKR], or [DAZQKR]. If all four of these failure code are displayed, harness (CAN
communication line) may have ground fault, short circuit, or hot short circuit. Since air conditioner
is also controlled via CAN communication, check whether air conditioner is operated (ON/OFF and
Related infor-
air flow adjustment) on air conditioner screen.
mation
a Air conditioner can be operated even when failure code is displayed on machine monitor screen. If
air conditioner is operated, there is no possibility of ground fault, short circuit, or hot short circuit in
wiring harness (CAN communication line).
q Since each controller and machine monitor are connected to continuous power supply, they receive
continuous power even while starting switch is at OFF position.
q Since active CAN communication line signal is pulse voltage, it cannot be measured by using mul-
timeter.
No. Cause Procedure, measuring location, criteria and remarks

2. Disconnect fusible link F05 and connect T-adapters to female side.
1 Defective fusible link F05
Between F05 (female) (1) and (2) Resistance Max. 1 z
a If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in fuse box 2. Remove fuse No. 17 in fuse box F01.
2
F01
If fuse is blown, circuit probably has ground fault.
Power supply to KOMTRAX termi-
3 Perform troubleshooting for E mode, "E-36"
nal defective
Defective CAN communication 2
4 Perform checks on cause 4 to 9 in troubleshooting for failure code [DB2QKR].
line
If no failure is found by above checks, KOMTRAX terminal is defective.
5 Defective KOMTRAX terminal
40-303 10 PC200, 200LC, 220, 220LC-8M0

Failure code [D8AQKR] CAN2 Discon (KOMTRAX) SEN06135-00
Circuit diagram related to power supply
PC200, 200LC, 220, 220LC-8M0 40-303 11

SEN06135-00 Failure code [DA22KK] Pump Solenoid Power Low Error
Failure code [DA22KK] Pump Solenoid Power Low Error

Action
Failure code Pump Solenoid Power supply voltage Low Error
level Failure
(input) (Pump controller system)
L03 DA22KK
Detail of failure q Power supply supply voltage of controller for driving solenoids is below 20 V.
q Stops generation of failure codes (open circuit and short circuit) for all solenoid systems while this
Action of con-
failure code is active.
troller
Problem on
q No solenoid valve is energized properly, so machine does not work properly.
machine
Related infor- sured at pump controller connector.
mation q If failure code [D110KB] is displayed, troubleshoot it first.

Defective fusible link F04 or fuse
1 If fusible link or fuse is blown, circuit probably has ground fault. (See Cause 5.)
No.2 of fuse box F01
2 Improper battery voltage 2. After measuring voltage, measure it again when starting engine.
Between battery (+) and ground Voltage 20 to 30 V
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect connector C02 and connect T-adapters to female side.
3 Defective wiring harness 3. Connect battery ground cable and turn starting switch to ON position.
Between each of (116), (118) and (121) of C02 and
Voltage 20 to 30 V
ground
2. Remove fusible link F04 and fuse (2) in fuse box F01.
4 Open circuit in wiring harness Between each of (116), (118) and (121) of C02
Resistance Max. 1 z
(female) and F01-2
Between F01-1A and F04 (male) (2) Resistance Max. 1 z
Between F04 (male) (1) and terminal R03 Resistance Max. 1 z
2. Remove fusible link F04 and fuse No. 2 of fuse box F01.
5 Between ground and each of (116), (118) and (121)
(contact with ground circuit) Resistance Min. 1 Mz
of C02 (female) or F01-2
Between F01-1A or F04 (male) (2) and ground Resistance Min. 1 Mz
Between F04 (male) (1) or terminal R03 and ground Resistance Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this
6 Defective pump controller
is an internal defect, troubleshooting cannot be performed.)
40-303 12 PC200, 200LC, 220, 220LC-8M0

Failure code [DA22KK] Pump Solenoid Power Low Error SEN06135-00
Circuit diagram related to solenoid power supply circuit
PC200, 200LC, 220, 220LC-8M0 40-303 13

SEN06135-00 Failure code [DA25KP] 5V Sensor 1 Power Abnormality
Failure code [DA25KP] 5V Sensor 1 Power Abnormality

Action
Failure code 5 V Sensor 1 Power supply voltage Abnormality
level Failure
DA25KP
Detail of failure q Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
Action of con- q Stops output of power from 5V sensor power supply output 1.
troller q Even if cause of failure disappears, machine does not become normal until starting switch is turned
q Automatic travel speed selector function does not work (pump pressure sensor system).
Problem on
q Auto-decelerator keeps working and is not canceled or fine control performance of work equipment
machine
is lowered (PPC pressure sensor system).
Related infor-
mation

2. Disconnect following sensors one by one, and turn starting switch to ON
position for each troubleshooting.
a If this failure code disappears, disconnected sensor is defective.
3. After each troubleshooting, turn starting swith to OFF position.
Sensor Connector
Bucket CURL PPC pressure sensor P01
Boom DOWN PPC pressure sensor P02
Defective pressure sensor Bucket DUMP PPC pressure sensor P05
1
(Internal short circuit)
Arm IN pressure sensor P04
Boom RAISE PPC pressure sensor P06
Swing RIGHT PPC pressure sensor P07
Arm DUMP PPC pressure sensor P08
Swing LEFT PPC pressure sensor P03
F pump pressure sensor P25
R pump pressure sensor P26
a To measure voltage before controller stops output of power.
2. Disconnect connectors P01 to P08 and P25, and P26.
Hot short circuit in wiring harness 3. Connect T-adapters to female side of either of disconnected connectors
2 (e.g. P07).
4. Turn starting switch to ON position (with connectors P01 to P08, and P25
and P26 disconnected).
Between P07 (female) (3) and ground Voltage 4.5 to 5.5 V
Ground fault in wiring harness 2. Disconnect connectors C01, P01 to P08, and P25 and P26.
3
(contact with ground circuit) 3. Connect T-adapters to female side of connector C01.
Between C01 (female) (9) and ground Resistance Min. 1 Mz
If no failure is found by above checks, the pump controller is defective. (Since
40-303 14 PC200, 200LC, 220, 220LC-8M0

Failure code [DA25KP] 5V Sensor 1 Power Abnormality SEN06135-00
Circuit diagram related to 5 V sensor 1 power supply circuit
PC200, 200LC, 220, 220LC-8M0 40-303 15

SEN06135-00 Failure code [DA26KP] 5V Sensor 2 Power Abnormality
Failure code [DA26KP] 5V Sensor 2 Power Abnormality

Action
Failure code 5V sensor 2 Power Supply voltage Abnormality
level Failure
DA26KP
Detail of failure q Voltage of 5 V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V.
Action of con- q Stops power supply from 5 V sensor power supply output 2 circuit.
Problem on
q Travel does not stable
machine
Related infor-
mation

2. Disconnect following sensors one by one, and turn starting switch to ON
position for each troubleshooting.
a If this failure code disappears, disconnected sensor is defective.
3. After each troubleshooting, turn starting swith to OFF position.
Defective pressure sensor Sensor Connector
1
(Internal short circuit)
L.H. travel FORWARD PPC pressure sensor P09
L.H. travel REVERSE PPC pressure sensor P10
R.H. travel FORWARD PPC pressure sensor P11
R.H. travel REVERSE PPC pressure sensor P12
a To measure voltage before controller stops output of power.
2. Disconnect connectors P09 to P12.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of either of disconnected connectors
2 (e.g. P09).
4. Turn starting switch to ON position (with connectors P09 to P12 discon-
nected).
Between P09 (female) (3) and ground Voltage 4.5 to 5.5 V
Ground fault in wiring harness 2. Disconnect connectors C01, P09 to P12.
3 3. Connect T-adapters to female side of connector C01.
40-303 16 PC200, 200LC, 220, 220LC-8M0

Failure code [DA26KP] 5V Sensor 2 Power Abnormality SEN06135-00
Circuit diagram related to 5 V sensor 2 power supply circuit
PC200, 200LC, 220, 220LC-8M0 40-303 17

SEN06135-00 Failure code [DA29KQ] Model Selection Abnormality
Failure code [DA29KQ] Model Selection Abnormality

Action
Failure code Model Selection Abnormality
level Failure
L01 DA29KQ
Detail of failure q Model code of input signal is not registered in controller.
Action of con- q Controls machine, taking it that machine is default model (PC200).
Problem on
q Because pump controller recognizes machine as "PC200", no particular problem occurs.
machine
q Model code input to pump controller can be checked by using monitoring function.
(Code: 00200 Controller model code)
Related infor-
q Input of model selection signal can be checked with monitoring function.
mation
(Code: 02201 Switch Input 2)
q PC200-8M0, PC200LC-8M0

2. Disconnect connector S30 and connect T-adapters to female side.
Between S30 (female) (1) and (2) Resistance Min. 1 Mz
Defective model selection connec-
1 tor Between S30 (female) (2) and (3) Resistance Min. 1 Mz
(internal open or short circuit) Between S30 (female) (3) and (4) Resistance Min. 1 Mz
Between S30 (female) (3) and (8) Resistance Max. 1 z
2 Open circuit in wiring harness 2. Disconnect connector C01 and connect T-adapters to female side.
Between C01 (female) (77) and ground Resistance Max. 1 z
Between C01 (female) (21) and C01 (female) (77) Resistance Min. 1 Mz
Between C01 (female) (39) and C01 (77) Resistance Min. 1 Mz
4 Between C01 (female) (40) and ground Resistance Min. 1 Mz
40-303 18 PC200, 200LC, 220, 220LC-8M0

Failure code [DA29KQ] Model Selection Abnormality SEN06135-00
Circuit diagram related to model selection signal (PC200-8M0, PC200LC-8M0)
PC200, 200LC, 220, 220LC-8M0 40-303 19

q PC220-8M0, PC220LC-8M0
Defective model selection connec-
1 tor Between S30 (female) (3) and (4) Resistance Min. 1 Mz
(internal open or short circuit) Between S30 (female) (4) and (7) Resistance Min. 1 Mz
3 Short circuit in wiring harness Between C01 (female) (21) and C01 (77) Resistance Min. 1 Mz
Ground fault in wiring harness Between C01 (female) (21) and ground Resistance Min. 1 Mz
4
(contact with ground circuit) Between C01 (female) (39) and ground Resistance Min. 1 Mz
40-303 20 PC200, 200LC, 220, 220LC-8M0

Failure code [DA29KQ] Model Selection Abnormality SEN06135-00
Circuit diagram related to model selection signal (PC220-8M0, PC220LC-8M0)
PC200, 200LC, 220, 220LC-8M0 40-303 21

40-303 22 PC200, 200LC, 220, 220LC-8M0

Failure code [DA2QKR] CAN2 Discon (Pump Con) SEN06135-00
Failure code [DA2QKR] CAN2 Discon (Pump Con)

Action
Failure code CAN2 Discon (Pump Con)
level Failure
L03 DA2QKR
q Machine monitor does not recognize pump controller through CAN communication 2 line
Detail of failure
(KOMNET/c).
Action of con-
q Holds information at the time of occurrence of failure.
troller
Information to be obtained from pump controller is not displayed or special function that uses infor-
q
Problem on
mation from pump controller does not work. Or received data (failure codes, monitoring codes, etc.
machine
transmitted from pump controller) is no longer updated.
q Start of CAN communication is recognized by each controller when ACC signal of starting switch
is received.
q Machine monitor uses four failure codes, [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR], to
indicated failure in CAN communication through CAN 2 line. When all of these failure code are dis-
played simultaneously on screen, ground fault, short circuit, or hot short circuit may occur in wiring
harness (CAN communication line). Since air conditioner is also controlled through CAN commu-
nication, check whether air conditioner is operated (ON/OFF and air flow adjustment) on air condi-
Related infor-
tioner screen.
mation
q This code appears even when pump controller power supply is shut off.
q Since signal of active CAN communication line is pulse voltage, it cannot be measured by using
multimeter.

2. Disconnect fusible link F05 and connect T-adapters to female side.
1 Defective fusible link F05
Resistance Between F05 (female) (1) and (2) Max. 1 z
a If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in fuse box 2. Remove fuse No. 17 in fuse box F01.
2
F01
When fuse is blown, circuit may have ground fault.
a Check ground terminal T04 for looseness and rust.
Improper power supply to pump
controller
Between C01 (female) (1) and (2) 20 to 30 V
Voltage
Between C01 (female) (4) and (5) 20 to 30 V
1. Turn starting switch to OFF position, and disconnect ground cable.
2. Remove fuse No. 17 in fuse box F01.
3. Disconnect fusible link F05 and connector C01, and connect Tadapters to
Open circuit in wiring harness each female side.
4 (wire breakage or defective con- Between terminal R04 and F05 (female) (1) Max. 1 z
tact of connector)
Between F05 (female) (2) and F01-16E Max. 1 z
Resistance
Between F01-17 and C01 (female) (1) Max. 1 z
Between F01-17 and C01 (female) (4) Max. 1 z
Defective CAN communication 2
line
PC200, 200LC, 220, 220LC-8M0 40-303 23

SEN06135-00 Failure code [DA2QKR] CAN2 Discon (Pump Con)

40-303 24 PC200, 200LC, 220, 220LC-8M0

Failure code [DA2QKR] CAN2 Discon (Pump Con) SEN06135-00
Circuit diagram related to pump controller power supply
PC200, 200LC, 220, 220LC-8M0 40-303 25

SEN06135-00 Failure code [DAF0MB] Monitor ROM Abnormality
Failure code [DAF0MB] Monitor ROM Abnormality

Action
Failure code Monitor ROM Abnormality
level Failure
DAF0MB
Detail of failure q Program of machine monitor is rewritten (program error).
Action of con-
troller
Problem on q Indication of machine monitor is unreliable.
machine q Machine monitor is incapable of normally exchanging data with controllers.
Related infor-
mation

Machine monitor is defective.
40-303 26 PC200, 200LC, 220, 220LC-8M0

Failure code [DAF0MC] Monitor Error SEN06135-00
Failure code [DAF0MC] Monitor Error

Action
Failure code Monitor Error
level Failure
DAF0MC
Detail of failure q Machine monitor malfunctions.
Action of con-
troller
Problem on q Indication of machine monitor is unreliable.
machine q Machine monitor is incapable of normally exchanging data with controllers.
Related infor-
mation

Machine monitor is defective.
PC200, 200LC, 220, 220LC-8M0 40-303 27

SEN06135-00 Failure code [DAF8KB] Camera Power Supply Short Circuit
Failure code [DAF8KB] Camera Power Supply Short Circuit

Action
Failure code Camera Power Supply Short Circuit
level Failure
L03 DAF8KB
q Output power supply voltage (rating: 8 V) from machine monitor to camera is below 6.0 V or above
Detail of failure
10 V.
Action of q Stops output of power supply voltage (Rating: 8 V) to camera.
machine moni- q Even if cause of failure disappears, machine does not become normal until starting switch is turned
tor to OFF position.
Problem on
q Camera image is not displayed on monitor screen.
machine
Related infor-
mation

2. Disconnect camera connector(s), and turn starting switch to ON position.
Defective camera (internal short
1 After above operation (disconnecting camera connector and performing failure
circuit)
code reproducing procedure), if failure code disappears, camera has internal
defect.
2. Disconnect connector CM04.
2 Defective machine monitor 3. Connect T-adapters to male side of connector CM04.
Between CM04 (male) (1) and ground Voltage 6 to 10 V
Ground fault in wiring harness 2. Disconnect connector CM04 and camera connector (s).
3 3. Connect T-adapters to female side of connector CM04.
Between CM04 (female) (1) and ground Resistance Min. 1 Mz
2. Disconnect camera connector(s).
Hot short circuit in wiring harness 3. Insert T-adapters into connector CM04.
(Disconnect camera and check that camera is not defective in advance.)
Between CM04 (1) and (5) Voltage Max. 10 V
40-303 28 PC200, 200LC, 220, 220LC-8M0

Failure code [DAF8KB] Camera Power Supply Short Circuit SEN06135-00
Circuit diagram related to camera power supply
PC200, 200LC, 220, 220LC-8M0 40-303 29

SEN06135-00 Failure code [DAF9KQ] Model Selection Abnormality
Failure code [DAF9KQ] Model Selection Abnormality

Action
Failure code Model selection abnormality
level Failure
L03 DAF9KQ
q Model registered in the machine monitor and pump controller differs.
Detail of failure
(Machine monitor or pump controller has been replaced with a wrong part.)
Action of con-
troller
Problem on
q Machine does not operate normally
machine
q Assembly part No. of pump controller program can be checked by using monitoring function (Code:
20229)
Related infor-
q Assembly part No. of machine monitor program can be checked by using monitoring function
mation
(Code: 20227)

1. Use monitoring function to display assembly part number and check
whether it is identical to that listed in Parts book.
(a different model is registered)
1. Use monitoring function to display assembly part number and check
whether it is identical to that listed in Parts book.
Defective pump controller
40-303 30 PC200, 200LC, 220, 220LC-8M0

Failure code [DAFGMC] GPS Module Error SEN06135-00
Failure code [DAFGMC] GPS Module Error

Action
Failure code GPS module error
level Failure
(KOMTRAX system)
DAFGMC
q Position data is not sent from GPS module (in KOMTRAX terminal) to KOMTRAX communication
Detail of failure
modem in 50 seconds after KOMTRAX started.
Action of
machine moni-
tor
Problem on
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position (wait at least 50 seconds
mation after starting switch is turned to ON position).

GPS module in KOMTRAX terminal may be defective.
1 Defective KOMTRAX terminal
PC200, 200LC, 220, 220LC-8M0 40-303 31

SEN06135-00 Failure code [DAFQKR] CAN2 Discon
Failure code [DAFQKR] CAN2 Discon

Action
Failure code CAN 2 Disconnection
level Failure
(Detected by KOMTRAX terminal) (KOMTRAX system)
DAFQKR
Detail of failure q KOMTRAX terminal does not recognize machine monitor through CAN communication 2 line.
Action of con-
troller
Problem on
q KOMTRAX system may not function normally.
machine
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is transmitted to and displayed on machine monitor by CAN communication. Accord-
ingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is not displayed on
Related infor-
machine monitor and it can be observed only through KOMTRAX system.
mation
timeter.

Defective power supply to
1 Perform troubleshooting for "E-5" in E mode troubleshooting.
machine monitor
Perform checks on cause 5 and up in troubleshooting for failure code
2 Defective CAN communication
[DB2QKR].
40-303 32 PC200, 200LC, 220, 220LC-8M0

Failure code [DAZ9KQ] A/C Model Selection Abnormality SEN06135-00
Failure code [DAZ9KQ] A/C Model Selection Abnormality

Action
Failure code Air Conditioner Model Selection Abnormality
level Failure
DAZ9KQ
q Model registered in the machine monitor and air conditioner controller differs.
Detail of failure
(Machine monitor or air conditioner controller has been replaced with a wrong part.)
Action of con-
troller
Problem on
q Machine does not operate normally
machine
q Model code registered in air conditioner controller can not be checked by using monitoring function.
q Model codes registered in machine monitor can be checked by using monitoring function. (Code:
00500)
Related infor- q Air conditioner control data (series and model) in the machine monitor can be checked by using
mation monitoring function. (Code: 55200)
q Air conditioner control data (series and model) in the air conditioner controller can be checked by
using monitoring function. (Code: 55201) (It is normal if control data is 01 (which means PC).)

Defective air conditioner controller
2 Defective air conditioner controller
PC200, 200LC, 220, 220LC-8M0 40-303 33

SEN06135-00 Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
Failure code [DAZQKR] CAN2 Discon (Aircon ECU)

Action
Failure code CAN2 Disconnection (Air Conditioner ECU)
level Failure
L01 DAZQKR
q Machine monitor does not recognize air conditioner controller over CAN communication-2 line
Detail of failure
(KOMNET/c).
Action of con- q Holds information at the time of occurrence of failure.
q Failure codes to be generate by air conditioner controller are not displayed.
Problem on q Monitoring data for which air conditioner controller is responsible are not updated.
machine q Air conditioner will be inoperable.
q Air conditioner control screen will not be displayed correctly on the machine monitor.
is received.
q For CAN communication error over CAN communication-2 line, machine monitor can generate four
failure codes; [D8AQKR], [DA2QKR], [DAZQKR] and [DB2QKR]. When all of these four failure
Related infor-
codes are displayed simultaneously on screen, ground fault, short circuit, or hot short circuit may
mation
occur in wiring harness (CAN communication line).
timeter.

Defective power supply to air con- a Perform troubleshooting in Chapter 80 "Troubleshooting for power supply
1
ditioner controller system".
Defective CAN2 communication
system
If no failure is found by above checks, air conditioner controller is defective.
3 Defective air conditioner controller
40-303 34 PC200, 200LC, 220, 220LC-8M0

Failure code [DAZQKR] CAN2 Discon (Aircon ECU) SEN06135-00
PC200, 200LC, 220, 220LC-8M0 40-303 35

SEN06135-00 Failure code [DB2QKR] CAN2 Discon (Engine Con)
Failure code [DB2QKR] CAN2 Discon (Engine Con)

Action
Failure code CAN 2 Disconnection Engine controller
level Failure
L03 DB2QKR
q Machine monitor cannot recognize engine controller through CAN communication 2 line (KOM-
Detail of failure
NET/c).
Action of con-
q Holds information at the time of occurrence of failure.
troller
Information to be obtained from engine controller is not displayed and special functions that use
q
Problem on
them do not work. Or, received data is no longer updated. (such as failure codes and monitoring
machine
codes sent from engine controller)
is received.
q Machine monitor indicates a CAN communication error in CAN2 with failure code [DA2QKR],
[DB2QKR], [D8AQKR], or [DAZQKR]. If all four of these failure code are displayed, harness (CAN
communication line) may have ground fault, short circuit, or hot short circuit. Since air conditioner
is also controlled via CAN communication, check whether air conditioner is operated (ON/OFF and
Related infor-
air flow adjustment) on air conditioner screen.
mation
timeter.

Defective fuses Nos. No.19 (30 A) 1. Turn starting switch to OFF position.
1 for (engine controller) in fuse box 2. Remove fuses No.19 (30 A) from fuse box F01.
F01 q When fuse is blown, engine controller may have short circuit in it.
a If fuse is not blown, this check is not required.
2 Defective engine controller 2. Disconnect connector CE03, and connect T-adapters to male side.
Between CE03 (male) (3) and (1) Resistance Min. 10 z
a Check ground terminal T12 for looseness and rust.
Improper power supply to engine 2. Disconnect connector CE03, and connect T-adapters to female side.
controller
a If result is abnormal, perform troubleshooting for [CA441].
Between CE03 (female) (3) and (1) Voltage 20 to 30 V
2. Disconnect connectors CM02 and K02, and connect T-adapters to each
Defective CAN terminating resis-
male side.
4 tor
(internal open or short circuit) Between K02 (male) (A) and (B) Resistance 120 12 z
Between CM02 (male) (7) and (9) Resistance 120 12 z
40-303 36 PC200, 200LC, 220, 220LC-8M0

Failure code [DB2QKR] CAN2 Discon (Engine Con) SEN06135-00

q CAN communication line
a Machine monitor also has 120 z CAN terminating resistor in it. Since 120 z
resistors are connected in parallel, if resistance measured at connector of
controller other than machine monitor is 60 z which is combined resistance,
there is no open circuit in wiring harness.
2. Disconnect related connectors and connect T-adapters to connector at
which measurement is performed.
a If short circuit occurs (if resistance between terminals is 1 z or less), discon-
nect all CAN communication connectors of each controller. Then, check
Open or short circuit in wiring har- whether short circuit is in wiring harness or within controller.
5 Approx.
ness Between CM02 (female) (8) and (9) Resistance
120 z
Approx.
Between CE02 (female) (46) and (47) Resistance
60 z
Approx.
Between C01 (female) (45) and (64) Resistance
60 z
Approx.
Between AC01 (female) (1) and (2) Resistance
60 z
Approx.
Between CK01 (female) (10) and (11) Resistance
60 z
Approx.
Between K02 (female) (A) and (B) Resistance
120 z
q ACC signal from starting switch (CAN communication start is not recog-
nized)
1. Turn starting switch to OFF position, and disconnect battery ground cable.
2. Disconnect connector at which measurement is performed and insert
T-adapters into it.
3. Connect battery ground cable, and turn starting switch to ON position.
Between CM01 (10) and (3) Voltage 20 to 30 V
Between CE02(39) and CE03(1) Voltage 20 to 30 V
Between C01 (24), (43) and (79) and (2) Voltage 20 to 30 V
Between AC02 (4) and (1) Voltage 20 to 30 V
Between CK02 (3) and (1) Voltage 20 to 30 V
Open circuit in wiring harness 1. Turn starting switch to OFF position, and disconnect battery ground cable.
6 (wire breakage or defective con- 2. Disconnect related connectors and connect T-adapters to female side of
tact of connector) connector at which measurement is performed.
Between CM02 (female) (8) and C01 (female) (45) Resistance Max. 1 z
Between CM02 (female) (9) and C01 (female) (64) Resistance Max. 1 z
Between CM02 (female) (8) and CE02 (female) (46) Resistance Max. 1 z
Between CM02 (female) (9) and CE02 (female) (47) Resistance Max. 1 z
Between CM02 (female) (8) and AC01 (female) (2) Resistance Max. 1 z
Between CM02 (female) (9) and AC01 (female) (1) Resistance Max. 1 z
Between CM02 (female) (8) and CK01 (female) (10) Resistance Max. 1 z
Between CM02 (female) (9) and CK01 (female) (11) Resistance Max. 1 z
Between CE02 (female) (46) and K02 (female) (A) Resistance Max. 1 z
Between CE02 (female) (47) and K02 (female) (B) Resistance Max. 1 z
a If no failure is found by checks on cause 5 (no open circuit), measure volt-
age at one connector.
2. Disconnect related connectors and connect T-adapters to female side of
7 connector at which measurement is performed.
Between ground and any point in C01 (female) (45),
CM02 (female) (7), (8) or CE02 (female) (46)
Between ground and any point in C01 (female) (64),
CM02 (female) (9) or CE02 (female)(47)
PC200, 200LC, 220, 220LC-8M0 40-303 37

SEN06135-00 Failure code [DB2QKR] CAN2 Discon (Engine Con)

a If no failure is found by check on cause 5 (no open circuit), measure in only
one place each.
1. Turn starting switch to OFF position, and disconnect battery ground cable.
2. Disconnect connector at which measurement is performed and insert
T-adapters into connector.
Short circuit or hot short circuit in a Since voltages of CAN H and CAN L lines are 2.5 1 V including during
8 wiring harness (contact with 24 V communication, harnesses are considered normal as long as their voltages
(contact with 24 V circuit) are between 1 and 4 V.
Between ground and any one of CM02 (female) (8),
C01 (female) (45), CK01 (female) (10), AC01 Voltage 1 to 4 V
(female) (2), CE02(female)(46)
Between ground and any one of CM02 (female) (9),
C01 (female) (64), CK01 (female) (11), AC01 Voltage 1 to 4 V
(female) (1), CE02 (female) (47)
q If all four failure codes [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR]
are displayed
a Repeat following steps 1. to 3. to disconnect controllers one by one from
CAN communication and to identify defective controller.
Defective engine controller, pump 2. Disconnect CAN communication connector of engine controller (connector
9 controller, air conditioner unit or CE03), pump controller (connector CP01), air conditioner unit (connector
KOMTRAX terminal AC01),and KOMTRAX terminal (connector CK01) one by one.
3. Connect battery ground cable, turn starting switch to ON position, then
perform troubleshooting.
4. Return to step 1. and troubleshoot next controller.
Has the number of displayed failure codes If YES, disconnected
decreased from four? controller is defective.
If no failure is found by above checks, engine controller is defective.
40-303 38 PC200, 200LC, 220, 220LC-8M0

Failure code [DB2QKR] CAN2 Discon (Engine Con) SEN06135-00
Circuit diagram related to CAN communication 2
PC200, 200LC, 220, 220LC-8M0 40-303 39

SEN06135-00 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit

Action
Failure code Hydraulic Oil Sensor Short Circuit
level Failure
L01 DGH2KB
q Signal voltage of hydraulic oil temperature sensor circuit is below 1 V, so pump controller deter-
Detail of failure
mines that circuit shorts.
Action of con-
troller
Problem on q Regardless of the hydraulic oil temperature, hydraulic oil temperature gauge meter is equivalent to
machine 50 degrees.
q Signal voltage from hydraulic oil temperature sensor can be checked with monitoring function.
Related infor-
(Code: 04402: Hydraulic oil temperature sensor voltage)
mation

Between P22 (male) (1) 10 C Resistance Approx. 90 kz
Defective hydraulic oil tempera- and (2) 30 C Resistance Approx. 35 kz
1 ture sensor a Temperature-Resis-
(internal open or short circuit) tance characteristics of 80 C Resistance Approx. 6.5 kz
oil temperature sensor 100 C Resistance Approx. 3.5 kz
Between P22 (male) (2) and ground Resistance Min. 1 Mz
1.
Turn starting switch to OFF position.
2.
Disconnect connector P22 and connect T-adapters to female side.
3.
Turn starting switch to ON position.
Open circuit or short circuit or a
If voltage is 0 V, wiring harness has open circuit, ground fault, or short cir-
2 ground fault or hot short circuit in cuit, and if voltage is 24 V, wiring harness has hot short circuit.
wiring harness a Voltage of about 5 V is applied to temperature sensor signal lines through
resistor in pump controller.
Between P22 (female) (1) and (2) Voltage Approx. 5 V
a Use Temperature-Resistance characteristics table for troubleshooting on
cause 1 as resistance criteria.
3 a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
ing harness
is below 1 z, wiring harness has short circuit.
Between C01 (female) (29) and (46) Resistance 3.5 to 90 kz
Ground fault in wiring harness 2. Disconnect connectors C01 and P22, and connect T-adapters to either
4
Between C01 (female) (29) and ground, or
between P22 (female) (2) and ground
40-303 40 PC200, 200LC, 220, 220LC-8M0

Failure code [DGH2KB] Hyd Oil Sensor Short Circuit SEN06135-00
Circuit diagram related to hydraulic oil temperature sensor
PC200, 200LC, 220, 220LC-8M0 40-303 41

SEN06135-00 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit

Action
Failure code Air cleaner clogging sensor open circuit
level Failure
L01 DHA4KA
q Air cleaner clogging switch signal voltage is not below 1 V while engine is running, so machine mon-
Detail of failure
itor determines that air cleaner is clogged (switch contact is open).
Action of con-
q Displays air cleaner clogging monitor in red on machine monitor.
troller
Problem on
q If machine is used as it is, engine may be broken.
machine
q Input signal status (ON/OFF) from air cleaner clogging switch can be checked by using monitoring
Related infor-
function (Code: 04501 Monitor input: 2).
mation

Open circuit in air cleaner clogging
1 Perform troubleshooting for failure code [AA10NX].
sensor
40-303 42 PC200, 200LC, 220, 220LC-8M0

Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit SEN06135-00
PC200, 200LC, 220, 220LC-8M0 40-303 43

SEN06135-00 Failure code [DHPAMA] F Pump Press Sensor Abnormality
Failure code [DHPAMA] F Pump Press Sensor Abnormality

Action
Failure code Front Pump Pressure Sensor Abnormality
level Failure
L01 DHPAMA
Detail of failure q Signal voltage of front pump pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking it that front pump pressure is 0 MPa {0 kg/cm2}.
Problem on Automatic travel speed selector function does not work.
q
machine Straight travel performance or steering performance lowers.
q
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
Related infor-
mation
q Front pump pressure can be checked with monitoring function.
(Code: 01100 F pump pressure).

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
Defective 5V sensor power supply 2. Disconnect connector P25, and connect T-adapters to female side.
1 system
a If power supply voltage is abnormal, proceed to check on cause 3.
Power sup-
Between P25 (female) (3) and (1) Voltage 4.5 to 5.5 V
ply
2. Insert T-adapters into connector P25.
Sensor out-
Between P25 (2) and (1) Voltage 0.5 to 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
is difficult to judge whether cause of failure is defective sensor, ground fault
Defective front pump pressure or hot short circuit in wiring harness. Check as below.
2
sensor (internal defect) 1. Turn starting switch to OFF position.
2. Replace connector P25 with connector P26 of R pump PPC pressure
sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, front pump pressure sensor
is defective.
a After finishing test, restore connectors.
2. Disconnect connectors C01 and P25, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z
3 (wire breakage or defective con- Between C01 (female) (18) and P25 (female) (1)
tact of connector)
Between C01 (female) (49) and P25 (female) (2) Resistance Max. 1 z
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P25 (female) (3)
2. Disconnect connectors C01 and P25, and connect T-adapters to either
4 female side.
Between C01 (female) (49) or P25 (female) (2) and
ground
40-303 44 PC200, 200LC, 220, 220LC-8M0

Failure code [DHPAMA] F Pump Press Sensor Abnormality SEN06135-00

2. Disconnect connector P25.
Hot short circuit in wiring harness 3. Connect T-adapters to female side of connector P25.
5
(Contact with 5 V or 24 V circuit) 4. Turn starting switch to ON position.
Circuit diagram related to front pump pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-303 45

SEN06135-00 Failure code [DHPBMA] R Pump Press Sensor Abnormality
Failure code [DHPBMA] R Pump Press Sensor Abnormality

Action
Failure code Rear Pump Pressure Sensor Abnormality
level Failure
L01 DHPAMA
Detail of failure q Signal voltage of rear pump pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking it that rear pump pressure is 0 MPa {0 kg/cm2}.
Problem on Automatic travel speed selector function does not work.
q
machine Straight travel performance or steering performance lowers.
q
Related infor-
mation
q Rear pump pressure can be checked with monitoring function.
(Code: 01101 R pump pressure)

1 system
Power sup-
ply
2. Connect T-adapters to connector P26.
Sensor out-
put
Defective rear pump pressure sen- or hot short circuit in wiring harness. Check as below.
2
sor (internal defect) 1. Turn starting switch to OFF position.
2. Replace connector P26 with connector P25 of front pump PPC pressure
sensor.
4. If E mark is not displayed for this failure code, rear pump pressure sensor
is defective.
female side.
tact of connector)
4 female side.
ground
40-303 46 PC200, 200LC, 220, 220LC-8M0

Failure code [DHPBMA] R Pump Press Sensor Abnormality SEN06135-00

5
(contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
Circuit diagram related to rear pump pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-303 47

SEN06135-00
2012 KOMATSU
All Rights Reserved
40-303 48
SEN06136-00
SEN05988-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ............................................................ 4
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality .................................................... 6
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality....................................................... 8
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality ...................................................... 10
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality .......................................................... 12
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality .......................................................... 14
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ........................................................ 16
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality .................................................... 18
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality....................................................... 20
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality ..................................................... 22
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality ...................................................... 24
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality ...................................................... 26
Failure code [DHX1MA] Overload Sensor Abnormality .............................................................................. 28
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality............................................................. 30
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality............................................................. 32
Failure code [DV20KB] Travel Alarm Short Circuit ..................................................................................... 34
Failure code [DW43KA] Travel Speed Sol Open Circuit ............................................................................. 36
Failure code [DW43KB] Travel Speed Sol Short Circuit ............................................................................. 38
Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit ................................................................... 40
Failure code [DW45KB] Swing Brake Sol Short Circuit .............................................................................. 42
PC200, 200LC, 220, 220LC-8M0 40-304 1

SEN06136-00
Failure code [DW91KA] Travel Neutral Sol Open Circuit ............................................................................ 44

Failure code [DW91KB] Travel Neutral Sol Short Circuit ............................................................................ 46
40-304 2 PC200, 200LC, 220, 220LC-8M0

SEN06136-00
PC200, 200LC, 220, 220LC-8M0 40-304 3

SEN06136-00 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality

Action
Failure code Arm Curl PPC Pressure Sensor Abnormality
level Failure
L01 DHS3MA
Detail of failure q Signal voltage of arm IN PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking it that arm IN PPC pressure is 0 MPa {0 kg/cm2}.
Problem on Automatic deceleration does not cancel.
q
machine Controllability of arm IN deteriorates.
q
Related infor-
mation
q Arm IN PPC pressure can be checked with monitoring function.
(Code: 07200 Arm IN PPC pressure)

Defective 5V sensor power supply 2. Disconnect connector P04 and connect T-adapters to female side.
1 system
Power sup-
ply
Sensor out-
put
Defective arm IN PPC pressure
2 or hot short circuit in wiring harness. Check as below.
sensor (internal defect)
2. Replace connector P04 with connector of other PPC pressure sensor.
4. If E mark is not displayed for this failure code, arm IN PPC pressure sensor
is defective.
female side.
tact of connector)
4 female side.
ground
40-304 4 PC200, 200LC, 220, 220LC-8M0

Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality SEN06136-00

5
(Contact with 24 V circuit) 4. Turn starting switch to ON position.
Circuit diagram related to arm in PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 5

SEN06136-00 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality

Action
Failure code Bucket CURL PPC Pressure Sensor Abnormality
level Failure
L01 DHS4MA
Detail of failure q Signal voltage of bucket CURL PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking it that bucket CURL PPC pressure is 0 MPa {0 kg/cm2}.
q
machine Controllability of bucket CURL deteriorates.
q
Related infor-
mation
q Bucket CURL PPC pressure can be checked with monitoring function.
(Code: 07300 Bucket CURL PPC pressure)

1
1 system 3. Turn starting switch to ON position.
Power sup-
ply
Sensor out-
put
Defective bucket CURL PPC pres- is difficult to judge whether cause of failure is defective sensor, ground fault
sure sensor (internal defect)
4. If E mark is not displayed for this failure code, bucket CURL PPC pressure
sensor is defective.
female side.
tact of connector)
4 female side.
Between C01(female) (73) and ground, or between
P01 (female) (2) and ground
40-304 6 PC200, 200LC, 220, 220LC-8M0

Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality SEN06136-00

5
Circuit diagram related to bucket curl PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 7

SEN06136-00 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality

Action
Failure code Boom Raise PPC Pressure Sensor Abnormality
level Failure
L01 DHS8MA
Detail of failure q Signal voltage of boom RAISE PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- Controls machine taking it that boom RAISE PPC pressure is 0 MPa {0 kg/cm2}.
q
troller If cause of failure disappears, machine becomes normal by itself.
q
Problem on q Automatic deceleration does not cancel.
machine q Controllability of boom RAISE deteriorates.
Related infor-
mation
q Boom RAISE PPC pressure can be checked with monitoring function.
(code: 07400 Boom RAISE PPC pressure)

1.
Defective 5V sensor power 2.
Disconnect connector P06 and connect T-adapters to female side.
1 3.
supply 1 system
a
If power supply voltage is abnormal, proceed to check on cause 3.
Power sup-
ply
2. Insert T-adapters in connector P06.
Sensor out-
put
a If power supply voltage is normal and sensor output voltage is abnormal, it is dif-
Defective boom RAISE PPC ficult to judge whether cause of failure is defective sensor, ground fault or hot
2 pressure sensor (internal short circuit in wiring harness. Check as below.
defect) 1. Turn starting switch to OFF position.
3. Turn starting switch to ON position and display "Abnormality Record" screen of
electrical system on machine monitor.
4. If E mark is not displayed for this failure code, boom RAISE PPC pressure
2. Disconnect connectors C01 and P06, and connect T-adapters to each female
side.
Open circuit in wiring har- a If power supply voltage measured in check on cause
ness (wire breakage or 1 is normal, this check is not required. Resistance Max. 1 z
3
defective contact of connec- Between C01 (female) (18) and P06 (female) (1)
tor) Between C01 (female) (53) and P06 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on cause
1 is normal, this check is not required. Resistance Max. 1 z
Ground fault in wiring har- 2. Disconnect connectors C01 and P06, and connect T-adapters to either female
4 ness (contact with ground side.
circuit) Between C01 (female) (53) and ground, or between P06
(female) (2) and ground
Hot short circuit in wiring har- 2. Disconnect connector P06.
5 ness (contact with 24 V cir- 3. Connect T-adapters to female side of connector P06.
cuit) 4. Turn starting switch to ON position.
40-304 8 PC200, 200LC, 220, 220LC-8M0

Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality SEN06136-00

If no failure is found by above checks, pump controller is defective. (Since this is an
internal defect, troubleshooting cannot be performed.)
Circuit diagram related to boom raise PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 9

SEN06136-00 Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality

Action
Failure code Boom Lower PPC pressure sensor Abnormality
level Failure
L01 DHS9MA
Detail of failure q Signal voltage of boom LOWER pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con-
troller
q
machine Controllability of boom LOWER deteriorates.
q
Related infor-
mation
q Boom lower PPC pressure can be checked with monitoring function.
(Code: 07500 Boom LOWER PPC pressure)

Defective 5 V sensor power sup- 2. Disconnect connector P02 and connect T-adapters to female side.
ply 2 line
Power sup-
ply
Sensor out-
put
Defective boom LOWER PPC is difficult to judge whether cause of failure is defective sensor, ground fault
pressure sensor (internal defect)
4. If E mark is not displayed again for this failure code, boom LOWER PPC
pressure sensor is defective.
female side.
tact of connector)
4 female side.
Between ground and C01 (female) (14) and ground,
or between P02 (female) (2)
40-304 10 PC200, 200LC, 220, 220LC-8M0

Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality SEN06136-00

5
Circuit diagram related to boom lower PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 11

SEN06136-00 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality

Action
Failure code Swing Right PPC Pressure Sensor Abnormality
level Failure
L01 DHSAMA
Detail of failure q Signal voltage of swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking it that swing RIGHT PPC pressure is 0 MPa {0 kg/cm2}.
q
machine Controllability of swing RIGHT deteriorates.
q
Related infor-
mation
q Swing RIGHT PPC pressure can be checked with monitoring function.
(Code 09002: Swing RIGHT PPC pressure)

1
Power sup-
ply
2. Connect T-adapters to connector P07.
Sensor out-
put
Defective swing RIGHT PPC pres- is difficult to judge whether cause of failure is defective sensor, ground fault
4. If E mark is not displayed for this failure code, swing RIGHT PPC pressure
female side.
tact of connector)
4 female side.
Between ground and C01 (female) (72) or P07
(female) (2)
40-304 12 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality SEN06136-00

5
Circuit diagram related to swing right PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 13

SEN06136-00 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality

Action
Failure code Swing Left PPC Pressure Sensor Abnormality
level Failure
L01 DHSBMA
Detail of failure q Signal voltage of swing LEFT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking it that swing LEFT PPC pressure is 0 MPa {0 kg/cm2}.
q
machine Controllability of swing LEFT deteriorates.
q
Related infor-
mation
q Swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)

1
Power sup-
ply
Sensor out-
put
Defective swing left PPC pressure is difficult to judge whether cause of failure is defective sensor, ground fault
2 sensor or hot short circuit in wiring harness. Check as below.
(internal defect) 1. Turn starting switch to OFF position.
4. If E-mark for this failure code is not displayed, swing LEFT PPC pressure
female side.
tact of connector)
4 female side.
(female) (2)
40-304 14 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality SEN06136-00

5
Circuit diagram related to swing left PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 15

SEN06136-00 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality

Action
Failure code Arm Dump PPC Pressure Sensor Abnormality
level Failure
L01 DHSCMA
Detail of failure q Signal voltage of arm OUT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con-
troller
q
machine The operativity of arm dumping is bad.
q
mation q Arm OUT PPC pressure can be checked with monitoring function.
(Code: 07600 Arm OUT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine, and select
arm crane mode (L).

1.
Defective 5 V sensor power sup- 2.
Disconnect connector P08, and connect T-adapters to female side.
1 3.
ply 2 line
a
If power supply voltage is abnormal, proceed to check on cause 3.
Power sup-
ply
Sensor out-
put
Defective arm OUT PPC pressure is difficult to judge whether cause of failure is defective sensor, ground fault
sensor (internal failure)
4. If E mark is not displayed again in this failure code column, arm OUT PPC
pressure sensor is defective.
female side.
tact of connector)
4 female side.
(female) (2)
40-304 16 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality SEN06136-00

5
Circuit diagram related to arm out PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 17

SEN06136-00 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality

Action
Failure code Bucket Dump PPC Pressure Sensor Abnormality
level Failure
L01 DHSDMA
Detail of failure q Signal voltage of bucket DUMP PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- Controls machine taking it that bucket DUMP PPC pressure is 0 MPa {0 kg/cm2}.
q
Problem on q Automatic deceleration does not cancel.
machine q Controllability of bucket DUMP deteriorates.
Related infor-
mation
q Bucket DUMP PPC pressure can be checked with monitoring function.
(Code: 07301 Bucket DUMP PPC pressure)

1 system
Power sup-
ply
Sensor out-
put
Defective bucket DUMP PPC pres-
4. If E mark is not displayed for this failure code, bucket DUMP PPC pressure
female side.
tact of connector)
4 female side.
(female) (2)
5
40-304 18 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality SEN06136-00

Circuit diagram related to bucket dump PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 19

SEN06136-00 Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality

Action
Failure code Travel Left Forward PPC Pressure Sensor Abnormality
level Failure
L01 DHSFMA
Detail of failure q Signal voltage of left travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking it that left travel FORWARD PPC pressure is 0 MPa {0 kg/cm2}.
q
machine Controllability of right travel REVERSE deteriorates.
q
Related infor-
mation
q Left travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07102 Left travel FORWARD PPC pressure)

1 system
Power sup-
ply
2. Insert T-adapter into connector P09.
Sensor out-
put
Defective left travel FORWARD is difficult to judge whether cause of failure is defective sensor, ground fault
2 PPC presure sensor or hot short circuit in wiring harness. Check as below.
4. If E mark is not displayed in this failure code column, left travel FORWARD
PPC pressure sensor is defective.
female side.
tact of connector)
4 female side.
(female) (2)
40-304 20 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality SEN06136-00

5
Circuit diagram related to travel PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0 40-304 21

SEN06136-00 Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality

Action
Failure code Travel Right Forward PPC Pressure Sensor Abnormality
level Failure
L01 DHSGMA
Detail of failure q Signal voltage of right travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking it that right travel FORWARD PPC pressure is 0 MPa {0 kg/cm2}.
q
q
Related infor-
mation
q Right travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07103 Right travel FORWARD PPC pressure)

1 system
Power sup-
ply
2. Insert T-adapter into connector P11.
Sensor out-
put
Defective right travel FORWARD is difficult to judge whether cause of failure is defective sensor, ground fault
2 PPC pressure sensor or hot short circuit in wiring harness. Check as below.
4. If E mark is not displayed in this failure code column, right travel
FORWARD PPC pressure sensor is defective.
2. Disconnect connectors C01 and P11 and connect T-adapters to each
female side of them.
tact of connector)
2. Disconnect connectors C01 and P11 and connect T-adapter to female side
4 of either connector.
ground
40-304 22 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality SEN06136-00

5
PC200, 200LC, 220, 220LC-8M0 40-304 23

SEN06136-00 Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality

Action
Failure code Travel Left Backward PPC Pressure Sensor Abnormality
level Failure
L01 DHSHMA
Detail of failure q Signal voltage of left travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking it that left travel REVERSE PPC pressure is 0 MPa {0 kg/cm2}.
q
q
Related infor-
mation
q Left travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07104 Left travel REVERSE PPC pressure)

1 system
Power sup-
ply
Sensor out-
put
Defective left travel REVERSE is difficult to judge whether cause of failure is defective sensor, ground fault
4. If E mark is not displayed in this failure code column, left travel REVERSE
female side.
tact of connector)
4 female side.
(female) (2)
40-304 24 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality SEN06136-00

5
PC200, 200LC, 220, 220LC-8M0 40-304 25

SEN06136-00 Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality

Action
Failure code Travel Right Backward PPC Pressure Sensor Abnormality
level Failure
L01 DHSJMA
Detail of failure q Signal voltage of right travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking it that right travel REVERSE PPC pressure is 0 MPa {0 kg/cm2}.
q
q
Related infor-
mation
q Right travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07105 Right travel REVERSE PPC pressure)

1 system
Power sup-
ply
Sensor out-
put
Defective right travel REVERSE is difficult to judge whether cause of failure is defective sensor, ground fault
4. If E mark is not displayed in this failure code column, right travel REVERSE
female side of them.
tact of connector)
2. Disconnect connectors C01 and P12, and connect T-adapter to female side
4 of either connector.
ground
40-304 26 PC200, 200LC, 220, 220LC-8M0

Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality SEN06136-00

5
PC200, 200LC, 220, 220LC-8M0 40-304 27

SEN06136-00 Failure code [DHX1MA] Overload Sensor Abnormality
Failure code [DHX1MA] Overload Sensor Abnormality

Action
Failure code Overload Sensor Abnormality
level Failure
L04 DHX1MA
Detail of failure q Monitor (overload alarm monitor) which is not set to be displayed is displayed.
Action of con- q None in particular
Problem on
machine
Related infor-
mation

Pump controller may be defective. (Since this is an internal defect, troubleshoot-
ing cannot be performed.)
40-304 28 PC200, 200LC, 220, 220LC-8M0

Failure code [DHX1MA] Overload Sensor Abnormality SEN06136-00
PC200, 200LC, 220, 220LC-8M0 40-304 29

SEN06136-00 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality

Action
Failure code Camera 2 Picture Reverse Drive Abnormality
level Failure
L01 DR21KX
q Output voltage of camera 2 image reverse drive line (pin 6 of connector CM04) differs from com-
Detail of failure
mand voltage output from machine monitor.
Action of con-
q Does not display image of camera 2.
troller
Problem on
q Image of camera 2 is not displayed.
machine
q When output voltage of camera 2 image reverse drive line (pin 6 of connect CM04) is 0 V, original
image is sent. When it is 8 V, mirror image is sent (since power supply voltage of camera is 8 V, 8
Related infor-
V is used as command voltage to sent mirror image).
mation
q You must check connector A41 to identify which camera is assigned to camera 2.

2. Disconnect connectors CM04 and A46, and connect T-adapters to each
female side.
tact of connector) Between CM04 (female) (6) and A46 (female) (3) Resistance Max. 1 z
Between CM04 (female) (5) and A46 (female) (4) Resistance Max. 1 z
2. Disconnect connectors CM04 and A46, and connect T-adapters to either
2 female side.
Between ground and CM04 (female) (6) or A46
(female) (3)
2. Disconnect connector A46 and connect T-adapters to female side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
3
(contact with 24 V circuit) a Check that camera 2 is set for original images.
Between A46 (female) (3) and (4), or between A46
Voltage Max. 1 V
2. Disconnect connector CM04, A46 and connect T-adapters to CM04 female
4 Short circuit in wiring harness side.
Between CM04 (female) (6) and each pin other
Resistance Max. 1 z
than pin (6)
If no failure is found by above checks, camera 2 is defective. (Since this is an
5 Defective camera 2
If no failure is found by above checks, machine monitor is defective. (Since
40-304 30 PC200, 200LC, 220, 220LC-8M0

Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality SEN06136-00
Circuit diagram related to camera
PC200, 200LC, 220, 220LC-8M0 40-304 31

SEN06136-00 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality

a This failure code does not relate to this machine because it is not equipped with camera 3. This failure
code is provided in case where camera 3 is installed in future.
a If this failure code appears, clear failure code by referring to "Classification and procedures for trouble-
shooting".
40-304 32 PC200, 200LC, 220, 220LC-8M0

Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality SEN06136-00
PC200, 200LC, 220, 220LC-8M0 40-304 33

SEN06136-00 Failure code [DV20KB] Travel Alarm Short Circuit
Failure code [DV20KB] Travel Alarm Short Circuit

Action
Failure code Travel Alarm Short Circuit
level Failure
L01 DV20KB
Detail of failure q Abnormal current flows when pump controller drives travel alarm circuit.
q Stops driving travel alarm circuit.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q Travel alarm does not sound.
machine
q Operation (ON or OFF) of travel alarm can be checked with monitoring function.
Related infor- (Code: 03701 Controller output 2)
mation q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-

2. Disconnect connector M14, and connect T-adapters to female side.
4. Operate travel lever to perform troubleshooting.
Travel lever:
Defective travel alarm Voltage Max. 1 V
1 Between M14 (female) (1) NEUTRAL
(internal defect)
and (2) Travel lever:
Voltage 20 to 30 V
Operated
a If the above voltage is normal but travel alarm does not sound, travel alarm
is defective.
2. Disconnect connectors C02 and M14, and connect T-adapters to either
Ground fault in wiring harness female side.
2
Between C02 (female) (107) and ground, or
between M14 (female) (1) and ground
2. Insert T-adapters into connector M14.
4. Operate travel lever to perform troubleshooting.
3 Defective pump controller Travel lever:
Voltage Max. 1 V
NEUTRAL
Between M14 (1) and (2)
Travel lever:
Voltage 20 to 30 V
Operated
40-304 34 PC200, 200LC, 220, 220LC-8M0

Failure code [DV20KB] Travel Alarm Short Circuit SEN06136-00
Circuit diagram related to travel alarm
PC200, 200LC, 220, 220LC-8M0 40-304 35

SEN06136-00 Failure code [DW43KA] Travel Speed Sol Open Circuit
Failure code [DW43KA] Travel Speed Sol Open Circuit

Action
Failure code Travel Speed Solenoid Open Circuit
level Failure
L01 DW43KA
q No current flows when pump controller drives travel speed selector solenoid, so pump controller
Detail of failure
determines that open circuit exists in travel speed selector solenoid circuit.
Action of con- q None in particular (Since no current flows, solenoid is not energized.)
Problem on q "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel speed is still
machine "Mi".)
q Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring
function. (As long as controller's command to solenoid is "ON", sensor status displayed on moni-
Related infor-
toring screen is "ON" even if solenoid is not energized due to short circuit.)
mation
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine, set travel speed to High and operate travel lever.

Defective travel speed selector 2. Disconnect connector V04, and connect T-adapters to male side.
1
solenoid (Internal open circuit)
Between V04 (male) (1) and (2) Resistance 20 to 60 z
Between C02 (female) (87) and each of (115) ,
Resistance 20 to 60 z
(117) and (120)
Open circuit in wiring harness a If no failure is found by above checks , this check is not required.
2 (wire breakage or defective con- 1. Turn starting switch to OFF position.
tact of connector) 2. Disconnect connectors C02 and V04, and connect T-adapters to each
female side.
Between C02 (female) (87) and V04 (female) (1) Resistance Max. 1 z
Between V04 (female) (2) and each of C02 (female)
Resistance Max. 1 z
(115), (117) and (120)
40-304 36 PC200, 200LC, 220, 220LC-8M0

Failure code [DW43KA] Travel Speed Sol Open Circuit SEN06136-00
Circuit diagram related to travel speed solenoid
PC200, 200LC, 220, 220LC-8M0 40-304 37

SEN06136-00 Failure code [DW43KB] Travel Speed Sol Short Circuit
Failure code [DW43KB] Travel Speed Sol Short Circuit

Action
Failure code Travel Speed Solenoid Short Circuit
level Failure
L01 DW43KB
q Abnormal current flows when pump controller drives travel speed selector solenoid, so pump con-
Detail of failure
troller determines that short circuit exists in travel speed selector solenoid circuit.
q Stops driving travel speed selector solenoid.
Action of con-
troller
to OFF position.
Problem on q "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel speed is still
machine "Mi".)
q Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring
Related infor-
function. (Code: 02300 Solenoid 1)
mation
q Method of reproducing failure code: Start engine, set travel speed to High and operate travel lever.

Defective travel speed 2. Disconnect connector V04, and connect T-adapters to male side.
1 selector solenoid (Internal
short circuit, ground fault)
Between V04 (male) (1) and ground Resistance Min. 1 Mz
Short circuit or ground fault
2 Between C02 (female) (87) and each of (115), (117) and
in wiring harness Resistance 20 to 60 z
(120)
a If no abnormality is found in check on cause 2, this check is not required.
Ground fault in wiring har-
2. Disconnect connectors C02 and V04, and connect T-adapters to either female
3 ness
side.
Between C02 (female) (87) or V04 (female) (1) and
ground
40-304 38 PC200, 200LC, 220, 220LC-8M0

Failure code [DW43KB] Travel Speed Sol Short Circuit SEN06136-00
PC200, 200LC, 220, 220LC-8M0 40-304 39

SEN06136-00 Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit
Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit

Action
Failure code Swing Brake Solenoid Valve Open Circuit
level Failure
L03 DW45KA
q Controller output voltage to solenoid is above standard value when pump controller does not drive
Detail of failure swing holding brake solenoid, so pump controller determines that open circuit exists in swing hold-
ing brake solenoid circuit.
q None in particular. (Since no current flows, solenoid is not energized, so swing holding brake is kept
Action of con-
applied.)
troller
Problem on
q Upper structure does not swing (swing holding brake is not released).
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing brake can-
cel switch to RELEASE position. (However, swing holding brake is not released while upper struc-
ture is stopped. swing holding brake continues to be applied.)
q Set swing brake cancel switch to RELEASE position during troubleshooting. When starting switch
is turned to ON position in this condition, normally current can flow in swing holding brake solenoid
Related infor-
circuit and break can be released.
mation
q Controller command (ON/OFF) to swing holding brake solenoid can be checked with monitoring
q Swing brake solenoid circuit is powered from pin (101) of pump controller connector C02 or No.1
of fuse box F01.

Blown fuse No. 1 (right top fuse) in
1 If fuse is blown, see failure code [DW45KB].
fuse box F01
Defective swing holding brake 2. Disconnect connector V03, and connect T-adapters to male side.
2
solenoid
2. Remove diode arrays D01 and D03, and connect T-adapters to each male
side.
3 Defective diode array D01 or D03 Between D01 (male) (3) (+) and (7) (-) No continuity
2. Remove diode D01.
3. Disconnect connector C02 and connect T-adapters to each female side.
a Swing lock switch OFF position.
Between C02 (female) (101) and D01 (female) (7) Resistance Max. 1 z
Open circuit in wiring harness Between D01 (female) (3) and C02 (female) (115) Resistance 20 to 60 z
4 (wire breakage or defective con- a If no failure is found by above checks, this check is not required.
tact of connector) 1. Turn starting switch to OFF position.
2. Disconnect connectors D01, C02, and V03, and connect T-adapters to
each female side.
Between D01 (female) (3) and V03 (female) (1) Resistance Max. 1 z
Between V03 (female) (2) and C02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
40-304 40 PC200, 200LC, 220, 220LC-8M0

Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit SEN06136-00
Circuit diagram related to swing holding brake
PC200, 200LC, 220, 220LC-8M0 40-304 41

SEN06136-00 Failure code [DW45KB] Swing Brake Sol Short Circuit
Failure code [DW45KB] Swing Brake Sol Short Circuit

Action
Failure code Swing Brake Solenoid Short Circuit
level Failure
L03 DW45KB
q Abnormal current flows when pump controller drives swing holding brake solenoid, so pump con-
Detail of failure
troller determines that short circuit exists in swing holding brake solenoid circuit.
q Stops driving swing holding brake solenoid.
Action of con-
troller
to OFF position.
Problem on
q Upper structure does not swing (swing holding brake is not released).
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing brake can-
cel switch to RELEASE position. (However, swing holding brake is not released while upper struc-
ture is stopped. swing holding brake continues to be applied.)
q Keep swing lock switch in OFF position and swing brake cancel switch in RELEASE position during
troubleshooting. When starting switch is turned to ON position in this condition, normally current
Related infor-
can flow in swing holding brake solenoid circuit and brake can be released.
mation
q Controller command (ON/OFF) to swing holding brake solenoid can be checked with monitoring
q swing holding brake solenoid circuit is powered from pin (101) of pump controller connector C02 or
pin (1) of fuse box F01.

Blown fuse No. 1 (right top fuse) in Even if fuse is blown, perform troubleshooting according to following steps to
1
fuse box F01 identify cause.
2. Disconnect connector V03, and connect T-adapters to male side.
Defective swing holding brake
2
solenoid Between V03 (male) (1) and (2) Resistance 20 to 60 z
2. Remove diode arrays D01 and D03, and connect T-adapters to each male
side.
3 Defective diode array D01 or D03 Between D01 (male) (3) (+) and (7) (-) No continuity
2. Remove fuse No.1 (right top, 10 A) in fuse box F01 and diode D01.
3. Disconnect connectors C02, D01 and V03.
4 4. Connect T-adapters to female sides of connectors C02 and D01.
Between D01 (female) (3) and ground Resistance Min. 1 Mz
2. Remove fuse No.1 (right top, 10 A) in fuse box F01 and diode D01.
3. Disconnect connector C02.
4. Connect T-adapters to female sides of connectors D01 and C02.
a Check the swing lock switch OFF position.
Between D01 (female) (3) and C02 (female) (115)
or (117) or (120) Resistance 20 to 60 z
a Swing brake solenoid coil resistance.
40-304 42 PC200, 200LC, 220, 220LC-8M0

Failure code [DW45KB] Swing Brake Sol Short Circuit SEN06136-00
Circuit diagram related to swing holding brake
PC200, 200LC, 220, 220LC-8M0 40-304 43

SEN06136-00 Failure code [DW91KA] Travel Neutral Sol Open Circuit
Failure code [DW91KA] Travel Neutral Sol Open Circuit

Action
Failure code Travel Neutral Solenoid Open Circuit
level Failure
L01 DW91KA
Detail of failure travel junction solenoid, so pump controller determines that open circuit exists in travel junction so-
lenoid circuit.
Problem on
q Machine does not turn during travel.
machine
q Controller's command (ON/OFF) to travel junction valve solenoid can be checked with monitoring
Related infor- function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is
mation not switched ON due to open circuit.) (Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine and turn machine with right and left travel levers.

Defective travel junction solenoid 2. Disconnect connector V05, and connect T-adapters to male side.
1
(Internal open circuit)
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side.
2
ness Between C02 (female) (110) and each of (115),
(117) and (120)
Open circuit in wiring harness 2. Disconnect connectors C02 and V05, and connect T-adapters to each
tact of connector) Between C02 (female) (110) and V05 (female) (1) Resistance Max. 1 z
Between V05 (female) (2) and C02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
40-304 44 PC200, 200LC, 220, 220LC-8M0

Failure code [DW91KA] Travel Neutral Sol Open Circuit SEN06136-00
Circuit diagram related to travel junction solenoid
PC200, 200LC, 220, 220LC-8M0 40-304 45

SEN06136-00 Failure code [DW91KB] Travel Neutral Sol Short Circuit
Failure code [DW91KB] Travel Neutral Sol Short Circuit

Action
Failure code Travel Neutral Solenoid Short Circuit
level Failure
L01 DW91KB
q Abnormal current flows when pump controller drives travel junction solenoid, so pump controller de-
Detail of failure
termines that short circuit exists in travel junction solenoid circuit.
q Stops driving travel junction solenoid.
Action of con-
troller
to OFF position.
Problem on
q Machine does not turn during travel.
machine
q Controller's command (ON/OFF) to travel junction valve solenoid can be checked with monitoring
Related infor- function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not
mation switched ON due to short circuit.) (Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine and turn machine with right and left travel levers.

Defective travel junction
solenoid
1
(internal short circuit or Between V05 (male) (1) and (2) Resistance 20 to 60 z
ground fault)
2 Between V05 (female) (110) and each of (115), (117)
and (120)
2. Disconnect connectors C02 and V05, and connect T-adapter to female side of
3 ness
either of them.
ground
40-304 46 PC200, 200LC, 220, 220LC-8M0

Failure code [DW91KB] Travel Neutral Sol Short Circuit SEN06136-00
Circuit diagram related to travel junction solenoid
PC200, 200LC, 220, 220LC-8M0 40-304 47

SEN06136-00
2012 KOMATSU
All Rights Reserved
40-304 48
SEN06137-00
SEN06009-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
Failure code [DWA2KA] Attachment Sol Open Circuit................................................................................ 4

Failure code [DWA2KB] Attachment Sol Short Circuit ................................................................................ 6
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit............................................................................ 8
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ............................................................................ 10
Failure code [DWK2KA] Variable Back Press Sol Open Circuit.................................................................. 12
Failure code [DWK2KB] Variable Back Press Sol Short Circuit .................................................................. 14
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit................................................................................ 16
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit................................................................................ 18
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ............................................................................... 20
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ............................................................................... 22
Failure code [DXE0KA] LS-EPC Sol Open Circuit...................................................................................... 24
Failure code [DXE0KB] LS-EPC Sol Short Circuit ...................................................................................... 26
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ...................................................................... 28
Failure code [DXE4KB] Attachment Flow EPC Short Circuit ...................................................................... 30
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ..................................................................... 32
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ..................................................................... 34
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit......................................................................... 36
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit......................................................................... 38
Failure code [DY20KA] Wiper Working Abnormality ................................................................................... 40
Failure code [DY20MA] Wiper Parking Abnormality ................................................................................... 42
PC200, 200LC, 220, 220LC-8M0 40-305 1

SEN06137-00
Failure code [DY2CKB] Washer Drive Short Circuit.................................................................................... 44

Failure code [DY2DKB] Wiper Drive (Fwd) Short ....................................................................................... 46
Failure code [DY2EKB] Wiper Drive (Rev) Short ........................................................................................ 48
40-305 2 PC200, 200LC, 220, 220LC-8M0

SEN06137-00
PC200, 200LC, 220, 220LC-8M0 40-305 3

SEN06137-00 Failure code [DWA2KA] Attachment Sol Open Circuit
Failure code [DWA2KA] Attachment Sol Open Circuit

Action
Failure code Attachment Single/multiple selector Solenoid Open Circuit
level Failure
L03 DWA2KA
q Controller output voltage to ATT return selector solenoid exceeds standard value when it stops out-
Detail of failure
putting drive current to ATT return selector solenoid.
Problem on
q Attachment return circuit does not change to 1-way circuit.
machine
q Controller's command (ON/OFF) to attachment return selector solenoid can be checked with mon-
itoring function. (If controller sends solenoid ON command, monitoring display is ON even if sole-
Related infor-
noid is not switched ON due to open circuit.) (Code: 02301 Solenoid 2)
mation
q Method of reproducing failure code: Turn starting switch to ON position and set machine in working
mode other than breaker mode (B).

Defective attachment return selec- 2. Disconnect connector V06, and connect T-adapters to male side.
1
tor solenoid (internal open circuit)
Open circuit or ground fault in wir- 2. Disconnect connector C02 and connect T-adapters to female side.
2
ing harness
Between C02 (female) (86) and ground Resistance 20 to 60 z
Between V06 (female) (2) and ground Resistance Max. 1 z
40-305 4 PC200, 200LC, 220, 220LC-8M0

Failure code [DWA2KA] Attachment Sol Open Circuit SEN06137-00
Circuit diagram related to ATT single/multiple selector solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 5

SEN06137-00 Failure code [DWA2KB] Attachment Sol Short Circuit
Failure code [DWA2KB] Attachment Sol Short Circuit

Action
Failure code Attachment single/multiple selector Solenoid Short Circuit
level Failure
L03 DWA2KB
q Abnormal current flows when pump controller drives attachment return selector solenoid, so pump
Detail of failure
controller determines that short circuit exists in attachment return selector solenoid circuit.
q Stops driving attachment return selector solenoid.
Action of con-
troller
to OFF position.
Problem on
q Attachment return circuit does not change to 1-way circuit.
machine
q Controller's command (ON/OFF) to attachment return selector solenoid can be checked with mon-
itoring function. (If controller sends solenoid ON command, monitoring display is ON even if sole-
Related infor-
noid is not switched ON due to short circuit.) (Code: 02301 Solenoid 2)
mation
q Method of reproducing failure code: Turn starting switch to ON position and set machine in breaker
mode (B).

Defective attachment return selec- 2. Disconnect connector V06, and connect T-adapters to male side.
1 tor solenoid (internal short circuit
or ground fault)
2
ing harness
Between C02 (female) (86) and ground Resistance 20 to 60 z
Ground fault in wiring harness 2. Disconnect connectors C02 and V06, and connect T-adapters to either
3
ground
40-305 6 PC200, 200LC, 220, 220LC-8M0

Failure code [DWA2KB] Attachment Sol Short Circuit SEN06137-00
Circuit diagram related to ATT single/multiple selector solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 7

SEN06137-00 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit

Action
Failure code 2-stage Relief Solenoid Open Circuit
level Failure
L01 DWK0KA
Detail of failure 2-stage relief solenoid, so pump controller determines that open circuit exists in 2-stage relief so-
lenoid circuit.
Problem on q Travel power is low (main relief valve is not set to high-pressure setting).
machine q One-touch power maximizing function does not work.
q Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring func-
tion. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not
switched ON due to open circuit.) (Code: 02300 Solenoid 1)
Related infor-
mation
q Controller detects open circuit only when it does not drive solenoid.

Defective 2-stage relief solenoid 2. Disconnect connector V02, and connect T-adapters to male side.
1
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is
2
ness below 1 z, wiring harness has short circuit.
Between C02 (female) (109) and each of
(115), (117) and (120)
2. Disconnect connectors C02 and V02, and connect T-adapters to each
female side.
Between C02 (female) (109) and V02
(female) (1)
Between V02 (female) (2) and each of C02
Resistance Max. 1 z
(female) (115), (117) and (120)
40-305 8 PC200, 200LC, 220, 220LC-8M0

Failure code [DWK0KA] 2-stage Relief Sol Open Circuit SEN06137-00
Circuit diagram related to 2-stage relief solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 9

SEN06137-00 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit

Action
Failure code 2-stage Relief Solenoid Short Circuit
level Failure
L01 DWK0KB
q Abnormal current flows when pump controller drives 2-stage relief solenoid, so pump controller de-
Detail of failure
termines that short circuit exists in 2-stage relief solenoid circuit.
q Stops driving 2-stage relief solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on q Travel power is low (main relief valve is not set to high-pressure setting).
machine q One-touch power maximizing function does not work.
q Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring func-
tion. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not
switched ON due to short circuit.) (Code: 02300 Solenoid 1)
Related infor-
mation
q Controller detects open circuit only when it does not drive solenoid.

Defective 2-stage relief solenoid 2. Disconnect connector V02, and connect T-adapters to male side.
1 (internal short circuit or ground
fault)
Between V02 (female) (1) and ground Resistance Min. 1 Mz
2. Disconnect connectors C02 and V02, and connect T-adapters to female
2 side of V02.
Between C02 (female) (109) or V02 (female) (1)
and ground
2. Disconnect connectors C02 and V02, and connect T-adapters to female
3 Short circuit in wiring harness side of V02.
Between V02 (male) (1) and (2) Resistance Min. 1 Mz
40-305 10 PC200, 200LC, 220, 220LC-8M0

Failure code [DWK0KB] 2-stage Relief Sol Short Circuit SEN06137-00
PC200, 200LC, 220, 220LC-8M0 40-305 11

SEN06137-00 Failure code [DWK2KA] Variable Back Press Sol Open Circuit
Failure code [DWK2KA] Variable Back Press Sol Open Circuit

Action
Failure code Variable Back Pressure Solenoid Open Circuit
level Failure
L01 DWK2KA
q No current flows when pump controller drives variable back pressure solenoid, so pump controller
Detail of failure
determines that open circuit exists in variable back pressure solenoid circuit.
Problem on
q Set pressure of back pressure value cannot be changed.
machine
q Controller's command (ON/OFF) to variable back pressure solenoid can be checked with monitor-
ing function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid
Related infor-
is not switched ON due to open circuit.) (Code: 02301 Solenoid 2)
mation
q The set pressure of back pressure value becomes low by solenoid ON.

Defective variable back pressure 1. Turn starting switch to OFF position.
1 solenoid valve 2. Disconnect connector V25, and connect T-adapter to male side.
(Internal open circuit) Between V25 (male) (1) and (2) Resistance 20 to 60 z
2
ing harness Between C02(female) (85) and each of
C02(female) (115), (117), (120)
2. Disconnect connectors C02 and V25, and connect T-adapters to each
female side.
Between C02(female) (85) and V25(female)
(1)
Between each of C02(female) (115), (117),
Resistance Max. 1 z
(120) and V25(female)(2)
40-305 12 PC200, 200LC, 220, 220LC-8M0

Failure code [DWK2KA] Variable Back Press Sol Open Circuit SEN06137-00
Circuit diagram related to variable back pressure solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 13

SEN06137-00 Failure code [DWK2KB] Variable Back Press Sol Short Circuit
Failure code [DWK2KB] Variable Back Press Sol Short Circuit

Action
Failure code Variable Back Pressure Solenoid Short Circuit
level Failure
L01 DWK2KB
q Abnormal current flows when pump controller drives variable back pressure solenoid, so pump con-
Detail of failure
troller determines that short circuit exists in variable back pressure solenoid circuit.
q Stops driving variable back pressure solenoid.
Action of con-
troller
to OFF position.
Problem on
q Set pressure of back pressure value cannot be changed.
machine
q Controller's command (ON/OFF) to variable back pressure solenoid can be checked with monitor-
ing function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid
Related infor-
is not switched ON due to short circuit.) (Code: 02301 Solenoid 2)
mation
q The set pressure of back pressure value becomes low by solenoid ON.

Defective variable back pressure
solenoid valve
1
(internal short circuit or ground Between V25 (male) (1) and (2) Resistance 20 to 60 z
fault)
2
ing harness Between C02(female) (85) and each of (115),
(117), (120)
3 female side.
Between ground and C02 (female) (85) or
V25 (female)(1)
40-305 14 PC200, 200LC, 220, 220LC-8M0

Failure code [DWK2KB] Variable Back Press Sol Short Circuit SEN06137-00
Circuit diagram related to variable back pressure solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 15

SEN06137-00 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit

Action
Failure code PC-EPC (Front) Solenoid Open Circuit
level Failure
L03 DXA8KA
Detail of failure q When PC-EPC (Front) solenoid is driven, no current flows and open circuit is detected.
Problem on
q If pump load increases, engine speed decreases largely and engine may stall.
machine
q When solenoid and wiring harness are normal, engine can be prevented from stalling by setting
emergency pump drive switch to ON position.
Related infor-
q Drive current of PC-EPC (F) solenoid can be checked with monitoring function.
mation
(Code: 01300 PC-EPC solenoid current (F))

Defective PC-EPC (F) solenoid 2. Disconnect connector V11, and connect T-adapters to male side.
1
2. Disconnect connector S25 and connect T-adapters to male side.
Switch position: Normal Resistance Max. 1 z
Defective emergency pump drive Between S25 (male) (3)
2 switch and (2) Switch position: Emer-
(Internal open circuit) gency
Between S25 (male) (6)
and (5) Switch position: Emer-
gency
3 a Check that emergency pump drive switch is at normal position (lower side).
ness
Between C02 (female) (96) and each of (115), (117)
and (120)
2. Disconnect connectors C02, S25 and V11, and connect T-adapters to each
female side.
Between C02 (female) (96) and S25 (female) (3) Resistance Max. 1 z
tact of connector) Between S25 (female) (2) and V11 (female) (1) Resistance Max. 1 z
Between S25 (female) (6) and each of C02 (female)
Resistance Max. 1 z
(115), (117) and (120)
Between S25 (female) (5) and V11 (female) (2) Resistance Max. 1 z
40-305 16 PC200, 200LC, 220, 220LC-8M0

Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit SEN06137-00
Circuit diagram related to PC-EPC solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 17

SEN06137-00 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit

Action
Failure code PC-EPC (Front) Solenoid Short Circuit
level Failure
L03 DXA8KB
q When PC-EPC (Front) solenoid is driven, abnormal current flows in circuit and short circuit is de-
Detail of failure
tected.
q Stops outputting current to PC-EPC solennoid.
Action of con-
troller
to OFF position.
Problem on
machine
Related infor-
q Drive current of PC-EPC (F) solenoid can be checked with monitoring function.
mation
(Code: 01300 PC-EPC solenoid current (F))

Defective PC-EPC (F) solenoid 2. Disconnect connector V11, and connect T-adapters to male side.
fault)
Defective emergency pump drive
2 switch (internal short circuit or Between S25 (male) and each of S25
ground fault) (male) (2) and (3) Switch posi-
Between ground and each of S25 tion: Normal
(male) (2) and (3)
Short circuit or ground fault in wir- a Check that emergency pump drive switch is at normal position (lower side).
3 Between C02 (female) (96) and each of (115), (117)
ing harness Resistance 3 to 14 z
and (120)
2. Disconnect connectors C02, S25 and V11, and connect T-adapters to
Ground fault in wiring harness either female side.
4
(contact with ground circuit) Between C02 (female) (96) or S25 (female) (3) and
ground
Between ground and S25 (female) (5) or V11
(female) (2)
40-305 18 PC200, 200LC, 220, 220LC-8M0

Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit SEN06137-00
PC200, 200LC, 220, 220LC-8M0 40-305 19

SEN06137-00 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit

Action
Failure code PC-EPC (Rear) Solenoid System Open Circuit
level Failure
L03 DXA9KA
Detail of failure q When PC-EPC (Rear) solenoid is driven, no current flows and open circuit is detected.
Problem on
machine
Related infor-
q Drive current of PC-EPC (R) solenoid can be checked with monitoring function.
mation
(Code: 01300 PC-EPC solenoid current (R))

Defective PC-EPC (R) solenoid 2. Disconnect connector V12, and connect T-adapters to male side.
1
Defective emergency pump drive Between S25 (male) (3)
2 switch and (2) Switch position: Emer-
(Internal open circuit) gency
Between S25 (male) (6)
and (5) Switch position: Emer-
gency
3 a Check that emergency pump drive switch is at normal position (lower side).
ness
Between C02 (female) (96) and each of (115), (117)
and (120)
2. Disconnect connectors C02, S25 and V12, and connect T-adapters to each
female side.
Between C02 (female) (96) and S25 (female) (3) Resistance Max. 1 z
tact of connector) Between S25 (female) (2) and V12 (female) (1) Resistance Max. 1 z
Between S25 (female) (6) and each of C02 (female)
Resistance Max. 1 z
(115), (117) and (120)
Between S25 (female) (5) and V12 (female) (2) Resistance Max. 1 z
40-305 20 PC200, 200LC, 220, 220LC-8M0

Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit SEN06137-00
PC200, 200LC, 220, 220LC-8M0 40-305 21

SEN06137-00 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit

Action
Failure code PC-EPC (Rear) Solenoid System Short Circuit
level Failure
L03 DXA9KB
Detail of failure q When PC-EPC (Rear) solenoid is driven, abnomal current flows and short circuit is detected.
q Cuts output to PC-EPC (R) solenoid OFF.
Action of con-
troller
to OFF position.
Problem on
machine
Related infor-
q Drive current of PC-EPC (R) solenoid can be checked with monitoring function.
mation
(Code: 01300 PC-EPC solenoid current (R))

Defective PC-EPC (R) solenoid 2. Disconnect connector V12, and connect T-adapters to male side.
fault)
Defective emergency pump drive
2 switch (internal short circuit or Between S25 (male) and each of S25
ground fault) (male) (2) and (3) Switch posi-
Between ground and each of S25 tion: Normal
(male) (2) and (3)
Short circuit or ground fault in wir- a Check that emergency pump drive switch is at normal position (lower side).
and (120)
2. Disconnect connectors C02, S25 and V12, and connect T-adapters to
4
(contact with ground circuit) Between C02 (female) (96) or S25 (female) (3) and
ground
Between ground and S25 (female) (5) or V12
(female) (2)
40-305 22 PC200, 200LC, 220, 220LC-8M0

Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit SEN06137-00
PC200, 200LC, 220, 220LC-8M0 40-305 23

SEN06137-00 Failure code [DXE0KA] LS-EPC Sol Open Circuit
Failure code [DXE0KA] LS-EPC Sol Open Circuit

Action
Failure code LS-EPC Solenoid Open Circuit
level Failure
L01 DXE0KA
Detail of failure q When LS-EPC solenoid is driven, no current flows and open circuit is detected.
Problem on q Travel speed is high with speed setting at Lo and Mi.
machine q Work equipment speed and swing speed are high in fine control mode (L).
q Drive current to LS-EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid current)
mation

Defective LS-EPC solenoid 2. Disconnect connector V19, and connect T-adapters to male side.
1
2
ness Between C02 (female) (88) and each of (115), (117)
and (120)
Resistance Max. 1 z
(115), (117) and (120)
40-305 24 PC200, 200LC, 220, 220LC-8M0

Failure code [DXE0KA] LS-EPC Sol Open Circuit SEN06137-00
Circuit diagram related to LS-EPC solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 25

SEN06137-00 Failure code [DXE0KB] LS-EPC Sol Short Circuit
Failure code [DXE0KB] LS-EPC Sol Short Circuit

Action
Failure code LS-EPC Solenoid Short Circuit
level Failure
L01 DXE0KB
Detail of failure q When LS-PEC solenoid is driven, abnormal current flows and short circuit is detected.
q Stops driving LS-EPC solenoid.
Action of con-
troller
to OFF position.
Problem on q Travel speed is high with speed setting at Lo and Mi.
machine q Work equipment speed and swing speed are high in fine control mode (L).
q Drive current to LS-EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid current)
mation

Defective LS-EPC solenoid 2. Disconnect connector V19 and connect T-adapters to male side.
1 (internal short circuit or
ground fault)
and (120)
2. Disconnect connectors C02 and V19, and connect T-adapters to either female
3 ness
side.
ground
40-305 26 PC200, 200LC, 220, 220LC-8M0

Failure code [DXE0KB] LS-EPC Sol Short Circuit SEN06137-00
Circuit diagram related to LS-EPC solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 27

SEN06137-00 Failure code [DXE4KA] Attachment Flow EPC Open Circuit
Failure code [DXE4KA] Attachment Flow EPC Open Circuit

Action
Failure code Attachment Flow EPC Open Circuit.
level Failure
DXE4KA
Detail of failure q When service flow throttle EPC solenoid is driven, no current flows and ope circuit is detected.
Problem on
q Attachment does not move.
machine
q Drive current of service current EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01700 Service solenoid current)
mation
q Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).
Defective attachment flow rate 1. Turn starting switch to OFF position.

1 adjustment (service current) EPC 2. Disconnect connector V30, and connect T-adapters to male side.
solenoid (Internal open circuit) Between V30 (male) (1) and (2) Resistance 3 to 14 z
2
and (120)
Resistance Max. 1 z
(115), (117) and (120)
40-305 28 PC200, 200LC, 220, 220LC-8M0

Failure code [DXE4KA] Attachment Flow EPC Open Circuit SEN06137-00
Circuit diagram related to service flow throttle EPC
PC200, 200LC, 220, 220LC-8M0 40-305 29

SEN06137-00 Failure code [DXE4KB] Attachment Flow EPC Short Circuit
Failure code [DXE4KB] Attachment Flow EPC Short Circuit

Action
Failure code Attachment Flow EPC Short Circuit
level Failure
DXE4KB
q When service flow throttle EPC solenoid is driven, abnormal current flows and short circuit is de-
Detail of failure
tected .
q Stops outputting current to service EPC solenoid.
Action of con-
troller
to OFF position.
Problem on
q Attachment does not move.
machine
q Drive current of service flow adjust EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01700 Service solenoid current)
mation
q Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).

Defective attachment flow rate
adjustment (service current) EPC
1
solenoid (internal short circuit or Between V30 (male) (1) and (2) Resistance 3 to 14 z
ground fault)
and (120)
3
ground
40-305 30 PC200, 200LC, 220, 220LC-8M0

Failure code [DXE4KB] Attachment Flow EPC Short Circuit SEN06137-00
Circuit diagram related to service flow throttle EPC
PC200, 200LC, 220, 220LC-8M0 40-305 31

SEN06137-00 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit

Action
Failure code Merge-divide Main Solenoid Open Circuit
level Failure
L01 DXE5KA
q When pump merge-divider (main) EPC solenoid is driven, no current flows and open circuit is de-
Detail of failure
tected .
q None in particular (Since no current flows, merge-divider main solenoid does not operate. Since no
Action of con- current flows, merge-divider LS solenoid does not operate, either.)
to OFF position.
Problem on q Single operation speed of work equipment and swing is high in fine control mode (L).
machine q Machine does not turn easily during travel.
q Drive current to merge-divider main EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 Merge-divider (main) solenoid current)
mation

Defective merge-divider main EPC 2. Disconnect connector V23, and connect T-adapters to male side.
1
solenoid (internal open circuit)
2
ness Between C02 (female) (112) and each of (115),
(117) and (120)
Resistance Max. 1 z
(115), (117) and (120)
40-305 32 PC200, 200LC, 220, 220LC-8M0

Failure code [DXE5KA] Merge-divide Main Sol Open Circuit SEN06137-00
Circuit diagram related to pump merge-divider main EPC solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 33

SEN06137-00 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit

Action
Failure code Merge-divide Main Solenoid Short Circuit
level Failure
L01 DXE5KB
q When pump merge-divider (main) EPC solenoid is driven, abnormal current flows and short circuit
Detail of failure
is detected.
q Stops outputting current to merge-divider (main) EPC solenoid. (Since no current flows, merge-
Action of con- divider LS solenoid does not operate, either.)
to OFF position.
q Drive current to merge-divider main EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 Merge-divider (main) solenoid current)
mation

Defective merge-divider main EPC 2. Disconnect connector V23, and connect T-adapters to male side.
1 solenoid (internal short circuit or
ground fault)
2 Between C02 (female) (112) and each of (115),
(117) and (120)
3
Between C02 (female) (112) or V23 (female) (1)
and ground
40-305 34 PC200, 200LC, 220, 220LC-8M0

Failure code [DXE5KB] Merge-divide Main Sol Short Circuit SEN06137-00
Circuit diagram related to pump merge-divider main EPC solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 35

SEN06137-00 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit

Action
Failure code Merge-divide LS Solenoid Open Circuit
level Failure
L01 DXE6KA
q When pump merge-divider (LS) EPC solenoid is driven, no current flows and open circuit is detect-
Detail of failure
ed.
q None in particular (Since no current flows, merge-divider LS solenoid does not operate. Since no
Action of con- current flows, merge-divider main solenoid does not operate, either.)
to OFF position.
q Drive current to merge-divider LS EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08001 Merge-divider (LS) solenoid current)
mation

Defective merge-divider LS EPC 2. Disconnect connector V24, and connect T-adapters to male side.
1
solenoid (internal open circuit)
2
and (120)
Resistance Max. 1 z
(115), (117) and (120)
40-305 36 PC200, 200LC, 220, 220LC-8M0

Failure code [DXE6KA] Merge-divide LS Sol Open Circuit SEN06137-00
Circuit diagram related to merge-divider LS EPC solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 37

SEN06137-00 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit

Action
Failure code Merge-divide LS Solenoid Short Circuit
level Failure
L01 DXE6KB
q When pump merge-divider (LS) EPC solenoid is driven, abnormal current flows and short circuit is
Detail of failure
detected.
q Stops outputting current to merge-divider (LS) EPC solenoid. (Since no current flows, merge-divider
Action of con- main solenoid does not operate, either.)
to OFF position.
q Drive current to merge-divider LS EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 Merge-divider (LS) solenoid current)
mation

Defective merge-divider LS EPC 2. Disconnect connector V24, and connect T-adapters to male side.
1 solenoid (internal short circuit or
ground fault)
and (120)
3
ground
40-305 38 PC200, 200LC, 220, 220LC-8M0

Failure code [DXE6KB] Merge-divide LS Sol Short Circuit SEN06137-00
Circuit diagram related to merge-divider LS EPC solenoid
PC200, 200LC, 220, 220LC-8M0 40-305 39

SEN06137-00 Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20KA] Wiper Working Abnormality

Action
Failure code Wiper Working Error
level Failure
DY20KA
Detail of failure q When windshield wiper works, W signal of working ends is not input.
Action of con- q Shuts off power supply to wiper motor.
Problem on
q Wiper motor does not work.
machine
Signal input (ON/OFF) of W contact that indicates wiper working area end can be checked with
q
monitoring function.
(Code: 02204 Switch input 5)
Related infor- q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
mation sured at pump controller connector.
a Single wiper does not have lower wiper of double wiper (Upper wiper is called wiper).
q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT
or ON.

2. Disconnect connector M05 and connect T-adapters to female side.
Wiper position: working
Resistance Max. 1 z
Defective wiper motor Between M05 (female) area end
1
(Internal open circuit) (6) and (5) Wiper position: other than
working area end
Between M05 (female) Wiper position: whole
(1) and (3) range
2. Disconnect connectors C01 and C02 and connect T-adapters to each
female side.
Wiper position: working
Open or short circuit in wiring har- Resistance Max. 1 z
2 Between C01 (female) area end
ness
(56) and ground Wiper position: other than
working area end
Between C02 (female) Wiper position: whole
(114) and (119) range
2. Disconnect connectors C01, C02, and M05.
3. Connect T-adapters to female sides of connector C01 and C02 and to male
Open circuit in wiring harness side of M05.
3 (wire breakage or defective con- Between C01 (female) (56) and M05 (male) (6) Resistance Max. 1 z
tact of connector)
Between M05 (male) (5) and ground (T05) Resistance Max. 1 z
Between C02 (female) (114) and M05 (male) (1) Resistance Max. 1 z
40-305 40 PC200, 200LC, 220, 220LC-8M0

Failure code [DY20KA] Wiper Working Abnormality SEN06137-00
Circuit diagram related to wiper
PC200, 200LC, 220, 220LC-8M0 40-305 41

SEN06137-00 Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY20MA] Wiper Parking Abnormality

Action
Failure code Wiper Parking Abnormality
level Failure
DY20MA
Detail of failure q When windshield wiper rests, P signal for rest area is not input.
Action of con- q Stops output for resting to wiper motor.
Problem on
q Wiper motor does not rest.
machine
q Condition of P contact signal of wiper resting area can be checked with monitoring function.
(Code: 02204 Switch input 5)
Related infor- q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
mation sured at pump controller connector.
q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch from
INT/ON to OFF.

2. Disconnect connector M05 and connect T-adapters to female side.
Defective wiper motor Wiper position: rest area Resistance Max. 1 z

1 Between M05 (female)
(Internal open circuit) (4) and (5) Wiper position: working
area
Between M05 (female) Wiper position: whole
(1) and (3) range
2. Disconnect connectors C01 and C02 and connect T-adapters to each
female side.
Open or short circuit in wiring har- Wiper position: rest area Resistance Max. 1 z
2 Between C01 (female)
ness Wiper position: working
(75) and ground Resistance Min. 1 Mz
area
Between C02 (female) Wiper position: whole
(114) and (119) range
2. Disconnect connectors C01, C02, and M05.
3. Connect T-adapters to female sides of connector C01 and C02 and to male
Open circuit in wiring harness side of M05.
3 (wire breakage or defective con- Between C01 (female) (75) and M05 (male) (4) Resistance Max. 1 z
tact of connector)
Between M05 (male) (5) and ground (T05) Resistance Max. 1 z
40-305 42 PC200, 200LC, 220, 220LC-8M0

Failure code [DY20MA] Wiper Parking Abnormality SEN06137-00
PC200, 200LC, 220, 220LC-8M0 40-305 43

SEN06137-00 Failure code [DY2CKB] Washer Drive Short Circuit
Failure code [DY2CKB] Washer Drive Short Circuit

Action
Failure code Window Washer Drive Short Circuit
level Failure
DY2CKB
q When outputting current to window washer motor, abnormal current flows and short circuit is de-
Detail of failure
tected.
q Shuts of power supply to washer motor.
Action of con-
troller
to OFF position.
Problem on
q Window washer does not operate.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and turn washer switch to
mation ON position.

1 Defective fuse No.4 If the fuse is broken, the circuit probably has a grounding fault, etc.
Defective washer motor 2. Disconnect connector M06 and connect T-adapters to male side.
2 (internal open circuit or ground
Between M06 (male) (1) and (2) Resistance 5 to 20 z
fault)
Between ground and M06 (male) (1) or (2) Resistance Min. 1 Mz
2. Disconnect connector D02 and connect T-adapters to male side.
Defective diode array D02 a Check the continuity in diode range.
3
(Internal short circuit) Between D02 (male) (7) (+) and (3) (-) Continuity
2. Remove fuse No.4
3. Disconnect connectors M06, C01, and D02, and connect T-adapters to
4
(contact with ground circuit) Between F01 (4) or M06 (female) (2) or D02
Between C01 (female) (3) or M06 (female) (1) or
D02 (female) (7) and ground
2. Disconnect connectors C01 and M06 and connect T-adapters to female
side of C01.
Hot short circuit in wiring harness 3. Remove fuse No.4
5
a Ignore failure code displayed on machine monitor.
Between C01 (female) (3) and ground Voltage Max. 1 V
40-305 44 PC200, 200LC, 220, 220LC-8M0

Failure code [DY2CKB] Washer Drive Short Circuit SEN06137-00
Circuit diagram related to window washer motor
PC200, 200LC, 220, 220LC-8M0 40-305 45

SEN06137-00 Failure code [DY2DKB] Wiper Drive (Fwd) Short
Failure code [DY2DKB] Wiper Drive (Fwd) Short

Action
Failure code Wiper motor Drive Foward rotation Short Circult
level Failure
DY2DKB
q When outputting current to normal rotation side of wiper motor drive, abnormal current flows in cir-
Detail of failure
cuit and short circuit is detected.
q Stops outputting current to wiper motor drive forward side.
Action of con-
troller
to OFF position.
Problem on
q Windshield wiper does not operate.
machine
mation q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT
or ON.

Defective wiper motor 2. Disconnect connector M05 and connect T-adapters to female side.
Between M05 (female) (3) and (1) Continuity
fault)
Between M05 (female) (3) and ground Resistance Min. 1 Mz
2. Disconnect connectors C02 and M05 and connect T-adapter to wiring
2 Short circuit in wiring harness harness side of either of them.
Between C02 (female) (119) and (114), or between
M05 (male) (1) and (3)
3 harness side of either of them.
Between C02 (female) (119) or M05 (male) (3) and
ground
If no abnormality is found by above checks, pump controller is defective. (Since
q Reference
4. Turn wiper switch ON and OFF, and troubleshoot.
Wiper switch:
Voltage Max. 3 V
Between M05 (3) and OFF
(5) Pulse below 3 V io
Wiper switch: ON Voltage
above 20 V
40-305 46 PC200, 200LC, 220, 220LC-8M0

Failure code [DY2DKB] Wiper Drive (Fwd) Short SEN06137-00
PC200, 200LC, 220, 220LC-8M0 40-305 47

SEN06137-00 Failure code [DY2EKB] Wiper Drive (Rev) Short
Failure code [DY2EKB] Wiper Drive (Rev) Short

Action
Failure code Wiper motor Drive Reverse rotation Short Circuit
level Failure
DY2EKB
q When outputting current to reverse rotation side of wiper motor drive is turned ON, abnormal cur-
Detail of failure
rent flows in circuit and short circuit is detected.
q Shuts off power supply to reverse rotation system of wiper motor drive.
Action of con-
troller
to OFF position.
Problem on
q Windshield wiper does not operate.
machine
mation q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT
or ON.

fault)
Between M05 (female) (1) and ground Resistance Min. 1 Mz
2 Short circuit in wiring harness harness side of either of them.
Between C02 (female) (119) and (114), or between
M05 (male) (1) and (3)
3 harness side of either of them.
Between C02 (female) (114) or M05 (male) (1) and
ground
If no abnormality is found by above checks, pump controller is defective. (Since
q Reference
4. Turn wiper switch ON and OFF, and troubleshoot.
Wiper switch:
Voltage Max. 3 V
Between M05 (1) and OFF
(5) Pulse below 3 V io
Wiper switch: ON Voltage
above 20 V
40-305 48 PC200, 200LC, 220, 220LC-8M0

Failure code [DY2EKB] Wiper Drive (Rev) Short SEN06137-00
PC200, 200LC, 220, 220LC-8M0 40-305 49

SEN06137-00
2012 KOMATSU
All Rights Reserved
40-305 50
SEN06138-00
SEN05989-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
400 Troubleshooting of electrical system
(E-mode)
Fuse locations............................................................................................................................................. 4
Information contained in troubleshooting table ........................................................................................... 6
E-1 Engine does not start (Engine does not crank) .................................................................................... 8
E-2 Preheater does not operate.................................................................................................................. 13
E-3 When starting switch is turned to ON position, machine monitor displays nothing .............................. 17
E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up. . 20
E-5 Precaution monitor lights up while engine is running ........................................................................... 21
E-6 Emergency stop monitor lights up while engine is running .................................................................. 23
E-7 Fuel level gauge does not indicate properly......................................................................................... 24
E-8 Engine coolant temperature gauge does not indicate properly ............................................................ 26
E-9 Hydraulic oil temperature gauge does not indicate properly ................................................................ 27
E-10 Displays on machine monitor are different from those for actual machine......................................... 30
E-11 Some areas of machine monitor screen are not displayed ................................................................ 31
E-12 Function switch does not operate....................................................................................................... 31
E-13 Automatic warm-up system does not operate (in cold season).......................................................... 32
E-14 Auto-decelerator does not operate properly....................................................................................... 33
E-15 Working mode does not change......................................................................................................... 34
E-16 Travel speed does not change ........................................................................................................... 35
PC200, 200LC, 220, 220LC-8M0 40-400 1

400 Troubleshooting of electrical system (E-mode)
SEN06138-00
E-17 Alarm buzzer cannot be canceled ...................................................................................................... 36

E-18 When starting switch is turned OFF, service meter is not displayed .................................................. 36
E-19 Service mode cannot be selected ...................................................................................................... 36
E-20 Any of work equipment, swing and travel do not operate or cannot be locked .................................. 37
E-21 Swing holding brake does not operate properly ................................................................................. 39
E-22 One-touch power maximizing function does not operate properly ..................................................... 42
E-23 Travel alarm does not sound or does not stop sounding.................................................................... 45
E-24 Horn does not sound or does not stop ............................................................................................... 46
E-25 Windshield wiper and window washer do not operate........................................................................ 48
E-26 BOOM DOWN indicator is not displayed properly with monitoring function ....................................... 50
E-27 ARM DUMP indicator is not displayed properly with monitoring function........................................... 50
E-28 ARM IN indicator is not displayed properly with monitoring function.................................................. 50
E-29 BOOM RAISE indicator is not displayed properly with monitoring function........................................ 51
E-30 BUCKET CURL indicator is not displayed properly with monitoring function ..................................... 51
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function .................................... 51
E-32 SWING indicator is not displayed properly with monitoring function .................................................. 52
E-33 TRAVEL indicator is not displayed properly with monitoring function................................................. 52
E-34 ATTACHMENT indicator is not displayed properly with monitoring function ...................................... 53
E-35 Attachment hydraulic circuit cannot be changed ................................................................................ 55
E-36 KOMTRAX system does not operate properly ................................................................................... 56
40-400 2 PC200, 200LC, 220, 220LC-8M0

SEN06138-00
PC200, 200LC, 220, 220LC-8M0 40-400 3

SEN06138-00 Fuse locations
Fuse locations
Connection table of fuse box
a This connection table shows the devices to which power supply from each fuse of the fuse box supplies
power (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power while the starting switch is in the
OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
Type of
Fuse
power Fusible link Fuse No. Destination of power
capacity
supply
Lamp relay, rear lamp relay, cab lamp relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve
1 10 A [When pump drive switch is operated in emergency]
Swing holding brake solenoid valve
[When swing holding brake release switch is operated]
2 30 A Pump controller (Solenoid power supply)
Switch power F04
supply (60 A) PPC oil pressure lock solenoid valve
3 10 A Starting motor cut-out relay (PPC lock)
Starting motor cut-out relay (Personal code)
Cigarette lighter
4 10 A
Windshield washer motor
5 10 A Horn relay, horn
6 10 A Electrical intake air heater relay
7 10 A Rotary lamp
Switch power F04 8 20 A Right headlamp, working lamp (boom), working lamp (rear)
supply (60 A) Radio
9 10 A
Left knob switch (pump controller input)
10 5A Air conditioner controller supply
11 20 A
Air conditioner compressor electromagnetic clutch
12 10 A (Spare)
Switch power F04
13 10 A Headlamp
supply (60 A)
Travel alarm
15 10 A
Optional power supply (2)
Radio (backup power supply)
16 10 A
Room lamp
Starting switch
Constant F05
17 20 A Machine monitor
power supply (30 A)
Pump controller
18 5A Air conditioner controller backup
19 30 A Engine controller
Switch power Starting switch
20 5A Engine controller (ACC signal)
supply ACC
40-400 4 PC200, 200LC, 220, 220LC-8M0

Locations of fusible links
Location of fuse box and fuse Nos.
PC200, 200LC, 220, 220LC-8M0 40-400 5

SEN06138-00 Information contained in troubleshooting table
Information contained in troubleshooting table

(Rev. 2012/2)
a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.
Failure Problem on machine
Related infor-
Information related to the detected failure or troubleshooting
mation
<Details of description>
q Procedure
q Measuring location
1 defective- a "Between A and B" means the measurement of voltage, resistance or others
between terminals A and B.
a "Between A and ground" means the measurement of voltage, resistance or
others between terminal A and the place which has a continuity with chassis
frame such as unpainted hexagonal head bolt or bolt hole which has no rust,
Open or short circuit in wir- etc.
2 q Criteria to judge probable causes (standard value), remarks
ing harness
<How to use troubleshooting sheet>
q Perform troubleshooting procedures in numerical order.
q If the check result does not meet the criteria, the probable cause described on the
left column is the actual cause of the failure.
Open circuit in wiring har-
q If the check result shows no failure, and unless otherwise specified, proceed to the
ness
3 next step (next cause item).
q Check that the failure is fixed after the failure was found and repaired.
<Failures in wiring harness>
q Open circuit in wiring
The connector connection is defective or the wire is broken.
Ground fault in wiring har- q Ground fault
4 ness A harness not connected to the ground circuit contacts with the ground wiring or
(contact with ground circuit) machine.
q Hot short circuit
A harness not connected to the power (24 V) circuit contacts with the power (24 V)
circuit.
q Short circuit
Hot short circuit An independent wire in the wiring harness contacts with other wire.
5
(contact with 24 V circuit) (poor insulation at connector and others)
<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapter as follows unless otherwise spec-
ified.
Short circuit in wiring har- q When "male" or "female" is not indicated with a connector number, disconnect
6
ness the connector, and insert T-adapter between the male and female connectors.
q When "male" or "female" is indicated with a connector number, disconnect the
connector, and connect T-adapter only to either male or female connector.
(2) Description sequence of pin number and handling of tester lead
For troubleshooting, connect the positive (+) and negative (-) leads as shown be-
low unless otherwise specified.
7 Defective controller q Connect the positive (+) lead to pin or wire indicated first.
q Connect the negative (-) lead to a pin or wire indicated second.
40-400 6 PC200, 200LC, 220, 220LC-8M0

Information contained in troubleshooting table SEN06138-00
This is the excerpted circuit diagram related to trouble-

shooting
q The circuit diagram contains the connector Nos., pin
Nos., and connector colors related to the failure.
q The "/" in a connector number is either:
1) An abbreviation (of more than three letters)
Example: T/C (Torque Converter)
2) Different connector number at male and female sides
Example: BREAK OUT/ E24
q The circuit diagram contains the destination or source of
the branch line in a wiring harness.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed
PC200, 200LC, 220, 220LC-8M0 40-400 7

SEN06138-00 E-1 Engine does not start (Engine does not crank)
E-1 Engine does not start (Engine does not crank)

Failure q Engine does not start (engine does not crank)
q Engine starting circuit has following two start lock mechanisms.
1) Start lock by password protection of machine monitor
Related infor-
2) Start lock by lock lever position
mation
q If failure symptom "Battery relay operation sound is not heard" appears when starting switch is
turned to ON position, perform troubleshooting for E-1 also.

1 Defective fusible links F04 or F05 2. Remove fusible links F04 and F05
Between terminals F04 and F05 Resistance Max. 1 z
Defective fuses Nos. 3 and 17 in
2 If fuse is broken, circuit probably has ground fault. (See Cause 16.)
fuse box F01
Loose terminal connection or open
3 Check terminals of starting motor, alternator, battery relay, grounds T04, T07
circuit at terminal
and T08, etc.
Between battery relay (terminal R01) and ground
Resistance Max. 1 z
a Use machine frame as ground.
a Perform followings when the above check result is abnormal (grounding is
defective).
a See figure.
Defective contact (ground)
1. Disconnect battery ground cable.
4 between battery relay bracket and
2. Remove battery relay (BAT RL)
frame
3. Remove battery bracket (BKT)
q Check contact faces of battery relay bracket (BKT) and frame for rust and
dirt (Check frame side, too).
a If there is rust etc., remove it.
q Check mounting bolt (B) for rust.
a If mounting bolt (B) is rusted, be sure to replace it with plated one.
q Tighten mounting bolt (B) to specified torque.
a Be ready with starting switch at OFF, then perform troubleshooting without
turning starting switch to ON position.
5 Insufficient battery capacity Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (each) Min. 1.26
q Battery relay bracket (BKT), Battery relay (BAT RL)
40-400 8 PC200, 200LC, 220, 220LC-8M0

E-1 Engine does not start (Engine does not crank) SEN06138-00

Engine controller power supply and ACC signal are diagnosed with proce-
6 Defective engine controller system dures for failure code [DB2QKR], If failure code [DB2QKR] is displayed, per-
form troubleshooting for it first.
2. Remove fuse No.19 (30 A) in fuse box F01. (to prevent engine from starting
during check)
Defective starting switch, starter 3. Insert T-adapters into connector E10.
7 cut relay R06, personal code relay 4. Turn starting switch to START position and hold (two persons required for
R07, battery relay, wiring harness this check).
Voltage Between E10 (1) and ground 20 to 30 V
a If voltage is normal, proceed to cause 14.
2. Disconnect connector H15 and connect T-adapters to male side.
3. After troubleshooting, perform troubleshooting again with starting switch at
ON and START positions.
Turn starting switch to
Between H15 (male) (1) OFF position.
and (2) Turn starting switch to
Defective starting switch Resistance Max. 1 z
8 ON position.
(Internal open circuit) Turn starting switch to
Resistance Max. 1 z
ON position.
Turn starting switch to
Between H15 (male) (1) Resistance Min. 1 Mz
OFF position.
and (4)
Starting switch: START Resistance Max. 1 z
Defective lock lever switch
9
(Internal open circuit) Between S14 (female) (1) Lock lever: FREE Resistance Min. 1 Mz
and (3) Lock lever: LOCK Resistance Max. 1 z
2. Replace starter cut relay (R06) with horn relay (R08).
Defective starter cut relay 3. Start engine.
10
If engine starts, original starter cut relay (R06) is defective.
a If no failure is found by check on causell, this check is not.

Defective personal code relay 2. Replace personal code relay (R07) with horn relay (R08).
11 3. Start engine.
(internal open or short circuit)
If engine starts, original personal code relay is defective.

2. Disconnect connector D01 and connect T-adapters to diode.
a Check by using multimeter in diode range.
Defective diode D01 Between D01 (male) (1) (+) and (5) (-) No continuity
12
(internal open or short circuit) Between D01 (male) (5) (+) and (1) (-) Continuity
PC200, 200LC, 220, 220LC-8M0 40-400 9


2. Disconnect cable only from C terminal on starting motor safety relay.
3. Insert T-adapter between male and female sides of connector R17.
4. Turn starting switch to START position and perform troubleshooting.
Power sup-
Between safety relay terminal B and E Voltage 20 to 30 V
ply
Input from
Between safety relay terminal R
alternator Voltage Max. 1 V
Defective starting motor safety (R17-2) and safety relay terminal E
generation
13 relay Starting
(internal defect) Between safety relay terminal S input to
Voltage 20 to 30 V
(R17-1) and safety relay terminal E starting
motor
Starting out-
Between safety relay terminal C (R28)
put to start- Voltage 20 to 30 V
and safety relay terminal E
ing motor
If power supply, input from alternator generation, and starting input to starting
motor normal but starting output to starting motor is abnormal, starting motor
safety relay is defective.
Between starting motor terminal B Power sup-
Voltage 20 to 30 V
(SB) and ground ply
Defective starting motor Starting
14
(internal defect) Between starting motor terminal C input to
Voltage 20 to 30 V
(SC) and ground starting
motor
If power supply and starting input to starting motor are normal but starting
motor does not rotate, starting motor is defective.
Defective alternator 3. Turn starting switch to ON position.
15
(Internal short circuit) Input from
Voltage Between E12 (1) and ground alternator Max. 1 V
generation
q Battery relay
Between terminal R01 and ground (T08) Resistance Max. 1 z
q Battery relay
a To check to where 24 V is supplied to locate open section
Between terminals R04 and R01 Voltage 20 to 30 V
Between terminal R01 and ground Voltage Max. 1 V
q Alternator and starting motor
tact of connector)
3. Insert T-adapters into connectors H15, S14, R07, R17, E10, and E12.
a Check to where 24 V power is supplied to isolate open section.
Between H15 (4) and ground Voltage 20 to 30 V
Between S14 (1) and ground Voltage 20 to 30 V
Between S14 (3) and ground Voltage 20 to 30 V
Between R07 (4) and ground Voltage 20 to 30 V
Between R17 (1) and ground Voltage 20 to 30 V
Between E10 (1) and ground Voltage 20 to 30 V
Between alternator B terminal and ground Voltage 20 to 30 V
Between starting motor terminal B and ground Voltage 20 to 30 V
40-400 10 PC200, 200LC, 220, 220LC-8M0

E-1 Engine does not start (Engine does not crank) SEN06138-00

a If fuse or fusible link is broken, replace it.
2. Disconnect H15, S14, R06 and R07.
3. Connect T-adapters to female sides of H15, R06 and R07, and to male side
of S14.
4. Remove fuse F01-3.
Between H15 (female) (4) and R06 (female) (5) Resistance Max. 1 z
Between R06 (female) (3) and R07 (female) (4) Resistance Max. 1 z
Between R07 (female) (1) and S14 (male) (1) Resistance Max. 1 z
Open circuit in wiring harness Between R07 (female) (2) and CM01 (female) (6) Resistance Max. 1 z
16 (wire breakage or defective con- Between R07 (female) (3) and starting motor safety
Resistance Max. 1 z
tact of connector) relay terminal S
Between alternator terminal B and starting motor
Resistance Max. 1 z
terminal B
Between starting motor B and battery relay R03 Resistance Max. 1 z
Between starting motor safety relay R terminal and
Resistance Max. 1 z
alternator L terminal
Between alternator terminal L and D01 (female) (6) Resistance Max. 1 z
Between F01-3 and S14 (male) (1) Resistance Max. 1 z
Between S14 (male) (3) and R06 (male) (1) Resistance Max. 1 z
Between R06 (male) (2) and ground (T04) Resistance Max. 1 z
Defective battery relay If only terminal R03 voltage is abnormal during battery relay check for cause
17
(Does not work) 16, battery relay is defective.
2. Disconnect H15, S14, R06 and R07.
3. Connect T-adapters to female sides of H15, R06 and R07, and to male side
of S14.
Between H15 (female) (4) and ground, or between
R06 (female) (5) and ground
Between R06 (female) (3) and ground, or between
R07 (female) (4) and ground
Ground fault in wiring harness Between R07 (female) (3), or R17 (female) (1) and
18 Resistance Min. 1 Mz
(contact with ground circuit) ground
Between starting motor safety relay B or battery
relay R03 and ground
Between starting motor safety relay C or starting
motor C (SC) and ground
Between ground and F01-3 or S14 (male) (1) Resistance Min. 1 Mz
Between ground and S14 (male) (3) or R06 (female)
(1)
Hot short circuit in wiring harness 2. Insert T-adapter between male and female sides of connector R17 or E08.
Between R17 (female) (2) or E08 (1) and ground Voltage Max. 1 V
PC200, 200LC, 220, 220LC-8M0 40-400 11

Circuit diagram related to engine start circuit
40-400 12 PC200, 200LC, 220, 220LC-8M0

E-2 Preheater does not operate SEN06138-00
E-2 Preheater does not operate

Failure 1) Manual preheating does not function.
a This troubleshooting describes procedures to be followed when manual preheating does not
function to heat electrical intake air heater (ribbon heater) mounting section.
q Automatic preheating and Manual preheating functions are available. When either function
is operated, preheating monitor lights up. (When only preheating monitor does not light up,
perform troubleshooting "3) While preheater is operating, preheating monitor does not light
Related information up")
q If "Machine monitor displays nothing" or "Battery relay operation sound is not heard" when
turning starting switch to ON position, main electric power supply system may be defective.
So, perform troubleshooting for E-3 and E-1.
q Before performing troubleshooting, check that no related failure code is displayed.
(If failure codes [D110KB] is displayed, troubleshoot it first.)

Defective fuse No. 17 in fuse box If fuse No. 17 in fuse box F01 is broken, circuit probably has ground fault. In
1
F01 this case, perform troubleshooting for cause 8 first.
Loose terminal or open circuit at
2 Check terminals of heater relay, battery relay, electrical intake air heater (rib-
terminal
bon heater), etc.
2. Disconnect connectors CM01 and H15, and connect T-adapter to female
side of H15.
a Heater relay coil resistance Approx.
Resistance
Between H15 (female) (3) and ground 20 z
3 Between input terminal on contact side of heater
ing harness Voltage 20 to 30 V
relay and ground
2. Disconnect heater relay terminal R16.
a To prevent current from flowing through heater when starting switch is
turned to HEAT position
3. Turn starting switch to HEAT position (Connect R1).
Between heater relay terminal R15 and ground Voltage 20 to 30 V
Defective heater relay If no failure is found by check on cause 3 and heater relay operation sound is
4
(Does not work) (Terminal R16) not heard, heater relay is defective.
2. Disconnect connector D02 and connect T-adapters to diode.
Defective diode D02 a Check by using multimeter in diode range.
5
(internal open or short circuit) Between D02 (male) (1) (+) and (5) (-) No continuity
Defective electrical intake air 1. Turn starting switch to OFF position.

6 heater (ribbon heater) 2. Disconnect terminal E01.
(Internal open circuit) Between E01 terminal and ground Continuity
7 Defective starting switch 4. Turn starting switch to OFF/HEAT position and perform troubleshooting.
OFF Resistance Min. 1 Mz
Between H15 (male) (1) and (3)
HEAT Resistance Min. 1 Mz
PC200, 200LC, 220, 220LC-8M0 40-400 13

SEN06138-00 E-2 Preheater does not operate

2. Disconnect connectors H15 and CM01, terminals R15 and E01, and
starting motor terminal B.
Ground fault in wiring harness Between heater relay terminal R15 (wiring harness
(contact with ground circuit) side) and ground
Between input terminal on contact side of heater
relay and ground
Between heater relay terminal E01 (wiring harness
side) and ground
Failure 2) Automatic preheating does not function.

q Automatic preheating starts when boost temperature is below -4 C.
(Monitoring code Boost temperature: 18500)
q If automatic preheating does not function, check if manual preheating functions.
Related informa-
q Engine controller checks primary (coil) side of preheater relay (connector R18) and generates fail-
tion
ure codes [CA2555] and [CA2556] if it is defective.
q Engine controller checks boost temperature sensor and generates failure codes [CA153] and
[CA154] if it is defective.

Defective fuse No. 6 in fuse If fuse No. 6 in fuse box 01 is broken, circuit probably has ground fault. In this case,
1
box F01 perform troubleshooting for cause 5 first.
2. Replace auto preheater relay (connector R18) with horn relay (connector R08),
Defective auto preheater for example.
2 relay R18 (open or short cir- 3. Turn starting switch to ON position.
cuit in internal wiring)
If automatic preheater operates when charged (boosted) air temperature is below
-4 C, original auto preheater relay is defective.
2. Disconnect connectors CM01 and R18, and connect T-adapter to female side of
R18.
Open circuit or ground fault in a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is be-
3
wiring harness low 1 z, wiring harness has short circuit.
a Heater relay coil resistance
Between R18 (female) (5) and ground Resistance Approx. 20 z
2. Disconnect connectors R18 and CM01, and connect T-adapters to female side
Open circuit in wiring har- of R18.
ness 3. Remove fuse No. 6 in fuse box F01.
4
(Wire breakage or defective
Between R18 (female) (3) and F01-6 Resistance Max. 1 z
contact)
Between R18 (female) (5) and heater relay terminal
Resistance Max. 1 z
R15
If fuse is not blown, this check is not required.
Ground fault in wiring har- 1. Turn starting switch to OFF position.
5 ness 2. Disconnect connectors CM01, R18, and starting motor terminal B, and connect
(contact with ground circuit) T-adapter to female side of R18.
Between R18 (female) (3) and ground Resistance Min. 1 Mz
40-400 14 PC200, 200LC, 220, 220LC-8M0

E-2 Preheater does not operate SEN06138-00
Failure 3) While preheater is operating, preheating monitor does not light up.
q "Automatic preheating" and "Manual preheating" functions are available. When either function is
Related informa-
operated, preheating monitor lights up.
tion
q Check if manual preheating functions first.

Open circuit in wiring har- 2. Disconnect connectors H15, CM01, and R18, and connect T-adapters to each
ness female side.
1
(Wire breakage or defective Between H15 (female) (3) and CM01 (female) (16) Resistance Max. 1 z
contact)
Between R18 (female) (5) and CM01 (female) (16) Resistance Max. 1 z
q Reference
2. Insert T-adapter into connector CM01.
3. Disconnect heater relay terminal R16.
a To prevent current from flowing through heater when starting switch is turned to
HEAT position
4. Turn the starting switch to HEAT position.
Between CM01 (16) and (3)
Resistance 20 to 30 V
a Between CM01(3) is ground
PC200, 200LC, 220, 220LC-8M0 40-400 15

SEN06138-00 E-2 Preheater does not operate
Circuit diagram related to preheating of engine
40-400 16 PC200, 200LC, 220, 220LC-8M0

E-3 When starting switch is turned to ON position, machine monitor displays nothing SEN06138-00
E-3 When starting switch is turned to ON position, machine monitor

displays nothing
Failure q When starting switch is turned to ON position, machine monitor displays nothing.
q When starting switch is turned to ON position, machine monitor displays KOMATSU logo screen,
password input screen (if set), breaker mode confirmation screen (if selected), check before start-
Related infor- ing screen, working mode and travel speed confirmation screen, and standard screen in order.
mation q When engine is started, battery voltage may lower suddenly, depending on ambient temperature
and condition of the battery.
In this case, machine monitor goes off for a moment. This phenomenon is not a failure, however.

Defective connection of battery
1 Check battery ground terminal (60B) connection.
ground terminal
a Be ready with starting switch at OFF position, then perform troubleshooting
without turning starting switch to ON position.
2 Insufficient battery capacity Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (each) Min. 1.26
Defective fusible link F05
3 If fusible link or fuse is blown, circuit probably has ground fault. (See Cause 7.)
Defective fuse F01-17
2. Insert T-adapter into connector CM01.
3. Connect battery ground cable, and turn starting switch to ON position (to
Defective wiring harness, starting connect ACC).
4
switch, or machine monitor Between CM01 (1) and (3) Voltage 20 to 30 V
3. Turn starting switch to ON position and perform troubleshooting again.
Defective starting switch
5 Turn starting switch to
(Internal open circuit) Resistance Min. 1 Mz
Resistance Max. 1 z
ON position.
If check result on cause 4 is normal, this check is not required.
2. Disconnect fusible link F05, No. 17 of fuse F01, and connectors H15 and
CM01.
3. Connect T-adapters to male side of connector F05 and female side of H15
and CM01.
Between battery (-) and ground Resistance Max. 1 z
6 (wire breakage or defective con- Between battery (+) and F05 (male) (1) Resistance Max. 1 z
tact of connector) Between F05 (male) (2) and F01-16E Resistance Max. 1 z
Between F01-17 and each of CM01 (female) (1)
Resistance Max. 1 z
and (2)
Between CM01 (female) (3), (4) and ground (T05) Resistance Max. 1 z
Between F01-17 and H15 (female) (1) Resistance Max. 1 z
Between H15 (female) (5) and CM01(female)(10) Resistance Max. 1 z
PC200, 200LC, 220, 220LC-8M0 40-400 17

SEN06138-00 E-3 When starting switch is turned to ON position, machine monitor displays nothing

If check result on cause 4 is normal, this check is not required.
2. Disconnect fusible link F05, No. 17 of fuse F01, terminal 20E, and connec-
tors H15, CM01, and C01.
3. Connect T-adapters to male side of connector F05 and female side of H15
and CM01.
Ground fault in wiring harness Between battery (+) or F05 (male) (1) and ground Resistance Min. 1 Mz
7
(contact with ground circuit) Between F05 (male) (2) and ground, or between
F01-16E and ground
Between F01-17 and ground, or between CM01
(female) (1), (2) and ground, or between H15 Resistance Min. 1 Mz
Between H15 (female) (5) and ground, or between
CM01 (female) (14) and ground
If no failure is found by above checks, machine monitor is defective. (Since
40-400 18 PC200, 200LC, 220, 220LC-8M0

E-3 When starting switch is turned to ON position, machine monitor displays nothing SEN06138-00
Circuit diagram related to machine monitor power supply
PC200, 200LC, 220, 220LC-8M0 40-400 19

SEN06138-00 E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights
E-4 When starting switch is turned to ON position (with engine stopped),

basic check monitor lights up.
1) When starting switch is turned to ON position (with engine stopped), engine oil level monitor
Failure
lights up in yellow.
Related information

Defective engine oil level switch
1 Perform troubleshooting for failure code [B@BAZK].
system (machine monitor system)
Failure 2) Radiator coolant level monitor lights up in yellow.

Related information

Radiator sub tank coolant level
1 Perform troubleshooting for failure code [B@BCZK].
switch system
40-400 20 PC200, 200LC, 220, 220LC-8M0

E-5 Precaution monitor lights up while engine is running SEN06138-00
E-5 Precaution monitor lights up while engine is running

Failure 1) Engine coolant temperature monitor lights up in white.
q Signal of engine coolant temperature sensor is input to engine controller and then data is
transmitted to machine monitor through CAN communication system.
Related information
q Engine coolant temperature can be checked with monitoring function

If monitor lights up in white, engine coolant temperature may be low (below
Insufficient warm-up of machine approximately 30 C). Warm up engine.
1
(when system works properly) q Lighting up in white: Engine coolant temperature is low.
q Lighting up in blue: Engine coolant temperature is proper.
If no failure is found by check on cause 1, engine coolant temperature gauge
Defective engine coolant tempera-
2 system may be defective. Perform troubleshooting for "E-8 Engine coolant
ture gauge system
temperature gauge does not indicate properly".
Failure 2) Hydraulic oil temperature monitor lights up in white.

q Signal of hydraulic oil temperature sensor is input to pump controller and then data is trans-
mitted to machine monitor through CAN communication system.
Related information
q Hydraulic oil temperature can be checked with monitoring function
(Code: 04401 Hydraulic oil temperature)

If monitor lights up in white, hydraulic oil temperature may be low (below
Insufficient warm-up of machine approximately 20 C). Warm up engine.
1
(when system works properly) q Lighting up in white: Hydraulic oil temperature is low.
q Lighting up in blue: Hydraulic oil temperature is proper.
If no failure is found by check on cause 1, hydraulic oil temperature gauge sys-
Defective hydraulic oil temperature
2 tem may be defective. Perform troubleshooting for "E-9 hydraulic oil tempera-
gauge system
ture gauge does not indicate properly".
Failure 3) Charge level monitor lights up while engine is running.

q Power generation signal of alternator can be checked with monitoring function.
Related information
(Code: 04300 Charge voltage)

1 Defective alternator system Perform troubleshooting for failure code [AB00KE].
Failure 4) Fuel level monitor lights up in red.

q Signal voltage of fuel level sensor can be checked with monitoring function.
Related information
(Code: 04200 Fuel sensor voltage)

Low fuel level (when system works
1 Fuel level may be low. Check it and add fuel if necessary.
properly)
If no failure is found by check on cause 1, fuel level gauge system may be
2 Defective fuel level gauge system defective. Perform troubleshooting for "E-7 Fuel level gauge does not indicate
properly".
PC200, 200LC, 220, 220LC-8M0 40-400 21

SEN06138-00 E-5 Precaution monitor lights up while engine is running
Failure 5) Air cleaner clogging monitor lights up in yellow.

q Air cleaner clogging switch signal can be checked with monitoring function.
Related information

Clogging of air cleaner
1 Air cleaner may be clogged. Check it, then clean or replace if necessary.
Defective air cleaner clogging
2 Perform troubleshooting for failure code [AA10NX].
switch system
6) Engine state monitor light up in yellow because of water separator sensor detection. (high
Failure
water level in water separator)
q Signal of water detection by fuel filter sensor can be checked with monitoring function.
Related information
(Code: 18800 Condition of WIF sensor)

High water level in water separator
1 Full of water is detected in water separator. Check and drain water separator.
Defective water-in-fuel sensor If no failure is found by check on cause 1, water-in-fuel sensor system may be
2
system (engine controller circuit) defective. Perform troubleshooting for failure codes [CA428] and [CA429]
If no failure is found by checks on causes 1 and 2, machine monitor may be
3 Defective machine monitor defective
40-400 22 PC200, 200LC, 220, 220LC-8M0

E-6 Emergency stop monitor lights up while engine is running SEN06138-00
E-6 Emergency stop monitor lights up while engine is running

Failure 1) Engine coolant temperature monitor lights up in red.
q Signal of engine coolant temperature sensor is input to engine controller and then data is trans-
Related infor- mitted to machine monitor through CAN communication system.
mation q Engine coolant temperature can be checked with monitoring function

If monitor lights up in red, engine coolant temperature may be high (above approxi-
mately 102 C). Cool down engine coolant (run engine at low idle).
Overheating of engine cool-
q Lighting up in red: Engine coolant temperature is high (overheating).
1 ant (when system works
q Lighting up in blue: Engine coolant temperature is proper.
properly)
Perform troubleshooting for "S-14 Coolant temperature becomes too high (over-
heating)".
If no failure is found by check on cause 1, engine coolant temperature gauge sys-
Defective engine coolant
2 tem may be defective. Perform troubleshooting for "E-8 Engine coolant temperature
temperature gauge system
gauge does not indicate properly".
Failure 2) Hydraulic oil temperature monitor lights up in red.

Related infor- ted to machine monitor through CAN communication system.
mation q Hydraulic oil temperature can be checked with monitoring function

If monitor lights up in red, hydraulic oil temperature may be high (above approxi-
Overheating of hydraulic oil
mately 102 C). Cool down hydraulic oil (run engine at low idle or stop engine).
1 (when system works prop-
q Lighting up in red: Hydraulic oil temperature is high (overheating).
erly)
q Lighting up in blue: Hydraulic oil temperature is proper.
If no failure is found by check on cause 1, hydraulic oil temperature gauge system
Defective hydraulic oil tem-
2 may be defective. Perform troubleshooting for "E-9 hydraulic oil temperature gauge
perature gauge system
does not indicate properly".
Failure 3) Engine oil pressure monitor lights up in red.

q Signal of engine oil pressure switch is input to engine controller. If engine oil pressure switch is
Related infor-
turned ON while engine is running, failure code [B@BAZG] is transmitted from engine controller
mation
to machine monitor through CAN communication.

Low engine oil pressure
Engine oil pressure may be low. Check it. If it is low, perform troubleshooting for
1 (when system works prop-
"S-12 Oil pressure decreases".
erly)
Defective engine oil pres- If no failure is found by check on cause 1, engine oil pressure switch system may be
2
sure switch system defective. Perform troubleshooting for failure code [CA435].
PC200, 200LC, 220, 220LC-8M0 40-400 23

SEN06138-00 E-7 Fuel level gauge does not indicate properly
E-7 Fuel level gauge does not indicate properly

1) While fuel is added, fuel level gauge indicator does not rise above red range (E).
Failure
2) While fuel level is low, fuel level gauge indicator does not lower below green range top (F).
Related infor- q Signal voltage of fuel level sensor can be checked with monitoring function.
mation (Code: 04200 Fuel sensor voltage)

Defective fuel level sensor 2. Disconnect connector P21 and connect T-adapters to male side.
1 (internal open or short cir-
Between P21 (male) (1) Fuel level: FULL Resistance 7 to 11 z
cuit)
and ground Fuel level: EMPTY Resistance 85 to 95 z
2. Disconnect connector CM01 and connect T-adapter to female side.
Open circuit or ground fault
2
in wiring harness Between CM01(female) Fuel level: FULL Resistance 7 to 11 z
(15) and ground Fuel level: EMPTY Resistance 85 to 95 z
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness 2. Disconnect connectors CM01 and P21, and connect T-adapters to each female
3
(wire breakage or defective side.
Between CM01(female) (15) and P21(female) (1) Resistance Max. 1 z
Ground fault in wiring har- 2. Disconnect connectors CM01 and P21, and connect T-adapters to either female
4 ness side.
(contact with ground circuit) Between CM01(female) (15) and ground, or between
P21(female) (1) and ground
Hot short circuit in wiring 3. Insert T-adapters into connector CM01 or connect T-adapters to female side of
5 harness connector P21.
(Contact with 24 V circuit) 4. Turn starting switch to ON position.
Between CM01(15) and ground, or between P21 Approx. 3.3
Voltage
(female) (1) and ground V
If no failure is found by above checks, machine monitor is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to fuel level sensor
40-400 24 PC200, 200LC, 220, 220LC-8M0

E-7 Fuel level gauge does not indicate properly SEN06138-00
3) Indication of fuel level gauge is different from actual fuel level.

Failure
4) Indication of fuel level gauge is different from display of fuel level monitor.
Related infor- q Signal voltage of fuel level sensor can be checked with monitoring function.
mation (Code: 04200 Fuel sensor voltage)

a Turn starting switch to ON position or start engine and perform troubleshooting.
Fuel level Reading of fuel level gauge Color of monitor light (a)
289 l 6
244.5 l 5
200 l 4 Blue
100 l 3
60 l 2
41 l 1 Red
Fuel level gauge and fuel level monitor
PC200, 200LC, 220, 220LC-8M0 40-400 25

SEN06138-00 E-8 Engine coolant temperature gauge does not indicate properly
E-8 Engine coolant temperature gauge does not indicate properly

1) While engine coolant temperature is rising properly, temperature gauge indicator does not rise
above white range (C).
Failure
2) While engine coolant temperature remains in normal range, temperature gauge indicator rises to
red range (H).
q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is
Related infor- transmitted to machine monitor through CAN communication system.

Defective engine coolant Engine coolant temperature sensor system may be defective. Perform troubleshoot-
1
temperature sensor system ing for failure codes [CA144] and [CA145].
If no failure is found by check on cause 1, machine monitor may be defective.
3) Indication of engine coolant temperature gauge is different from actual engine coolant tempera-
ture.
Failure
4) Indication of engine coolant temperature gauge is different from display of engine coolant temper-
ature monitor.
q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is
Related infor- transmitted to machine monitor through CAN communication system.

Engine coolant tempera- Coolant temperature
Color of monitor light (a)
ture gauge level
105 C 6
Red
102 C 5
100C 4
85 C 3 Blue
60 C 2
30C 1 White
Engine coolant temperature gauge and coolant

temperature monitor
40-400 26 PC200, 200LC, 220, 220LC-8M0

E-9 Hydraulic oil temperature gauge does not indicate properly SEN06138-00
E-9 Hydraulic oil temperature gauge does not indicate properly

1) While hydraulic oil temperature is rising properdy, temperature gauge does not rise from white
Failure range (C).
2) While hydraulic oil temperature is stabilized properly, temperature gauge rises to red range (H).

Approx.
10C Resistance
90 kz
Defective hydraulic oil tem-
Approx.
perature sensor Between P22 (male) (1) and (2) 30C Resistance
1 35 kz
(internal open or short cir- a Temperature characteristics of oil
Approx.
cuit) temperature sensor 80C Resistance
6.5 kz
Approx.
100C Resistance
3.5 kz
Between P22 (male) (2) and ground Resistance Min. 1 Mz
Open circuit or ground fault Between C01 (female) (29) and (46)
2
in wiring harness a Resistance accords with temperature characteristics Resistance 3.5 to 90 kz
table in cause 1.
ness 2. Disconnect connectors C01 and P22, and connect T-adapters to each female
3 side.
contact of connector) Between C01 (female) (29) and P22 (female) (2) Resistance Max. 1 z
2. Disconnect connectors C01 and P22, and connect T-adapters to either female
4 ness
side.
Between C01 (female) (29) and ground, or between
Hot short circuit in wiring har- 3. Insert T-adapters into connector C01 or connect T-adapters to female side of
5 ness connector P22.
Between C01 (29) and ground, or between P22
Voltage Approx. 5 V
If no failure is found by above checks, the pump controller is defective. (Since this is
PC200, 200LC, 220, 220LC-8M0 40-400 27

SEN06138-00 E-9 Hydraulic oil temperature gauge does not indicate properly
Circuit diagram related to hydraulic oil temperature sensor
40-400 28 PC200, 200LC, 220, 220LC-8M0

E-9 Hydraulic oil temperature gauge does not indicate properly SEN06138-00
3) Indication of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Failure 4) Indication of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.

Reading of hydraulic oil
Hydraulic oil temperature Color of monitor light (a)
temperature gauge
105 C 6
Red
102 C 5
100C 4
85 C 3 Blue
40C 2
20C 1 White
Hydraulic oil temperature gauge and hydraulic

oil temperature monitor
PC200, 200LC, 220, 220LC-8M0 40-400 29

SEN06138-00 E-10 Displays on machine monitor are different from those for actual machine
E-10 Displays on machine monitor are different from those for actual
machine
Failure q Displays on machine monitor are different from those for actual machine
Related information
q PC200-8M0, PC200LC-8M0
a Turn starting switch to ON position and perform troubleshooting (with moni-
toring function).
Model selection 1
= OFF
Model selection 2
= OFF
00201 Switch Input Model selection 3
1 Defective model code signal Monitoring code Monitoring display
2 = ON
Model selection 4
= OFF
Model selection 5
= OFF
If display on monitor is incorrect, perform troubleshooting for failure code
[DA29KQ].
If no failure is found by check on cause 1, machine monitor is defective. (Since
q PC220-8M0, PC220LC-8M0
a Turn starting switch to ON position and perform troubleshooting (with moni-
toring function).
Model selection 1
= ON
Model selection 2
= OFF
00201 Switch Input Model selection 3
1 Defective model code signal Monitoring code Monitoring display
2 = ON
Model selection 4
= OFF
Model selection 5
= OFF
If display on monitor is incorrect, perform troubleshooting for failure code
[DA29KQ].
If no failure is found by check on cause 1, machine monitor is defective. (Since
40-400 30 PC200, 200LC, 220, 220LC-8M0

E-11 Some areas of machine monitor screen are not displayed SEN06138-00
E-11 Some areas of machine monitor screen are not displayed

Failure q Machine monitor does not display some items
q LCD panel may have black pixels (that do not light up) or bright pixels (that stay on). If number
Related information
of bright and black pixels do not exceed ten, it does not indicate failure or defect of LCD panel.

a Turn starting switch to ON position and perform troubleshooting.
Defective machine monitor When following switches are operated, if whole LCD panel is lighted up (whole
1
(LCD panel) surface becomes white), LCD panel has no failure.
q Operation of switches: [4] and [F2] (Press simultaneously)
Defective machine monitor If no failure is found by check on cause 1, machine monitor may be defective.
2
(body) (Since this is an internal defect, troubleshooting cannot be performed.)
E-12 Function switch does not operate

Failure q Function switch does not work.
q Signal of function switch can be checked with monitoring function.
Related information
(Code: 04503 Monitor function switch)

Machine monitor may be defective. (Since this is an internal defect, trouble-
shooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0 40-400 31

SEN06138-00 E-13 Automatic warm-up system does not operate (in cold season)
E-13 Automatic warm-up system does not operate (in cold season)
Failure q Automatic warm-up system does not operate (in cold weather)
q Automatic warm-up function increases engine speed to 1,200 rpm when engine coolant tem-
perature is below 30 C.
q With starting switch at ON position or after engine is started, if fuel control dial is kept at 70%
throttle position or higher for 3 seconds, automatic warm-up operation is canceled.
q If machine is equipped with air conditioner, when blower is turned on, ambient temperature is
Related information
below 5 C and engine coolant temperature is below 55 C, automatic warm-up function in-
creases engine speed to 1,300 rpm. If engine coolant temperature reaches 60 C, automatic
warm-up function is canceled.
q If engine coolant temperature is below 10 C, turbocharger protection function works to keep
engine speed below 1,000 rpm for up to 5 seconds after engine is started.

a Turn starting switch to ON position or start engine and perform trouble-
shooting.
Engine coolant tempera- Coolant temperature
Monitoring code
ture gauge level
105 C 6 (a: Red)
102 C 5 (a: Red)
Defective engine coolant tempera- 04107 100 C 4 (a: Blue)
1
ture signal system Engine coolant tempera-
ture 85 C 3 (a: Blue)
60 C 2 (a: Blue)
30 C 1 (a: White)
If engine coolant temperature does not match with coolant temperature gauge
level, perform troubleshooting for "E-8 Engine coolant temperature gauge
does not indiate properly".
If no failure is found by cause 1, engine controller is defective. (Since this is an
Engine coolant temperature gauge and engine

coolant temperature monitor
40-400 32 PC200, 200LC, 220, 220LC-8M0

E-14 Auto-decelerator does not operate properly SEN06138-00
E-14 Auto-decelerator does not operate properly

1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does
Failure
not go off.
q Condition of signal of auto-decelerator switch can be checked with monitoring function.
Related information
(Code: 04504 Monitor 1st, 2nd line switches)

Failure 2) Auto-decelerator is not operated or canceled with lever.

q Since set speed of auto-decelerator is 1,050 rpm, it is not operated or canceled if fuel control
Related information dial is set below this speed.
q Auto-deceleration does not function in arm crane mode (L) for machines with arm crane.

a Start engine and perform troubleshooting (with monitoring function).
Monitoring code Item Correct display
Swing
Travel
When lever is operated:
01900 Boom LOWER ON
Pressure switch 1 Boom RAISE When lever is in neutral:
OFF
1 Defective PPC oil pressure signal Arm IN
Arm OUT
Bucket CURL When lever is operated:
01901 ON
Bucket DUMP
Pressure Switch 2 When lever is in neutral:
Service OFF
If display of monitor is incorrect, perform troubleshooting for "E-26 - 34 Moni-
toring function does not display *** properly".
If no problem is found in check on cause 1, machine monitor may be defective.
If no problem is found in checks on causes 1 and 2, pump controller may be
3 Defective pump controller defective (Since this is an internal defect, troubleshooting cannot be per-
formed.)
If no problem is found in checks on causes 1 and 3, engine controller may be
4 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot be per-
formed.)
PC200, 200LC, 220, 220LC-8M0 40-400 33

SEN06138-00 E-15 Working mode does not change
E-15 Working mode does not change

Failure 1) When working mode switch is operated, working mode selection screen is not displayed.
q Signal of working mode switch can be checked with monitoring function.
Related information

Failure 2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related information

Pump controller may be defective. (Since this is an internal defect, trouble-
40-400 34 PC200, 200LC, 220, 220LC-8M0

E-16 Travel speed does not change SEN06138-00
E-16 Travel speed does not change

1) When travel speed selector switch is operated, display of travel speed monitor does not
Failure
change.
q Signal of travel speed selector switch can be checked with monitoring function.
Related information

Failure 2) When selection of travel speed is changed, actual travel speed does not change.
q When failure due to cause 1 occurs, actual travel speed does not decrease when travel speed
setting is changed to "Lo".
Related information
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be
measured at pump controller connector.

Hot short circuit in wiring harness 2. Disconnect connector V04 and connect T-adapters to female side.
Between V04 (female) (2) and ground Voltage Max. 3 V
If no problem is found in check on cause 1, machine monitor may be defective.
If no problem is found in checks on causes 1 and 2, pump controller may be
3 Defective pump controller defective (Since this is an internal defect, troubleshooting cannot be per-
formed.)
PC200, 200LC, 220, 220LC-8M0 40-400 35

SEN06138-00 E-17 Alarm buzzer cannot be canceled
E-17 Alarm buzzer cannot be canceled

Failure q Alarm buzzer does not stop sounding.
q Signal of alarm buzzer cancel switch can be checked with monitoring function.
Related information

E-18 When starting switch is turned OFF, service meter is not displayed
Failure q When starting switch is at OFF position, service meter is not displayed.
q While starting switch is at OFF position, if following switches are operated, service meter is
Related information displayed at top center of screen.
Operation of switches: [4] and [1] (Press simultaneously)

When starting switch is turned to ON position, if machine monitor displays
Defective backup power supply nothing, backup power supply system may be defective. In this case, perform
1
system troubleshooting for "E-3 When starting switch is turned to ON position,
machine monitor displays nothing".
If no failure is found by check on cause 1, machine monitor may be defective.
E-19 Service mode cannot be selected

Failure q Machine monitor cannot be set in service mode
q Following switch operation sets machine monitor in service mode.
Related information
Switch operation: [4] and [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in order)

40-400 36 PC200, 200LC, 220, 220LC-8M0

E-20 Any of work equipment, swing and travel do not operate or cannot be locked SEN06138-00
E-20 Any of work equipment, swing and travel do not operate or cannot
be locked
Failure 1) All of work equipment, swing, and travel mechanism do not move.
Related infor-
mation
1 Defective fuse F01-3 If fuse is blown, circuit probably has grounding fault. (See Cause 6.)

Defective lock lever 2. Disconnect connector S14 and connect T-adapters to female side.
2 switch (internal open cir-
Between S14 (male) (1) and Lock lever: LOCK Resistance Min. 1 Mz
cuit)
(2) Lock lever: FREE Resistance Max. 1 z
Defective PPC lock sole- 2. Disconnect connector V01 and connect T-adapters to male side.
3 noid (open or short circuit
Between V01 (male) (1) and (2) Resistance 20 60 z
in internal wiring)
2. Remove diode array D01 and connect T-adapters to male side.
Defective diode array D01 a Check the continuity in diode range.
4
(Internal short circuit) Between D01 (male) (8) (+) and (4) (-) Continuity
2. Set lock lever to FREE position.
Between F01-3 and ground (coil resistance of PPC lock
Resistance 20 60 z
solenoid)
Open circuit in wiring har- a If no failure is found by above check, this check is not required.
ness 1. Turn starting switch to OFF position.
5
(wire breakage or defec- 2. Remove fuse F01-3.
tive contact of connector) 3. Disconnect connectors S14 and V01 and then connect T-adapters to male side of
S14 and female side of V01.
Between F01-3 and S14 (male) (1) Resistance Max. 1 z
Between S14 (male) (2) and V01 (female) (1) Resistance Max. 1 z
Between V01 (female) (2) and ground (T09) Resistance Max. 1 z
Ground fault in wiring har- 3. Disconnect connectors S14, V01, and D01, and then connect T-adapters to male
ness side of S14 or female side of V01 or D01.
6
(contact with ground cir- Between ground and F01-3 or S14 (male) (1) Resistance Min. 1 Mz
cuit)
Between ground and S14 (male) (2), V01 (female) (1) or
D01 (female) (4)
PC200, 200LC, 220, 220LC-8M0 40-400 37

SEN06138-00 E-20 Any of work equipment, swing and travel do not operate or cannot be locked
Failure 2) All of work equipment, swing, and travel mechanism are not locked.
Related informa-
tion

2. Disconnect connector S14, and connect T-adapters to male side.
Defective lock lever switch
1
(Internal short circuit) Between S14 (male) (1) Lock lever: LOCK Resistance Min. 1 Mz
and (2) Lock lever: FREE Resistance Max. 1 z
Hot short circuit in wiring 2. Disconnect connector V01 and connect T-adapter to female side.
2 harness 3. Turn starting switch to ON position.
Between V01 (male) (1) and (2) Voltage Max. 1 V
40-400 38 PC200, 200LC, 220, 220LC-8M0

E-21 Swing holding brake does not operate properly SEN06138-00
E-21 Swing holding brake does not operate properly

Failure 1) When swing brake cancel switch is set to CANCEL position, machine cannot swing.
Related infor- q Signal of swing lock switch can be checked with monitoring function.
mation (Pump controller system code: 02200 Switch input 1)

If fuse F01-1 is broken, circuit probably has ground fault. In this case, perform trou-
1 Defective fuse F01-1
bleshooting for cause 6 first.
Defective swing brake can-
swing brake cancel switch:
2 cel switch (internal short cir- Resistance Min. 1 Mz
cuit) Between S25 (male) (13) Normal
and (14) swing brake cancel switch:
Resistance Max. 1 z
FREE
2. Remove diode arrays D01 and D03, and connect T-adapters to male side.
Defective diode array D01 or Between D01 (male) (7) (+) and (3) (-) Continuity
3
D03 (internal short circuit) Between D01 (male) (3) (+) and (7) (-) No continuity
2. Disconnect connector V03 and connect T-adapters to female side.
4 Defective wiring harness swing brake cancel switch:
Voltage 20 to 30 V
Between V03 (female) (1) FREE
Voltage Max. 1 V
Normal
ness 2. Disconnect connectors V03 and S25 and connect T-adapters to each male side.
5
(wire breakage or defective Between V03 (female) (1) and S25 (female) (14) Resistance Max. 1 z
Between V03 (female) (2) and C02 (female) (115) Resistance Max. 1 z
6 ness 2. Disconnect connectors S25, V03, D01 and D03, and connect T-adapters to
(contact with ground circuit) female side of V03.
Between V03 (female) (1) and ground Resistance Min. 1 Mz
PC200, 200LC, 220, 220LC-8M0 40-400 39

SEN06138-00 E-21 Swing holding brake does not operate properly
Failure 2) When swing brake cancel switch is set to Normal position, swing holding brake does not operate.
Related infor-
mation

Defective swing brake can-
swing brake cancel switch:
1 cel switch (internal short cir- Resistance Min. 1 Mz
cuit) Between S25 (male) (13) Normal
Resistance Max. 1 z
FREE
Hot short circuit in wiring 2. Disconnect connector V03 and connect T-adapters to female side.
(contact with 24 V circuit) 4. Set swing lock switch to ON position.
40-400 40 PC200, 200LC, 220, 220LC-8M0

E-21 Swing holding brake does not operate properly SEN06138-00
Circuit diagram related to swing brake solenoid
PC200, 200LC, 220, 220LC-8M0 40-400 41

SEN06138-00 E-22 One-touch power maximizing function does not operate properly
E-22 One-touch power maximizing function does not operate properly

1) When L.H. knob switch is pressed, one-touch power max. monitor is not displayed.
Failure
2) When L.H. knob switch is pressed, work equipment power is not increased.
q One-touch power max. function does not operate when selected working mode is not power
mode (P) or economy mode (E).
Related information
q Signal of L.H. knob switch can be checked with monitoring function.
(Code: 02200 Switch Input 1)

When L.H. knob switch is pressed, if work equipment power is increased but
one-touch power max. monitor is not displayed on machine monitor, machine
monitor may be defective. (Since this is an internal defect, troubleshooting can-
not be performed.)
2 Defective fuse No. 9 If fuse is blown, circuit probably has grounding fault. (See Cause 6.)

2. Disconnect connector S11, and connect T-adapters to male side.
Defective left knob switch L.H. knob switch:
(Internal open circuit) Between S11 (female) (1) Released
and (2) L.H. knob switch:
Resistance Max. 1 z
Pressed
Open circuit or ground fault in wir- a Ignore displayed failure code.
4
ing harness L.H. knob switch:
Voltage Max. 1 V
Between C01 (female) Released
(41) and ground L.H. knob switch:
Voltage 20 to 30 z
Pressed
3. Disconnect connectors C01 and S11 and connect T-adapters to each female
side.
tact of connector)
Between F01-9 and S11 (female) (1) Resistance Max. 1 z
Between S11 (female) (2) and C01 (female) (41) Resistance Max. 1 z
Ground fault in wiring harness 3. Disconnect connectors C01 and S11 and connect T-adapters to female side
6 of S11.
Between F01-9 or S11 (female) (1) and ground Resistance Min. 1 Mz
Between S11 (female) (2) or C01 (female) (41) and
ground
40-400 42 PC200, 200LC, 220, 220LC-8M0

E-22 One-touch power maximizing function does not operate properly SEN06138-00
Circuit diagram related to one-touch power maximizing switch
PC200, 200LC, 220, 220LC-8M0 40-400 43

SEN06138-00 E-22 One-touch power maximizing function does not operate properly
Failure 3) When L.H. knob switch is released, work equipment power is not returned to normal.
Related informa- q Signal of L.H. knob switch can be checked with monitoring function.
tion (Code: 02200 Switch Input 1)

Hot short circuit in wiring 2. Disconnect connector V02 and connect T-adapters to female side.
Between V02 (female) (1) and (2) Voltage Max. 3 V
If no failure is found by check on cause 1, pump controller is defective. (Since this is
40-400 44 PC200, 200LC, 220, 220LC-8M0

E-23 Travel alarm does not sound or does not stop sounding SEN06138-00
E-23 Travel alarm does not sound or does not stop sounding
Failure 1) Alarm does not sound during travel.
Related infor- q Output to travel alarm can be checked with monitoring function.
mation (Code: 03701 Controller output 2)

Defective travel alarm 2. Disconnect connector M14 and connect T-adapters to male side.
1
(internal defect)
Between M14 (male) (1) and (2) Continuity
Open circuit in wiring har- 2. Disconnect connectors M14 and C02 and connect T-adapters to each female
ness side.
2
(wire breakage or defective Between C02 (female) (107) and M14 (female) (1) Resistance Max. 1 z
Between C02 (female) (115) and M14 (female) (2) Resistance Max. 1 z
Ground fault in wiring har- 2. Disconnect connectors C02 and M14, and connect T-adapters to either female
3 ness side.
(contact with ground circuit) Between C02 (female) (107) and ground, or between
M14 (female) (1) and ground
Failure 2) Alarm does not stop sounding while machine is stopped.

Related infor-
mation

Hot short circuit in wiring 2. Disconnect connector M14 and connect T-adapters to female side.
Between M14 (female) (1) and ground Voltage Max. 3 V
Circuit diagram related to travel alarm
PC200, 200LC, 220, 220LC-8M0 40-400 45

SEN06138-00 E-24 Horn does not sound or does not stop
E-24 Horn does not sound or does not stop

Failure 1) Horn does not sound.
Related infor-
mation

If fuse F01(5) is broken, circuit probably has ground fault. In this case, perform
1 Defective fuse F01-5
troubleshooting for cause 7 first.
2. Replace horn relay (connector: R08) with another relay.
Defective horn relay 3. Turn starting switch to ON position.
2
(internal open or short circuit) 4. Press L.H. knob switch.
If horn sounds, original horn relay is defective.
Defective horn switch
3
(internal open or short circuit) Between S10 (male) (1) Switch: OFF Resistance Min. 1 Mz
and (2) Switch: ON Resistance Max. 1 z
2. Disconnect connectors M07 and M08, and connect T-adapters to each male
Defective high-tone horn (M07)
side.
4 or low-tone horn (M08) (internal
open or short circuit) Between M07 (male) (1) and (2) Continuity
Between M08 (male) (1) and (2) Continuity
2. Disconnect connector R08 and connect T-adapters to female side.
5 Defective wiring harness 4. Press L.H. knob switch.
Between R08 (female) (1) and (2) Voltage 20 to 30 V
Between R08 (female) (3) and (2) Voltage 20 to 30 V
2. Disconnect connector R08 and connect T-adapters to female side.
Between R08 (female) (5) and ground Continuity
Between R08 (female) (1) and ground Continuity
a If no failure is found by above checks, this check is not required.
6 (Wire breakage or defective con- 2. Remove fuse F01-5.
tact) 3. Disconnect connectors R08 and S10, and connect T-adapters to each female
side.
Between F01-5 and S10 (female) (1) Resistance Max. 1 z
Between S10 (female) (2) and R08 (female) (1) Resistance Max. 1 z
Between R08 (female) (2) and ground Resistance Max. 1 z
Between R08 (female) (3) and F01(5) Resistance Max. 1 z
a If fuse is not blown, this check is not required.
3. Disconnect connectors R08, M07, and M08, and connect T-adapters to
Ground fault in wiring harness female side of R08.
7
40-400 46 PC200, 200LC, 220, 220LC-8M0

E-24 Horn does not sound or does not stop SEN06138-00

Defective horn
8 If no failure is found by above checks, horn may be defective.
(internal defect)
Failure 2) Horn does not stop sounding.

Related infor-
mation

Defective horn relay (R08) 2. Remove horn relay (connector R08).
If horn stops sounding, original horn relay is defective.
2. Disconnect connectors M07 and M08, and connect T-adapters to each
female side.
Hot short circuit in wiring harness
Between M07 (female) (2) and (1) Voltage Max. 1 V
Between M08 (female) (2) and (1) Voltage Max. 1 V
Circuit diagram related to horn
PC200, 200LC, 220, 220LC-8M0 40-400 47

SEN06138-00 E-25 Windshield wiper and window washer do not operate
E-25 Windshield wiper and window washer do not operate

Failure 1) When wiper switch is operated, wiper monitor does not light up or go off.
Related informa- q Signal of wiper switch can be checked with monitoring function.
tion (Code: 04504 Monitor 1st, 2nd line switches)

Machine monitor may be defective. (Since this is an internal defect, troubleshooting
Failure 2) When wiper switch is operated, windshield wiper does not operate.
q Signal of window rear limit switch can be checked with monitoring function.
Related informa- (Code: 02204 Switch input 5)
tion q Wiper motor is checked and its failure is expressed in failure code [DY20KA], [DY20MA],
[DY2DKB], or [DY2EKB].

2. Disconnect connector W03.
Defective window rear limit Front window: when set in
switch (Internal short circuit) Between W03 (male) (1) position
and (2) Front window: when pulled
Resistance Max. 1 z
up
2
a Wiper motor system
See troubleshooting for failure codes [DY20KA], [DY20MA], [DY2DKB], and
Open circuit in wiring har- [DY2EKB].
ness a Wiper rear limit switch system
3 1. Turn starting switch to OFF position.
contact of connector) 2. Disconnect connector C01 and connect T-adapters to female side.
3. Pull up front window.
Ground fault in wiring har- 2. Disconnect connector C01 and connect T-adapters to female side.
4 ness 3. Set front window in position.
If no failure is found by above checks, the pump controller is defective. (Since this is
Failure 3) When window washer switch is operated, window washer does not operate.
q Signal of window washer switch can be checked with monitoring function.
Related informa-
tion
q Window washer is checked and its failure is expressed in failure codes [DY2CKA] or [DY2CKB].

Machine monitor may be defective. (Since this is an internal defect, troubleshooting
40-400 48 PC200, 200LC, 220, 220LC-8M0

E-25 Windshield wiper and window washer do not operate SEN06138-00
PC200, 200LC, 220, 220LC-8M0 40-400 49

SEN06138-00 E-26 BOOM DOWN indicator is not displayed properly with monitoring function
E-26 BOOM DOWN indicator is not displayed properly with monitoring

function
Failure "Boom DOWN" operation signal is not displayed properly on monitoring screen.
Related information q Monitoring code: 01900 Pressure switch 1

Defective boom DOWN PPC oil
1 pressure sensor system (internal Perform troubleshooting for failure code [DHS9MA].
open circuit or short circuit)
E-27 ARM DUMP indicator is not displayed properly with monitoring

function
Failure "Arm DUMP" operation signal is not displayed properly on monitoring screen.

Defective arm DUMP PPC oil
1 pressure sensor system (internal Perform troubleshooting for failure code [DHSCMA].
open circuit or short circuit)
E-28 ARM IN indicator is not displayed properly with monitoring function

Failure "Arm IN" operation signal is not displayed properly on monitoring sceen.

Defective arm IN PPC pressure
1 sensor system (internal open or Perform troubleshooting for failure code [DHS3MA].
short circuit)
40-400 50 PC200, 200LC, 220, 220LC-8M0

E-29 BOOM RAISE indicator is not displayed properly with monitoring function SEN06138-00
E-29 BOOM RAISE indicator is not displayed properly with monitoring

function
Failure "Boom RAISE" operation signal is not displayed properly on monitoring screen.
Related informa-
q Monitoring code: 01900 Pressure switch 1
tion

Defective boom RAISE PPC
pressure sensor system
1 Perform troubleshooting for failure code [DHS8MA].
(internal open or short cir-
cuit)
E-30 BUCKET CURL indicator is not displayed properly with monitoring

function
Failure "Bucket CURL" operation signal is not displayed properly on monitoring screen.

Defective bucket CURL PPC pres-
1 Perform troubleshooting for failure code [DHS4MA].
sure sensor system
E-31 BUCKET DUMP indicator is not displayed properly with monitoring

function
Failure "Bucket DUMP" operation signal is not displayed properly on monitoring screen.

Defective bucket DUMP PPC pres-
1 Perform troubleshooting for failure code [DHSDMA].
sure sensor system
PC200, 200LC, 220, 220LC-8M0 40-400 51

SEN06138-00 E-32 SWING indicator is not displayed properly with monitoring function
E-32 SWING indicator is not displayed properly with monitoring function

Failure "Swing" operation signal is not displayed properly on monitoring screen.

Defective swing PPC pressure
1 sensor system Perform troubleshooting for failure codes [DHSAMA] and [DHSBMA].
E-33 TRAVEL indicator is not displayed properly with monitoring func-

tion
Failure "Travel" operation signal is not displayed properly on monitoring screen.

Defective travel PPC oil pressure
Perform troubleshooting for failure codes [DHSFMA], [DHSGMA], [DHSHMA]
1 sensor system
and [DHSJMA].
40-400 52 PC200, 200LC, 220, 220LC-8M0

E-34 ATTACHMENT indicator is not displayed properly with monitoring function SEN06138-00
E-34 ATTACHMENT indicator is not displayed properly with monitoring

function
Failure "Attachment" operation signal is not displayed properly on monitoring screen.
q Monitoring code: 01901 Pressure switch 2
q For safety, use "short connector" 799-601-7230 for 2-pin X connector in troubleshooting for
Related information cause 1 and 2.
k Do not check pressure switch connector while engine is running.

A. If "Service" operation signal displayed on monitoring screen is not "ON"
when engine is started and attachment control pedal is depressed at front end
2. Disconnect connector P14 and connect "short connector" to male side.
a After finishing troubleshooting, return connectors as they were.
Defective PPC pressure switch If "Service" operation signal displayed on monitoring screen changes to "ON",
1 (P14) for front end of attachment front service PPC pressure switch (P14) is defective (Note 1).
control pedal B. If "Service" operation signal displayed on monitoring screen is ON" when
starting switch is turned to ON position
If "Service" operation signal displayed on monitoring screen changes to
"OFF", front service PPC pressure switch (P14) is defective (Note 2).
A. If "Service" operation signal displayed on monitoring screen is not "ON"
when engine is started and attachment control pedal is depressed at rear end
2. Disconnect connector P15 and connect "short connector" to male side.
a After finishing troubleshooting, return connectors as they were.
Defective PPC pressure switch If "Service" operation signal displayed on monitoring screen changes to "ON",
2 (P15) for rear end of attachment rear service PPC pressure switch (P15) is defective (Note 1).
control pedal B. If "Service" operation signal displayed on monitoring screen is ON" when
starting switch is turned to ON position
If "Service" operation signal displayed on monitoring screen changes to
"OFF", rear service PPC pressure switch (P15) is defective (Note 2).
2. Insert T-adapters into P13.
3. Start engine.
4. Operate attachment control pedal, and perform troubleshooting.
Defective wiring harness or pump
3 attachment control pedal:
controller Between P13 (1) and (2) Voltage Approx. 7 V
Neutral
attachment control pedal:
Between P13 (1) and (2) front end or rear end Voltage Max. 1 V
depressed
PC200, 200LC, 220, 220LC-8M0 40-400 53

SEN06138-00 E-34 ATTACHMENT indicator is not displayed properly with monitoring function

2. Disconnect connectors C01, P14, and P15, and connect T-adapters to
each female side.
Open circuit in wiring harness Between C01(female) (76) and P14(female) (1) Resistance Max. 1 z
tact of connector) Between C01(female) (76) and P15(female) (1) Resistance Max. 1 z
Between P14 (female) (2) and ground (T06) Resistance Max. 1 z
Between P15 (female) (2) and ground (T06) Resistance Max. 1 z
2. Disconnect connectors C01, P14, and P15, and connect T-adapters to
5
Between ground C01 (female) (76), P14 (female)
(1) or P15 (female) (1)
2. Disconnect connectors P14 and P15, and connect T-adapters to either
female side.
Between P14 (female) (1) and ground, or between
Voltage Approx. 7 V
Note 1: If "Service" operation signal displayed on monitoring screen is "OFF" while voltage between C01 (52)
and ground is below 1 V, pump controller is defective.
Note 2: If "Service" operation signal displayed on monitoring screen is "ON" while voltage between C01 (52)
and ground is approximately 7 V, pump controller is defective.
Circuit diagram related to attachment control pedal PPC oil pressure switch (service pressure switch)
40-400 54 PC200, 200LC, 220, 220LC-8M0

E-35 Attachment hydraulic circuit cannot be changed SEN06138-00
E-35 Attachment hydraulic circuit cannot be changed

q Attachment circuit is not changed
Failure 1) When working mode P or E is selected, crusher circuit (two-way circuit) is not selected.
2) When working mode B is selected, breaker circuit (one-way circuit) is not selected.
Related infor- q Failures (open circuit, short circuit) of attachment oil return selector solenoid are troubleshot for fail-
mation ure codes [DWA2KA] and [DWA2KB].

Defective attachment oil return 2. Disconnect connector V06 and connect T-adapter to male side.
1 selector solenoid (internal short
Between V06 (male) (1) and (2) Resistance 20 60 z
circuit)
Hot short circuit in wiring harness 2. Disconnect connector V06 and connect T-adapters to female side.
Circuit diagram related to attachment oil return selector solenoid
PC200, 200LC, 220, 220LC-8M0 40-400 55

SEN06138-00 E-36 KOMTRAX system does not operate properly
E-36 KOMTRAX system does not operate properly

Failure q KOMTRAX system does not operate properly.
q Perform following troubleshooting if administrator of KOMTRAX system requests to check whether
Related infor- failure is occurring in system on machine.
mation q Even when KOMTRAX system is defective, no problem appears on machine.
q Check all of results of troubleshooting on service menu display of machine monitor.

2. Display Terminal status screen.
1 Defective communication 1
Monitoring Check item:
To be completed
display Station set-up check
2. Display GPS & Communication Status screen.
N ###.##.## (Latitude)
E ###.##.## (Longitude)
2 Defective positioning by GPS display Positioning
In positioning
If latitude and longitude are not displayed within 5 minutes with machine
stayed outdoor where opens clearly for sky, contact KOMTRAX service hot
line.
Defective communication environ- Satellite in View or No Satellite in View
3 display Communication
ment
If Communication Status does never display Satellite in View within 15 min-
utes with machine stayed outdoor where opens clearly for sky, check if con-
nector of TC330 or antenna on top of cab are properly connected.
4 Defective communication 2 Check item:
Monitoring
Number of message not 0 to 60 (normally 0)
display
yet sent
a Select 01 Terminal Status from 11 KOMTRAX a Select 02 GPS & Communication Status from
settings in service menu of machine monitor. 11 KOMTRAX settings in service menu of ma-
chine monitor.
40-400 56 PC200, 200LC, 220, 220LC-8M0

E-36 KOMTRAX system does not operate properly SEN06138-00
PC200, 200LC, 220, 220LC-8M0 40-400 57

SEN06138-00
2012 KOMATSU
All Rights Reserved
40-400 58
SEN06139-00
SEN05990-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
500 Troubleshooting of hydraulic and
mechanical system (H-mode)
System diagram of hydraulic and mechanical system ................................................................................ 4

Failure mode and cause table..................................................................................................................... 6
H-1 Speed or power of whole work equipment, swing, and travel is low .................................................... 9
H-2 Engine speed lowers significantly or engine stalls ............................................................................... 11
H-3 Work equipment, swing, and travel systems do not work .................................................................... 12
H-4 Unusual noise comes out from around hydraulic pump ....................................................................... 13
H-5 Fine control performance or response is low ....................................................................................... 14
H-6 Speed or power of boom is low ............................................................................................................ 15
H-7 Speed or power of arm is low............................................................................................................... 16
H-8 Speed or power of bucket is low .......................................................................................................... 17
H-9 Work equipment does not move in its single operation........................................................................ 18
H-10 Hydraulic drift of work equipment is large .......................................................................................... 19
H-11 Time lag of work equipment is large................................................................................................... 21
H-12 Other work equipment moves when one of work equipment is relieved ............................................ 22
H-13 One-touch power maximizing function does not work........................................................................ 23
H-14 In combined operation of work equipment, equipment having heavier load moves slower. .............. 24
H-15 In combined operation of swing and boom RAISE, boom rising speed is low ................................... 25
PC200, 200LC, 220, 220LC-8M0 40-500 1

500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN06139-00
H-16 Travel speed drops largely in combined operation of swing and travel.............................................. 26
H-17 Machine does not travel straight ........................................................................................................ 27
H-18 Travel speed is low............................................................................................................................. 28
H-19 Machine is hard to steer or travel power is low .................................................................................. 29
H-20 Travel speed does not change or travel speed is low/high................................................................. 30
H-21 One of tracks does not run ................................................................................................................. 31
H-22 Upper structure does not swing.......................................................................................................... 32
H-23 Swing acceleration is poor or swing speed is low .............................................................................. 34
H-24 Upper structure overruns remarkably when it stops swinging ............................................................ 36
H-25 Shock is large when upper structure stops swinging ......................................................................... 37
H-26 Large sound is made when upper structure stops swinging .............................................................. 38
H-27 Hydraulic drift of swing is large........................................................................................................... 39
H-28 Attachment circuit cannot be changed ............................................................................................... 40
H-29 Oil flow in attachment circuit cannot be controlled ............................................................................. 41
40-500 2 PC200, 200LC, 220, 220LC-8M0

SEN06139-00
PC200, 200LC, 220, 220LC-8M0 40-500 3

SEN06139-00 System diagram of hydraulic and mechanical system
System diagram of hydraulic and mechanical system
40-500 4 PC200, 200LC, 220, 220LC-8M0

System diagram of hydraulic and mechanical system SEN06139-00
a This system diagram is a rough general hydraulic circuit diagram made as reference material for trouble-
shooting of the hydraulic and mechanical systems.
PC200, 200LC, 220, 220LC-8M0 40-500 5

SEN06139-00 Failure mode and cause table
Failure mode and cause table

Failed parts Tank Hydraulic pump Control valve
Pump merge-divider main EPC valve

Pump merge-divider LS-EPC valve
Pump merge-divider main valve
Pressure compensation valve
Pump merge-divider LS valve

Self-pressure reducing valve
Boom throttle EPC solenoid

Pump swash plate sensor
Boom regeneration valve

Boom lock valve
Main relief valve
Engine system
LS line throttle
PC-EPC valve
LS-EPC valve
Unload valve
Piston pump
Servo piston
Hydraulic oil
PC valve
LS valve
Damper
stainer
Spool
Cap
Failure mode
All of work equipment, swing and travel work slow or
Any of work equipment,
q q q q q q q q q q q q
lack power
swing and travel
Engine speed lowers extremely or engine stalls q q q q q q q q

All work equipment, travel, and swing systems do not
q q q q
work.
Unusual sound is heard from around hydraulic pump q q q q
Fine control performance or response is poor q q q q
Speed or power of boom is low q q q q q q q q q

Speed or power of arm is low q q q q q q
Speed or power of bucket is low q q
Work equipment does not move in single operation q
Work equipment
Boom q q
Hydraulic drift of work
Arm q q
equipment is large
Bucket q q
Time lag of work equipment operation is large q q q
Other wok equipment moves when one of work equip-
q
ment is relieved
One-touch power maximizing function does not work. q
In combined operation of work equipment, equipment
q
having heavier load moves slower
Swing Swing
In combined operations of swing and boom RAISE,

travel boom
and
boom rising speed is low
Travel speed drops largely in combined operation of

and
swing and travel

Machine does not travel straight q q q q q
Travel speed is low. q q q q
Travel
Machine is hard to steer or travel power is low q q q q q q

Travel speed does not change or travel speed is too
q
low or high
One of tracks does not run
Upper structure swings
q
Upper structure does not neither to the right nor left
swing Upper structure does not
q
swing in only one direction
Poor or low for both of the
q
Swing acceleration is poor right and left
or swing speed is low Poor or low for only in one
q q
direction
Swing
Largely for both of the right

Upper structure overruns
and left
considerably when it stops
Largely for only in one
swinging q
direction
Shock is larger when upper structure stops swinging
Large unsual noise is heard when upper structure
stops swinging
Swing drift on a slope is When swing brake works
large When swing brake works q q
Attachment circuit is not changed
Attach
-ment
Oil flow in attachment circuit cannot be changed
40-500 6 PC200, 200LC, 220, 220LC-8M0

q
q
q
q
Safety valve
q
Suction valve
q
q q
q q
q
q q q
q q q
LS shuttle valve
q
Arm regeneration valve
Arm quick return valve
q q q q q q
q
Arm lock valve
q
Swing LS select valve
Control valve
q
q
Travel junction valve
q
Back pressure valve
Failure mode and cause table
q
Service valve (safety valve)
q
q
PPC valve (right lever)
q
q
q
q
q q
PPC valve (left lever)
PC200, 200LC, 220, 220LC-8M0

q
q
q
PPC valve (travel lever)
q
PPC valve (service)
q
q
Swing PPC slow return valve
q
Oil flow adjuster EPC valve for attachment
q
Work equipment lock solenoid
q
2-stage relief solenoid
q
q
Travel interconnection solenoid
q
Travel speed selector solenoid
q
q
Swing holding brake solenoid
Solenoid valve
q
ATT return selector solenoid
Piston motor
q
q q
q q
q q
Safety valve
q q
Check valve
q
q q
q q
Suction valve
q q q q
q
Shockless valve
Swing motor
q
Parking brake
q
q q
q q
Swing machinery
Center swivel joint
q q
q
q
q
Piston motor
Counterbalance valve
q q q q
Check valve
q q
Safety valve
Parking brake
Travel motor
q q q q
q
Final drive
Hydraulic cylinder
q
q
q
q
q
40-500
Diagnosis codes
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
q H-10
7
SEN06139-00
a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting,
understand that information fully.
Failure Description of failure code
Related infor-
Information related to detected failure or troubleshooting
mation
Cause Criteria and troubleshooting procedure
Probable 2
Probable causes of trouble <Contents of description>
causes and cri- (Given numbers are refer- q Standard value in normal condition to judge probable
teria ence numbers, which do causes
not indicate priority) q Remarks on judgment
3
40-500 8 PC200, 200LC, 220, 220LC-8M0

H-1 Speed or power of whole work equipment, swing, and travel is low SEN06139-00
H-1 Speed or power of whole work equipment, swing, and travel is low
Failure q Speed or power of all work equipment, swing, and travel is low.
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation

a Be ready with engine stopped, then troubleshoot with engine
high idle.
1 Malfunction of unload valve Control lever Unload pressure
3.5 1.0 MPa
All levers in the neutral position
{36 10 kg/cm2}
high idle.
Left work equipment control
Main relief pressure
lever
Defective adjustment or mal- 33.3 to 37.2 MPa
2
function of main relief valve Arm IN relief
{340 to 380 kg/cm2}
If normal oil pressure is not obtained by adjustment, main relief
valve may malfunction or have internal defect. Check main relief
valve.
high idle.
Malfunction of self-pressure Control lever Control circuit source pressure
3
reducing valve
2.84 to 3.43 MPa
{29 to 35 kg/cm2}
a Be ready with engine stopped, then troubleshoot with engine at
Probable low speed and engine high idle.
causes and cri- PC-EPC valve out-
teria Engine Control lever
Malfunction of PC-EPC put pressure
4 Approx. 2.9 MPa
valve Low idle
All levers in the neu- {Approx. 30 kg/cm2}
tral position 0.52 to 0.91 MPa
High idle
{5.3 to 9.3 kg/cm2}
full speed.
Measured oil pres- Measurement condi-
Ratio of oil pressures
sure tions
Defective adjustment or mal- Pump discharge
5 Swing lock 1
function of PC valve pressure
Switch: ON
PC valve output pres- Approx. 0.6 (Approx.
Arm IN relief
sure 3/5)
If normal oil pressure is not obtained after adjustment, PC valve
may malfunction or have internal defect. Check PC valve.
full speed.
LS-EPC valve
Travel speed Travel lever
output pressure
6 Malfunction of LS-EPC valve Approx. 2.9 MPa
Lo Neutral
{30 kg/cm2}
0 MPa
Hi Operation
{0 kg/cm2}
PC200, 200LC, 220, 220LC-8M0 40-500 9

SEN06139-00 H-1 Speed or power of whole work equipment, swing, and travel is low

high idle.
Operation of levers and oil pressure ratio
Measured oil pres- Run the track off
sure All levers in the neu-
ground.
Defective adjustment or mal- tral position
Probable 7 (lever at half stroke)
function of LS valve Pump discharge
causes and cri- 1
teria pressure Almost same pres-
PC valve output pressure Approx. 0.6 (Approx.
sure 3/5)
If normal oil pressure is not obtained by adjustment, the LS valve
may malfunction or have internal defect. Check LS valve.
8 Malfunction of servo piston Servo piston may malfunction. Check it.
Piston pump may have performance deterioration, malfunction or
9 Defective piston pump
internal defect.
40-500 10 PC200, 200LC, 220, 220LC-8M0

H-2 Engine speed lowers significantly or engine stalls SEN06139-00
H-2 Engine speed lowers significantly or engine stalls
Failure q Engine speed lowers significantly or engine stalls

Related infor-
mation

high idle.
Main relief pressure
lever
Defective adjustment or mal- 33.3 to 37.2 MPa
1
function of main relief valve Arm IN relief
{340 to 380 kg/cm2}
If normal oil pressure is not obtained by adjustment, main relief
valve may malfunction or have internal defect. Check main relief
valve.
low speed and engine high idle.
PC-EPC valve out-
Engine Control lever
Malfunction of PC-EPC put pressure
2 Approx. 2.9 MPa
valve Low idle
All levers in the neu- {Approx. 30 kg/cm2}
tral position 0.52 to 0.91 MPa
High idle
{5.3 to 9.3 kg/cm2}
high idle.
Probable Measured oil pres- Measurement condi-
Ratio of oil pressures
causes and cri- sure tions
teria Defective adjustment or mal- Pump discharge
3 Swing lock 1
function of PC valve pressure
Switch: ON
PC valve output pres- Approx. 0.6 (Approx.
Arm IN relief
sure 3/5)
If normal oil pressure is not obtained after adjustment, PC valve
may malfunction or have internal defect. Check PC valve.
high idle.
ground.
Defective adjustment or mal- tral position
4 (lever at half stroke)
1
pressure Almost same pres-
sure 3/5)
Clogging of orifice or filter in Orifices or filters in pump servo devices may be clogged. Check
5
serve device them.
PC200, 200LC, 220, 220LC-8M0 40-500 11

SEN06139-00 H-3 Work equipment, swing, and travel systems do not work
H-3 Work equipment, swing, and travel systems do not work
Failure q All work equipment, swing, and travel do not work

Related infor-
mation

high idle.
PPC lock solenoid valve
Lock lever
Malfunction of PPC lock output pressure
1 0 MPa
solenoid valve LOCK
{0 kg/cm2}
Approx. 2.9 MPa
FREE
{Approx. 30 kg/cm2}
Probable
high idle.
causes and cri-
teria 2
reducing valve
2.84 to 3.43 MPa
{29 to 35 kg/cm2}
Piston pump may malfunction or have internal defect. Check it by
following method.
1) Remove pump discharge pressure pickup plugs (F and R).
3 Defective piston pump
2) Crank engine at flywheel (manually).
3) If the oil flows out of the pump discharge pressure pickup ports,
it is normal.
Pump shaft may not revolve because of internal defect of damper.
4 Defective damper
Check damper.
40-500 12 PC200, 200LC, 220, 220LC-8M0

H-4 Unusual noise comes out from around hydraulic pump SEN06139-00
H-4 Unusual noise comes out from around hydraulic pump
Failure q Unusual sound is heard from around hydraulic pump

Related infor-
mation

Lowering of hydraulic oil
1 Hydraulic oil level may be low. Check it.
level
Probable 2 Defective hydraulic oil Air may be mixed in hydraulic oil. Check oil.
causes and cri- Clogging of hydraulic tank Negative pressure may be generated in hydraulic tank because of
teria 3
cap clogged hydraulic tank cap. Check cap.
Clogging of hydraulic tank Negative pressure may be generated in suction circuit because of
4
strainer clogged hydraulic tank strainer. Check strainer.
5 Defective piston pump Piston pump may have internal defect. Check it.
PC200, 200LC, 220, 220LC-8M0 40-500 13

SEN06139-00 H-5 Fine control performance or response is low
H-5 Fine control performance or response is low

Failure q Fine control performance or response is low.
Related infor-
mation

full speed.
LS-EPC valve
output pressure
Lo Neutral
{Approx. 30 kg/cm2}
0 MPa
Hi Operation
{0 kg/cm2}
Orifice of LS circuit (pump piping control valve) may be
2 Clogging of LS circuit orifice
Probable clogged. Check it.
causes and cri- a Be ready with engine stopped, then troubleshoot with engine at
teria full speed.
ground.
tral position
Defective adjustment or mal- (lever at half stroke)
3
1
sure 3/5)
40-500 14 PC200, 200LC, 220, 220LC-8M0

H-6 Speed or power of boom is low SEN06139-00
H-6 Speed or power of boom is low

Failure q Speed or power of boom is low
Related infor-
mation

full speed.
Right work equipment control
PPC valve output pressure
lever
Malfunction of right PPC
1 0 MPa
valve (boom circuit) Neutral
{0 kg/cm2}
Boom RAISE 2.84 to 3.43 MPa
Boom LOWER {29 to 35 kg/cm2}
Malfunction of merge-divider
2 Merge-divider main EPC valve may malfunction. Check it.
main EPC valve
3 Merge-divider LS-EPC valve may malfunction. Check it.
LS-EPC valve
4 Merge-divider main valve may malfunction. Check it.
main valve
5 Merge-divider LS valve may malfunction. Check it.
LS valve
Malfunction of boom control
6 Spool of boom control valve may malfunction. Check it.
valve (spool)
Probable Malfunction of boom control
Pressure compensation valve of boom control valve may malfunc-
causes and cri- 7 valve (pressure compensa-
tion. Check it.
teria tion valve)
Malfunction of boom control Regeneration valve of boom control valve may malfunction. Check
8
valve (regeneration valve) it.
Malfunction of boom control Lock valve of boom control valve may have malfunction.
9
valve (lock valve) Check it.
Malfunction or defective
Safety valve for lock valve may malfunction or sealing may be
10 sealing of safety valve for
defective. Check it.
lock valve
Suction valve of boom control valve may malfunction or sealing
11 sealing of boom control
may be defective. Check it.
valve (suction valve)
Safety-suction valve of boom control valve may malfunction or
12 sealing of boom control
sealing may be defective. Check it.
valve (safety-suction valve)
Malfunction of each control LS shuttle valve of left travel control valve, bucket control valve, or
13
valve (LS shuttle valve) service control valve may malfunction. Check it.
full speed.
14 Defective boom cylinder Right work equipment control
Leakage from boom cylinder
lever
Boom RAISE relief 20 cc/min
PC200, 200LC, 220, 220LC-8M0 40-500 15

SEN06139-00 H-7 Speed or power of arm is low
H-7 Speed or power of arm is low

Failure q Speed or power of arm is low
Related infor-
mation

high idle.
lever
Malfunction of left PPC valve
1 0 MPa
(arm circuit) Neutral
{0 kg/cm2}
Arm IN 2.84 to 3.43 MPa
Arm OUT {29 to 35 kg/cm2}
main EPC valve
3 Merge-divider LS-EPC valve may malfunction. Check it.
LS-EPC valve
4 Merge-divider main valve may malfunction. Check it.
main valve
LS valve
Malfunction of arm control
6 Spool of arm control valve may malfunction. Check it.
valve (spool)
Malfunction of arm control
Probable Pressure compensation valve of boom control valve may malfunc-
7 valve (pressure compensa-
causes and cri- tion. Check it.
tion valve)
teria Malfunction of arm control Regeneration valve of arm control valve may malfunction.
8
valve (regeneration valve) Check it.
Malfunction of arm control Quick return valve of arm control valve may have malfunction.
9
valve (quick return valve) Check it.
Safety valve for lock valve may malfunction or sealing may be
10 sealing of safety valve for
lock valve
11 sealing of arm control valve Suction valve of arm control valve may malfunction. Check it.
(suction valve)
Safety-suction valve of arm control valve may malfunction or seal-
12 sealing of arm control valve
ing may be deflective. Check it.
(safety-suction valve)
LS shuttle valve of right travel control valve, boom control valve,
Malfunction of each control
13 left travel control valve, bucket control valve, or service control
valve (LS shuttle valve)
valve may malfunction. Check it.
full speed.
14 Defective arm cylinder Left work equipment control
Leakage from arm cylinder
lever
Arm IN relief 20 cc/min
40-500 16 PC200, 200LC, 220, 220LC-8M0

H-8 Speed or power of bucket is low SEN06139-00
H-8 Speed or power of bucket is low

Failure q Speed or power of bucket is low
Related infor-
mation

high idle.
Right work equipment control
lever
Malfunction of right PPC
1 0 MPa
valve (bucket circuit) Neutral
{0 kg/cm2}
Bucket CURL 2.84 to 3.43 MPa
Bucket DUMP {29 to 35 kg/cm2}
Malfunction of bucket control
2 Spool of bucket control valve may malfunction. Check it.
valve (spool)
Probable
causes and cri- Malfunction of bucket control
Pressure compensation valve of bucket control valve may malfunc-
teria 3 valve (pressure compensa-
tion. Check it.
tion valve)
Safety-suction valve of bucket control valve may malfunction or
4 sealing of bucket control
sealing may be defective. Check it.
valve (safety-suction valve)
Malfunction of service con- LS shuttle valve of service control valve may malfunction.
5
trol valve (LS shuttle valve) Check it.
high idle.
6 Defective bucket cylinder Right work equipment control
Leakage from bucket cylinder
lever
Bucket CURL relief 20 cc/min
PC200, 200LC, 220, 220LC-8M0 40-500 17

SEN06139-00 H-9 Work equipment does not move in its single operation
H-9 Work equipment does not move in its single operation

(1) Boom does not move independently.
Failure (2) Arm does not move independently.
(3) Bucket does not move independently.
Related infor-
mation

high idle.
Work equipment control lever PPC valve output pressure
Probable
1 Malfunction of PPC valve 0 MPa
causes and cri- Neutral
teria {0 kg/cm2}
2.84 to 3.43 MPa
Operation
{29 to 35 kg/cm2}
Malfunction of control valve
2 Spool of control valve may malfunction. Check it.
(spool)
40-500 18 PC200, 200LC, 220, 220LC-8M0

H-10 Hydraulic drift of work equipment is large SEN06139-00
H-10 Hydraulic drift of work equipment is large

Failure (1) Hydraulic drift of boom is large.
Related infor-
mation

high idle.
1 Defective boom cylinder Right work equipment control
Leakage from boom cylinder
Probable lever
causes and cri- Boom RAISE relief 20 cc/min
teria
Defective seal of boom con- Sealing of the lock valve of the boom control valve may be defec-
2
trol valve (lock valve) tive. Check it.
Defective seal of safety
3 Seal of safety valve for lock valve may be defective. Check it.
valve for lock valve
Failure (2) Hydraulic drift of arm is large.

Related infor-
mation

high idle.
1 Defective arm cylinder Left work equipment control
Leakage from arm cylinder
lever
Arm IN relief 20 cc/min
Defective seal of arm con-
2 Seal of arm control valve spool may be defective. Check it.
Probable trol valve (spool)
causes and cri- Defective seal of arm con-
Seal of pressure compensation valve of arm control valve may be
teria 3 trol valve (pressure compen-
sation valve)
Seal of suction valve of arm control valve may be defective. Check
it.
Defective seal of arm con-
4 * Judgment can be made by checking a change of phenomenon
trol valve (suction valve)
after exchanging suction valve with one for other than the arm
control valve.
Defective seal of safety
5 Seal of safety valve for lock valve may be defective. Check it.
valve for lock valve
PC200, 200LC, 220, 220LC-8M0 40-500 19

SEN06139-00 H-10 Hydraulic drift of work equipment is large
Failure (3) Hydraulic drift of bucket is large.

Related infor-
mation

high idle.
1 Defective bucket cylinder Left work equipment control
Leakage from bucket cylinder
lever
Bucket CURL relief 20 cc/min
Probable Defective seal of bucket con-
2 Seal of bucket control valve spool may be defective. Check it.
causes and cri- trol valve (spool)
teria Defective seal of bucket con
Seal of pressure compensation valve of bucket control valve may
3 trol valve (pressure compen-
be defective. Check it.
sation valve)
Seal of safety-suction valve of bucket control valve may defective.
Defective seal of bucket con- Check it.
4 trol valve (safety-suction * You may replace the safety suction valves of the control valves
valve) on the bottom side and head side with each other and judge
from the change of the phenomenon.
40-500 20 PC200, 200LC, 220, 220LC-8M0

H-11 Time lag of work equipment is large SEN06139-00
H-11 Time lag of work equipment is large

Failure q Time lag of work equipment operation is large
Related infor-
mation

high idle.
LS-EPC valve
output pressure
Lo Neutral
{Approx. 30 kg/cm2}
0 MPa
Hi Operation
Probable {0 kg/cm2}
causes and cri- Malfunction of control valve
teria 2 (regeneration valve) [Boom Regeneration valve of control valve may malfunction. Check it.
and arm only]
Safety-suction valve of control valve may malfunction. Check it.
* Judgment can be made by checking a change of phenomenon
Malfunction of control valve after exchanging safety-suction valves of control valves with
3
(safety-suction valve) those on a normal control valve.
(Set pressure of safety-suction valve for boom head circuit is
different, however.)
Malfunction of control valve
Pressure compensation valve of control valve may malfunction.
4 (pressure compensation
Check it.
valve)
PC200, 200LC, 220, 220LC-8M0 40-500 21

SEN06139-00 H-12 Other work equipment moves when one of work equipment is relieved
H-12 Other work equipment moves when one of work equipment is

relieved
Failure q Other wok equipment moves when one of work equipment is relieved
Related infor-
mation

Probable
causes and cri- Defective seal of control
Seal of pressure compensation valve of control valve on moving
teria 1 valve (pressure compensa-
side may be defective. Check it.
tion valve) on moving side
40-500 22 PC200, 200LC, 220, 220LC-8M0

H-13 One-touch power maximizing function does not work SEN06139-00
H-13 One-touch power maximizing function does not work

Failure q One-touch power maximizing function does not work.
Related infor-
mation

high idle.
2-stage relief solenoid valve
Swing lock switch
output pressure
Probable Malfunction of 2-stage relief
1 0 MPa
causes and cri- solenoid valve
OFF
teria {0 kg/cm2}
Approx. 2.9 MPa
ON
{Approx. 30 kg/cm2}
Malfunction of main relief
2 The main relief valve may malfunction. Check it.
valve
PC200, 200LC, 220, 220LC-8M0 40-500 23

SEN06139-00 H-14 In combined operation of work equipment, equipment having heavier load moves slower.
H-14 In combined operation of work equipment, equipment having

heavier load moves slower.
Failure q In combined operation of work equipment, equipment having heavier load moves slower
Related infor-
mation

Pressure compensation valve of control valve on smaller load side
may malfunction. Check it.
Combination of com-
Larger load side Smaller load side
bined operation
Boom RAISE
+ Boom RAISE Arm IN
Arm IN
Probable Boom RAISE
causes and cri- Malfunction of control valve + Arm OUT Boom RAISE
teria 1 (pressure compensation Arm OUT
valve) on smaller load side
Boom RAISE
+ Boom RAISE Bucket CURL
Bucket CURL
Arm OUT
+ Arm OUT Bucket CURL
Bucket CURL
Boom LOWER
+ Arm OUT Boom LOWER
Arm OUT
40-500 24 PC200, 200LC, 220, 220LC-8M0

H-15 In combined operation of swing and boom RAISE, boom rising speed is low SEN06139-00
H-15 In combined operation of swing and boom RAISE, boom rising

speed is low
Failure q In combined operations of swing and boom RAISE, boom rising speed is low
Related infor- q If boom RAISE speed is also low when it is operated singly, perform troubleshooting for "H- 6 Boom
mation operation lacks speed or power".

Probable
causes and cri- Malfunction or defective
LS select valve of swing control valve may malfunction or sealing
teria 1 sealing of swing control
may be defective. Check it.
valve (LS select valve)
PC200, 200LC, 220, 220LC-8M0 40-500 25

SEN06139-00 H-16 Travel speed drops largely in combined operation of swing and travel
H-16 Travel speed drops largely in combined operation of swing and

travel
Failure q Travel speed drops largely in combined operation of swing and travel
Related infor- q If speed of single travel operation is also low, carry out troubleshooting for "H-18 Travel speed is
mation low" first.
Probable Cause Criteria and troubleshooting procedure

causes and cri- Malfunction of each control LS shuttle valve of left travel control valve or swing control valve
teria 1
valve (LS shuttle valve) may malfunction. Check it.
40-500 26 PC200, 200LC, 220, 220LC-8M0

H-17 Machine does not travel straight SEN06139-00
H-17 Machine does not travel straight

Failure q Machine does not travel straight
Related infor-
mation

high idle.
Travel lever PPC valve output pressure
Malfunction of travel PPC
1 0 MPa
valve Neutral
{0 kg/cm2}
Forward 2.84 to 3.43 MPa
Reverse {29 to 35 kg/cm2}
high idle.
2
reducing valve
2.84 to 3.43 MPa
{29 to 35 kg/cm2}
high idle.
ground.
tral position
Defective adjustment or mal- (lever at half stroke)
3
1
Probable PC valve output pressure Approx. 0.6 (Approx.
causes and cri- sure 3/5)
teria
high idle.
Travel junction solenoid valve
Travel lever
output pressure
Malfunction of travel junc-
4 0 MPa
tion solenoid valve Both sides in the NEUTRAL
position {0 kg/cm2}
Approx. 2.9 MPa
Either side operated
{Approx. 30 kg/cm2}
5 Travel junction valve may malfunction. Check it.
tion valve
Malfunction of travel control
6 Spool of travel control valve may malfunction. Check it.
valve (spool)
high idle.
7 Defective travel motor Travel lever Leakage from travel motor
Travel system relief 27.2 l/min
Final drive may have internal defect. Check it.
8 Defective final drive * It may be checked by abnormal sound, abnormal heating,metal
chips in drain oil, etc.
PC200, 200LC, 220, 220LC-8M0 40-500 27

SEN06139-00 H-18 Travel speed is low
H-18 Travel speed is low

Failure q Travel speed is low.
Related infor-
mation

high idle.
Travel lever PPC valve output pressure
1 0 MPa
valve Neutral
{0 kg/cm2}
Forward 2.84 to 3.43 MPa
Reverse {29 to 35 kg/cm2}
high idle.
2
reducing valve
2.84 to 3.43 MPa
{29 to 35 kg/cm2}
high idle.
LS-EPC valve
output pressure
Probable 3 Malfunction of LS-EPC valve Approx. 2.9 MPa
Lo Neutral
causes and cri- {Approx. 30 kg/cm2}
teria 0 MPa
Hi Operation
{0 kg/cm2}
valve (spool)
Pressure compensation valve of travel control valve may malfunc-
tion. Check it.
tion valve)
6 Suction valve of travel control valve may malfunction. Check it.
Malfunction of bucket control LS shuttle valve of bucket control valve may have malfunction.
7
valve (LS shuttle valve) Check it.
high idle.
9 Defective final drive * It may be checked by abnormal sound, abnormal heating,metal
40-500 28 PC200, 200LC, 220, 220LC-8M0

H-19 Machine is hard to steer or travel power is low SEN06139-00
H-19 Machine is hard to steer or travel power is low

Failure q Machine is hard to steer or travel power is low
Related infor-
mation

high idle.
Travel lever
(Steering)
1 0 MPa
valve (steering spool) Both sides in the NEUTRAL
position {0 kg/cm2}
2.84 to 3.43 MPa
{29 to 35 kg/cm2}
high idle.
Travel junction solenoid valve
Travel lever
output pressure
2 0 MPa
tion solenoid valve Both sides in the NEUTRAL
position {0 kg/cm2}
Approx. 2.9 MPa
{Approx. 30 kg/cm2}
3 Travel junction valve may malfunction. Check it.
tion valve
main EPC valve
Probable 5 Merge-divider LS-EPC valve may malfunction. Check it.
LS-EPC valve
causes and cri-
teria 6 Merge-divider main valve may malfunction. Check it.
main valve
LS valve
valve (spool)
Pressure compensation valve of travel control valve may malfunc-
tion. Check it.
tion valve)
10 Suction valve of travel control valve may malfunction. Check it.
Malfunction of bucket control
11 LS shuttle valve of bucket control valve may malfunction. Check it.
valve (LS shuttle valve)
Defective seal of check valve
Seal of check valve of LS pressure sensing part (control valve
12 of LS pressure sensing part
side) may be defective. Check it.
(control valve side)
Seal of safety valve of travel motor may malfunction. Check it.
* Judgment can be made by checking a change of phenomenon
Defective seal of travel
13 after exchanging safety valves between forward and reverse
motor (safety valve)
circuit of the same motor or between right and left motor cir-
cuits.
Seal of check valve of travel motor may malfunction. Check it.
Defective seal of travel * You may replace the check valves of forward and reverse sec-
14
motor (check valve) tions of the same motor or those of the right and left motors
with each other and judge from the change of the phenomenon.
PC200, 200LC, 220, 220LC-8M0 40-500 29

SEN06139-00 H-20 Travel speed does not change or travel speed is low/high
H-20 Travel speed does not change or travel speed is low/high

Failure q Travel speed does not change or travel speed is too low or high
Related infor-
mation

a Troubleshoot with engine high idle (with monitoring function).
Monitoring
code: 01500
663 mA(PC200-8M0,
PC200LC-8M0)
Lo 578 mA(PC220-8M0,
PC220LC-8M0)
(See *)
Operation 424 mA(PC200-8,
PC200LC-8M0)
Mi
641 mA(PC220-8M0,
1 Malfunction of LS-EPC valve
PC220LC-8M0)
Hi 0 mA
Probable high idle.
causes and cri- LS-EPC valve
teria output pressure
Approx. 2.9 MPa
Lo Neutral
{Approx. 30 kg/cm2}
0 MPa
Hi Operation
{0 kg/cm2}
high idle.
Travel speed shifting
Travel speed Travel lever solenoid valve output
Malfunction of travel speed pressure
2
shifting solenoid valve 0 MPa
Lo Neutral
{0 kg/cm2}
Approx. 2.9 MPa
Hi Operation
{Approx. 30 kg/cm2}
Malfunction of travel motor
3 Speed shifting section of travel motor may malfunction. Check it.
(speed shifting section)
*: Travel speed Lo can be adjusted with the adjusting function of the machine monitor. Accordingly, if the
initial value has been changed, the measured value varies more or less.
40-500 30 PC200, 200LC, 220, 220LC-8M0

H-21 One of tracks does not run SEN06139-00
H-21 One of tracks does not run

Failure q One of tracks does not run
Related infor-
mation

Defective seal of travel con-
1 Seal of suction valve of travel motor may malfunction. Check it.
trol valve (suction valve)
Seal of safety valve of travel motor may malfunction. Check it.
Defective seal of travel * You may replace the safety valves of forward and reverse sec-
2
motor (safety valve) tions of the same motor or those of the right and left motors
with each other and judge from the change of the phenomenon.
Seal of check valve of travel motor may malfunction. Check it.
Defective seal of travel * You may replace the check valves of forward and reverse sec-
3
Probable motor (check valve) tions of the same motor or those of the right and left motors
causes and cri- with each other and judge from the change of the phenomenon.
teria Malfunction of travel motor
4 Parking brake of travel motor may malfunction. Check it.
(parking brake)
full speed.
6 Defective final drive * It may be checked by abnormal sound, abnormal heating,
metal chips in drain oil, etc.metal chips in drain oil, etc.
PC200, 200LC, 220, 220LC-8M0 40-500 31

SEN06139-00 H-22 Upper structure does not swing
H-22 Upper structure does not swing

Failure (1) Upper structure swings neither to the right nor left
Related infor-
mation

high idle.
Output pressure of swing holding
brake
lever
Malfunction of swing holding solenoid valve
1
brake solenoid valve 0 MPa
Neutral
{0 kg/cm2}
Left swing Approx. 2.9 MPa
Right swing {Approx. 30 kg/cm2}
Malfunction of swing control
2 Spool of swing control valve may malfunction. Check the spool.
valve (spool)
Malfunction of swing motor
3 Swing brake may malfunction. Check it.
(swing holding brake)
Probable a Be ready with engine stopped, then troubleshoot with engine
causes and cri- high idle.
teria Swing lock Left work equipment
Swing relief pressure
Improper adjustment or Mal- switch control lever
4 function of swing motor 28.9 to 32.9 MPa
Swing to hydraulic
(safety valve) ON
relief {295 to 335 kg/cm2}
If normal oil pressure is not obtained by adjustment, swing motor
safety valve may malfunction or may internal defect. Check it.
high idle.
Swing lock Left work equipment Leakage from swing
5 Defective swing motor
switch control lever motor
Swing to hydraulic
ON Below 10 l/min
relief
Swing machinery may have internal defect. Check it.
6 Defective swing machinery * It may be checked by abnormal sound, abnormal heating,
metal chips in drain oil, etc.
40-500 32 PC200, 200LC, 220, 220LC-8M0

H-22 Upper structure does not swing SEN06139-00
Failure (2) Upper structure does not swing in only one direction.
Related infor-
mation

high idle.
lever
Malfunction of swing PPC
1 0 MPa
valve Neutral
{0 kg/cm2}
Left swing 2.84 to 3.43 MPa
Probable Right swing {29 to 35 kg/cm2}
causes and cri-
teria 2 Spool of swing control valve may malfunction. Check the spool.
valve (spool)
Suction valve of swing motor may malfunction. Check the valve.
Malfunction of swing motor * This failure can be checked by interchaning right and left suc-
3
(suction valve) tion valves of swing motor and watching how condition
changes.
Check valve of swing motor may malfunction. Check the valve.
Malfunction of swing motor * You may replace the check valves of the right and left motor-
4
(check valve) swith each other and judge from the change of the phenome-
non.
PC200, 200LC, 220, 220LC-8M0 40-500 33

SEN06139-00 H-23 Swing acceleration is poor or swing speed is low
H-23 Swing acceleration is poor or swing speed is low

Failure (1) Swing acceleration performance is poor or swing speed is slow in both right and left directions.
Related infor-
mation

valve (spool)
Malfunction of all control LS shuttle valves of all control valves may malfunction. Check
2
valves (LS shuttle valves) them.
high idle.
Swing lock Left work equipment
Probable
4 function of swing motor 28.9 to 32.9 MPa
causes and cri- Swing to hydraulic
(safety valve) ON
teria relief {295 to 335 kg/cm2}
high idle.
Swing to hydraulic
ON Below 10 l/min
relief
6 Defective swing machinery * It may be check by abnormal sound, abnormal heating, metal
40-500 34 PC200, 200LC, 220, 220LC-8M0

H-23 Swing acceleration is poor or swing speed is low SEN06139-00
Failure (2) Swing acceleration performance is poor or swing speed is slow in only one direction.
Related infor-
mation

high idle.
lever
1 0 MPa
valve Neutral
{0 kg/cm2}
Right swing {29 to 35 kg/cm2}
Probable Malfunction of swing control
causes and cri- valve (spool)
teria Malfunction of swing control
Pressure compensation valve of swing control valve may malfunc-
tion. Check it.
tion valve)
4
changes.
5
(check valve) tion valves of swing motor and watching how condition
changes.
PC200, 200LC, 220, 220LC-8M0 40-500 35

SEN06139-00 H-24 Upper structure overruns remarkably when it stops swinging
H-24 Upper structure overruns remarkably when it stops swinging

Failure (1) Upper structure overruns excessively when stop swinging in both right and left directions.
Related infor-
mation

high idle.
Swing lock Left work equipment
1 function of swing motor 28.9 to 3 2.9 MPa
Swing to hydraulic
(safety valve) ON
Probable relief {295 to 335 kg/cm2}
causes and cri-
teria
high idle.
Swing to hydraulic
ON Below 10 l/min
relief
Failure (2) Upper structure overruns excessively when stop swinging in only one direction.
Related infor-
mation

high idle.
lever
1 0 MPa
valve Neutral
{0 kg/cm2}
Probable Swing PPC slow return valve may malfunction. Check it.
Clogged swing PPC slow
causes and cri- 2 * This failure can be checked by interchaning right and left swing
return valve
teria PPC slow return valve and watching how condition changes.
valve (spool)
4
changes.
5
(check valve) tion valves of swing motor and watching how condition
changes.
40-500 36 PC200, 200LC, 220, 220LC-8M0

H-25 Shock is large when upper structure stops swinging SEN06139-00
H-25 Shock is large when upper structure stops swinging

Failure q Shock is larger when upper structure stops swinging
Related infor-
mation

high idle.
lever
1 0 MPa
valve Neutral
Probable {0 kg/cm2}
causes and cri-
teria
Swing PPC slow return valve may malfunction. Check it.
Clogged swing PPC slow
2 * This failure can be checked by interchaning right and left swing
return valve
PPC slow return valve and watching how condition changes.
3 Shockless valve of swing motor may malfunction. Check it.
(shockless valve)
PC200, 200LC, 220, 220LC-8M0 40-500 37

SEN06139-00 H-26 Large sound is made when upper structure stops swinging
H-26 Large sound is made when upper structure stops swinging

Failure q Large sound is made when upper structure stops swinging
Related infor-
mation

Malfunction of back pressure
1 Backpressurevalve may have malfunction. Check it.
valve
2 Safety valve of swing motor may malfunction. Check the valve.
(safety valve)
Probable
causes and cri- Suction valve of swing motor may malfunction. Check the valve.
teria Malfunction of swing motor * This failure can be checked by interchaning right and left suc-
3
changes.
4 Defective swing machinery * It may be checked by abnormal sound, abnormal heating,metal
40-500 38 PC200, 200LC, 220, 220LC-8M0

H-27 Hydraulic drift of swing is large SEN06139-00
H-27 Hydraulic drift of swing is large

Failure (1) Swing drift on a slope is large (when swing holding brake is being applied)
q When swing lock switch is turned to ON position or when swing brake cancel switch is set to normal
Related infor- position, swing holding brake is applied and swinging motion of upper structure is stopped with disc
mation brake.

high idle.
Output pressure of swing holding
brake
lever
Probable Malfunction of swing holding solenoid valve
1
causes and cri- brake solenoid valve 0 MPa
teria Neutral
{0 kg/cm2}
Left swing Approx. 2.9 MPa
Right swing {Approx. 30 kg/cm2}
Failure (2) Swing drift on a slope is large (when swing brake is being released).
q When swing holding brake release switch is in release position, swing holding brake is released
Related infor-
andupper structure is secured by only hydraulic pressure.
mation

Malfunction or defective seal Swingcontrolvalve spool may have malfunction or defective seal.
1
of swing control valve (spool) Check it.
Defective seal of swing con-
Sealofpressure compensation valve of swing control valve may be
2 trol valve (pressure compen-
sation valve)
Probable Defective seal of swing Sealing for safety valve of swing motor may be defective .Check
causes and cri- 3
motor (safety valve) the valve.
teria
Defective seal of swing Sealing of the suction valve of the swing motor may be defective.
4
motor (suction valve) Check it.
Defective sealing of swing
5 Sealing for check valve of swing motor may be defective . Check it.
motor (check valve)
Defective seaing for swing Sealing for shockless valve of swing motor may be defective.
6
motor (shockless valve) Check it.
PC200, 200LC, 220, 220LC-8M0 40-500 39

SEN06139-00 H-28 Attachment circuit cannot be changed
H-28 Attachment circuit cannot be changed

For machines with provision for attachment
Failure q Attachment circuit is not changed
q When attachment installation specification is employed, service circuit is changed as follows ac-
cording to selected working mode.
Related infor- 1) ATT mode: Service circuit is changed to double acting circuit and safety valve is set to low pres-
mation sure.
2) B mode: Service circuit is changed to single acting circuit and safety valve is set to high pressure.
q Safety valve set pressure on only B port side is changed; that on A port side is kept low.

high idle.
ATT return selector solenoid
Working mode
valve output pressure
MalfunctionofATT return
1 0 MPa
Probable selector solenoid valve
ATT mode
causes and cri- {0 kg/cm2}
teria Approx. 2.9 MPa
B mode
{Approx. 30 kg/cm2}
Malfunction of ATT return
2 ATT return selector valve may have malfunction. Check it.
selector valve
Malfunction of service valve Safety valve (port B side) of service valve may malfunction. Check
3
(safety valve) it.
40-500 40 PC200, 200LC, 220, 220LC-8M0

H-29 Oil flow in attachment circuit cannot be controlled SEN06139-00
H-29 Oil flow in attachment circuit cannot be controlled

For machines with provision for attachment
Failure q Oil flow in attachment circuit cannot be changed
q When attachment installation specification is employed, oil flow in service circuit changes accord-
Related infor- ing to selected user mode.
mation q How to adjust flow rate in ATT mode is different from that in B mode. For details, see Operation
and Maintenance Manual.

Malfunction of attachment
Probable Attachment flow rate adjustment EPC valve may malfunction.
1 flow rate adjustment EPC
causes and cri- Check it.
valve
teria
Malfunction of service PPC
2 Service PPC valve may have malfunction. Check it.
valve
PC200, 200LC, 220, 220LC-8M0 40-500 41

SEN06139-00
2012 KOMATSU
All Rights Reserved
40-500 42
SEN06140-00
SEN05991-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
40 Troubleshooting
600 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart........................................................................................................ 2

S-1 Startability is poor ................................................................................................................................. 6
S-2 Engine does not start ........................................................................................................................... 7
S-3 Engine does not pick up smoothly........................................................................................................ 10
S-4 Engine stops during operation.............................................................................................................. 11
S-5 Engine runs rough or is unstable.......................................................................................................... 12
S-6 Engine lacks power .............................................................................................................................. 13
S-7 Exhaust smoke is black (incomplete combustion)................................................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 15
S-9 Oil becomes contaminated early .......................................................................................................... 16
S-10 Fuel consumption is excessive........................................................................................................... 17
S-11 Oil is in coolant (or coolant spurts or coolant level goes down).......................................................... 18
S-12 Oil pressure drops .............................................................................................................................. 19
S-13 Oil level rises (coolant or fuel in oil).................................................................................................... 20
S-14 Coolant temperature rises too high (overheating) .............................................................................. 21
S-15 Unusual noise is made ....................................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................................... 23
PC200, 200LC, 220, 220LC-8M0 40-600 1

SEN06140-00 Method of using troubleshooting chart
Method of using troubleshooting chart
The troubleshooting chart consists of the "Ques-

tions", "Check items", "Causes", and "Troubleshoot-
ing" blocks.
The Questions and Check items are used to narrow
down high probability causes by simple inspection
or from symptoms without using troubleshooting
tools.
Next, use troubleshooting tools or perform direct in-
spection to check the selected Causes in the order
of probability to determine the real cause according
to the troubleshooting procedure.
Questions:
Questions placed in the sections A and B in the
table on the right are those to be answered by
the customer or operator.
Questions in section A are for basic information
about the failure. Depth and accuracy of their an-
swers to the questions in section B may depend
on their concerns on the machine condition.
Check items:
Check items placed in the section C in the table
on the right are to be simply checked by the tech-
nician to select highly probable causes.
Causes:
Various causes are listed is this block.
The technician will be able to narrows down the
probable causes by taking the actions listed in
the blocks A, B, and C.
Troubleshooting:
This section includes various items of trouble-
shooting that are performed in order to verify the
results of the diagnosis made by asking the
questions and inspecting the machine. The trou-
bleshooting is performed in order from the most
probable one by applying troubleshooting tools
or direct inspection.
40-600 2 PC200, 200LC, 220, 220LC-8M0

Method of using troubleshooting chart SEN06140-00
This troubleshooting chart marks the content of the questions and check items with E, Q or w according to
their closer relationship with the causes.
E: Reference information for estimation of the cause
Q: Information and inspection result that indicate the cause of the failure
w: A cause particularly probable among those marked with Q above.
a Count the priority level of each marking as w > Q when determining the cause.
Don't count E when determining the cause. The item with this marking may be counted, however, if no
difference is present than this and the cause cannot be determined.
PC200, 200LC, 220, 220LC-8M0 40-600 3

SEN06140-00 Method of using troubleshooting chart
<Example of troubleshooting> Exhaust gas is black (Incomplete combustion)

Let us assume that a trouble of Exhaust gas is black occurred and we checked the [Questions] and [Check
items] and found the following 3 items to be the causal symptoms; [Color of exhaust gas gradually became
black], [Power was lost gradually], and [Dust indicator indicates a red zone].
40-600 4 PC200, 200LC, 220, 220LC-8M0

Method of using troubleshooting chart SEN06140-00
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 Step 3 shown below.
PC200, 200LC, 220, 220LC-8M0 40-600 5

SEN06140-00 S-1 Startability is poor
S-1 Startability is poor
General causes why startability is poor Cause
Leakage or clogging of fuel piping or air in the fuel piping

q Defective electrical system
q Insufficient supply of fuel
q Insufficient intake of air
q Improper selection of fuel
a The common rail fuel injection system (CRI) controls the fuel injection timing
Clogged air breather hole in fuel tank cap

Defective contact of valve with valve seat
electrically. Accordingly, even if the engine is cranked properly, the engine
Defective alternator (generator section)

Defective alternator (regulator section)
may not start until the crankshaft rotates two turns under the most disadvan-
Stuck or seized supply pnmp pluger

tageous condition. This phenomenon does not mean a problem, however.
Defective intake air heater system
Defective or deteriorated battery

Clogged air cleaner element
Worn piston ring or cylinder
Clogging of fuel filter
Defective injector
Check recent repair history.
Machine opera-
Operated for long period E E E
tion hours
Starting perfor- Became worse gradually Q w w Q
Engine starts easily when warm. w w
Questions
mance
Fuel other than specified one is used Q Q Q
Filters are not replaced as indicated in the Operation and Maintenance Man-
w w Q Q
ual.
Engine oil must be added more frequently. w
When engine is preheated or when temperature is low, preheating monitor
w
does not indicate proper functioning of preheating system.
During operation, charge level monitor indicates abnormal charge. w w
Dust indicator indicates a red zone w
Air breather hole in fuel tank cap is clogged. w
Fuel leaks from fuel piping. w Q
If priming pump is operated, no resistance is felt or it is heavy. w Q
Starting motor cranks engine slowly. w
When engine is Even if air bleeding plug in fuel filter head is removed, fuel
w
cranked with does not flow out.
Check items
starting motor, If spill hose from injector is disconnected, little fuel spills. w
When exhaust manifold is touched immediately after starting engine, temper-
w
ature of some cylinders is low.
Engine does not pick up smoothly and combustion is irregular. Q Q w
Engine hunts. Q w Q
Blowby gas is excessive w
Check air cleaner. q
When compression pressure is measured, it is found to be low. q q
When air is bled from fuel system, air comes out. q
Check fuel filter. q
Troubleshooting
Perform troubleshooting for "Supply pump pressure low error according to

q
failure code (*1).
Even if a cylinder is cut out, engine speed does not change. q
Even if starting switch is turned to HEAT, intake air heater mount does not
q
become warm.
Is voltage 20 30 V between alternator terminal B and terminal E Yes q
when engine is running at low idle speed? None q
Specific gravity of electrolyte and voltage of battery are low. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Remedy
*1: Failure codes [CA559] and [CA2249]
40-600 6 PC200, 200LC, 220, 220LC-8M0

S-2 Engine does not start SEN06140-00
S-2 Engine does not start
a) Engine does not crank Cause
General causes why engine does not crank
Defective connection of battery cable terminal

q Internal parts of engine seized.
oSee "S-4 Engine stops during operations"
Defective starting motor (motor section)

q Defective electrical system
q Defect in hydraulic pump
Defective starting circuit wiring

Broken flywheel ring gear
Defective hydraulic pump

Defective starting switch
Defective battery relay
Defective safety relay

Machine operation
Questions
Operated for long period EE

hours
Condition of horn Horn does not sound. Q Q w
when starting switch
Horn volume is low. w
is turned ON
Battery electrolyte level is low. w
Battery cable terminal is loose w
When starting switch is turned ON, no operating sound is heard from battery relay. Q w
When starting switch is turned to START, starter pinion does not plunge. Q Q w
Check items
When starting switch Rotation speed is low. w

is turned to START, Unusual noise is heard around ring gear. w w
starter pinion Pinion returns halfway. w
plunges, but: Unusual noise is heard around relay and engine does not rotate. Q QQ Q
Check flywheel ring gear. q
Perform H-mode troubleshooting

Perform E-mode troubleshooting
Voltage (20 30 V) between battery relay terminal B and termi-
q
nal E is not found.
Troubleshooting
Turn starting switch to When terminal B and terminal C of starting switch are connected, q
OFF position and engine cranks.
connect cable, and When terminal B at safety relay outlet and terminal C are con-
q
perform troubleshoot- nected, engine cranks.
ing with starting Even if terminal B at safety relay outlet and terminal C are con-
q
switch at ON. nected, engine will not crank.
When terminal at safety switch and terminal B at starting motor
q
are connected, engine cranks.
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Remedy

PC200, 200LC, 220, 220LC-8M0 40-600 7

SEN06140-00 S-2 Engine does not start
b) Engine cranks but no exhaust smoke comes out Cause

General causes why engine cranks but no exhaust smoke comes out
q Fuel is not being supplied.
Malfunction of overflow valve (Does not close)

q Supply of fuel is extremely small.
q Improper selection of fuel (particularly in winter)
Seized or prematurely worn feed pump
Defective common rail pressure limiter

Stuck or seized supply pump plunger
Defective IMV for supply pump
Broken supply pump shaft
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Machine opera-
Questions

tion hours
Exhaust smoke suddenly stopped coming out (at restarting after short time
w Q w w
stoppage).
Fuel other than specified one is used w
Filters are not replaced as indicated in the Operation and Maintenance
w E
Manual.
Fuel tank is found to be empty. w
Rust and water are found when fuel tank is drained. QE EE
There is no fuel in the removal fuel filter. w w
Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. w Q
Check items
Even if air bleeding plug in fuel filter head is removed, fuel

When engine is Q Q w Q
does not flow out.
cranked with
Even if spill hose from injector is disconnected, little fuel
starting motor, Q w w w Q
spills.
Troubleshooting
Check feed pump. q

q q
failure code (*1).
Perform troubleshooting for the error "IMV/IMA short or open circuit" accord-
q
ing to failure code (*2).
Check pressure relief valve. q
Fuel flows out when pressure limiter return piping is disconnected. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Add
Remedy

40-600 8 PC200, 200LC, 220, 220LC-8M0

S-2 Engine does not start SEN06140-00
c) Exhaust smoke comes out but engine will not start (fuel is injected) Cause
Leakage or clogging of fuel piping or air in the fuel system
Defective coolant temperature sensor or wiring harness

General causes why exhaust smoke comes out but engine does not start
q Lack of cranking force due to defective electrical system

Worn valve system (valve, rocker lever, etc.)

Insufficient intake of air
Clogged injection nozzle, or defective spray

q

Defective intake air heater system


Use of improper fuel
Machine operation
hours
Suddenly become unstartable. w w Q
Questions
Fuel other than specified one is used Q Q

Filters are not replaced as indicated in the Operation and Maintenance Man-
w w
ual.
Oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor
w
does not indicate proper function of preheating system.
Air breather hole of fuel tank cap is clogged. Q
Rust and water are found when fuel tank is drained. w
There is no fuel in the removal fuel filter. w
When priming pump is operated, no resistance is felt or it is heavy. wQ
Starting motor cranks engine slowly. w
When engine is running, unusual noise is heard around cylinder head. w
Even if air bleeding plug in fuel filter head is removed, fuel
Check items
When engine is Q w
does not flow out.
cranked with start-
Even if spill hose from injector is disconnected, little fuel
ing motor, w
spills.
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low.
Check valve system. q
When compression pressure is measured, it is found to be low. q
Troubleshooting

q
failure code (*1).
Coolant temperature gauge indication is not correct. q
Even if starting switch is turned to HEAT, intake air heater mount does not
q
become warm.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Remedy
PC200, 200LC, 220, 220LC-8M0 40-600 9

SEN06140-00 S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly
General causes why engine will not pick up smoothly Cause
Leaking or clogging of fuel piping or air in the fuel piping

q Improper of fuel injection
Clogged injection nozzle, or defective spray

q Controller is controlling in derate mode

(limiting injection rate (power) because of an error in electrical system)
Seizure or interference at turbocharger


Improper valve clearance

Machine opera-
Operated for long period EE E E
Questions
tion hours
Engine pickup suddenly became worse. w QQ Q
Fuel other than specified one is used www
Filters are not replaced as indicated in the Operation and Maintenance Manual. w w
Rust and water are found when fuel tank is drained. w
When priming pump is operated, no resistance is felt or it is heavy. wQ
When exhaust manifold is touched immediately after starting engine, temperature of
Qw
some cylinders is low.
Color of exhaust Blue under light load. w
Check items
smoke Black. wQ w w
While engine is running, unusual noise is heard around cylinder head. w
While engine is running, interference sound is heard around turbocharger. w
High idle speed is normal, but speed suddenly drops when load is applied. Q w
Engine hunts. Q Q Q
Blowby gas is excessive. w
Troubleshooting
Check valve clearance. q

When turbocharger is rotated by hand, it is found to be heavy. q
Perform troubleshooting for "Supply pump pressure low error according to failure
q
code (*1).
When a certain cylinder is cut out, engine speed does not change. q
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Clean
Clean
Remedy
40-600 10 PC200, 200LC, 220, 220LC-8M0

S-4 Engine stops during operation SEN06140-00
S-4 Engine stops during operation
General causes why engine stops during operation Cause
Broken auxiliary equipment (pump or air compressor, etc.)

q Internal parts of engine seized
Damage of valve system (valve, rocker lever, etc.)

q Engine overheating
Defective engine controller power supply wiring

q Defect in hydraulic pump

Broken or seized piston connecting rod
Broken or seized crankshaft bearing

Clogging of feed pnmp gauze filter
Defective starting switch wiring

Clogged or leaking fuel piping
Broken or seized feed pump

Broken or seized gear train
Broken supply pump shaft
Defective hydraulic pump


Machine operation
Operated for long period. EE
hours
Unusual noise was heard and engine
wwww QwQw w
Questions
Condition when stopped suddenly.

engine stopped
Engine overheated and stopped. wQ Q
Engine stopped slowly. w Q Q QQ
Engine hunted and stopped. wQ Q QQ QQ
Fuel other than specified one is used Q QQ Q
Filters are not replaced as indicated in the Operation and Mainte-
w w
nance Manual.
Fuel level monitor indicates low level. w
When priming pump is operated, no resistance is felt or it is wQQ
Rust and water are found when fuel tank is drained. ww
Metal particles are found in oil drained from oil pan. ww QQ
Check items
It does not rotate at all. ww

When engine is It rotates only in opposite direction. w
Crankshaft moves by amount of gear
rotated by hand: w w
backlash.
Supply pump shaft does not turn. w
Engine operates, but stops when load is applied from machine. w
Perform H-mode trouble-
Check piston and connecting rod. q

Check crankshaft bearing. q
Check gear train. q
Troubleshooting
shooting

Check feed pump gauze filter. q
Check the feed pump. q
Perform troubleshooting for "Supply pump pressure low error
qq
according to failure code (*1).
Engine operates if auxiliary equipment (pump, air compressor,
q
etc.) is removed.
Check engine controller power supply wiring. q
Check starting switch wiring. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Clean
Clean
Add
Remedy

PC200, 200LC, 220, 220LC-8M0 40-600 11

SEN06140-00 S-5 Engine runs rough or is unstable
S-5 Engine runs rough or is unstable
General causes why engine runs rough or is unstable Cause

q Air in fuel system
q Defective engine speed sensor (error at degree that does not generate failure code)
Clogged injector or defective spray (dirt in injector)

Defective Ne speed sensor, or wiring harness
Defective Ne speed sensor, or wiring harness

Machine operation
Operated for long period E
hours
Questions
Occurs at a certain speed range. Q Q

Occurs at low idle. Q Q Q Q Q
Hunting:
Occurs even when speed is raised. Q Q Q
Occurs on slope. w
Filters are not replaced as indicated in the Operation and Maintenance Manual. w
Troubleshooting Check items
Rust and water are found when fuel tank is drained. Q

When priming pump is operated, no resistance is felt or it is heavy. w Q
Perform troubleshooting for "Eng Ne Speed Sensor Error" according to failure code (*1). q
Perform troubleshooting for "Eng Backup Speed Sensor Error" according to failure code (*2). q
Replace
Replace
Replace
Replace
Replace
Clean
Add
Remedy
*1: Failure code [CA689]

*2: Failure code [CA778]
40-600 12 PC200, 200LC, 220, 220LC-8M0

S-6 Engine lacks power SEN06140-00
S-6 Engine lacks power

General causes why engine lacks power Causes
Clogged injector nozzle, or defective spray (dirt in injector)

Defective installation of boost pressure sensor (air leak)

q Improper fuel injection
Defective boost pressure sensor or wiring harness

Air leakage from air intake piping and aftercooler

oSee S-14 Coolant temperature becomes too high (overheating).
Defective injector drive (signal or solenoid)

q Controller is controlling in derate mode.


Clogged or leaking fuel piping
Clogged fuel spill piping


Machine operation
hours
Operated for long period E E E E
Q w Q Q Q Q
Questions
suddenly
Power was lost
gradually Q Q Q Q Q Q
Fuel other than specified one is used QQ Q
Filters are not replaced as indicated in the Operation and Maintenance Manual. w w
Oil must be added more frequently. Q Q
Dust indicator indicates a red zone w w
Power becomes insufficient after short stop of operation. w
Color of exhaust black w w
smoke blue under light load w
w w
w
Check items
While engine is running, interference sound is heard around turbocharger.

High idle speed is too high. Q
High idle speed is normal, but speed suddenly drops when load is applied. Q wQ Q
Engine does not pick up smoothly and combustion is irregular. w w QQ w
Engine hunts. QQQ Q Q
Blowby gas is excessive w w
Check air intake piping. q
When boost pressure is measured, it is found to be low. q q q
Troubleshooting
Check fuel piping. q

Check spill port check valve. q
Perform troubleshooting for "Supply pump pressure low error according to failure
code (*1).
q
When a certain cylinder is cut out, engine speed does not change. q q
Check boost air pressure sensor mount. q
Perform troubleshooting for "Charge pressure sensor error" according to failure code
(*2).
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Adjust
Clean
Clean
Remedy

PC200, 200LC, 220, 220LC-8M0 40-600 13

SEN06140-00 S-7 Exhaust smoke is black (incomplete combustion)
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black Cause
Air leak at tubing between turbocharger and cylinder head

q Improper fuel injection
oSee S-14 Coolant temperature becomes too high (overheating).

q Controller is controlling in derate mode.

Improper fuel injection pressure

Improper fuel injection timing

Crushed or clogged muffler
Prematurely worn injector

Cloggedor seized injector
Machine opera-
Operated for long period E E E E
tion hours
Color of exhaust Suddenly became black. w w QQQ
Questions
smoke
Gradually became black. w Q Q
Is blue under light load. w
Fuel other than specified one is used QQ
Power was lost
Suddenly w Q QQ
Gradually Q Q Q Q
Muffler is crushed. w
Air leaks at tubing between turbocharger and cylinder head, and loose
w
clamp.
Engine is operated in low-temperature mode at normal temperature. QQQ
When exhaust manifold is touched immediately after starting engine, tem-
Qw
perature of some cylinders is low.
While engine is running, interference sound is heard around turbocharger. w
Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected
Q
excessively).
Exhaust noise is unusual. Q w Q
Engine does not pick up smoothly and combustion is irregular. Q QQQ Qw
When spill hose from injector is disconnected, fuel spills excessibly. w
When turbocharger is rotated by hand, it is fount to be heavy. q
Troubleshooting

If muffler is removed, exhaust sound improves. q
q q
failure code (*1).
Perform troubleshooting for "Coolant sensor error" according to failure code
q
(*2).
Check the condition by using monitoring function of the machine monitor. qq
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Clean
Remedy

40-600 14 PC200, 200LC, 220, 220LC-8M0

S-8 Oil consumption is excessive (or exhaust smoke is blue) SEN06140-00
S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive Cause
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

q Excessive oil carry-over
q Long-time operation of engine at low idle or high idle
Worn/damaged valve (stem, guide, seal)

(Do not idle the engine for more than 20 minutes continuously)
q External leakage of oil
Dust sucked in at air intake system
Clogged breather or breather hose

q Wear of parts in lubrication system
Worn or damaged rear oil seal
Oil leakage from oil drain plug

Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Machine operation
Questions
Operated for long period EEE E

hours
Oil consumption suddenly increased. w Q
Engine oil must be added more frequently. w Q
Oil becomes contaminated quickly. Q Q w
Outside of engine is dirty with oil. w w w w w
Loose hose clamps are found in air intake system. w
Inside of air outlet pipe at turbo compressor side is dirty with oil. w
Inside of turbo exhaust outlet pipe is dirty with oil. Q w
Check items
Oil in coolant w
Oil level in damper chamber is increasing. w
Exhaust smoke is blue under light load. w w
Excessive Q Q w w
Amount of blowby gas
None w
When intake manifold is removed, dust is found inside. q
When intake manifold is removed, inside is abnormally dirty. q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather or breather hose. q
Check rear oil seal. q
Pressure tightness test result of oil cooler shows oil leakage. q q
External leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Repair
Repair
Clean
Remedy
PC200, 200LC, 220, 220LC-8M0 40-600 15

SEN06140-00 S-9 Oil becomes contaminated early
S-9 Oil becomes contaminated early
General causes why oil becomes contaminated early Cause
Clogged turbocharger lubrication oil drain tube

Defective sealing at turbocharger turbine end
q Entry of exhaust gas into oil due to internal wear
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather or breather hose

q Operation under excessive load
Defective oil filter safety valve

Worn valve or valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions
Machine operation hours Operated for long period EEE

Fuel other than specified one is used Q Q
Oil must be added more frequently. w
Metal particles are found in the removed oil filter. Q Q w
Inside of exhaust pipe is dirty with oil. w
Engine oil temperature rises quickly. w
Blue under light load w
Check items
Color of exhaust smoke

Black w
Excessive Q Q w Q
Amount of blowby gas
None w
Excessive play of turbocharger shaft q
Troubleshooting

Check breather or breather hose. q
See S-7
Check oil cooler. q
Check oil filter. q
Spring of oil filter safety valve is stuck or broken. q
Check turbocharger lubrication oil drain tube. q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy

40-600 16 PC200, 200LC, 220, 220LC-8M0

S-10 Fuel consumption is excessive SEN06140-00
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Cause

q Leakage of fuel
q Improper fuel injection (fuel pressure or injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective atomization by injector

Improper common rail pressure
Defective supply pump plunger
Defective operation of injector

Fuel leakage at cylinder head
Defective feed pump oil seal
Improper injection timing

Machine opera-
Questions
Operated for long period EE E

tion hours
is more than that on other machines of same model. Q QQQ
Fuel consump-
Gradually increased. Q Q
tion:
Suddenly increased. QQ
External leakage of fuel from engine w
Combustion is irregular. w
Engine oil level rises and oil smells of diesel fuel. w w
w
Check items

Low idle speed is high. Q
Pump relief speed is high. Q
Color of exhaust Black QQ QQ
smoke White Q
Remove head cover and check for fuel leak. q
Check oil seal of feed pump. q
Troubleshooting
Perform troubleshooting for "Supply pump pressure low error according to failure code
q
(*1).
Too much fuel is returned from injector. q
Perform troubleshooting for "Coolant sensor error" according to failure code (*2). q
Check the condition by using monitoring function of machine monitor. q q
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy

PC200, 200LC, 220, 220LC-8M0 40-600 17

SEN06140-00 S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
General causes why oil is present in coolant Cause
Broken cylinder head or cylinder head gasket

q Internal leakage in lubrication system
q Internal leakage in cooling system
Internal cracks in cylinder block
Broken oil cooler core or O-ring

Holes caused by pitting
Machine operation
Questions
hours
suddenly Q Q
Oil level rose:
gradually Q Q
Hard water is being used as coolant. Q Q
Oil level has risen and oil is milky. Q Q w
Check items
Unusual air bubbles are found in radiator, or coolant spurts. w

Troubleshooting
Pressure tightness test result of cylinder head shows oil leakage. q
Check cylinder block. q q
Pressure tightness test result of oil cooler shows oil leakage. q

Replace
Replace
Replace
Replace
Remedy
40-600 18 PC200, 200LC, 220, 220LC-8M0

S-12 Oil pressure drops SEN06140-00
S-12 Oil pressure drops
General causes why oil pressure drops Cause

q Leakage, clogging, or wear on lubrication system
q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Operation and Maintenance
Manual is not observed.
q Deterioration of oil due to overheating
Leaking, crushed, clogged oil piping

Clogged or broken pipe in oil pan
Clogged strainer in oil pan
Defective regulator valve

Coolant or fuel in oil
Lack of oil in oil pan
Worn main hearing
Defective oil pump
Clogged oil filter

Machine opera-
Questions

tion hours
Oil pressure monitor indicates low oil pressure. Qw
Oil other than specified one is used Q Q
Filters are not replaced as indicated in the Operation and Maintenance Manual. w
Indicates pressure drop at low idle. w
Oil pressure
Indicates pressure drop at low and high idle. Q wwwQ
monitor:
Indicates pressure drop on slope. w
(if installed)
Sometimes indicates pressure drop. w Q
Oil pressure monitor indicates low oil pressure. w w
Oil level in oil pan is low. w
External lubrication piping is leaking or crushed. w
Troubleshooting Check items
Oil is milky or smells of diesel fuel. w

Metal particles are found in oil drained from oil pan. w
Metal particles are found in the removed oil filter. w Q
Metal particles are found in oil filter. q
Inspect oil pan strainer and pipe. qq
See S-13
Oil pump rotation is heavy or there is play in oil pump. q

Valve and spring of regulator valve are fatigued or damaged. q
Check oil filter. q
If oil level sensor is replaced, oil level monitor indicates correct oil level. q
Replace
Replace
Replace
Repair
Adjust
Adjust
Clean
Clean
Add
Remedy

PC200, 200LC, 220, 220LC-8M0 40-600 19

SEN06140-00 S-13 Oil level rises (coolant or fuel in oil)
S-13 Oil level rises (coolant or fuel in oil)
General causes why oil level rises Causes
Defective seal of auxiliaries (water pump or air compressor)

q Coolant in oil (milky)
q Fuel in oil (oil smell of diluted diesel fuel)
a If oil is in coolant, perform troubleshooting for S-11 Oil is in coolant.
Internal cracks in cylinder block
Broken oil cooler core or O-ring

Worn or damaged rear oil seal
Defects in supply pump

Broken injector O-ring
Questions
Machine opera-
Operated for long period E EE E
tion hours
Fuel must be added more frequently. w w
Coolant must be added more frequently. Q Q
Oil in coolant QQQQ w
Oil smells of diesel fuel w w
Oil is milky. Q Q
While engine is running, drops of water come from muffler. Q
If radiator cap is removed and engine is run at low idle, an unusual number of bubbles
Check items
w Q
appears, or coolant spurts.
Exhaust smoke is white. Q
Oil level in damper chamber decreases. w
Troubleshooting
Remove injector and check O-ring. q

Check cylinder block. qq
Check rear oil seal. q
Pressure tightness test result of oil cooler shows oil leakage. q
Remove and check supply pump. q
Check seal of auxiliaries. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
40-600 20 PC200, 200LC, 220, 220LC-8M0

S-14 Coolant temperature rises too high (overheating) SEN06140-00
S-14 Coolant temperature rises too high (overheating)
General causes why coolant temperature rises too high Causes

q Lack of cooling air (deformation or damage of fan)
q Drop in heat dissipation efficiency
q Problem in coolant circulation system
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Slipping fan belt or worn fan pulley
Rise in hydraulic oil temperature

Clogged or crushed radiater fins
Clogged or broken oil cooler
Malffunction of water pump

Malfunction of thermostat
Clogged radiator core

Lack of coolant
Machine opera-
Operated for long period EE EE
Questions
tion hours
Suddenly occurred. Q w Q
Overheating
Tends to occur always. Q w w Q
Coolant temper- Indiacates quick temperature rise. Q w
ature gauge: Does not go down from red range. w
Radiator coolant level monitor indicates drop of coolant level. w
Engine oil level has risen and oil is milky. w Q
Fan belt tension is low. w
When fan pulley is turned, it has play. w
Milky oil is floating on coolant. w
Unusual air bubbles are found in radiator or coolant spurts. w
Check items
When light bulb is held behind radiator core, no light passes through. w
Radiator shroud and inside of underguard are clogged with dirt or mud. w w
Coolant is leaking because of cracks in hose or loose clamps. w
Coolant flows out from radiator overflow hose. w
Fan belt whines under sudden acceleration. w
Hydraulic oil temperature gauge enters red range faster than engine coolant
w
temperature gauge.

Check cylinder. q
Perform H-mode troubleshooting.
Check oil cooler. q

Temperature difference between upper and lower tanks of radiator is large. q
Troubleshooting
When operation of thermostat is tested, it does not open at specified opening

q
temperature.
Temperature difference between upper and lower tanks of radiator is slight. q
Check radiator core. q
When operation of radiator cap is tested, its opening pressure is low. q
Check fan belt and pulley. q
When coolant temperature is measured, it is found to be normal. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Add
Remedy

PC200, 200LC, 220, 220LC-8M0 40-600 21

SEN06140-00 S-15 Unusual noise is made
S-15 Unusual noise is made
General causes why unusual noise is heard Cause
(defect in low coolant temperature sensor or boost temperature sensor)

q Abnormality due to defective parts
q Abnormal combustion
q Air sucked in from air intake system
a Judge if the noise is an internal noise or an external noise before starting troubleshoot-
Deformed cooling fan, loose fan belt, interference of fan belt

ing.
Defective inside of muffler (partition board out of position)

Air leak at tubing between turbocharge and cylinder head
a The engine is operated in the low-temperature mode while it is not warmed up suffi-
ciently. Accordingly, the engine sound becomes a little larger. This does not indicate
abnormality, however.
Damage of valve system (valve or rocker lever)

a When the engine is accelerated, it is operated in the acceleration mode and its sound
becomes a little larger for up to about three seconds. This does not indicate abnormal-
ity, however.
Excessively worn piston ring or cylinder

Dislocated or seized bushing
Improper fuel injection timing

Improper gear train backlash
Clogged or seized injector

Dirt caught in injector

Machine opera-
Operated for long period E
Questions
tion hours
Gradually occurred. Q Q
Abnormal noise
Sudden occurred. QQ Q
Fuel other than specified one is used Q
Metal particles are found in the removed oil filter. w w
Air leaks at tubing between turbocharger and cylinder head. w
While engine is running, interference sound is heard from turbocharger. w
While engine is running, unusual noise is heard around cylinder head. w w
While engine is running, beat noise is heard around muffler. w
Check items

wQ
Color of exhaust Blue under light load w
smoke: Black Qw Q
Engine does not pick up smoothly and combustion is irregular. w
Unusual noise is loud when engine is accelerated Q Q QQ
When turbocharger is rotated by hand, it is found to be heavy. q
If muffler is removed, unusual noise disappears. q
Troubleshooting

When compression pressure measured, it is found to be low. q
Check gear train. qq
Check fan and fan belt. q
Even if a cylinder is cut out, engine speed does not change. qq
Unusual noise is heard only when engine is cranked. q
Check the condition by using monitoring function of machine monitor. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Remedy
40-600 22 PC200, 200LC, 220, 220LC-8M0

S-16 Vibration is excessive SEN06140-00
S-16 Vibration is excessive
General causes why vibration is excessive Cause
Improper injection timing (Problem with coolant or boost temperature sensor)

q Defective parts (premature wear or breakage)
q Misalignment between engine snd hydraulic pump
q Abnormal combustion
a If unusual noise is made and vibration is excessive, perform troubleshooting also
for S-15 Unusual noise is made.
Worn main bearing and connecting rod bearing
Loose engine mount bolts or broken cushions

Stuck valve system (valve, rocker arm, etc.)
Misalignment of engine and hydraulic pump

Broken parts in damper chamber
Improper gear train backlash
Worn camshaft bushing
Machine opera-
Questions

tion hours
Suddenly increased. Q Q
Vibration
Gradually increased. Q Q Q
Oil other than specified one is used Q Q
Metal particles are found in the removed oil filter. w w
Metal particles are found in oil drained from oil pan. w w
Oil pressure is low at low idle. Q Q
Check items
Vibration occurs at mid-range speed. Q Q

Vibration follows engine speed. Q Q Q Q
Exhaust smoke is black. w Q
Check main bearing and connecting rod bearing. q
Troubleshooting
Check gear train. q

Check camshaft bushing. q
Check the condition by using monitoring function of machine monitor. q
Check engine mounting bolts and cushions. q
When radial runout and facial runout are checked, misalignment is found. q
Check inside of damper chamber. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
PC200, 200LC, 220, 220LC-8M0 40-600 23

SEN06140-00
2012 KOMATSU
All Rights Reserved
40-600 24
SEN06142-00
HYDRAULIC EXCAVATOR
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
50 Disassembly and assembly 1
100 General information on disassembly

and assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools .............................................................................................................................. 12
PC200, 200LC, 220, 220LC-8M0 50-100 1

100 General information on disassembly and assembly
SEN06142-00 How to read this manual
How to read this manual (Rev. 2009.1)1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In Removal section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2] etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in Removal section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this Installation section.
6:
model. They have a new part num-
Amount of oil or coolant to be drained
ber respectively.
R: Tools made available by redesign- 4: Weight of part or component
ing the existing tools which were
developed for other models. Each
of them has a new part number Installation
assigned by setting forward the q Unless otherwise instructed, installation of
part number of the existing tool. parts is to be done in the reverse order to
Blank : Tools already available for other removal.
models. They can be used without q Instructions and precautions for parts installa-
any modification. tion is shown with the mark ([*1], [*2]...) which
3) Circle mark Q in sketch column: corresponds to the mark in Removal section.
q The sketch of the special tool is pre- q Common tools that are necessary for installa-
sented in the section of Sketches of tion are described as [1], [2] etc. and their
special tools. part numbers, part names and quantities are
q Part No. of special tools starting with not described.
Marks shown in the Installation section stand
79 T-
* *** ****
- :
means that they are not available
q
for the following.
from Komatsu Ltd. (i.e. tools to be
made locally). k: Precautions related to work safety
a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
50-100 2 PC200, 200LC, 220, 220LC-8M0

How to read this manual SEN06142-00
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In Disassembly section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2] etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in Disas-
tuted and should always be used. sembly section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
6:
2) Distinction of new and existing special
Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num-
ber respectively. Assembly
R: Tools made available by redesign- q In Assembly section, the work procedures,
ing the existing tools which were precautions and know-how to do the work, and
developed for other models. Each the amount of oil and coolant to be replenished
of them has a new part number are described.
assigned by setting forward the q Common tools that are necessary for assem-
part number of the existing tool. bly are described as [1], [2] etc. and their
Blank : Tools already available for other part numbers, part names and quantities are
models. They can be used without not described.
any modification. q The meanings of the symbols used in Assem-
3) Circle mark Q in sketch column: bly section are as follows.
q The sketch of the special tool is pre-
sented in the section of Sketches of k : Precautions related to work safety
special tools. a : Guidance or precautions for the work
q Part No. of special tools starting with 2 : Type of coating material
3 : Tightening torque
* *** ****
79 T- - :
means that they are not available 5 : Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
PC200, 200LC, 220, 220LC-8M0 50-100 3

SEN06142-00 Coating materials list
Coating materials list 1

(Rev. 2009.08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
q Use to prevent rubber gaskets, rubber cushions,

LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropy-
20 g Polyethylene lene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.
Polyethylene q Features: Resistance to heat and chemicals.
LT-2 790-129-9040 50 g
container q Use to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Use to bond and seal metal, glass and plastics.
sive and hard- Hardener:
ener) 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g q Use to seal plugs for blank holes
container
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instantaneous adhesive.
ThreeBond Polyethylene q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Use mainly to bond metals, rubbers, plastics, and
woods.
q Instantaneous adhesive.
Aron-alpha Polyethylene q Quick-curing type (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes)
q Use mainly to bond rubbers, plastics, and metals.
q Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc q Use for fitted portions subjected to high tempera-
648-50 container
ture.
q Use to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container q Use to seal taper plugs, elbows, and nipples for
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube
q Use to seal flange surfaces and threaded portions.
Liquid gasket
q Use to seal oil pan, final drive case, etc.

q Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat and cold-resistant,
ThreeBond 419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the
ThreeBond 790-129-9310 200 g Tube
weld which must be caulked, etc.
1206D
q Can be coated with paint.
50-100 4 PC200, 200LC, 220, 220LC-8M0

Coating materials list SEN06142-00
Cate- Komatsu
gory code
LG-10 q Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket
1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steer-
1121 ing case etc.
ThreeBond
790-129-9090 100 g Tube q Liquid gasket used to repair engine.
1211
q Use to prevent galling and seizure of press-fitted
Molybdenum disulfide
portions, shrinkage-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
lubricant
q Use to lubricate linkages, bearings, etc.

q Spray type
q Thin molybdenum disulphide films are made on
09995-00250 190 g Can metal surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound
q Feature: Seizure and galling prevention com-

LC-G pound with metallic super-fine-grain, etc.
Seizure
NEVER- Can q Use for the mounting bolt in the high temperature
SEEZ area of the exhaust manifold and the turbocharger,
etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold brication performance, general purpose type.
SYG0-400LI-A
district
(*)
SYG0-160CNLI
(*)
q Use for parts under heavy load.
Molybde- Caution:
num disul- SYG2-400M 400 g 10 Bellows-type q Do not use this grease for rolling bearings like
fide grease SYG2-400M-A 400 g 20 container swing circle bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg Can q Use this grease for work equipment pins only
(G2-M) when installing them, but do not use it after-
ward.
SYG2-400T-A
Grease
Hyper White
SYG0-400T-A q Seizure resistance, heat resistance and water re-
G2-T, Bellows-type
(*) 400 g sistance higher than molybdenum disulfide
G0-T (*) container
SYG2-16CNT grease.
*: For cold 16 kg Can
SYG0-16CNT q Not conspicuous on machine since color is white.
district
(*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT
Bellows-type q Since this grease is biodegradable in short period,
*: For use at (*) 400 g
container it has less impact on microorganisms, animals,
high temper- SYGA-16CNB
16 kg Can and plants.
ature and SYGA-16CNBT
under high (*)
load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
PC200, 200LC, 220, 220LC-8M0 50-100 5

SEN06142-00 Coating materials list
Cate- Komatsu
gory code
q Feature: Urea (organic system) grease with heat
resistance and long life, can be packed into the
Grease
G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
20 ml
PRIMER tainer (Effective period: four months after date of
580 SUPER manufacture)
417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
20 ml (Effective period: four months after date of
For adhered window glass

PRIMER tainer
manufacture)
580 SUPER
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
Primer
22M-54-27230 20 ml
435-95 manufacture)
q Use as primer for black ceramic-coated
SUNSTAR
glass surface and for hard polycarbonate-
GLASS
22M-54-27240 150 ml Can coated surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
GP-402 manufacture)
SUNSTAR q Use "S" in high-temperature season and "W"
PENGUINE in low-temperature season as adhesive for
Polyethylene
SEAL580 417-926-3910 320 ml glass.
container
SUPER "S" (Effective period: four months after date of
Adhesive
or "W" manufacture)
Sika Japan, q Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
container
For adhered window glass
256HV manufacture)
SUNSTAR q Use as adhesive for glass.
Ecocart (Spe-
PENGUINE 22M-54-27210 320 ml (Effective period: six months after date of
cial container)
SUPER 560 manufacture)
SUNSTAR
q Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
Caulking material
2505
SEKISUI q Use to seal front window.
Polyethylene
SILICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE
q Use to seal glass-to-glass joint. Translucent
TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL
manufacture)
381
50-100 6 PC200, 200LC, 220, 220LC-8M0

Special tools list SEN06142-00
Special tools list 1
a Tools with part number 79 T-

tools to be made locally).
* *** **** - means that they are not available from Komatsu Ltd. (i.e.
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
Sketches of special tools).
Necessity
Sym-
Sketch
Work item Part number Part name Work content
bol
Q'ty
N/R
Installation of engine front oil
Engine front oil seal 1 795-799-6400 Seal puller t 1 N
seal
Installation of engine rear oil
Engine rear oil seal 2 795-799-6500 Seal puller t 1 N
seal
3 795-799-6700 Primer t 1 N Removal of fuel injector
Cylinder head assembly, Positioning with 3RD and
4 795-799-1131 Gear t 1
fuel injector assembly 4TH cylinder top
5 795-799-8150 Remover q 1 N Removal of inlet connector
Wrench
6 790-331-1120 q 1 Angle tightening of bolt
(Angle)
Cylinder head assembly
A Judgment of cylinder head
7 795-790-4510 Gauge q 1 N
bolt length
8 796T-401-1110 Plate q 1 N Q Removal and installation of
Engine and hydraulic
engine and hydraulic pump
pump assembly 9 795-790-9300 Lifting tool q 1 N assembly
Hydraulic pump assembly,
Engine and hydraulic 10 796-460-1210 Oil stopper q 1
pump assembly, Control Stopping oil
valve assembly, Center 11 796-770-1320 Adapter q 1
swivel joint assembly
Fuel supply pump Removal and installation of
12 795-799-6130 Support t 1
assembly gear
1 796T-426-1410 Push tool t 1 Q Press fit of main bearing
2 796-426-1120 Push tool t 1 Press fit of sub bearing
Swing motor and swing
F 796T-426-1130 Plate t 1 Q
machinery assembly
3 790-101-5421 Grip t 1 Press fit of oil seal
01010-81240 Bolt t 1
796-427-1400 Wrench assembly t 1 N
796-427-1410 Wrench 1 N Removal and installation of
Final drive assembly J 1
796-427-1140 Pin 3 nut
01314-20612 Screw 3
PC200, 200LC, 220, 220LC-8M0 50-100 7

SEN06142-00 Special tools list
Necessity
Sym-
Sketch
bol
Q'ty
N/R
796T-427-1510 Push tool t 1 N Q
790-101-2510 Block t 1
790-101-3310 Block t 1
790-101-2610 Rod t 2
790-101-2730 Adapter t 2
2 Installation of bearing
01580-11613 Nut t 2
790-101-2570 Plate t 2
01643-31645 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
3 796-427-1520 Installer t 1 N Installation of floating seal
Removal and installation of
4 796-427-1400 Wrench assembly t 1
Final drive assembly J ring nut
5 796-427-1520 Installer t 1 Installation of floating seal
796T-427-1510 Push tool t 1 Q
790-101-2510 Block t 1
790-101-3310 Plate t 1
790-101-2610 Leg t 2
790-101-2730 Adapter t 2
6 Installation of hub assembly
01580-11613 Nut t 2
790-101-2570 Plate t 2
01643-31645 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
7 790-331-1110 Wrench t 1 Angle tightening of bolt
Carrier roller assembly 1 790-434-1660 Installer t 1
Track roller assembly L 2 796-670-1020 Installer t 1 Installation of floating seal
Idler assembly 3 791-530-1510 Installer t 1
50-100 8 PC200, 200LC, 220, 220LC-8M0

Necessity
Sym-
Sketch
bol
Q'ty
N/R
791-600-2001 Compressor (A) t 1
or
791-685-8006 Compressor (B) t 1
790-201-2780 Spacer t 1
1 791-635-3160 Extension t 1
Cylinder
790-101-1600 t 1
(686 kN {70 ton})
790-101-1102 Pump t 1
790-640-2180 Guide bolt t 1 Disassembly and assembly
Recoil spring assembly M
of recoil spring assembly
790-101-5201 Push tool kit (B) q 1
790-101-5241 Plate 1
2
790-101-5221 Grip 1
01010-51225 Bolt 2
790-201-1500 Push tool kit q 1
790-201-1620 Plate 1
3
790-101-5021 Grip 1
01010-50816 Bolt 1
791-630-3000 Remover and installer t 1
Cylinder Separation and installation of
Track shoe assembly R 790-101-1300 t 1
(980 kN {100 ton}) track shoe assembly
790-101-1102 Pump t 1
1 796T-467-2410 Push tool t 1 N Q Press fit of input shaft oil seal
2 796T-416-1010 Push tool t 1 N Q
Hydraulic pump assembly S Press fitting of bushing
3 796T-416-1030 Push tool t 1 N Q
4 796T-416-1020 Push tool t 1 N Q Press fitting of pin
790-101-2501 Push puller q 1
790-101-2510 Block 1
790-101-2520 Screw 1
791-112-1180 Nut 1
Disassembly and assembly
Center swivel joint
T 1 790-101-2540 Washer 1 of center swivel joint
assembly
assembly
790-101-2630 Leg 2
790-101-2570 Plate 4
790-101-2560 Nut 2
790-101-2650 Adapter 2
PC200, 200LC, 220, 220LC-8M0 50-100 9

SEN06142-00 Special tools list
Necessity
Sym-
Sketch
bol
Q'ty
N/R
796-946-1310 Guide f21.8 mm
t 1
(For 723-46-40100)
796-946-1610 Guide f21.4 mm
t 1
(For 723-46-41100)
796-946-1810 Guide f21.2 mm
2 t 1
(For 723-46-43100 and 723-46-43400)
796-946-1910 Guide f21.0 mm
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2210 Guide f20.6 mm
t 1
(For 723-46-45100 and 723-46-45700)
796-946-1320 Guide f21.8 mm
t 1
(For 723-46-40100)
796-946-1620 Guide f21.4 mm
t 1
(For 723-46-41100)
796-946-1820 Guide f21.2 mm
t 1
(For 723-46-43100 and 723-46-43400)
3
796-946-1920 Guide f21.0 mm Replacement of pressure
Control valve assembly T t 1
(For 723-46-46101 and 723-46-46300) compensation valve seal
796-946-2220 Guide f20.6 mm
t 1
(For 723-46-45100)
796-946-1420 Guide f21.6 mm
t 1
(For 723-46-42700)
796-946-1330 Sleeve
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
t 1
(For 723-46-43100 and 723-46-43400)
4
796-946-1930 Sleeve
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)
50-100 10 PC200, 200LC, 220, 220LC-8M0

Necessity
Sym-
Sketch
bol
Q'ty
N/R
790-502-1003 Cylinder repair stand q 1 Disassembly and assembly
1 of hydraulic cylinder
790-101-1102 Pump q 1 assembly
790-102-4300 Wrench assembly t 1 Removal and installation of
2
790-102-4310 Pin t 2 piston assembly
3 790-720-1000 Expander q 1
Rubber band
796-720-1670 q 1
(for boom and arm)
07281-01279 Clamp q 1 Installation of piston ring
4
Rubber band
796-720-1680 q 1
(for bucket)
07281-01589 Clamp q 1
Hydraulic cylinder 790-201-1702 Push tool kit t 1
U
assembly Push tool
790-201-1841 1
(for boom and bucket)
5 Push tool Press fit of bushing
790-201-1851 1
(for arm)
790-101-5021 Grip 1
01010-50816 Bolt 2
790-201-1500 Push tool kit q 1
Push tool
790-201-1650 1
6 Plate Press fit of dust seal
790-201-1660 1
(for arm)
790-101-5021 Grip 1
01010-50816 Bolt 2
796-900-1200 Remover t 1
796-900-1210 Sleeve 1
792-900-1520 Plate 1
799-900-1230 Screw 1
Work equipment 796-900-1240 Adapter 1
V Removal of foot pin
assembly
01643-33080 Washer 1
01803-13034 Nut 1
Puller
790-101-4000 t 1
(490 kN {50 ton} long)
790-101-1102 Pump (294 kN {30 ton}) t 1
Operator cab glass 2 793-498-1210 Lifter (Suction cup) t 2 Installation of operator cab
X
(stuck glass) 3 20Y-54-13180 Stopper rubber t 2 glass (stuck glass)
Commercially
Impact wrench q 1 Removal and installation of
available
Counterweight assembly Z the counterweight mounting
Commercially Socket wrench bolt
q 1
available (width across flats: 41 mm)
PC200, 200LC, 220, 220LC-8M0 50-100 11

SEN06142-00 Sketches of special tools
Sketches of special tools 1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A8 Plate
F1 Push tool
50-100 12 PC200, 200LC, 220, 220LC-8M0

Sketches of special tools SEN06142-00
F3 Plate
J2, J6 Push tool
PC200, 200LC, 220, 220LC-8M0 50-100 13

SEN06142-00 Sketches of special tools
S1 Push tool
S2 Push tool
50-100 14 PC200, 200LC, 220, 220LC-8M0

Sketches of special tools SEN06142-00
S3 Push tool
S4 Push tool
PC200, 200LC, 220, 220LC-8M0 50-100 15

SEN06142-00

2012 KOMATSU
All Rights Reserved
50-100 16
SEN06143-00
HYDRAULIC EXCAVATOR
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 6
Removal and installation of engine front oil seal........................................................................................... 13
Removal and installation of engine rear oil seal ........................................................................................... 18
Removal and installation of cylinder head assembly .................................................................................... 21
Removal and installation of radiator assembly ............................................................................................. 36
Removal and installation of hydraulic oil cooler assembly ............................................................................ 38
Removal and installation of aftercooler assembly......................................................................................... 40
Removal and installation of fuel cooler assembly ......................................................................................... 43
Removal and installation of engine and hydraulic pump assembly .............................................................. 44
PC200, 200LC, 220, 220LC-8M0 50-200 1

SEN06143-00 Removal and installation of fuel supply pump assembly
Removal and installation of fuel 7. Disconnect fuel return hose (4). [*1]
supply pump assembly 1
Special tools
Necessity
Symbol
Part number Part name
Qty
A 12 795-799-6130 Support t 1
Removal
k Park the machine on a level ground, lower
the work equipment to the ground stably,
and stop the engine. 8. Remove fuel filter and bracket assembly (5).
k Disconnect the cable from the negative ()
terminal of the battery.
1. Turn the upper structure by 90.
2. Remove the cover under the fuel tank (B section).
3. Close the fuel stop valve.
9. Disconnect connector CP3 (6).
10. Disconnect fuel supply hose (7).
5. Open the engine hood.
6. Disconnect fuel filter hoses (2) and (3) from

fuel supply pump (16). [*1]
a Remove dirt on the connector in advance.
(Because dirt sometimes makes lock (L) fit
tight.)
a Pull out the hose while pushing lock (L)
from both sides.
a When disconnecting the hose, fuel will
flow out. Plug the fitting of the hose to pre-
vent fuel from flowing out. (Place an oil
container below.)
50-200 2 PC200, 200LC, 220, 220LC-8M0

Removal and installation of fuel supply pump assembly SEN06143-00
11. Remove bellows (8). [*2] 17. Remove 3 nuts (A parts) and remove fuel injec-
tion pump assembly (16). [*4]
12. Disconnect high-pressure pipe (9). [*2]
a Fuel injection pump assembly (16) comes

13. Disconnect 2 tube clamps (10). [*2] off in one piece with the gear. No treat-
ment (tooth extraction etc.) has been
given to the gear teeth for aligning the 1st
and 6th cylinder tops.
14. Disconnect fuel return tube (11). [*3]
15. Remove bellows (15). [*2]

18. When disassembling the fuel pump drive gear
16. Disconnect tube (9). [*2] from the fuel supply pump, follow the proce-
dure described below. [*5]
1) Use a support A12 and a 1/2 inch spinner
handle [1] to retain the gear, then loosen
the nut (18).
a Do not remove the nut (18) from the
shaft.
PC200, 200LC, 220, 220LC-8M0 50-200 3

SEN06143-00 Removal and installation of fuel supply pump assembly
2) Install a puller [2] between the flange and Installation

gear (19). q Installation is done in the reverse order of
3) Install a puller [3] onto the puller [2] and removal.
the shaft.
4) Rotate the center bolt [4] until the gear is a Figure: Refer to Removal.
separated from the shaft. [*1]
5) Remove the pullers [2], [3]. a The internal parts of the hose adapter may be
damaged when the hose is removed. Accord-
ingly, do not reuse the adapter but use new
one when installing the hose again, as a rule.
[*2]
q How to install high-pressure pipe (9)
1. Tighten the sleeve nuts by hand. (both sides)
2. Tighten the sleeve nuts in the order of firstly
the pump side, then the common rail side.
3 Sleeve nut:
35 3.5 Nm {3.57 0.36 kgm}
3. Install 2 tube clamps (10).
3 Clamp mounting bolt:
24 4 Nm {2.45 0.41 kgm}
4. Install bellows (8) and (15).
a Set the slits of each bellows out and down.
a The bellows are installed so that fuel will
not spout over the hot parts of the engine
and catch fire when it leaks for some rea-
son.
[*3]
3 Fuel return tube (11) mounting bolt:
24 4 Nm {2.45 0.41 kgm}
[*4]
a If too much grease is applied to O-ring (17), it
6) Remove the nut (18), lock washer (20), will ooze out. Accordingly, do not apply grease
and gear (19) from the shaft (21). so much. (Apply grease to the O-ring groove
area of part A.)
a When installing new fuel supply pump mount-
ing stud bolts (SB) to replace the existing ones,
apply LOCTITE to them.
3 Fuel supply pump mounting nut:
24 4 Nm {2.45 0.41 kgm}
50-200 4 PC200, 200LC, 220, 220LC-8M0

Removal and installation of fuel supply pump assembly SEN06143-00
[*5]
q How to install the gear (19)
a The shaft (21) and gear (19) mating face must
be clean (without dirt or foreign material) and
dry prior to assembly.
1. Install the gear (19) onto the shaft (21).
2. Install the lock washer (20) and nut (18) and

finger tighten.
3. Use the support A12 and 1/2 inch spinner han-

dle [1] to hold the gear in place while tightening
the nut (18).
3 Mounting nut of fuel supply pump gear:
105 5 Nm {10.7 0.51 kgm}
q Air bleeding
Bleed air from the fuel injection system.
a Refer to the "Testing and adjusting" chapter.
PC200, 200LC, 220, 220LC-8M0 50-200 5

SEN06143-00 Removal and installation of fuel injector assembly
Removal and installation of fuel a When removing head cover (9), take care
injector assembly 1
not to hit it against the peripheral parts.
Special tools
Necessity
Symbol
Qty
3 795-799-6700 Primer t 1
A 4 795-799-1131 Gear t 1
5 795-799-8150 Remover q 1
a In the case of exchanging fuel injector assem-

bly, exchange inlet connector, too. (See Instal-
lation item 1. 6))
3. Remove twelve wiring harness nuts (11) from
Removal six fuel injectors (10). [*2]
the work equipment to the ground stably, 4. Remove the three connectors of engine wiring
and stop the engine. harness (12). [*3]
k Disconnect the cable from the negative () a Pull out each connector while pressing the
terminal of the battery. lock stopper. At this time, hold the gasket
with the hand to prevent it from moving.
1. Remove clamp (7) of wiring harness (10) and
two bands (7a). 5. Lift up and remove gasket assembly (13).
a When removing the gasket, take care that
foreign material does not enter the engine.
a When removing head cover (9), check
gasket assembly (13) visually. If gasket
assembly (13) is cracked, deteriorated, or
worn, replace it with a new one.
2. Remove five head cover mounting bolts (8) to

remove head cover (9). [*1]
a After loosening head cover mounting bolts
(8), remove mud and foreign material
sticking around the head cover by blowing
air while holding the head cover with the
hand in order to prevent entry of mud and
foreign material.
50-200 6 PC200, 200LC, 220, 220LC-8M0

Removal and installation of fuel injector assembly SEN06143-00
6. Remove cap (14) of high-pressure pipe (15). 9. Remove crossheads (19).

a Record the installed position and direction
7. Disconnect six high-pressure pipes (15) from (shapes of holes (a) and (b)) of each
the cylinder head. [*4] crosshead. (When reassembling, install
a Remove the cap on the common rail side, the crosshead in the recorded direction)
as well, and loosen the sleeve nut.
a Do not remove fuel pressure sensor (10a)
for any purpose other than replacement.
[*5]
8. Remove the mounting bolts to remove rocker

arms (16).
a Loosen locknut (17) and loosen adjust-
ment screw (18) two to three turns so that
an excessive force is not applied to the
push rod when the rocker arm is installed.
10. Remove retainer (20) and remove inlet con-

nector (21).
a Remove mud and dirt sticking around the
inlet connector in advance so that they do
not enter the hole of the inlet connector.
a Tool A5 is provided to remove inlet con-
nector (21).
PC200, 200LC, 220, 220LC-8M0 50-200 7

11. Remove mounting bolts (23) of fuel injector Installation

assembly (22). 1. Fuel injector assembly
When replacing a fuel injector assembly with a
new one, be sure to replace the inlet connector
with a new one as well.
a Check that the fuel injector sleeve is free
from flaws and dirt.
1) Fit O-ring (24) and gasket (25) to fuel
injector (22).
2) Apply engine oil (EO15W-40) to the O-ring
of fuel injector (22) and the mounting hole
on the head.
3) Install holder (26), while setting its con-
cave part (C) to convex part (A) of fuel
injector (22).
12. By using tool A2, remove fuel injector assem-

bly (22).
a Do not pry up the injector top.
a Take care that dirt and foreign material do
not enter the fuel injector assembly
mounting area.
4) Insert fuel injector (22) in the cylinder

head, while directing its fuel inlet hole
toward the air intake manifold.
5) Tighten mounting bolts (23) of fuel injector
(22) by 3 to 4 turns.
a When replacing the fuel injector

assembly with a new one, be sure to
replace the inlet connector with a new
one as well.
50-200 8 PC200, 200LC, 220, 220LC-8M0

6) Check the inlet connector visually. If it has 7) Apply engine oil (EO15W-40) to the
any of the following faults, replace it with a mounting hole of inlet connector (21) on
new one. the head.
1] There is a burr or a worn part at front 8) Apply engine oil (EO15W-40) to O-ring
end (a) or rear end (b) of the inlet (24) of inlet connector (21) and insert inlet
connector. connector (21) fully into the head while
2] There is foreign material in the edge matching part (B) with the groove in the
filter at rear end (c) of the inlet con- head.
nector.
3] The O-ring at upper part (d) of the
inlet connector is cracked or deterio-
rated.
9) Tighten inlet connector (21) lightly by

using retaining nut (20). (Push into the
hole of the injector)
3 Retaining nut:
4] There is a worn part or an uneven 15 5 Nm {1.5 0.5 kgm}
seat contact mark on sealing surface 10) Tighten mounting bolts (23) of fuel injector
(e) at the front end of the inlet con- (22) alternately.
nector. 3 Fuel injector mounting bolt:
a If high-pressure fuel leaks through 8 0.8 Nm {0.8 0.08 kgm}
the inlet connector, the sealing 11) Tighten retaining nut (20).
surface has fine streaks or cracks. 3 Retaining nut:
50 5 Nm {5.1 0.5 kgm}
PC200, 200LC, 220, 220LC-8M0 50-200 9

2. Crosshead and rocker arm q Perform the subsequent installation in the

1) Install the crosshead and rocker arm. reverse order to removal.
a Since the hole shapes at parts "a"
and "b" of each crosshead are differ- [*1]
ent, install them to their respective 3 Head cover mounting bolt:
intake and exhaust valves in the origi- 24 4 Nm {2.4 0.4 kgm}
nal directions. [*2]
3
a Check that the spherical portion of Fuel injector wiring harness nut:
adjustment screw (18) is fitted prop- 1.5 0.25 Nm {0.15 0.025 kgm}
erly in the socket of the push rod, and a Check the wiring harness that does not
then tighten the mounting bolt. interfere with the rocker arm.
3 Rocker arm mounting bolt:
36 5 Nm {3.7 0.5 kgm}
[*3]
k
2) Adjust the valve clearance. For details, see Install each high-pressure pipe and wiring
Testing and adjusting, "Adjusting valve harness at least 10 mm apart from each other.
clearance".
3 Lock nut (17):
[*4]
20 to 28 Nm {2.04 to 2.86 kgm} q High-pressure pipe
k Do not bend the fuel high-pressure pipe to
collect before installing.
k Be sure to use the Komatsu genuine high-
p r e s s u r e p i p e c l a m ps a n d o b s e r v e t h e
specified tightening torque.
a Before installing the high-pressure pipe, check
it for the following. If the high-pressure pipe
has any defect, replace it with a new one since
fuel may leak.
q Check that the taper seal part (part "a": area of
2 mm from end) of the joint portion is free of
visible lengthwise slit "b" and dent "c".
q Check that part "d" (end of taper seal part: part
at 2 mm from end) is free of stepped wear
(fatigue) felt with a fingernail.
50-200 10 PC200, 200LC, 220, 220LC-8M0

1. Install and fasten lightly high pressure-pipes [*5]

(25) to (30) between common rail (24) and q Fuel pressure sensor and relief valve
cylinder head. 1) Replace fuel pressure sensor (2), if neces-
3 Sleeve nut: sary, according to the following procedure.
0.2 to 0.8 Nm {0.02 to 0.08 kgm} a Do not remove fuel pressure sensor
(2) from common rail (1) unless
2. Fasten high-pressure pipes (25) to (30) replacement of the sensor is neces-
according to the following procedure. sary.
3 Sleeve nut:
a Once the fuel pressure sensor is
35 3.5 Nm {3.6 0.4 kgm} removed from the common rail, be
1) Cylinder head side of high-pressure pipes sure to replace it with a new one.
(25) and (30) 1] Before removing the fuel pressure
2) Common rail side of high-pressure pipes sensor, clean around it to remove
(30) and (25) mud, etc. thoroughly.
3) Cylinder head side of high-pressure pipes 2] Remove the fuel pressure sensor.
(26), (27), (28), and (29) in order 3] Check the fuel pressure sensor con-
4) Common rail side of high-pressure pipes nector for crack, breakage, damage
(26), (27), (28), and (29) in order of the seal, foreign material on the
pin, and corrosion, bend, and break-
age of the pin.
4] Install a new fuel pressure sensor.
2 Threaded portion of fuel pressure
sensor:
Gear oil (#90)
3 Fuel pressure sensor:
70 5 Nm {7.1 0.5 kgm}
5] Connect the engine wiring harness.
At this time, take care not to connect
reversely.
6] Start the engine and check that there
is no leakage.
For the testing procedure, see Testing
and adjusting, "Testing fuel system for
3. Install the cap to each high-pressure pipe.
leakage".
a Install each cap with the slits out and
down.
a The cap is installed for fire prevention and is
expected to prevent fuel from flying directly
to highly heated portions of the engine if fuel
leaks.
PC200, 200LC, 220, 220LC-8M0 50-200 11

2) Replace relief valve (3), if necessary,

1] Before removing the relief valve,
remove dirt around the valve thor-
oughly.
2] Remove the relief valve.
3] If the leakage through the relief valve
exceeds the specified value, do not
reuse the relief valve.
4] Check that there is no damage on
high-pressure sealing surfaces (A) on
the relief valve and common rail.
5] Install the relief valve.
2 Threaded portion of relief valve:
Gear oil (#90)
3 Relief valve:
100 4 Nm {10.2 0.4 kgm}
Take care not to tighten exces-
sively. Excessive tightening can
cause leakage.
6] Start the engine and check that there
is no leakage.
For the testing procedure, see Testing
and adjusting, "Checking fuel system
for leakage".
50-200 12 PC200, 200LC, 220, 220LC-8M0

Removal and installation of engine front oil seal SEN06143-00
Removal and installation of a Hydraulic oil cooler hoses (5a) and (5b)
engine front oil seal 1
have already been removed at 2. above
Special tools
Necessity
Symbol
Qty
1 795-799-6400 Seal puller t 1
A Wrench
6 790-331-1120 q 1
(Angle)
Removal
1. Remove the radiator assembly referring to the
section of "Removal and installation of radiator
assembly".
2. Remove the hydraulic oil cooler assembly

referring to the section of "Removal and instal-
lation of hydraulic oil cooler assembly".
3. Remove the aftercooler assembly referring to

the section of "Removal and installation of
aftercooler assembly".
4. Remove mounting bolts for air conditioner con-

denser (1) and put aside air conditioner con-
denser (1).
5. Remove bracket (2).

8. Remove fan guards (6), (6a) and (7).
7. Remove nets (4) and (5).
PC200, 200LC, 220, 220LC-8M0 50-200 13

SEN06143-00 Removal and installation of engine front oil seal
9. Remove fan (8). [*1] 14. Remove 6 mounting bolts and remove vibra-
tion damper (13).
10. Loosen air conditioner compressor bracket
adjustment bolts (9).
a There is another bolt behind.
11. Move air conditioner compressor assembly

(10).
12. Remove air conditioner compressor drive belt

(11). [*2]
15. Remove dust seal (17).
13. Remove fan belt (12) as follows. [*3]

q Insert a wrench to the portion (A) (width
across flats T 12.7 mm) of the tensioner
assembly (16), and rotate it to the oppo-
site to the winding-up direction (R) to
decrease the fan belt (12) tension, then
remove. 16. Remove oil seal (14).
at the portion (A) before rotating it.
(The spring of the tensioner assembly
(16) is strong. If the wrench is loosely
care.
(12) during work.
50-200 14 PC200, 200LC, 220, 220LC-8M0

17. Remove engine front oil seal (14) according to Installation

the following procedure. 1. Install front oil seal (14) using tool A1.
1) Install tool A1 to crankshaft. a Before installing the seal, check that the
2) Screw in tapping screw [1] of tool A1 to end corners and lip sliding surfaces of the
seal carrier part of engine front oil seal crankshaft are free from flaw, burr, and
(14). rust of the housing.
3) Rotate the handle clockwise to remove a When installing the seal, do not apply oil,
engine front oil seal (14). grease, etc. to the shaft and seal lip. Also,
wipe off grease from the shaft completely.
a Take care not to damage the crankshaft

while removing the seal. a From cover (C) of oil seal (14)
q Extrusion (x): less than 0.38 mm
q Facial runout (y): less than 0.25 mm
PC200, 200LC, 220, 220LC-8M0 50-200 15

SEN06143-00 Removal and installation of engine front oil seal
2. Install dust seal (17). a When angle tightening tool A6 is not

a Check the installed dimension (L). used
Installed dimension (L): 12 +0.1/0 mm 5] After above steps 1] to 3] are finished,
put a paint mark across vibration
damper (13) and mounting bolts.
6] Retighten the bolts by 90 5 degrees.
3. Vibration damper
1) Match dowel pin (a) to dowel pin hole, and
install vibration damper (13).
2) Tighten mounting bolts (15) according to
1] Tighten the bolts diagonally with a
torque of 55 5 Nm {5.6 0.5 kgm}.
2] Loosen bolts by 180 degrees.
3] Tighten the bolts diagonally with a
torque of 55 5 Nm {5.6 0.5 kgm}.
4] Using tool A6 and retighten the bolts
by 90 5 degrees.
50-200 16 PC200, 200LC, 220, 220LC-8M0

q Carry out the rest of installation in the reverse

order to removal.
[*1]
3 Fan mounting bolt:
43 6 Nm {4.4 0.6 kgm}
[*2]
a Refer to the "Checking and adjusting air condi-
tioner compressor belt tension" section in the
Testing and adjusting chapter in this manual.
[*3]
a Install fan belt (12) as follows.
assembly (16), and rotate it to the oppo-
site to the winding-up direction (R) to
install the fan belt (12).
(16) is strong. If the wrench is loosely
k After installing the fan belt (12), return
care.
(12) during work.
PC200, 200LC, 220, 220LC-8M0 50-200 17

SEN06143-00 Removal and installation of engine rear oil seal
Removal and installation of 6. Lift off flywheel assembly (4) to remove it. [*2]
engine rear oil seal 1 4 Flywheel assembly: 35 kg
Special tools
Necessity
Symbol
Qty
A 2 795-799-6500 Seal puller t 1
Removal
1. Remove the hydraulic pump assembly refer-
ring to the section of "Removal and installation
of hydraulic pump assembly".
2. Remove mounting bolt (1) and set guide bolt 7. Remove oil seal (5) as follows.
[1]. 1) Set tool A2 to crankshaft.
2) Install tapping screw [1] of the tool A2 to
3. Remove damper assembly (2). seal carrier of rear oil seal.
a Remove rear oil seal (5) not to break
the crankshaft.
4. Remove mounting bolt (3) and insert guide

bolts [2]. [*1]
a Width across flats: 18 mm
5. Lift temporarily flywheel assembly (4) and pull

out flywheel assembly (4).
a Be careful not to let the guide bolts drop
out.
50-200 18 PC200, 200LC, 220, 220LC-8M0

Removal and installation of engine rear oil seal SEN06143-00
Installation 4. Install oil seal (5) on flywheel housing (7) to the

1. Install the oil seal according to the following proper depth by using tool A2.
procedure. a Push in oil seal (5) taking care that there
a Do not remove pilot [5] which is attached are no bend etc. on it.
to oil seal (5) until oil seal (5) is inserted to a Extrusion of oil seal (5) from flywheel
the crankshaft. housing (7)
a Before installing the oil seal, degrease, (X): less than 0.38 mm
clean and dry the crankshaft sealing face
and the seal lip face to prevent oil leak-
age.
2. Insert pilot [5] to crankshaft (6) and push oil

seal (5) into flywheel housing (7).
3. Push in oil seal (5) further and pull out pilot [5].
PC200, 200LC, 220, 220LC-8M0 50-200 19

SEN06143-00 Removal and installation of engine rear oil seal
q Carry out the rest of installation in the reverse q Measurement of facial runout
order to removal. a Facial runout: less than 0.20 mm
1) As in the case of measurement of facial
[*1] runout, bring the dial gauge probe into
a Tighten the 8 flywheel mounting bolts in the contact with end surface (b) near the outer
order of (1) through (8) as shown in the figure perimeter of the flywheel at a right angle.
below. a Conduct measurement pulling the
3 Flywheel assembly mounting bolt: crankshaft to either the front or rear
137 7 Nm {13.97 0.71 kgm} side to prevent errors caused by
shakiness.
2) Rotate the flywheel 360 and measure the
difference of the maximum swing of the
dial gauge indicator.
a Tighten the bolts using plate [3] for preventing

rotation of the flywheel assembly.
[*2]
q Measurement of radial runout
a Radial runout: less than 0.13 mm
1) Set dial gauge [4] to the stand, and set it
to flywheel housing (7).
2) Bring the dial gauge probe into contact
with faucet joint portion (a) or the outer
perimeter surface of the flywheel at a right
angle.
3) Rotate the flywheel 360 and measure the
difference of the maximum swing of the
dial gauge indicator.
a Check that the dial gauge indicator is
back in the original position after the
flywheel is rotated 360.
50-200 20 PC200, 200LC, 220, 220LC-8M0

Removal and installation of cylinder head assembly SEN06143-00
Removal and installation of 4. Disconnect fuel filter hoses (2) and (3) from
cylinder head assembly 1
fuel supply pump (FSP). [*1]
a Remove dirt on the connector in advance.
(Because dirt sometimes makes lock (L) fit
Special tools tight.)
a Pull out the hose while pushing lock (L)
Necessity
Symbol
from both sides.

Qty
5. Disconnect fuel return hoses (4) and (4a). [*1]
3 795-799-6700 Primer t 1
4 795-799-1131 Gear t 1 6. Remove fuel filter and bracket assembly (5).
A 5 795-799-8150 Remover q 1
6 790-331-1120 Wrench (Angle) q 1
7 795-790-4510 Gauge q 1
Removal
2. Drain the engine coolant.

6 Coolant: 20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
3. Remove the following referring to the section

of "Removal and installation of engine and
hydraulic pump assembly", steps 5 to 20 in
"Removal".
q Engine hood
q Top cover on control valve
q Cover between hydraulic pump and en-
gine
q Frame between control valve and engine
q Cover between control valve and engine
a The frame between the control valve and
the engine should be kept installed as a
foothold.
PC200, 200LC, 220, 220LC-8M0 50-200 21

SEN06143-00 Removal and installation of cylinder head assembly
8. Remove clamp (7).
9. Remove the mounting bolt and lift off muffler

assembly (8) to remove it. [*2]
4 Muffler assembly: 19 kg
14. Disconnect ambient pressure sensor (14) and

boost pressure sensor connector (15).
10. Remove hose (10). [*3]

a MIKALOR clamp
a Mark the hose edge and tube to show the
original hose installation positions. (See
figure below.)
a If disconnecting air intake connector (C),
replace the gasket.
11. Disconnect radiator hoses (11). [*4]
a When disconnecting ambient pressure sen-
12. Disconnect heater hose (12). sor connector (14), move the lock to right
(R) and pull out the connector while press-
13. Remove fan guard (13). ing stopper (T).
a Move wiring harness to the left.
50-200 22 PC200, 200LC, 220, 220LC-8M0

15. Disconnect coolant temperature sensor con- 22. Remove clamp (25a) from the cylinder block
nector (17). and disconnect high-pressure pipe (25b). [*11]
a FSP: Fuel supply pump
a Remove the bellows from the sleeve nut
portions.
16. Disconnect fuel pressure sensor connector

(18).
17. Remove fuel return hose (19) from common 23. Remove protection cover (26).
rail (20) and cylinder head rear surface. [*5]
24. Loosen air tube clamp (27). [*12]
18. Remove the two clamps of high-pressure pipe
(21) between the common rail and fuel supply 25. Loosen hose clamp (28). [*13]
pump. [*6]
19. Remove cap (22) and remove high-pressure

pipe (21). [*7]
20. Remove caps (23) and remove six high-pres-

sure pipes (24). [*8]
21. Remove common rail (20). [*9]

a Do not remove fuel pressure sensor and
relief valve (25) for any purpose other than
replacement. [*10]
PC200, 200LC, 220, 220LC-8M0 50-200 23

26. Disconnect lubrication inlet tube (29) and lubri- 30. Remove fan (32). [*17]
cation outlet tube (30). [*14] a Keep the fan dropped down.
a When loosening the lubrication inlet hose
mounting nut, fix the connector with a
spanner to prevent it from being dragged.
27. Remove all the mounting bolts for exhaust

manifold (31) except a few pieces. [*15]
31. Loosen air conditioner compressor bracket

mounting bolts (33) and (34).
32. Remove air conditioner compressor drive belt

(35). [*18]
28. Lift temporarily exhaust manifold and turbo- 33. Disconnect connector AC02 (36).
charger assembly (80), and remove the
remaining mounting bolts. [*16] 34. Remove air conditioner compressor assembly
(37).
29. Lift off exhaust manifold and turbocharger a Remove air conditioner compressor as-
assembly (80) to remove it. sembly in one piece with the bracket and
4
put them on the counterweight.
Exhaust manifold and turbocharger
assembly: 25 kg
50-200 24 PC200, 200LC, 220, 220LC-8M0

35. Remove fan belt (38) from alternator (39) as 39. Remove five head cover mounting bolts (45) to
follows. [*19] remove head cover (46) together with blowby
q Insert a wrench to the portion (A) (width duct (47).
across flats T 12.7 mm) of the tensioner a After loosening head cover mounting bolts
assembly (38a), and rotate it to the oppo- (45), remove mud and foreign material
site to the winding-up direction (R) to sticking around the head cover by blowing
decrease the fan belt (38) tension, then air while holding the head cover with the
remove. hand in order to prevent entry of mud and
k Make sure that the wrench is secured foreign material.
at the portion (A) before rotating it. a When removing head cover (46), take
(The spring of the tensioner assembly care not to hit it against the peripheral
(38a) is strong. If the wrench is loosely parts.
inserted, the wrench may accidentally 40. Remove blowby duct (47) from head cover
come off while being rotated and it is (46). Remove fuel return tube (46a).
extremely dangerous.) 41. Remove fuel return tube (46a).
the tensioner assembly (38a) slowly
with care.
(38) during work.
36. Disconnect connectors AB (40) and E12 (41).
37. Remove alternator (39).
42. Remove twelve wiring harness nuts (49) from

six fuel injectors (48).
43. Remove the three connectors of engine wiring

harness (50). [*20]
a Pull out each connector while pressing the
lock stopper. At this time, hold the gasket
with the hand to prevent it from moving.
44. Lift up and remove gasket assembly (51).

a When removing the gasket, take care that
38. Remove clamp (43) and two bands (44) of wir- foreign material does not enter the engine.
ing harness (42). a When removing head cover (46), check
gasket assembly (51) visually. If gasket
assembly (51) is cracked, deteriorated, or
worn, replace it with a new one.
PC200, 200LC, 220, 220LC-8M0 50-200 25

45. Remove the mounting bolts to remove rocker 47. Remove retaining nut (56) and remove inlet
arms (52). connector (57).
a Loosen locknut (53) and loosen adjust- a Remove mud and dirt sticking around the
ment screw (54) two to three turns so that inlet connector in advance so that they do
an excessive force is not applied to the not enter the hole of the inlet connector.
push rod when the rocker arm is installed. a Tool A5 is provided to remove inlet con-
nector.
46. Remove crossheads (55).

a Record the installed position and direction 48. Remove mounting bolts (59) of fuel injector
(shapes of holes (a) and (b)) of each assembly (58).
crosshead. (When reassembling, install
the crosshead in the recorded direction)
50-200 26 PC200, 200LC, 220, 220LC-8M0

49. By using tool A3, remove fuel injector assem- Installation

bly (60). 1. Cylinder head assembly
a Do not pry up the injector top. 1) Measure stem length "a" of mounting bolt
a Take care that dirt and foreign material do for every cylinder head and check that it is
not enter the fuel injector assembly less than the using limit.
mounting area. q Using limit length of bolt: Below
132.1 mm
a If a bolt is longer than the using limit,
do not reuse it but replace it.
50. Remove push rod (61).
2) Set cylinder head gasket (64) on the cylin-

der block.
a Check that the cylinder head mount-
ing face and inside of the cylinder are
free of dirt and foreign material.
a Check that the cylinder head gasket
is matched with the holes on the cyl-
inder head.
3) Sling cylinder head assembly (63) and set
it on the cylinder block, and then finger-
tighten mounting bolts (62) at least two to
three turns.
51. Remove mounting bolts (62), and then sling
and remove cylinder head assembly (63).
3 Cylinder head assembly: 75 kg
52. Remove cylinder head gasket (64).
PC200, 200LC, 220, 220LC-8M0 50-200 27

4) Tighten the cylinder head mounting bolts 2. Install push rods (61).
in the order from [1] to [26] according to
2 Apply engine oil (EO15W-40) to the
threaded portion and seat surface
of each cylinder head mounting
bolt.
1] Tighten bolt to 90 3 Nm {9.2 0.3
kgm}.
2] Confirm that the bolt is tightened to
the torque of 90 3 Nm {9.2 0.3
kgm}.
3] Using tool A6 and retighten the bolts
by 90 5 degrees.
3. Fuel injector assembly

a When replacing the fuel injector assembly
with a new one, be sure to replace the
inlet connector with a new one as well.
a Check that the fuel injector sleeve is free
of flaw and dirt.
1) Fit O-ring (58a) and gasket (58b) to fuel
injector (58).
2) Apply engine oil (EO15W-40) to the O-ring
of fuel injector (58) and the mounting hole
on the head.
3) Install holder (58c), while setting its con-
cave part (C) to convex part (A) of fuel
a When angle tightening tool A6 is not injector (58).
used
4] After above steps 1] to 2] are finished,
put a paint mark across cylinder head
and mounting bolts.
5] Retighten the bolts by 90 5 degrees.
50-200 28 PC200, 200LC, 220, 220LC-8M0

4) Insert fuel injector (58) in the cylinder 4] There is a worn part or an uneven
head, while directing its fuel inlet hole seat contact mark on sealing surface
toward the air intake manifold. (e) at the front end of the inlet con-
5) Tighten mounting bolts (59) of fuel injector nector.
(58) by 3 to 4 turns. a If high-pressure fuel leaks through
the inlet connector, the sealing
surface has fine streaks or cracks.
6) Check the inlet connector visually. If it has

any of the following faults, replace it with a
new one. 7) Apply engine oil (EO15W-40) to the mount-
1] There is a burr or a worn part at front ing hole of inlet connector (57) on the cylin-
end (a) or rear end (b) of the inlet der head.
connector. 8) Apply engine oil (EO15W-40) to O-ring
2] There is foreign material in the edge (57a) of inlet connector (58) and insert
filter at rear end (c) of the inlet con- inlet connector (57) fully into the head
nector. while matching part (B) with the groove in
3] The O-ring at upper part (d) of the the head.
inlet connector is cracked or deterio-
rated.
PC200, 200LC, 220, 220LC-8M0 50-200 29

9) Tighten inlet connector (57) lightly by

using retaining nut (56). (Push into the
hole of the injector)
3 Retaining nut:
15 5 Nm {1.5 0.5 kgm}
10) Tighten mounting bolts (57) of fuel injector
(58) alternately.
3 Fuel injector mounting bolt:
8 0.8 Nm {0.8 0.08 kgm}
11) Tighten retaining nut (60).
3 Retaining nut:
50 5 Nm {5.1 0.5 kgm}
5. Install harnesses and nuts (49).

a Check the wiring harness that does not
interfere with the rocker arm.
3 Mounting nut (49):
1.5 0.25 Nm {0.15 0.03 kgm}
4. Crosshead and rocker arm

1) Install the crosshead and rocker arm.
a Since the hole shapes at parts "a"
and "b" of each crosshead are differ-
ent, install them to their respective
intake and exhaust valves in the origi-
nal directions.
a Check that the spherical portion of 6. Install gasket assembly (51).
adjustment screw (54) is fitted prop-
erly in the socket of the push rod and
then tighten the mounting bolt.
3 Rocker arm mounting bolt:
36 5 Nm {3.7 0.5 kgm}
2) Adjust the valve clearance. For details, see
Testing and adjusting, "Adjusting valve
clearance".
3 Locknut (53):
20 to 28 Nm {2.04 to 2.86 kgm}
50-200 30 PC200, 200LC, 220, 220LC-8M0

7. Install head cover (46). q Carry out the following installation in the
3 Mounting bolt (45): reverse order to removal.
24 4 Nm {2.4 0.4 kgm}
[*1]
8. Install blow-by duct (47). a The internal parts of the hose adapter may be
3 Blow-by duct mounting bolt: damaged when the hose is removed. Accord-
7 2 Nm {0.71 0.2 kgm} ingly, do not reuse the adapter but use new
one when installing the hose again, as a rule.
9. Install fuel drain hose (46a).
3 Joint bolt: 24 4 Nm {2.4 0.4 kgm}
[*2]
Install muffler assembly (8) according to the follow-
ing procedure.
1. Sling muffler assembly (8), and set it to the
mounting position.
3 Whole circumference of (e) of exhaust
pipe (8a): Heat-hardening sealant
(FIREGUM manufactured by Holts or
equivalent)
2. Install muffler assembly (8) and exhaust pipe
(8a) loosely.
3. Install muffler assembly (8) and turbocharger
assembly loosely, then check the installing
position of them.
4. Install U-bolt (8c), and tighten nut (8d).
3 Nut (8d):
9.8 to 14.7 Nm (1.0 to 1.5 kgm)
5. Tighten turbocharger outlet port clamp (8e).
3 Turbocharger outlet port clamp (8e):
6.8 to 8.8 Nm {0.7 to 0.9 kgm}
6. Tighten seal clamp (8f).
3 Seal clamp (8f):
1st time: 39.2 to 49.9 Nm {4 to 5
kgm}
2nd time: 68.6 to 122.5 Nm {7.0 to
12.5 kgm}
a Be sure to replace the seal clamp (8f) with
the new one.
PC200, 200LC, 220, 220LC-8M0 50-200 31

q When using a new hose

Tighten until dimension (BDG) is 7 10 mm.
[*3]
3 Air intake connector mounting bolt:
24 4 Nm {2.4 0.4 kgm} [*4]
3 Radiator hose clamp:
q MIKALOR clamp 10.8 11.8 Nm {1.1 1.2 kgm}
a Use a new clamp.
1) Align the hose to the original position [*5]
(marking position). 3 Fuel return hose joint bolt:
a Reference 24 4 Nm {2.4 0.4 kgm}
Depth of insertion: 60 mm (aftercooler
side) [*6]
2) Set the bridge (BR) under the clamp bolt k When installing, keep the distance of more
and lap it over band (BD) at least (b) than 10 mm between the high-pressure
reaches 5 mm. pipe and the harness.
a Do not use an impact wrench.
2 Clamp bolt (BC): Lubricating oil [*7], [*8], [*9], [*10], [*11]
(THREEBOND PANDO 18B) q High-pressure pipes and common rail
k Do not use high-pressure pipes with bend-
q When reusing the hose ing modification.

Install the clamp to the clamp mark made on k Be sure to use a genuine high-pressure
the hose. pipe fixing clamp and observe strictly the

3 Tighten to torque of at least 6 Nm {0.6 tightening torque.
kgm}. a A high-pressure pipe which has depressions
such as visible vertical slit scar (b), patchy scars
(c) etc. on the taper seal section of its connector
((a) part: within 2 mm from the tip), or a high-
pressure pipe whose (d) part (end of the taper
seal section: 2 mm from the tip) catches on a
finger nail due to fatigue, may cause fuel leak-
age. In these cases, replace the high-pressure
pipe.
50-200 32 PC200, 200LC, 220, 220LC-8M0

1) Assemble common rail (20) and high-

pressure pipes (71) (76) temporarily.
3 Sleeve nut and mounting bolt:
0.2 0.8 Nm {0.02 0.08 kgm}
2) Tighten high-pressure pipes (71) (76)
3 Sleeve nut:
35 3.5 Nm {3.57 0.36 kgm}
1] Head side of high-pressure pipes (71)
and (76)
2] Common rail side of high-pressure
pipes (76) and (71)
3] Head side of high-pressure pipes
(72), (73), (74) and (75)
4] Common rail side of high-pressure
pipes (72), (73), (74) and (75)
3) Tighten the sleeve nut of high-pressure
pipe (25b) temporarily.
4) Tighten high-pressure pipe (25b) in the
order of firstly pump (FSP) side, then com-
mon rail (20) side.
3 Sleeve nut:
35 3.5 Nm {3.57 0.36 kgm}
5) Tighten clamp (25a) of high-pressure pipe
(25b).
3 Mounting bolt:
24 4 Nm {2.4 0.4 kgm}
6) Tighten common rail (20) with 4 bolts.
a Coat the 2 bolt threads on the inner
side of the engine with sealant (LG-7).
3 Mounting bolt:
24 4 Nm {2.4 0.4 kgm}
7) Install bellows (22) and (23) to each high-
pressure pipe. (14 pieces)
a Set the slits of each bellows out and
down.
a The bellows are installed so that fuel
will not spout over the hot parts of the
engine and catch fire when it leaks for
some reason.
a FSP: Fuel supply pump
PC200, 200LC, 220, 220LC-8M0 50-200 33

Reference 2. Relief valve (RV)

q Handling of fuel pressure sensor (PS) and a If the leakage from the relief valve (RV)
relief valve (RV) exceeds the specified value, do not reuse
1. Fuel pressure sensor (PS). it.
a Check the fuel pressure sensor connector q Replace relief valve (RV), if necessary,
for crack, breakage, damage of the seal, according to the following procedure.
foreign matter on the pin and corrosion, 1) Before removing the fuel pressure
bend and breakage of the pin. sensor, remove mud etc. from around
a Do not remove fuel pressure sensor (PS) it thoroughly and clean it.
from common rail (CR) for a purpose other 2) Remove relief valve (RV).
than replacement. 3) Check that high-pressure seal sur-
a Once the fuel pressure sensor (PS) is faces (A) of the relief valve (RV) and
removed from the common rail (CR), be rail (CR) are free from damage.
sure to replace it. 4) Install a new relief valve (RV).
q Fuel pressure sensor (PS), if necessary, 2 Threaded section:
according to the following procedure. Gear oil (#90)

3 Relief valve:
1) Before removing the fuel pressure 100 4 Nm {10.2 0.4 kgm}

sensor, remove mud etc. from around a Excessive tightening can cause
it thoroughly and clean it. leakage. Take care not to tighten
2) Remove the fuel pressure sensor too strongly.
(PS).
3) Install a new fuel pressure sensor.
2 Threaded part of fuel pressure
sensor: Gear oil (#90)
3 Fuel pressure sensor:
70 5 Nm {7.1 0.5 kgm}
5) Start the engine and check that fuel

does not leak.
a For the testing procedure, see
Testing and adjusting, "Measur-
ing fuel return rate and leakage".
4) Connect the engine wiring harness. [*12]

At this time, take care not to connect 3 Air tube clamp:
the wiring harness in reverse. 10.0 11.0 Nm {1.02 1.12 kgm}
5) Start the engine and check that fuel
does not leak. [*13]
a For the testing procedure, see q MIKALOR clamp
Testing and adjusting, "Measur- a Reference
ing fuel return rate and leakage". Length of insertion: 40 mm (turbocharger side)
a Refer to [*4].
50-200 34 PC200, 200LC, 220, 220LC-8M0

[*14] (38a) is strong. If the wrench is loosely

3 Lubrication inlet hose tightening sleeve nut: inserted, the wrench may accidentally
35 5 Nm {3.5 0.5 kgm} come off while being rotated and it is
a When tightening the hose mounting nut, extremely dangerous.)
secure the connector with a spanner since k After installing the fan belt (38), return
the connector tightening torque is small. the tensioner assembly (38a) slowly
3 Connector on turbocharger side with care.
(if loosened): k Be careful not to get your fingers
9.8 12.7 Nm {1.0 1.3 kgm} caught between the pulley and fan belt
3 Lubrication outlet hose mounting bolt: (38) during work.
12 2 Nm {1.2 0.2 kgm}
[*15], [*16]
a Tighten the bolts in the order shown below.
3 Exhaust manifold mounting bolt:
First time: in the order of [1] [12]
Tighten to a torque of
24 4 Nm {2.4 0.4 kgm}.
Second time: in the order of [1] [12]
53 6 Nm {5.4 0.6 kgm}.
Third time: in the order of [1] [4]
53 6 Nm {5.4 0.6 kgm}.
[*20]
k Install each high-pressure pipe and wiring
harness at least 10 mm apart from each
other.
q Refilling engine coolant

Refill coolant through the coolant filler port up
to the specified level. Start the engine and cir-
culate the coolant, and then check the coolant
level.
5 Coolant: 20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
[*17]
43 6 Nm {4.4 0.6 kgm}
[*18]
a Refer to the "Checking and adjusting of air
conditioner compressor belt tension" section in
the Testing and adjusting chapter of this man-
ual.
[*19]
a Install fan belt (38) as follows.
assembly (38a), and rotate it to the oppo-
site to the winding-up direction (R), then
install fan belt (38).
PC200, 200LC, 220, 220LC-8M0 50-200 35

SEN06143-00 Removal and installation of radiator assembly
Removal and installation of 7. Remove cover (5).

radiator assembly 1
8. Disconnect radiator hoses (6) and (6a). [*1]
Removal original hose installation positions. (See
k Park the machine on a level ground, lower figure below.)
k If you drain the coolant when it is still hot,
you may be scalded. Wait until the coolant
temperature drops before starting the work.

6 Coolant: 20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
9. Disconnect radiator hose (7). [*2]
4. Open up the engine hood.
original hose installation positions. (Refer
to the above figure.)
5. Disconnect reservoir tank hose (2).
10. Move cover (8).
a In order to avoid the contact with the
flange.
50-200 36 PC200, 200LC, 220, 220LC-8M0

Removal and installation of radiator assembly SEN06143-00
11. Remove the mounting bolts (10) and lift out Installation
radiator assembly (9). [*3] q Installation is done in the reverse order of
4 Radiator assembly: 15 kg removal.
[*1], [*2]
a Align the hose to the original position (marking
position).
a Align the clamp to the original position.
a Reference
Inserted air hose length
q 45 mm (Radiator side)
q 40 mm (Engine side)
10.8 11.8 Nm {1.1 1.2 kgm}
[*3]
a Confirm that the heat insulating seal material
(sponge) of the radiator peripheral part is not
damaged. If the heat insulating seal material
(sponge) is damaged, replace it to the new
one.
Confirm from the under cover side that convex-
ity (A) of the radiator is correctly set to concav-
ity (B).
q Refilling engine coolant

Refill coolant through the coolant filler port up
to the specified level. Start the engine and cir-
culate the coolant, and then check the coolant
level.
5 Coolant: 20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)
PC200, 200LC, 220, 220LC-8M0 50-200 37

SEN06143-00 Removal and installation of hydraulic oil cooler assembly
Removal and installation of 6. Open the left side cover.

hydraulic oil cooler assembly 1
7. Disconnect control valve drain hose (4).
a Stop oil flow.
Removal
k Lower the work equipment to the ground
completely, after the engine is stopped,
loosen the hydraulic tank cap gradually to
reduce the pressure inside, and set the lock
lever in the lock position.
4. Remove hydraulic oil cooler drain plug (2) to

drain the hydraulic oil.
a Loosen upper side (return) hose (7) of the
hydraulic tank and induce air into the tank. 10. Disconnect hydraulic tank return hose (7).
a Stop oil flow.
6 Hydraulic oil cooler: 7 l
11. Remove hydraulic oil cooler mounting bolt (8).
5. Move cover (3).
50-200 38 PC200, 200LC, 220, 220LC-8M0

Removal and installation of hydraulic oil cooler assembly SEN06143-00
12. Move cover (9). Installation

q Installation is done in the reverse order of re-
moval.
[*1]
one.
Confirm from the under cover side that convexity

(A) of the radiator is correctly set to concavity (B).
13. Lift out hydraulic oil cooler assembly (10) by

using eyebolt (M10) [1]. [*1]
4 Hydraulic oil cooler assembly: 25 kg
q Refilling with oil (hydraulic tank)

Refill hydraulic oil through the oil filler port to
the specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
PC200, 200LC, 220, 220LC-8M0 50-200 39

SEN06143-00 Removal and installation of aftercooler assembly
Removal and installation of 6. Remove hose (4). [*1]

aftercooler assembly 1
a MIKALOR clamp
Removal figure below.)
k Park the machine on a level ground, lower a Inserted air hose length: 80 mm
50-200 40 PC200, 200LC, 220, 220LC-8M0

Removal and installation of aftercooler assembly SEN06143-00
8. Disconnect tube (6) from the lower side. [*2] Installation

q Installation is done in the reverse order of
9. Move cover (7). removal.
a In order to avoid the contact with the
flange. [*1]
1. Install hose and tube assembly (4).
a Use a new MIKALOR clamp.
1) Align the hose to the original position
(marking position).
a Inserted air hose length
q Aftercooler side: 60 mm
q Engine side: 80 mm
10. Remove the mounting bolt and lift out after-

cooler assembly (8). [*3]
4 Aftercooler assembly: 15 kg
2)Set the bridge (BR) under the clamp bolt

and lap it over band (BD) at least (b)
reaches 5 mm.
2 Clamp bolt (BC): Lubricating oil
(THREEBOND PANDO 18B)
q When reusing the hose

Install the clamp to the clamp mark made
on the hose.
3 Tighten to torque of at least
6 Nm {0.6 kgm}.

Tighten until dimension (BDG) is 7
10 mm.
PC200, 200LC, 220, 220LC-8M0 50-200 41

SEN06143-00 Removal and installation of aftercooler assembly
[*2]
a Replace the O-ring to the new one.
[*3]
one.
Confirm from the under cover side that convex-

ity (A) of the radiator is correctly set to concav-
ity (B).
50-200 42 PC200, 200LC, 220, 220LC-8M0

Removal and installation of fuel cooler assembly SEN06143-00
Removal and installation of fuel Installation

cooler assembly 1 q Installation is done in the reverse order of
removal.
Removal
a If the fuel is too much, drain the fuel in order to
stop the fuel flow from the fuel tank return
hose.
1. Disconnect fuel hoses (1) and (2) with the pre-
caution described below.
a Be sure to disconnect the hoses in avoid-
ing the input force to the cooler body by
fixing elbow (L) with wrench (1).
a Be sure to use wrench [1], otherwise the
force is loaded to the cooler body and the
weld portion (M) may be separated.
2. Remove fuel cooler assembly (3).
PC200, 200LC, 220, 220LC-8M0 50-200 43

SEN06143-00 Removal and installation of engine and hydraulic pump as-

engine and hydraulic pump
assembly
Special tools
Necessity
Symbol
Qty
8 796T-401-1110 Plate q 1
9 795-790-9300 Lifting tool q 1
A
10 796-460-1210 Oil stopper q 1
11 796-770-1320 Adaptor q 1
Removal 6 Coolant: 20.3 l (PC200/200LC-8M0)
k After lowering the work equipment to the 19.9 l (PC220/220LC-8M0)
g ro u n d c om p l e t e l y a n d s t o p p i n g t he
engine, release the internal pressure of the
hydraulic tank by gradually loosening the 5. Temporarily sling engine hood (2).
cap of the hydraulic tank. a When slinging the engine hood, take care
k Disconnect the cable from the negative () not to damage the rubber seal.
terminal of the battery. 6. Remove pins (3) and (4), then remove 2 gas
k If you drain the coolant when it is still hot, springs (5).
you may be scalded. Wait until the coolant
temperature drops before starting the work. 7. Lift off engine hood (2) to remove it.
4
a Attach an identification tag to each piping to Engine hood: 50 kg
avoid a mistake in the position of installation
later.
2. Remove hydraulic tank strainer and stop oil

flow-out using tool A10, A11.
a If tool A10, A11 are not used, remove the
drain plug and drain oil from the hydraulic
tank and piping.
6 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
50-200 44 PC200, 200LC, 220, 220LC-8M0

Removal and installation of engine and hydraulic pump assembly SEN06143-00
8. Disconnect pre-cleaner (6), pre-cleaner base

pipe (7). (If equipped)
9. Remove covers (8) and (9).
a The hatched area is made of rubber

(lower side).
10. Disconnect hose (10a).
12. Remove frame (11).

a Cover (15) cannot be removed unless
16. Remove mounting bolt (16).
removing cover (9).
17. Remove mounting bolt (17).
21. Remove frame (22) between the control valve
and the engine.
a Cover (24) can be removed after removing
frame (22).
22. Remove mounting bolt (23) and remove cover
(24) upwards.
a As cover (24) is just stuck, there is no
need to remove the lower bolt.
PC200, 200LC, 220, 220LC-8M0 50-200 45

a Install frame (22). (For scaffold) 27. Remove fan guard (29).
23. Remove fuel filter and bracket assembly (25).

28. Disconnect air cleaner tube (30). [*4]
a Put it on the engine.
29. Remove aftercooler hose and tube assembly
(31).
a MIKALOR clamp [*5]
figure below.)
24. Remove hose (26).

a MIKALOR clamp [*2]
figure below.)
a If disconnecting air intake connector (C),
replace the gasket.
25. Disconnect radiator hose (27). [*3]

original hose installation positions.
26. Disconnect heater hose (28).
50-200 46 PC200, 200LC, 220, 220LC-8M0

30. Disconnect fuel filter hose (32) from fuel supply

pump (FSP). [*6]
a The fuel filter hose can be disconnected
by pushing locks (L) at both sides.
31. Disconnect fuel supply hose (33).
32. Disconnect fuel return hose (34).

a Disconnect the clamp.
40. Disconnect connectors CE02 (41) and (42)

from the engine controller.
a The connector is locked with the inside
hex head bolt L6 (4 mm).
a Connector (42) is attached at the engine
side, however it needs to be removed not
to be obstructive in removing the engine
mounting bolts.
41. Disconnect connector (43) from the engine
33. Remove fan (35). [*7] controller by pushing the lock.
34. Loosen air conditioner compressor bracket 42. Disconnect connector E06 (44).
adjusting bolt (36).
a There is another bolt behind.
35. Shift air conditioner compressor assembly

(37). [*8]
36. Remove fan belt (38).
37. Disconnect connector AC02 (39).
38. Remove air conditioner compressor assembly

(37).
a Remove air conditioner compressor as-
sembly in one piece with the bracket and
put them on the counterweight.
39. Disconnect electrical intake air heater connec-

tor E01 (40).
PC200, 200LC, 220, 220LC-8M0 50-200 47

43. Disconnect engine controller ground T12 (45). 52. Disconnect 6 hoses.
q (56): Rear load pressure input port hose
44. Disconnect bracket (46) and remove spacer (Color band: No color)
(47). q (57), (58): EPC basic pressure port hose
(Color band: No color)
45. Disconnect clamp (48).
q (59): Pump pressure input port hose
(Color band: blue)
q (60): Front load pressure input port hose
(Color band: red)
q (61): Drain port hose
53. Disconnect bracket (62).
54. Turn elbow (63) downward.

a Not to be obstructive in removing the
engine.
46. Disconnect terminal (49) from the starter (ST).
47. Disconnect connector E10 (50).

a Connector at the starting motor side: T13
48. Disconnect connectors E08 (51) and P44 (52).
55. Disconnect 4 hoses and 1 tube.

q (64): Branch hose
q (65): Rear pump discharge port hose
q (66): Front pump discharge port hose
q (67): Pump suction port tube
56. Return bracket (62) to the original position.

(Install it to the pump.)
51. Remove filter and bracket assembly (55).

a Put it on hose bracket (HB).
50-200 48 PC200, 200LC, 220, 220LC-8M0

57. Disconnect pump wiring connectors at 4 60. Disconnect hydraulic tank hoses (74) and (75).
points. a Not to be obstructive in removing the
q (68): V12 PC-EPC R solenoid valve engine.
(Color band: yellow)
q (69): P22 hydraulic oil temperature sensor
(Color band: no color)
q (70): V19 LS-EPC solenoid valve
(Color band: red)
q (71): V11 PC-EPC F solenoid valve
(Color band: white)
a It is behind bracket (72).
61. Remove fan belt (76) from the alternator with

wrench [1].
62. Disconnect connectors AB (77) and E12 (78).
63. Remove alternator (79).
65. Remove 3 bolts and disconnect radiator hose

and flange assembly (81). [*9]
PC200, 200LC, 220, 220LC-8M0 50-200 49

66. Disconnect engine ground (82). 68. Lift out engine and hydraulic pump assembly
(84).
67. Remove 4 engine mounting bolts (83). [*10] a Lift it at the 3 points, i.e. 2 points at the
a The nut is not welded except at the engine engine and 1 point at the hydraulic pump.
ground point. Due to that reason firstly fix Recommended lifting tool A9 (Refer to the
nut locking tool (plate) A8 with bolt (B) to special tool list) is proposed from Cum-
restrict nut (N) from turning, then remove mins.
engine mounting bolt (83). a Before removing the assembly, make sure
that all the necessary wiring and piping
are disconnected.
4 Engine and hydraulic pump assembly:
800 kg
50-200 50 PC200, 200LC, 220, 220LC-8M0

Installation [*3]
q Installation is done in the reverse order of a Align the hose to the original position (marking
removal. position).
a Align the clamp to the original position.
[*1] a Reference
3 Air cleaner band: Inserted air hose length: 49 mm
8.8 10.8 Nm {0.9 1.1 kgm} 3 Radiator hose clamp:
10.8 11.8 Nm {1.1 1.2 kgm}
[*2], [*5]
a Use a new MIKALOR clamp. [*4]
1) Align the hose to the original position 3 Tube clamp:
(marking position). 10.0 11.0 Nm {1.02 1.12 kgm}
a Reference
Inserted air hose length [*5]
q Aftercooler side: 60 mm Refer to [*2].
q Engine side: 80 mm
q Turbocharger side: 65 mm [*6]
2) Set the bridge (BR) under the clamp bolt a The internal parts of the hose adapter may be
and lap it over band (BD) at least (b) damaged when the hose is removed. Accord-
reaches 5 mm. ingly, do not reuse the adapter but use new
a Do not use an impact wrench. one when installing the hose again, as a rule.
(THREEBOND PANDO 18B) [*7]
q When reusing the hose 43 6 Nm {4.4 0.6 kgm}
Install the clamp to the clamp mark made on
the hose. [*8]
3 Tighten to torque of at least 6 Nm {0.6 a Refer to the "Checking and adjusting air com-
kgm}. pressor belt tension" section in the Testing and
adjusting chapter in this manual.
Tighten until dimension (BDG) is 7 10 mm. [*9]
3 Flange mounting bolt:
43 6 Nm {4.4 0.6 kgm}
a Reference
Inserted radiator hose length: 40 mm
10.8 11.8 Nm {1.1 1.2 kgm}
[*10]
a The bolt length of the engine front side is
shorter than that of rear side.
a The engine mounting rubber size of the engine
front side is smaller than that of rear side.
PC200, 200LC, 220, 220LC-8M0 50-200 51

3 Engine mounting bolt (4 points): q Refilling engine coolant

245 308.9 Nm {25 31.5 kgm} Refill coolant through the coolant filler port up
a The nut is not welded except at the engine to the specified level. Start the engine and cir-
ground point. Due to that reason firstly fix nut culate the coolant, and then check the coolant
locking tool (plate) A8 with bolt (B) to restrict nut level.
(N) from turning, then remove engine mounting
bolt (82). 5 Coolant: 20.3 l (PC200/200LC-8M0)
19.9 l (PC220/220LC-8M0)

5 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
3 Hydraulic tank drain plug:

58.8 78.5 Nm {6.0 8.0 kgm}
a Reference
3 Engine mounting bracket (4 points) bolts (B): q Air bleeding
122.5 147 Nm {12.5 15 kgm} Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see
Testing and adjusting, "Bleeding air from each
part".
a Reference
Overview of the depth of the insertion of the air
hoses and radiator hoses.
50-200 52 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 50-200 53

SEN06143-00

2012 KOMATSU
All Rights Reserved
50-200 54
SEN06144-00
HYDRAULIC EXCAVATOR
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
300 Power train

Removal and installation of final drive assembly ............................................................................................ 2
Disassembly and assembly of final drive assembly........................................................................................ 4
Removal and installation of swing motor and swing machinery assembly ................................................... 22
Disassembly and assembly of swing motor and swing machinery assembly ............................................... 24
Removal and installation of swing circle assembly ....................................................................................... 34
PC200, 200LC, 220, 220LC-8M0 50-300 1

300 Power train
SEN06144-00 Removal and installation of final drive assembly
Removal and installation of final a PC200-8M0, PC200LC-8M0

drive assembly 1
4. Temporarily sling the final drive assembly (6).
5. Remove 18 mounting bolts (7) and sling final

Removal drive assembly (6) to remove it. [*1]
1. Remove the sprocket, referring to the section a Be careful so that the nipple sealing sur-
Removal and installation of sprocket. face on the hose mounting block may not
be damaged.
k Completely lower the work equipment 4 Final drive assembly: 300 kg
to the ground and stop the engine.
Then loosen the oil filler cap for the
hydraulic tank to release the pressure
inside the tank.
k Disconnect the cable from the negative
() terminal of the battery.
a PC220-8M0, PC220LC-8M0
6. Temporarily sling the final drive assembly (8).
7. Remove 18 mounting bolts and sling final drive

assembly (8) to remove it. [*2]
a Be careful so that the nipple sealing sur-
face on the hose mounting block may not
3. Disconnect the travel speed selector hose (2),
be damaged.
the motor hoses (3) and (4), and the drain
hose (5). 4 Final drive assembly: 350 kg
50-300 2 PC200, 200LC, 220, 220LC-8M0

300 Power train
Removal and installation of final drive assembly SEN06144-00
Installation
removal.
[*1]
3 Mounting bolts:
245 309 Nm {25 31.5 kgm}
[*2]
3 Mounting bolts:
265 309 Nm {27 31.5 kgm}
(Average torque: 275 Nm or more
{28 kgm or more})
q Refilling with oil

Fill the power train oil (TO30) via the oil filler
port to the specified level. Start the engine to
circulate the oil through the pipings and
recheck the oil level.
q Air bleeding
Refer to the Bleeding air from each part in the
Testing and adjusting chapter of this manual.
PC200, 200LC, 220, 220LC-8M0 50-300 3

300 Power train
SEN06144-00 Disassembly and assembly of final drive assembly
Disassembly and assembly of 3. Washer

final drive assembly 1
Remove washer (2).
4. No.1 planetary carrier assembly

a PC200-8M0, PC200LC-8M0 1) Remove No.1 planetary carrier assembly
Special tools (3).
Necessity
Symbol
Qty
796-427-1400 Wrench assembly t 1
796-427-1410 Wrench 1
1
796-427-1140 Pin 3
01314-20612 Screw 3
796T-427-1510 Push tool t 1
790-101-2510 Block t 1
790-101-3310 Block t 1
790-101-2610 Rod t 2
J
790-101-2730 Adapter t 2 2) Disassemble No.1 planetary carrier
2 assembly in the following procedure.
01580-11613 Nut t 2
1] Drive pin (4) into shaft (5) to remove
790-101-2570 Plate t 2 shaft (5) from No.1 planetary carrier
01643-31645 Washer t 2 (6).
790-101-2102 Puller (30 t) t 1 a Remove pin (4) from shaft (5)
790-101-1102 Pump t 1
after shaft (5) is removed.
2] Remove thrust washer (7), No.1 plan-
3 796-427-1520 Installer t 1 etary gear (8), needle bearing (9) and
7 790-331-1110 Wrench t 1 thrust washer (10).
Disassembly
1. Oil drain
Remove drain plug to drain the oil from final
drive case.
6 Final drive case: 3.8 l
2. Cover
Remove 18 mounting bolts and sling cover (1)
using eyebolts [1] to remove it.
4 Cover: 20 kg
a When ring gear (12) is lifted together, sep-
arate the ring gear by lightly tapping it with
a plastic hammer.
50-300 4 PC200, 200LC, 220, 220LC-8M0

300 Power train
Disassembly and assembly of final drive assembly SEN06144-00
5. No.1 sun gear shaft

Remove No.1 sun gear shaft (11).
2) Disassemble No.2 planetary carrier

assembly in the following procedure.
6. Ring gear 1] Drive pin (17) into shaft (18) to
Remove ring gear (12). remove shaft (18) from No.2 plane-
4 Ring gear: 40 kg tary carrier (19).
a Remove pin (17) from shaft (18)
7. Thrust washer after shaft (18) is removed.
Remove thrust washer (13). 2] Remove thrust washer (20), No.2
planetary gear (21), needle bearing
8. No.2 sun gear (22) and thrust washer (23).
Remove No.2 sun gear (14).
11. Ring nut

9. Thrust washer 1) Remove lock (24).
Remove thrust washer (15). 2) Use the tool J1 to remove ring nut (25).
10. No.2 planetary carrier assembly

1) Remove No.2 planetary carrier assembly
(16).
PC200, 200LC, 220, 220LC-8M0 50-300 5

300 Power train
12. Hub assembly 13. Remove floating seals (32) and (33) from
1) Using eyebolts [2], sling hub assembly travel motor (31).
(26) and remove from travel motor. a The floating seals (32) and (33) may be
4
both on the hub assembly (26) and the
Hub assembly: 80 kg
travel motor (31).
2) Remove bearing (27). 14. Use the puller [3] and push tool [4] to remove
bearing (34).
a Bearing may come off without using the
puller.
3) Remove bearing outer races (29) and (30)

from hub (28).
50-300 6 PC200, 200LC, 220, 220LC-8M0

300 Power train
Assembly 3. Use the tool J3 to install floating seal (33) to

a Clean the parts completely and inspect them travel motor (31).
for any foreign material or damage. Apply a Install floating seal with the O-ring and O-
power train oil (TO30) on the sliding surfaces ring contact surface degreased and dried
before assembly. completely.
a After installing the floating seal, check that
1. Hub assembly the angle of the floating seal is within 1
1) Use push tool to press fit bearing outer mm.
races (29) and (30) into hub (28). a After floating seal installation, apply a thin
coat of power train oil (TO30) on the slid-
ing surfaces.
2) Use the tool J3 to install floating seal (32).

a Install floating seal with the O-ring
and O-ring contact surface degreased 4. Using eyebolts [2], set hub assembly (26) to
and dried completely. travel motor.
a After installing the floating seal, check
that the angle of the floating seal is
within 1 mm.
a After floating seal installation, apply a
thin coat of power train oil (TO30) on
the sliding surfaces.
5. Install bearing (27) by tapping it lightly with the

push tool.
2. Install bearing (34) to travel motor (31).

a Warm the inner race of the bearing (34) to
50 70C with heater.
a Cool the bearing (34) down. Tap the bear-
ing (34) with a drift and listen to the sound
to check that it is fully seated.
PC200, 200LC, 220, 220LC-8M0 50-300 7

300 Power train
6. Ring nut
1) Install ring nut as follows.
1] Rotate the hub 2-3 times.
2] Use the tool J2 and the push tool [5]
to press the inner race of the bearing
(27).
a Pressing force:
29.4 38.2 kN {3.0 3.9 ton}
3] Rotate the hub to the both directions
at least 5 times in total with the bear-
ing inner race pressed.
4] Release the pressing force.
5] Press the bearing again.
a Pressing force:
17.7 21.6 kN {1.8 2.2 ton} 2) Measure the tangential force of the hub
6] Rotate the hub 2 3 times. against the motor case in the rotation
direction using the push scale [6].
a Tangential force:
490 N or less {50 kg or less}
a The tangential force denotes the
maximum force at start of the rotation.
7] Measure the size (a) under the condi-

tion described in 6] above.
a After measuring the size (a), remove
the tool J2.
3) Install lock plate (24).

a Install the lock plate so that the
splines (A) of the lock plate and the
motor are in full contact.
2 Mounting bolt thread:
Adhesive (LT-2)
a Do no apply the adhesive (LT-2) to
the tapped portion of the nut.
8] (b) is the thickness of the ring nut

(25) itself.
9] Calculate the value of (c) by subtract
(b) from (a).
10] Using tool J1, tighten ring nut (25)
until dimension (d) becomes value
below.
Dimension (d): c (+0.06/-0.04) mm
50-300 8 PC200, 200LC, 220, 220LC-8M0

300 Power train
7. No.2 planetary carrier assembly a After the pin is inserted, stake the
1) Assemble No.2 planetary carrier assembly pin (B) on the carrier.
as follows.
a Replace thrust washers (20) and (23)
as well as pin (17) with new ones.
a There are traces of expansion on the
end surface of No.2 planetary carrier
side hole (e) which were originally
caused when the pin was inserted.
Make such the end surfaces are
smooth enough before reassembly.
1] Assemble needle bearing (22) to
No.2 planetary gear (21), fit top and
bottom thrust washers (20) and (23)
and then set the gear assembly on
No.2 planetary carrier (19).
2] Align the pin holes on the shaft (18)
and the carrier, and install the shaft
(18) by tapping it lightly with a plastic
hammer.
a Install the shaft, rotating the No.2
planetary gear (21). Take care so
the thrust washer is not dam-
aged.
2) Install No.2 planetary carrier assembly

(16).
a Align the 4 gear shaft ends of the
No.2 planetary carrier assembly (16)
with the 4 dimples on the motor case
end surface to install.
8. Thrust washer
3] Insert pin (17).
Install thrust washer (15).
a When inserting the pin, take care
so that any of the three pawls on
the circumference (Portion (f))
may not touch the thin-walled
portion on the No.2 planetary
carrier (Portion (g)).Take note,
however, that the thin-walled por-
tion is likely to be on the opposite
side of the carrier, depending on
ac tual indi vid ual i tems . Pay
attention so that a pin pawl will
not come to the slender side of
the No.2 planetary carrier any
way. And when traces of the
groove are present, assembly
must be done avoiding such
locations.
a After assembling the No.2 plane-
tary carrier assembly, check that
No.2 planetary gear (21) rotates
smoothly.
PC200, 200LC, 220, 220LC-8M0 50-300 9

300 Power train
9. No.2 sun gear 13. No.1 planetary carrier assembly

Install No.2 sun gear (14). 1) Assemble No.1 planetary carrier assembly
as follows.
10. No.1 sun gear shaft a Replace thrust washers (7) and (10)
Install No.1 sun gear shaft (11). and pin (4) with new ones. (Refer to
Pin (4): 3].)
11. Thrust washer a There are remains of caulking when
Install thrust washer (13). the pin is inserted at the end face of
hole (h) at the side of the No.1 plane-
tary carrier. Remove the caulked
metal from the inside diameter of the
hole before starting to assemble.
1] Assemble bearings (8) and (9), fit top
and bottom thrust washers (7) and
(10) and then set the No.1 planetary
gear assembly on carrier (6).
12. Ring gear

1) Install O-ring to the hub.
2) Install ring gear (12) to hub.
4 Ring gear: 40 kg
a Degrease the mating surfaces of the ring
gear and the hub, and do not apply liquid
gasket on the mating surfaces.
a Align the holes in the ring gear and the 2] Align the pin holes on the shaft (5)
hub. and the No.1 planetary carrier, and
install the shaft (5) by tapping it lightly
with a plastic hammer.
a Install the shaft, rotating the
planetary No.1 planetary gear.
Take care so the thrust washer is
not damaged.
3] Insert pin (4).
so that any of the three pawls on
the circumference (Portion (f))
may not touch the thin-walled
portion on the No.1 planetary
carrier (Portion (g)).Take note,
however, that the thin-walled por-
tion is likely to be on the opposite
side of the carrier, depending on
actu al i ndiv idua l i tems. Pay
attention so that a pin pawl will
not come to the slender side of
the carrier any way. And when
traces of the groove are present,
assembly must be done avoid-
ing such locations.
50-300 10 PC200, 200LC, 220, 220LC-8M0

300 Power train
a After assembling the No.1 plane- 14. Washer

tary carrier assembly, check that Install washer (2).
No.1 planetary gear (8) rotates a After installing washer (2), measure dis-
smoothly. tance (i) from the top of No.1 planetary
a After the pin is inserted, stake the gear (8) to the top of ring gear (12) and
pins (C) on the carrier at 2 loca- check the assembly condition.
tions. a If dimension (i) is not within 0.54 0.56
mm range, they are not assembled cor-
rectly. In this case, check again.
2) Install No.2 planetary carrier assembly (3).
PC200, 200LC, 220, 220LC-8M0 50-300 11

300 Power train
15. Cover
1) Using eyebolts [1], install cover (1)
4 Cover: 20 kg
2 Contacting face of cover and ring gear:
2)Using tool J7, tighten the 18 mounting

bolts.
3 Mounting bolts:
First time: 98 Nm {10 kgm}
Sencond time: 80 90 (rotating angle)
16. Oil refill

Tighten drain plug and fill power train oil
(TO30) from the oil filler port.
5 Final drive case: Approx. 3.8 l
a Do a final check of the oil level at the

determined position after installing the
final drive assembly to the chassis.
50-300 12 PC200, 200LC, 220, 220LC-8M0

300 Power train
a PC220-8M0, PC220LC-8M0 3. Washer

Special tools Remove washer (2).
Necessity
Symbol
4. No. 1 planetary carrier assembly

1) Remove No. 1 planetary carrier assembly
Qty
(3).
4 796-427-1400 Wrench assembly t 1
5 796-427-1520 Installer t 1
796T-427-1510 Push tool t 1
790-101-2510 Block t 1
790-101-3310 Plate t 1
790-101-2610 Leg t 2
J 790-101-2730 Adapter t 2
6
01580-11613 Nut t 2
790-101-2570 Plate t 2
01643-31645 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
7 790-331-1110 Wrench t 1
2) Disassemble No. 1 planetary carrier
assembly according to the following pro-
Disassembly cedure.
1. Oil draining 1] Drive pin (4) into shaft (5) to remove
Remove the drain plug to drain the oil from the shaft (5) from No. 1 planetary carrier
final drive case. (6).
6 Final drive case: 5.4 l a After removing shaft (5), remove
pin (4) from shaft (5).
2. Remove 20 mounting bolts. Using eyebolts [1], 2] Remove thrust washer (7), No. 1
sling and remove cover (1). planetary gear (8), needle bearing
(9), and thrust washer (10).
4 Cover: 25 kg
a If ring gear (12) is slung together with the
cover, gently tap the ring gear off the
cover by using a plastic hammer.
PC200, 200LC, 220, 220LC-8M0 50-300 13

300 Power train
5. No. 1 sun gear shaft 9. Thrust washer

Remove No. 1 sun gear shaft (11). Remove thrust washer (15).

1) Remove No. 2 planetary carrier assembly
(16).
6. Ring gear
Remove ring gear (12).
4 Ring gear: 45 kg
2) Disassemble the No. 2 planetary carrier
7. Thrust washer
assembly according to the following pro-
Remove thrust washer (13).
cedure.
1] Drive pin (17) into shaft (18) to
8. No. 2 sun gear
remove shaft (18) from No. 2 plane-
Remove No. 2 sun gear (14).
tary carrier (19).
a After removing shaft (18),
remove pin (17) from shaft (18).
2] Remove thrust washer (20), No. 2
planetary gear (21), needle bearing
(22), and thrust washer (23).
50-300 14 PC200, 200LC, 220, 220LC-8M0

300 Power train
11. Ring nut 3) Remove bearing outer races (29) and (30)
1) Remove lock plate (24). from hub (28).
2) By using tool J4, remove ring nut (25).
13. Remove floating seals (32) and (33) from

travel motor (31).
12. Hub assembly a Floating seals (32) are attached to hub
1) Using eyebolts [2], sling and remove hub assembly (26) and travel motor.
assembly (26) from the travel motor.
4 Hub assembly: 80 kg
14. Use the puller [3] and push tool [4] to remove
bearing (34).
2) Remove bearing (27). a Bearing may come off without using the
puller.
PC200, 200LC, 220, 220LC-8M0 50-300 15

300 Power train
Assembly 2. Install bearing (34) to travel motor (31).

a Clean the parts completely and inspect them a Warm the inner race of the bearing (34) to
for any foreign material or damage. Apply 50 to 70C with heater.
power train oil (TO30) to the sliding surfaces a Cool bearing (34) down. Tap the bearing
before assembly. (34) with a wood bar and listen to the
sound to check that it is fully seated.
1. Hub assembly
1) Use push tool to press fit bearing outer 3. Using tool J5, install floating seal (33) to travel
races (29) and (30) into hub (28). motor (31).
a Install the floating seal after degreasing
and drying the O-rings and O-ring contact-
ing surfaces completely.
a After installing the floating seal, check the
inclination of the seal. It must be 1 mm or
less.
a After floating seal installation, apply a thin
coat of power train oil on the sliding sur-
faces.
2 Sliding surface: Power train oil (TO30)
2) Using tool J5, install floating seal (32).

a Install the floating seal after degreas-
ing and drying the O-rings and O-ring
contacting surfaces completely.
a After installing the floating seal, check
the inclination of the seal. It must be 1
mm or less.
a After floating seal installation, apply a
thin coat of power train oil on the slid-
ing surfaces.
2 Sliding surface: 4. Using eyebolts [2], place hub assembly (26) on
Power train oil (TO30) the travel motor.
4 Hub assembly: 80 kg
50-300 16 PC200, 200LC, 220, 220LC-8M0

300 Power train
5. Install bearing (27) by tapping it lightly with the 7] Measure dimension (a) under the
push tool. condition described in 6].
a After measuring dimension (a),
remove tool J6.
6. Ring nut
1) Install the ring nut according to the follow-
ing procedure. 8] Measure the thickness of ring nut (25)
1] Rotate the hub two to three times. and name it (b) dimension.
2] Use tool J6 and push tool [5] to press 9] Subtract (b) from (a), and name it (c).
the inner race of bearing (27). 10] By using tool J4, tighten ring nut (25)
a Pressing force: until dimension (d) is as shown.
29.4 to 38.2 kN {3.0 to 3.9 ton} Dimension (d): c (+0.06/-0.04) mm
3] Rotate the hub to the both directions
at least five times in total with the
bearing inner race pressed.
4] Release the pressing force.
5] Press the bearing again.
a Pressing force:
17.7 to 21.6 kN {1.8 to 2.2 ton}
6] Rotate the hub two to three times.
2) Measure the tangential force of the hub

against the motor case in the rotation
direction using the push scale [6].
a Tangential force: Max. 490 N {50 kg}
a The tangential force denotes the
maximum force at start of the rotation.
PC200, 200LC, 220, 220LC-8M0 50-300 17

300 Power train
3) Install lock plate (24).

a Install the lock plate so that the
splines (A) of the motor and the lock
plate are in full contact.
2 Mounting bolt threads:
Adhesive (LT-2)
a Do not apply the adhesive (LT-2) to
the thread portion of the nut.
3] Insert pin (17).

that the three claws (parts (f)) on
the periphery of the pin will not
be placed on the thin-wall parts
of No. 2 planetary carrier (parts
(g)). The thin-wall part may be on
7. No. 2 planetary carrier assembly the opposite side depending on
1) Assemble No. 2 planetary carrier accord- carriers. Check each carrier and
ing to the following procedure. avoid setting any claw of the pin
a Replace thrust washers (20) and (23) to the thin-wall part. If there is a
as well as pin (17) with new ones. groove, avoid the groove.
a There is trace of punching on the end a After assembling the No. 2 plan-
face of carrier side hole (e) which was etary carrier, check that No. 2
caused when the pin was inserted p l a n e ta r y g e a r ( 2 1 ) r o ta t e s
and locked. Before pin installation, smoothly.
remove the protrusion in the pin hole a After the pin is inserted, punch
as a result of punching. the pin (B) on the carrier.
1] Install needle bearing (22) to No. 2
planetary gear (21). Fit upper and
lower thrust washers (20) and (23)
and set the gear assembly to No. 2
planetary carrier (19).
2] Align the pin holes on shaft (18) and
the carrier, and install shaft (18) by
tapping it lightly with a plastic ham-
mer.
a Install the shaft, while rotating
No. 2 planetary gear (21) with
care not to damage the thrust
washer.
50-300 18 PC200, 200LC, 220, 220LC-8M0

300 Power train
9. No. 2 sun gear

Install No. 2 sun gear (14).
10. No. 1 sun gear shaft

Install No. 1 sun gear shaft (11).
11. Thrust washer

Install thrust washer (13).
2) Install No. 2 planetary carrier assembly

(16).
a Align the four gear shaft ends of No. 2
planetary carrier assembly (16) with
the four dimples on the motor case
end face to install.
8. Thrust washer
Install thrust washer (15). 12. Ring gear
1) Install the O-ring to the hub.
2) Install ring gear (12) on the hub.
4 Ring gear: 45 kg
a Degrease the mating faces of the ring
gear and hub. Do not apply liquid gasket
on the mating faces.
a Align the bolt holes of the ring gear with
those of the hub.
PC200, 200LC, 220, 220LC-8M0 50-300 19

300 Power train

1) Assemble the No. 1 planetary carrier
a Replace thrust washers (7) and (10)
as well as pin (4) with new ones. (See
Pin (4): 3].)
a There is a punching mark made when
the pin was inserted on the end face
of carrier side hole (h) and the inside
wall of the hole is swelled at that
mark. Flatten the swelled part in
advance.
1] Assemble needle bearing (9) in No. 1
planetary gear (8), fit top and bottom
thrust washers (7) and (10), and then
set the gear assembly on No. 1 plan-
etary carrier (6).
2) Install No. 1 planetary carrier assembly

(3).
2] Align the pin holes in shaft (5) and the

No. 1 planetary carrier, and install the
shaft (5) by tapping it lightly with a
plastic hammer.
a Install the shaft, while rotating
No. 1 planetary gear (8) with care
not to damage the thrust washer.
3] Insert pin (4).
that the three claws (parts (f)) on
the periphery of the pin will not
be placed on the thin-wall parts
of No. 1 planetary carrier (parts
(g)). The thin-wall part may be on
the opposite side depending on
carriers. Check each carrier and
avoid setting any claw of the pin
to the thin-wall part. If there is a
groove, avoid the groove.
a After assembling the carrier,
check that No. 1 planetary gear
(8) rotates smoothly.
a After the pin is inserted, punch
the pins (C) on the carrier at 2
locations.
50-300 20 PC200, 200LC, 220, 220LC-8M0

300 Power train
14. Washer 15. Cover

Install washer (2). 1) Using eyebolts [1], install cover (1).
a After installing washer (2), measure
4 Cover: 25 kg
2
dimension (i) from the upper end face of
Mating faces of cover and ring gear:
No. 1 planetary gear (8) to that of ring
gear (12) to check for the correct assem-
a Do not apply liquid gasket (LG-6) to tap.
bly condition.
a If dimension (i) does not fall within 2.11
0.97 mm, the assembly is built incorrectly.
Recheck.
2) Using tool J7, install the 20 mounting

bolts.
3 Mounting bolt
1st time: 98 Nm {10 kgm}
2nd time:
80 to 90 deg. (rotating angle)
16. Refilling of oil

Tighten drain plug and supply power train oil
(TO30) from the oil filler port.
5 Final drive case: 5.4 l
a Do a final check of the oil level at the
determined position after installing the
final drive assembly to the chassis.
PC200, 200LC, 220, 220LC-8M0 50-300 21

300 Power train
SEN06144-00 Removal and installation of swing motor and swing machin-
Removal and installation of swing

motor and swing machinery
assembly 1
Removal
completely, after the engine is stopped,
loosen the hydraulic tank cap gradually to
reduce the pressure inside, and set the lock
a Attach an identification tag to each piping to 5. Disconnect 5 pcs. of swing motor hose (7)
avoid a mistake in the position of installation (11).
later. q (7): Between the swing motor
the control valve (port MA)
1. Remove cover (1). q (8): Between the swing motor
the control valve (port MB)
q (9): Suction hose (port S)
q (10), (11): Drain hose (port T)
6. Remove nipple (12) (port T).
8. Disconnect hose (14).
2. Open engine hood (2) and remove cover (3).
9. Remove mounting bolts (15) and disconnect

drain hose (16).
3. Disconnect hoses (4) and (5). (If equipped)
4. Disconnect the bracket hose assembly (6). (If

equipped)
50-300 22 PC200, 200LC, 220, 220LC-8M0

300 Power train
Removal and installation of swing motor and swing machin- SEN06144-00
10. Pull drain hose (16) out.
11. Disconnect pilot hose to cancel swing brake

(17) (B port).
Installation
12. Remove 12 pcs. of mounting bolt (18). [*1] q Installation is done in the reverse order of
removal.
[*1]
3 Mounting bolt: 490 608 Nm {50 62 kgm}

q Air bleeding
Bleed the air from the circuit between the valve
13. Lift and remove the swing motor and swing Testing and adjusting, Bleeding air from each
machinery assembly (19). part.
a Being careful not to damage hose (H), etc.
with bar [1], lift the swing motor and swing
m a c h i n e r y as s e m b l y g r a d ua l l y a n d
remove them.
a Being very careful for the drain hose, lift
them.
a Lift them with full attention until surpass
the hose of the center swivel joint.
4 Swing motor and swing machinery
assembly: 250 kg
PC200, 200LC, 220, 220LC-8M0 50-300 23

300 Power train
SEN06144-00 Disassembly and assembly of swing motor and swing ma-
Disassembly and assembly of Disassembly

swing motor and swing machinery 1. Set the swing motor and the swing machinery
assembly 1
assembly into block [1].
2. Oil drain
Special tools Loosen drain plug (39) and drain the oil inside
the swing machinery case.
Necessity
Symbol
Part number Part name 5 Swing machinery case:
Qty
PC200, 200LC-8M0: 7.1 l
1 796T-426-1410) Push tool t 1
PC220, 220LC-8M0: 8.2 l
2 796-426-1120 Push tool t 1 6
F 796T-426-1130 Plate t 1
3. Remove drain hose (1).
3 790-101-5421 Grip t 1
01010-81240 Bolt t 1 4. Remove 6 pcs. of the mounting bolt and
remove the swing motor assembly (2).
q Sectional view 4 Swing motor assembly: 70 kg
a A number shows the number in the text.
a Though the drawing is for PC200, 200LC-
8M0, PC220, 220LC-8M0 also operates in a
similar way basically. The different parts are
indicated in the text.
5. Remove No.1 sun gear (3).
6. No.1 carrier assembly

1) Remove No.1 carrier assembly (4).
50-300 24 PC200, 200LC, 220, 220LC-8M0

300 Power train
Disassembly and assembly of swing motor and swing ma- SEN06144-00
2) Disassemble No.1 carrier assembly by the 7. Remove No.2 sun gear (12).
following order.
1] Remove snap ring (5), thrust washer 8. Remove the mounting bolt and remove ring
(6), gear (7), bearing (8), thrust gear (13).
washer (9) in order.
2] Remove plate (10).
3] Reverse carrier (34) and remove
snap ring (35).
a PC200-8M0, PC200LC-8M0
9. Remove holder mounting bolt (14).
10. No.2 carrier assembly

1) Remove No.2 carrier assembly (15).
a PC220-8M0, PC220LC-8M0
3) Using push tool [2], remove shaft (11) from

carrier (34).
q Input pin press (reference):
11.2 25.8 kN {1,140 2,630 kg}
PC200, 200LC, 220, 220LC-8M0 50-300 25

300 Power train
2) Disassemble No.2 carrier assembly as fol- 11. Shaft and case assembly
lows. 1) Reverse shaft and case assembly (23).
1] Push pin (16) and shaft (17) from car- 2) Remove cover mounting bolt (24).
rier (18).
a After removing the shaft, remove
pin (16).
2] Remove thrust washer (19), gear
(20), and bearing (21).
3] Remove plate (22).
a PC200-8M0, PC200LC-8M0
3) Reverse shaft and case assembly (23)

again and set to the press.
4) Using push tool [3], remove shaft assem-
bly (25) from shaft and case assembly
(23).
a PC220-8M0, PC220LC-8M0
50-300 26 PC200, 200LC, 220, 220LC-8M0

300 Power train
12. Shaft assembly 14. Remove bearing (31) from case (30).
1) Using push tools [4], [5], remove shaft a Apply a suitable tool on the circumference
(26). of the outer race (thick line: (Q) section),
2) Remove bearing (27) and oil seal (29) strike the tool on the circumference with
from cover (28). the hammer lightly, equally, by turns, and
remove the bearing gradually.
a If the outer race is made incline, bearing
becomes hard, so remove it horizontally.
a PC220-8M0, PC220LC-8M0 only

13. Remove spacer (41) and O-ring (42) from shaft
(26).
PC200, 200LC, 220, 220LC-8M0 50-300 27

300 Power train
Assembly 2. Using push tool [9], press fit bearing (27) into
a Wash each part finely and check if there are case (30).
not a garbage, a crack, etc., and apply power a Use the new bearing.
train oil to the sliding portion and assemble
them.
a The bearing and the oil seal, which were

removed, are not re-used. New ones should be
used.
1. Oil seal
Using tool F3, install oil seal (29) into cover
(28).
a Be careful for the direction of the oil seal
(up and down).
2 Outside perimeter of oil seal:
Gasket sealant (LG-6)
a When press-fitting, take care so that gas- 3. Install cover assembly (33) into case assembly
ket sealant (LG-6) will not stick to the lip (32).
surface of the oil seal. 2 Cover mounting face:
a Be careful not to adhere gasket sealant
(LG-6) to drain port section (DP).
a Align the drain process section of cover
into the drain port section (DP).
a If tool F3 is not used, use the push tool

which can push outside perimeter section
(A) of oil seal (29).
a Be careful not to incline oil seal (29).
50-300 28 PC200, 200LC, 220, 220LC-8M0

300 Power train
4. Shaft and case assembly

a 1) and 2): PC220-8M0, PC220LC-8M0
only
1) Install O-ring (42) to spacer (41).
2) Using push tool [16], press-fit spacer (41)
to shaft (26).
a Be careful not to bite O-ring (42) to
the spacer.
3) Set case assembly (32) into shaft (26).

2 Oil seal lip section: Grease (G2-LI)
a Put case assembly not to interfere the
oil seal.
4) Using tool F1, push tool [10], and hammer
[11], strike inner race section of bearing
(27) not to fall down the shaft. 5. Bearing
a Let lifting tool [12] be slacked. Using tool F2 and push tool [15], press fit bear-
ing (31).
a When press-fitting the bearing, press both
inner and outer races of the bearing at the
same time. Avoid pressing the inner race
only.
9.4 35.5 kN {960 3,620 kg}
a After the bearing is press-fitted, check that
the case will turn freely.
5) Set into the press.

6) Using tool F1, push tools [13], [14], press
fit inner race section of bearing (27).
a Put in push tool [14] for the cases that
the case assembly is inclined a lot.
a If case assembly (32) is inclined,
strike the flange section lightly and
correct it.
a Just before oil seal (29) goes into
shaft (B) part, case assembly (32) is
leveled so that case assembly (32)
may be located at the center of shaft
(26), and be careful not to damage
the oil seal lip part.
PC200, 200LC, 220, 220LC-8M0 50-300 29

300 Power train
6. No.2 carrier assembly 4] Strike lightly with plastic hammer,

1) Assemble No.2 carrier assembly as fol- etc., align pin hole location of shaft
lows. (17) and carrier and install shaft (17).
a Since there is a mark to be caulked in a Install the shaft, rotating the plan-
the side hole (h) of carrier (18) at the etary gear. Take care so the
time of pin insertion, remove protru- thrust washer is not damaged.
sion for hole inner diameter before- 5] Insert pin (16),
hand. a As inserting the pin, install not to
(Refer to 5]) interfere claw section ((a) sec-
1] Incorporate plate (22) into carrier tion) which is in 3 places on cir-
(18). cumference into carrier thin part
2] Incorporate bearing (21) and 2 pcs. of ((b) section).
upper and lower thrust washer (19) However, actual thing may have
into gear (20). the thin section on the other side.
3] Set gear assembly into carrier (18). So make sure to confirm the
a PC200-8M0, PC200LC-8M0 actual thing and assemble not to
interfere claw section of the pin
into the thin part.
a After inserting the pin, caulk 2
parts of the carrier (c) around the
pin hole.
a PC220-8M0, PC220LC-8M0
2) Install No.2 carrier assembly (15) with bolt

(14).
2 Mounting bolt threaded section:
Adhesive compound (LT-2)
3 Mounting bolts:
157 196 Nm {16 20 kgm}
3) Install O-ring (36) into case (30).
50-300 30 PC200, 200LC, 220, 220LC-8M0

300 Power train
7. No.2 sun gear a PC220-8M0, PC220LC-8M0

Install No.2 sun gear (12).
8. Ring gear
Using eyebolt (M10 x 1.5), install ring gear
(13).
a Degrease mating face of ring gear (13)

and case (30).
a Do not adhere gasket sealant in mating
face of the ring gear and the case.
a Align the counter mark on the ring gear
(Portion (c)) and the convex portion on the
case flange (Portion (d)) in the position
illustrated in the following figure, and then
install it. 10. No.1 carrier assembly
3 Mounting bolts: 1) Assemble No.1 carrier assembly as fol-
157 196 Nm {16 20 kgm} lows.
1] Press fit shaft (11) into carrier (34) in
9. Install O-ring (37). the arrow direction (1st) until the slot
on the snap ring can be seen.
2] After installing snap ring (35), push
back (to the 2nd direction) from the
opposite side until the snap ring
adheres to the carrier (P) surface. Be
careful not to push too much.
11.2 25.8 kN {1,140 2,630 kg}
a PC200-8M0, PC200LC-8M0
3] Install plate (10) into carrier (34).

4] Install thrust washer (9), bearing (8),
gear (7), thrust washer (6), snap ring
(5) in order.
PC200, 200LC, 220, 220LC-8M0 50-300 31

300 Power train
a PC200-8M0, PC200LC-8M0 a PC200-8M0, PC200LC-8M0
a PC220-8M0, PC220LC-8M0 a PC220-8M0, PC220LC-8M0

a P: Press-fit plate
2) Install No.1 carrier assembly (4).

12. Swing motor assembly
11. No.1 sun gear assembly Put swing motor assembly (2) on ring gear
Install No.1 sun gear (3). (13).
a When installing the No.1 sun gear, be 4 Swing motor assembly: 70 kg
careful not to install it upside down.
a Install the No.1 sun gear with the tooth a Degrease mating face of swing motor
portion (Portion (e)) facing down. assembly (2) and ring gear (13).
a Do not adhere gasket sealant in mating
face of swing motor assembly (2) and ring
gear (13).
a After aligning the position of swing motor

assembly (2) and ring gear (13) as follows
and install them.
3 Mounting bolts:
59 74 Nm {6.0 7.5 kgm}
a PC200-8M0, PC200LC-8M0
q Align the relation between the positions of
the filler ((f) section) and convex portion of
the case ((d) section) as mentioned in the
drawing and install them.((c), (d): Above-
mentioned)
50-300 32 PC200, 200LC, 220, 220LC-8M0

300 Power train
14. Install the drain hose.

a As installing the hose, be careful that the
drain plug to be downward.
3 Drain hose:
128 186 Nm {13.0 19.0 kgm}
15. Oil refill

Fill the power train oil (TO30) from oil filler port
up to the standard level by tightening the drain
plug.
3 Drain plug:
19.6 24.5 Nm {2.0 2.5 kgm}
5 Swing machinery case
PC200, 200LC-8M0: 7.1 l
a PC220-8M0, PC220LC-8M0 PC220, 220LC-8M0: 8.2 l
q Align the relation between the positions of
the motor port ((g) section) and convex a Check oil level by using oil level gauge.
portion of the case ((d) section) as men-
tioned in the drawing and install them.((c),
(d): Above-mentioned)
13. Confirm mounting angle of elbow for drain (38):

15 and the tightening torque.
3 Elbow mounting nut:
128 186 Nm {13.0 19.0 kgm}
PC200, 200LC, 220, 220LC-8M0 50-300 33

300 Power train
SEN06144-00 Removal and installation of swing circle assembly
Removal and installation of swing Installation

circle assembly 1 q Installation is done in the reverse order of
removal.
Removal [*1]
1. Disassemble the revolving frame assembly a Let the soft zone position S mark of an inner
referring to the section Removal and installa- race: (a) and the soft zone position S mark of
tion of revolving frame assembly. an outer race: (b) to be right side of the body
as mentioned below and install it to the track
2. Sling swing circle assembly (1) at three points frame.
and remove the mounting bolt to remove the 2 Amount of filled grease:
assembly. [*1] Grease (G2-LI) :
4 Swing circle assembly: 270 kg 14.6 l (PC200, 200LC-8M0)
15.8 l (PC220, 220LC-8M0)
2 Swing circle mounting bolt threaded portion:
q In case of torque tightening:
3 Swing circle mounting bolt:
588 677 Nm {60 69 kgm}
(PC200/200LC-8M0)
716 814 Nm {73 83 kgm}
(PC220/220LC-8M0
q In case of angle tightening:
a For PC200-8M0
3 Swing circle mounting bolt:
1) Initial torque:
191.3 19.6 Nm {19.5 2 kgm}
2) After that, rotate the bolt 48 5.
50-300 34 PC200, 200LC, 220, 220LC-8M0

300 Power train
Removal and installation of swing circle assembly SEN06144-00
PC200, 200LC, 220, 220LC-8M0 50-300 35

SEN06144-00

2012 KOMATSU
All Rights Reserved
50-300 36
SEN06145-00
HYDRAULIC EXCAVATOR
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

Disassembly and assembly of carrier roller assembly .................................................................................... 2
Disassembly and assembly of track roller assembly ...................................................................................... 5
Removal and installation of idler and idler cushion assembly......................................................................... 7
Disassembly and assembly of idler................................................................................................................. 8
Disassembly and assembly of idler cushion ..................................................................................................11
Removal and installation of sprocket ............................................................................................................ 13
Separation and connection of track shoe assembly ..................................................................................... 14
Removal and installation of revolving frame assembly ................................................................................. 18
Removal and installation of counterweight assembly ................................................................................... 20
PC200, 200LC, 220, 220LC-8M0 50-400 1

SEN06145-00 Disassembly and assembly of carrier roller assembly
Disassembly and assembly of

carrier roller assembly 1
Special tools
Necessity
Symbol
Qty
L 1 790-434-1660 Installer t 1
q Sectional view
a A number shows the number in the text.
3. Remove ring (5) from roller (4).
4. Remove floating seal (6) from ring (5).

a Take care not to damage the sealing sur-
face.
Disassembly
1. Remove plug (9) and drain the oil from carrier
roller (1).
6 Carrier roller: 75 85 ml
5. Remove floating seal (7) from roller (4).
a Take care not to damage the sealing sur-
face.
2. Using push tool [1], push the end surface of a

shaft and remove followings from carrier roller
(1):
q Roller (4), ring (5) assembly, shaft (2) and
cover (3).
q Press fitting force (reference):
59 kN {6,000 kg} min.
a The press fitted shaft (2) and ring (5), and
also roller (4) and cover (3) will be both
disassembled.
a Cover (3) is placed under shaft (2).
50-400 2 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of carrier roller assembly SEN06145-00
6. Using push tools [2] and [3], remove bushing

(8) from roller (4).
Assembly
1. Using push tools [3] and [4], press fit bushing
(8) to roller (4).
a Press it from the side of cover (3).
2. Floating seal
1) Using tool L1, install floating seal (7) to
roller (4).
2) Using tool L1, install floating seal (6) to
ring (5).
a When installing the floating seal,
completely wash, degrease and dry
both O-ring and the surfaces where
the O-ring and the floating seal will
contact each other (hatched area in
the sketch). And take care that there
is no dust sticking on the contact sur-
face of floating seal.
a When fitting the floating seal, use tool
L1 and be sure that the O-ring is
pushed during the insertion.
a After inserting the floating seal, verify
that the inclination of the seal is less
than 1 mm per its diameter and that
the protrusion height of the seal
shown as (a) in the illustration falls
within the range of 7 11 mm.
PC200, 200LC, 220, 220LC-8M0 50-400 3

SEN06145-00 Disassembly and assembly of carrier roller assembly
3. Install roller (4) and ring (5) to shaft (2).

a On the sliding surfaces of floating seals,
apply some oil and take care not to have
any dirt stuck on them.
6. Fill carrier roller assembly (1) with oil and

tighten plug (9).
5 Carrier roller: 75 85 cc (EO30-DH)
3 Plug: 15 5 Nm {1.5 0.5 kgm}
4. To make the height gap between roller (4) and
ring (5) 1.8 0.2 mm, put washer [7] between
push tool [6] and roller (4), then press fit ring
(5) to shaft (2).
a The thickness of washer [7] is 1.8 0.2
mm.
a Use push tool [5] to support shaft (2) on it.
5. Using push tool [8], press fit cover (3) to roller

(4).
a Degrease, wash and dry the surfaces
where roller (4) and cover (3) fit tight.
q Press fitting force (reference):
59 kN {6,000 kg} min.
50-400 4 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of track roller assembly SEN06145-00
Disassembly and assembly of Assembly

track roller assembly 1 1. Using push tool [1], press fit bushings (9) and
(10) to roller (4).
Special tools 2. Fit an O-ring and install collar (8) to shaft (5),
and insert pin (7).
Necessity
Symbol
Qty
L 2 796-670-1020 Installer t 1
Disassembly
1. Remove pin (1) and then collar (2).
2. Remove floating seal (3) from collar (2) and

roller (4).
3. Pull out roller (4) from shaft (5) and collar (8)
assembly.
a Since 195 cc of oil is filled in, drain it at 3. Using tool L2, install floating seal (6a) to collar
this timing, or underlay some cloth to pre- (8).
vent any careless smearing. a When installing the floating seal, com-
pletely wash, degrease and dry both O-
4. Pull out other side floating seal (6) from roller ring and the surfaces of floating seal
(4), shaft (5) and collar (8) assembly. where they contact each other (shown
hatched area in the illustration). And take
5. Remove pin (7) and then collar (8) from shaft care that there is no dust sticking on the
(5). contact surfaces of floating seal.
a After inserting the floating seal, verify that
6. Remove bushings (9) and (10) from roller (4). the inclination of the seal is less than 1
mm per its diameter and that the protru-
sion height shown as (a) in the illustration
falls within the range of 7 11 mm.
PC200, 200LC, 220, 220LC-8M0 50-400 5

SEN06145-00 Disassembly and assembly of track roller assembly
4. Using tool L2, install floating seals (6b) and 7. Using tool L2, install floating seal (3a) to collar
(3b) to roller (4). (2).
a As to notes for installation of floating seals a As to notes for installation of floating seal
(6b) and (3b), refer to a marked com- (3a), refer to a marked comments in the
ments in the step 3. step 3.
a On the sliding surfaces of the floating
seals, apply some oil and take care not to
have any dust stuck on them.
8. Fit an O-ring and install collar (2) to the shaft

with pin (1).
9. Add oil and tighten the plug.

5 Amount of oil: 190 200 cc (EO30-DH)
3 Plug: 15 5 Nm {1.5 0.5 kgm}
5. Install shaft (5) to roller (4).
6. Put roller (4) and shaft (5) assembly upside

down.
50-400 6 PC200, 200LC, 220, 220LC-8M0

Removal and installation of idler and idler cushion assem- SEN06145-00
Removal and installation of idler 4. Disconnect idler cushion assembly (4) from
and idler cushion assembly 1
idler assembly (3).
4 Idler assembly: 105 kg
Removal
1. Separate the track shoe assembly. For details, 4 Idler cushion assembly: 130 kg
see "Separation and connection of track shoe
assembly".
2. By using bar [1], move idler and idler cushion

assembly (1) forward to a position where it can
be lifted.
Installation
q Perform installation in the reverse order to
removal.
3. Lift idler and idler cushion assembly (1), pull it
forward to remove it from track frame (2).
4 Idler and idler cushion assembly:
235 kg
PC200, 200LC, 220, 220LC-8M0 50-400 7

SEN06145-00 Disassembly and assembly of idler
Disassembly and assembly of 4. Remove floating seals (6) on the other side
idler 1
from idler (4) and the assembly of shaft (5) and
support (7).
Special tools
Necessity
Symbol
Qty
L 3 791-530-1510 Installer t 1
Figure of structure
5. Remove dowel pin (8), and then remove sup-

port (7) from shaft (5).
6. Remove bushings (9) and (10) from idler (4).
Disassembly
1. Remove dowel pin (1) to remove support (2).
2. Remove floating seals (3) from support (2) and

idler (4).
3. Remove idler (4) from the assembly of shaft (5)

and support (7).
a Since approximately 250 cc of oil is filled
in, drain it at this timing, or underlay some
cloth against any careless smearing.
50-400 8 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of idler SEN06145-00
Assembly
1. Press fit bushings (9) and (10) to idler (4).
2. Install shaft (5) with O-ring (12) to support (2),

and insert dowel pin (1).
4. Install the assembly of shaft (5) and support (2)

to idler (4).
3. By using tool L3, install floating seals (3) to

idler (4) and the assembly of shaft (5) and sup-
port (2).
a Completely clean, degrease, and dry the
contact surfaces (hatched area shown in
the figure) of the floating seal and the O-
ring.
a Apply oil to the sliding surface of the float-
ing seal, and take care not to have any dirt
stuck on it.
a After inserting the floating seals, check
that the inclination is less than 1 mm and
the protrusion (a) is within the range of 7
to 11 mm.
PC200, 200LC, 220, 220LC-8M0 50-400 9

SEN06145-00 Disassembly and assembly of idler
5. Turn it over, and supply oil between shaft (5) 7. Install shaft (5) with O-ring (11) to support (7),
and idler (4). and insert dowel pin (8).
a See figure of structure.
5 Amount of oil to be sealed (EO-30DH):
245 to 255 cc
8. Supply oil and tighten plug (13).
3 Plug (13):
157 to 255 Nm {16 to 26 kgm}
6. By using tool L3, install floating seal (6) to idler

(4) and support (7).
a Completely clean, degrease, and dry the a When mounting the idler assembly on the
contact surfaces (hatched area shown in machine, make sure that plug (13) faces
the figure) of the floating seal and the O- right side of the machine.
ring.
a Apply oil to the sliding surface of the float-
ing seal, and take care not to have any dirt
stuck on it.
a After inserting the floating seals, check
that the inclination is less than 1 mm and
the protrusion (a) is within the range of 7
to 11 mm.
50-400 10 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of idler cushion SEN06145-00

idler cushion 1 1. Remove piston assembly (2) from idler cushion
assembly (1).
Special tools 2. Disassembly of idler cushion assembly

1) Set idler cushion assembly (1) to tool M1.
Necessity
Symbol
Part number Part name a Load at installed length of spring:

PC200-8M0: 109.3 kN {11,150 kg}
Qty
PC200LC-8M0, PC220-8M0,
791-600-2001 Compressor (A) t 1 PC220LC-8M0: 126.5 kN {12,900 kg}
or
791-685-8006 Compressor (B) t 1
790-201-2780 Spacer t 1
1 791-635-3160 Extension t 1
Cylinder
790-101-1600 t 1
(686 kN {70 ton})
790-101-1102 Pump t 1
M 790-640-2180 Guide bolt t 1
790-101-5201 Push tool kit (B) q 1
790-101-5241 Plate 1
2
790-101-5221 Grip 1
01010-51225 Bolt 2 2) Apply hydraulic pressure gradually to
790-201-1500 Push tool kit q 1 compress the spring and remove lock
790-201-1620 Plate 1 plate (3) and nut (4).
3 a Compress the spring until the nut
790-101-5021 Grip 1
becomes loose.
01010-50816 Bolt 1 a Release the hydraulic pressure slowly
k Since the load at installed length of the to release the compression of the
spring is large and dangerous, set the spring.
spring securely to the tool. a Free length of spring:
PC200-8M0: 503 mm
a Figure of structure PC200LC-8M0, PC220-8M0,
PC220LC-8M0: 561 mm
3) Remove yoke (6) and cylinder (7) from
spring (5).
4) Remove snap ring (8), dust seal (9) and
bushing (10), in turn from cylinder (7).
3. Further disassembly of piston assembly (2)

1) Remove lock plate (12) from piston (11),
and then remove valve (13).
2) Remove snap ring (14), then remove U-
packing (15) and ring (16).
PC200, 200LC, 220, 220LC-8M0 50-400 11

SEN06145-00 Disassembly and assembly of idler cushion
Assembly 5) Apply hydraulic pressure slowly to com-

1. Assembly of piston (2) press the spring, and then tighten nut (4)
1) Install ring (16) and U-packing (15) to pis- so that the installed length of the spring is
ton (11), and secure them with snap ring dimension (a) and secure it with lock plate
(14). (3)
2) Tighten valve (13) lightly, and secure it a Installed length (a) of spring:
with lock plate (12). PC200-8M0: 389 mm
PC200LC-8M0, PC220-8M0,
2. Assembly of idler cushion PC220LC-8M0: 433 mm
1) Using tool M2, press fit bushing (10) into
cylinder (7).
2) Using tool M3, install dust seal (9) to cylin-
der (7).
3) Secure them by using snap ring (8).
6) Remove idler cushion assembly (1) from

tool M1.
3. Install piston assembly (2) to idler cushion

assembly (1).
4) Install plate (7a), cylinder (7) and yoke (6) 2 Sliding surface of cylinder:
to spring (5). Install the assembly to tool Grease (G2-LI)

M1. 2 Wear ring: Grease (G2-LI)
2 Sliding surface of cylinder: a Install the piston assembly with the valve
Grease (G2-LI) installed position facing outward.
a Pump 300 cc of grease (G2-LI) into the
cylinder and bleed air. Check that grease
comes out of the grease hole.
50-400 12 PC200, 200LC, 220, 220LC-8M0

Removal and installation of sprocket SEN06145-00
Removal and installation of Installation

sprocket 1 q Installation is done in the reverse order of
removal.
Removal [*1]
1. Expand the track shoe assembly referring to 2 Thread of sprocket mounting bolts:
"Expansion and installation of track shoe Adhesive compound (LT-2)
assembly". 3 Sprocket mounting bolts:
441 490 Nm {45 50 kgm}
2. Swing work equipment 90, push up chassis
with work equipment and place block [1]
between track frame and track shoe.
3. Remove sprocket (2), hanging as follows.

1) Remove fixing bolt (1). [*1]
a Before removing the final fixing bolt,
place block [2] under sprocket (2).
2) Put sprocket (2) on block [2], make a
clearance from final drive (FD), and lead
sling [3] in between.
4 Sprocket: 40 kg
PC200, 200LC, 220, 220LC-8M0 50-400 13

SEN06145-00 Separation and connection of track shoe assembly
Separation and connection of

track shoe assembly 1
Special tools
Necessity
Symbol
Qty
791-630-3000 Remover and installer t 1
Cylinder
R 790-101-1300 t 1
(980 kN {100 ton})
790-101-1102 Pump t 1
Separation 4. Remove track shoes (5) on the right and left

1. Turn the upper structure by 90. sides of master pin (2) of track (3). [*2]
a Loosen the four bolts by one to two turns
respectively and check that they rotate
2. Loosen lubricator (1) to decrease the track
lightly, and then pull them out.
shoe tension. [*1]
k Since the internal pressure of the
a If a bolt does not turn smoothly and it is
unscrewed forcibly, the threads of itself
adjustment cylinder is very high, do not
and the link may be damaged.
loosen the lubricator more than one
turn. If the grease does not come out
sufficiently, start the engine and move
the machine backward and forward.
5. Using tool R, remove master pin (2). [*3]

a Press out master pin (2) with guide pin [1].
3. Position master pin (2).

1) Lift tracks (3) by stretching the work equip-
ment against ground.
2) Move master pin (2) to a position above
the idler where it can be removed easily.
3) Relieve the extended work equipment,
and lower the machine.
50-400 14 PC200, 200LC, 220, 220LC-8M0

Separation and connection of track shoe assembly SEN06145-00
6. Move guide pin [1] and place block [2] under Installation
track shoe (3) to support in front of the idler. 1. While tensing wire [3] with a forklift truck, work
equipment, etc., move the machine forward
7. Pull out guide pin [1] and remove block [2] so slowly to wind track shoe (3).
that track shoe (3) can be separated.
2. By using bar [4], hammer [5], etc., wind track

8. Move the machine slowly in reverse to sepa- shoe (3) and match the pin holes of link (6).
rate the track shoe (3). [*4] a Place block [2] etc. under track shoe (3) in
front of the idler to support the track shoe.
PC200, 200LC, 220, 220LC-8M0 50-400 15

SEN06145-00 Separation and connection of track shoe assembly
3. Drive guide pin [1] into link (6).
[*3]
a Apply grease to master pin (2). (in the area
where bushing (4) and master pin (2) come
Perform connection in the reverse order to separa- contact: shown hatched)
2 Between bushing and master pin (hatched
tion.
area):
[*1] Grease NIGTIGHT LYK-2 from Nippon
a See Testing and adjusting, "Testing and adjust- grease Co., Ltd.: part No. 44392708
ing track shoe tension".
[*2]
Installation of track shoe (5)
1. Remove mud, dirt, and rust from the mating
faces of shoe (5) and link and the seating
faces of bolt (7) and nut.
2. Install shoe (5).

3 Mounting bolts (7) (4 pieces):
1) Tighten to 490 50 Nm {50 5 kgm}.
a Finger-tighten the four bolts until the
mating faces of the link are fitted.
a If the bolts are tightened forcibly
before the link mating faces are fitted,
the threads of bolts and link may be
damaged.
2) Retighten by 120 10.
50-400 16 PC200, 200LC, 220, 220LC-8M0

Separation and connection of track shoe assembly SEN06145-00
a Apply grease to the contact surfaces (B) of the

bushing end and dust seal.
2 Contact surface (B portion) between bushing
and dust seal:
Grease NIGTIGHT LYK-2 from Nippon
grease Co., Ltd.: part No. 44392708
a Press fit master pin (2) to push guide pin [1]
out.
a Using tool R, press fit master pin (2), so that
the protrusion amount (a) of the master pin is
the dimension designated below.
Protrusion of master pin
a: 2.5 1 mm
PC200, 200LC, 220, 220LC-8M0 50-400 17

SEN06145-00 Removal and installation of revolving frame assembly

revolving frame assembly 1
Removal
k Safely lower the work equipment to the
ground by extending the arm and the
bucket completely. Set the lock lever in the
lock position,
1. Disassemble the work equipment assembly,

referring to the "Removal and installation of
work equipment assembly" section in this man-
ual.
2. Disassemble the counterweight assembly,

referring to the "Removal and installation of
counterweight assembly" section in this man-
ual.
3. Disconnect 4 boom cylinder hoses (1).

a Plug the hose to stop oil flow-out.
6. Remove fuel filter and bracket assembly (5).

a Fix it temporarily on the engine.
a When other parts can interfere with the lift-
ing hook in removal of the revolving frame,
such parts must be removed beforehand.
4. Sling boom cylinder assembly (2).
5. Remove plate (3) and pin (4), and then lift

boom cylinder assembly (2) to remove.
a Remove the boom cylinder assembly on
the opposite side in the same manner.
4 Boom cylinder assembly:
180 kg (PC200/200LC-8M0)
200 kg (PC220/220LC-8M0)
50-400 18 PC200, 200LC, 220, 220LC-8M0

Removal and installation of revolving frame assembly SEN06145-00
7. From center swivel joint assembly, disconnect Installation

6 hoses (8) (13). q Installation is done in the reverse order of
q (8): Center swivel joint (D port) removal.
Swing motor (T port)
q (9): Center swivel joint (E port) [*1]
solenoid valve 2 Swivel circle mating surface:
q (10): Center swivel joint (B port) Gasket sealant (LG-1)
L.H. travel control valve (A2 port) 2 Thread of revolving frame mounting bolts:
q (11): Center swivel joint (D port) Adhesive compound (LT-2)
R.H. travel control valve (B5 port) q In case of torque tightening:
q (12): Center swivel joint (A port) 3 Mounting bolts:
L.H. travel control valve (B2 port) 716 814 Nm {73 83 kgm}
q (13): Center swivel joint (C port) q In case of angle tightening:
R.H. travel control valve (A5 port) 3 Mounting bolts:
1) Initial torque:
8. Pull out pin (14) on the center swivel joint, and 294.2 29.4 Nm {30 3 kgm}
disconnect jam plate (15) from the center 2) Then tighten the bolts turning by 60 6.
swivel joint.
q Refilling with oil (Hydraulic tank)

q Air bleeding
Bleed air from the travel motor referencing the
"Bleeding air from each part" section in the
Testing and adjusting chapter of this manual.
9. Remove 32 mounting bolts, and remove

revolving frame assembly (16) off slinging it up.
[*1]
a Using levers and blocks, hold the balance
of revolving frame assembly front and
rear, and left and right.
k When removing the revolving frame
assembly, take care so that it does not
hit the center swivel joint assembly.
4 Revolving frame assembly:
5,100 kg (PC200/200LC-8M0)
5,500 kg (PC220/220LC-8M0)
PC200, 200LC, 220, 220LC-8M0 50-400 19

SEN06145-00 Removal and installation of counterweight assembly

counterweight assembly 1
Special tools
Necessity
Symbol
Part No. Part Name
Q'ty
Commercially
Impact wrench q 1
available
Z
Commercially Socket wrench
q 1
available (width across flats: 41 mm)
a Use an impact wrench or a socket wrench cor-

responding to the tightening torque of the
counterweight mounting bolt.
3 Counterweight mounting bolt:
1,180 1,470 Nm {120 150 kgm}
Removal
1. Mirror specification
1) Remove mirror (1).
2) Sling counterweight assembly (2) tempo-
rarily.
2. Remove 4 pieces of mounting bolt (3). [*1]

a Record the locations where the shims
were used.
3. Sling counterweight assembly (2) off. [*2]

a Be careful not to bump it against the
engine or radiator or cooler assembly.
4 Counterweight assembly:
3,750 kg (PC200/200LC-8M0)
5,050 kg (PC220/220LC-8M0)
50-400 20 PC200, 200LC, 220, 220LC-8M0

Removal and installation of counterweight assembly SEN06145-00
Installation a Rear view (Enlarged drawing for right

q Confirm the followings before installing the hand side)
counterweight.
a Confirm that recirculation prevention sheets (4)
to (9) are installed securely.
PC200/200LC: (4) only
PC220/220LC: (4) to (9)
a Install recirculation prevention sheets (4) to (9)
securely. If they are peeled, heated air in the
engine room may flow into cooling side, and it
will cause engine over heat.

moval.
[*1]
2 Mounting bolt threaded section:
3 mounting bolts:
1,180 1,470 Nm {120 150 kgm}
[*2]
a Installation and adjustment of counterweight
1) Using shims, adjust the differences in
level or gaps between the counterweight
and the exterior of machine body.
2) Fix the counterweight so that the clear-
ances in the direction of front and rear are
even and within the limit of 10 5 mm for
both from the doors and from the revolving
frame.
3) The difference in level in left to right direc-
tion between the exterior of door (D) and
counterweight (C)
(a): 10 4 mm
The difference in level in left to right direc-
tion between revolving frame (R) and
counterweight (C)
(b): 5 mm or less
The difference in level in up and down
direction between exterior upper cover
(UC) and counterweight (C)
(c): 0 5 mm
are the respective limits for the mounting
adjustment.
PC200, 200LC, 220, 220LC-8M0 50-400 21

SEN06145-00

2012 KOMATSU
All Rights Reserved
50-400 22
SEN06146-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
500 Hydraulic system

Removal and installation of center swivel joint assembly ............................................................................... 2
Disassembly and assembly of center swivel joint assembly ........................................................................... 4
Removal and installation of hydraulic tank assembly...................................................................................... 5
Removal and installation of control valve assembly ....................................................................................... 9
Disassembly and assembly of control valve ................................................................................................. 14
Removal and installation of hydraulic pump assembly ................................................................................. 19
Removal and installation of oil seal in hydraulic pump input shaft ................................................................ 23
Disassembly and assembly of work equipment PPC valve assembly .......................................................... 24
Disassembly and assembly of travel PPC valve........................................................................................... 26
Disassembly and assembly of work equipment cylinder............................................................................... 28
PC200, 200LC, 220, 220LC-8M0 50-500 1

SEN06146-00 Removal and installation of center swivel joint assembly
Removal and installation of center 4. Disconnect 8 hoses (7) through (14).

swivel joint assembly 1
q (7): Center swivel joint (E port)
L.H travel motor (P port)
q (8): Center swivel joint (E port)
Removal R.H travel motor (P port)
k Lower the work equipment to the ground q (9): Center swivel joint (D port)
completely, after the engine is stopped, Swing motor (T port)
loosen the hydraulic tank cap gradually to q (10): Center swivel joint (E port)
reduce the pressure inside, and set the lock Solenoid valve
lever in the lock position. q (11): Center swivel joint (B port)
k Disconnect the cable from the negative () L.H. travel control valve (A2 port)
terminal of the battery. q (12): Center swivel joint (D port)
a Attach an identification tag to each piping to R.H. travel control valve (B5 port)
avoid a mistake in the position of installation q (13): Center swivel joint (A port)
later. L.H. travel control valve (B2 port)
q (14): Center swivel joint (C port)
1. Swing to right 45. (For hydraulic tank oil drain) R.H. travel control valve (A5 port)
a For the way not to drain the hydraulic tank
oil by using oil stopper, see "Removal and 5. Pull out pin (15) on the center swivel joint side,
installation of hydraulic pump assembly". and remove the jam plate from center swivel
2. Drain hydraulic tank oil. joint. [*1]
6 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
3. Disconnect 6 center swivel joint horses (1)

through (6) from the travel motor.
q (1): Center swivel joint (T port)
L.H. travel motor (T port)
q (2): Center swivel joint (T port)
R.H. travel motor (T port)
q (3): Center swivel joint (B port)
L.H travel motor (PA port)
q (4): Center swivel joint (D port)
R.H travel motor (PB port)
q (5): Center swivel joint (A port)
L.H travel motor (PB port)
q (6): Center swivel joint (C port)
R.H travel motor (PA port)
50-500 2 PC200, 200LC, 220, 220LC-8M0

Removal and installation of center swivel joint assembly SEN06146-00
6. Remove 4 pieces of mounting bolt (16). Installation

removal.
[*1]
a Set the lock plate with red mark at upper side.
[*2]
Install the center swivel joint (CSJ) facing in the
direction shown in the figure. (The figure shows the
machine body as seen from above.)
a S: Sprocket
A D: Port name
7. Lift off center swivel joint assembly (17) to

remove. [*1]
4 Center swivel joint assembly: 40 kg

5 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
58.8 78.5 Nm {6.0 8.0 kgm}
q Air bleeding
part".
PC200, 200LC, 220, 220LC-8M0 50-500 3

SEN06146-00 Disassembly and assembly of center swivel joint assembly
Disassembly and assembly of 1. Remove elbows (1), (2) and tee (3).
center swivel joint assembly 1
3. Remove snap ring (5) and ring (6).

Special tools
4. Using tool T1, pull out swivel shaft (8) from
Necessity
Symbol
Part number Part name swivel rotor (7).
Qty
790-101-2501 Push puller q 1
790-101-2510 Block 1
790-101-2520 Screw 1
791-112-1180 Nut 1
T1 790-101-2540 Washer 1
790-101-2630 Leg 2
790-101-2570 Plate 4
790-101-2560 Nut 2
790-101-2650 Adapter 2
5. Remove seal (9) and O-ring (10) from swivel

Disassembly rotor (7).
6. Remove dust seal (11) from cover (12).
Assembly
a See figure at left.
1. Install seal (9) and O-ring (10) to swivel rotor

(7).
2. Install dust seal (11) to cover (12).
3. Install cover (12) to swivel shaft (8).
4. Set swivel shaft (8) to block, then using push

tool, tap swivel rotor (7) with a plastic hammer
to install.
2 Contact surface of rotor, shaft:
Grease (G2-LI)
a When installing rotor, be extremely careful
not to damage the dust seal and O-ring.
5. Install ring (6) and fix with snap ring (5).
6. Fit O-ring and install cover (4).

3 Mounting bolts:
31.4 2.9 Nm {3.2 0.3 kgm}
7. Install elbows (1), (2) and tee (3).

3 Elbow (1): 128 186 Nm {13 19 kgm}
3 Elbow (2), tee (3):
35 63 Nm {3.5 6.5 kgm}
50-500 4 PC200, 200LC, 220, 220LC-8M0

Removal and installation of hydraulic tank assembly SEN06146-00
Removal and installation of 4. Carry out item 5. 19. of "Removal and instal-
hydraulic tank assembly 1
lation of hydraulic pump assembly" and
remove frame (2) between hydraulic tank and
engine. For that purpose, remove below
k Lower the work equipment to the ground mainly.
completely, after the engine is stopped, q Engine hood
loosen the hydraulic tank cap gradually to q Control valve upper cover
reduce the pressure inside, and set the lock q Cover between hydraulic pump and en-
lever in the lock position. gine
k Disconnect the cable from the negative () q Air cleaner upper cover
Removal
a Attach an identification tag to each piping to
later.
1. Swing to right 45. (For hydraulic tank oil drain)
5. Shift cover (3) forward.

a Keep away from bolt (B).
3. Drain hydraulic tank oil. [*1]

6 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
PC200, 200LC, 220, 220LC-8M0 50-500 5

SEN06146-00 Removal and installation of hydraulic tank assembly
7. Disconnect drain hoses (6) through (8). 10. Disconnect drain hoses (13) through (18).
q (6), (7): From control valve q (13): Solenoid valve drain
q (8): From oil cooler upper side q (14): Main valve drain
q (15): Pressure reducing valve drain
8. Disconnect filter bracket (11). q (16): PPC drain
q (17): Swing motor drain
9. Remove frame (12). q (18): Pump drain
12. Disconnect suction hose (20). [*2]

figure below.)
50-500 6 PC200, 200LC, 220, 220LC-8M0

Removal and installation of hydraulic tank assembly SEN06146-00
13. Remove 6 mounting bolts (21). [*3] Installation

removal.
[*1]
58.8 78.5 Nm {6.0 8.0 kgm}
[*2]
a Use new MIKALOR clamps.
1) Apply adhesive evenly over the tube side.
2 Apply evenly over the tube side:
Adhesive (THREEBOND No.4314)
2) Set the hose to the original position.
a Reference
14. Lift off hydraulic tank assembly (22) to remove Hose insertion length: 85 mm (L.H and R.H)
it. 3) Set the bridge (BR) under the clamp bolt and
4 Hydraulic tank assembly: 130 kg lap it over band (BD) at least (b) reaches 5
mm.
4) Tightening of the clamp.
(THREEBOND PANDO 18B)
q When reusing the hose

Install the clamp to the clamp mark made on
the hose.
3 Clamp bolt (BC): Min. 6 Nm {0.6 kgm}

Tighten until dimension (BDG) is as follows.
BDG: 7 10 mm
PC200, 200LC, 220, 220LC-8M0 50-500 7

SEN06146-00 Removal and installation of hydraulic tank assembly
[*3]
3 Mounting bolt:
245 309 Nm {25 31.5 kgm}

5 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
q Air bleeding
part".
50-500 8 PC200, 200LC, 220, 220LC-8M0

Removal and installation of control valve assembly SEN06146-00
Removal and installation of 4. Disconnect connector (9) from clip.

control valve assembly 1
(From the top)
V06
V05
Removal V04
k Park the machine on a level surface, lower V03
the work equipment to the ground so that it V02
is stable, and stop the engine. V01
terminal of the battery. 5. Disconnect clamp (10).
k Release the remaining pressure in the
hydraulic circuit. For details, see Testing 6. Keep away solenoid assembly (11) from con-
and adjusting, "Releasing residual pres- trol valve bracket (B).
sure from hydraulic circuit".
later.
7. See "Removal and installation of engine and

hydraulic pump assembly" to remove below.
q Engine hood
q Control valve upper cover
q Cover between hydraulic pump and en-
gine
2. Drain hydraulic tank oil. q Frame between control valve and engine
a Make the swing angle almost 0 for below q Cover between control valve and engine
(3. 6.) and to remove the control valve
mounting bolt. 8. Disconnect PLS1 port hose (12).
a Hose band: No color
6 Hydraulic tank:
237 l (PC200/200LC-8M0)
9. Disconnect PLS2 port hose (13).
244 l (PC220/220LC-8M0)
a Hose band: red
a For the way not to drain the hydraulic tank
oil by using oil stopper, see "Removal and
installation of hydraulic pump assembly".
3. Disconnect drain hoses (2) through (8).

(Band color)
q (2): No color
q (3): Red
q (4): No color
q (5): No color
q (6): Red and yellow
q (7): Brown
q (8): No color
PC200, 200LC, 220, 220LC-8M0 50-500 9

SEN06146-00 Removal and installation of control valve assembly
10. Disconnect connectors V 23 (14) and V24 (15). 16. Disconnect hoses (20) through (23).
a Band: (14) red, (15) white a Hose band: No color
q (20): relief valve
11. Disconnect connectors (14) and (15) from clip. q (21) (23): If equipped
12. Disconnect bracket (16). 17. Disconnect L.H. PPC hose (24). From the top,
Bucket DUMP (Hose band: black)
L.H. travel reverse (Hose band: no color)
Boom RAISE (Hose band: green)
L.H. swing (Hose band: red)
R.H. travel reverse (Hose band: blue)
Arm OUT (Hose band: yellow)
18. Disconnect Ls separation hose (25).
14. Disconnect R.H. PPC hose (18). From the top,

OPT (Hose band: yellow)
Bucket CURL (Hose band: white)
L.H. travel forward (Hose band: red)
Boom LOWER (Hose band: brown)
R.H. swing (Hose band: no color)
R.H. travel forward (Hose band: green)
Arm IN (Hose band: blue)
20. Disconnect drain hose (27).
15. Disconnect hose (19). (Hose band: brown) a Disconnect the hose clamp.
q (19): PST port hose (solenoid)
50-500 10 PC200, 200LC, 220, 220LC-8M0

21. Disconnect connector P26 (28). 25. Disconnect hoses (32) through (36) from the
(front pump pressure sensor) rear side.
q (32): PP1 port hose (rear pump)
22. Disconnect bracket (29), then bracket junction q (33): PPS2 port hose (front pump)
box (J). Hose band: blue
q (34): PR port hose (pump)
Hose band: yellow
q (35): PP2 port hose (front pump)
q (36): Drain hose (hydraulic tank)
23. Disconnect hoses (30) and (31).

q (30): Between control valve and swing
motor
q (31): Between control valve and hydraulic
tank 26. Disconnect connector P25 (37).
(Rear pump pressure sensor)
27. Disconnect hoses (38) and (39).

q (38): ATT port hose (filter) (If equipped)
q (39): T port hose (under the oil cooler)
24. Disconnect back pressure compensation con-

nector (31a).
a Rear figure
PC200, 200LC, 220, 220LC-8M0 50-500 11

SEN06146-00 Removal and installation of control valve assembly
28. Remove boom tube mounting clamp (40). q (46): From the top
B-1 port hose (If equipped)
29. Disconnect 4 boom hoses (41). B1 port hose (Bucket bottom side)
B2 port hose (Swivel joint A port)
30. Disconnect horn (42) from bracket. B3 port tube (Boom head side)
B4 port hose (Swing motor MB port)
B5 port hose (Swivel joint D port)
B6 port hose (Arm bottom side)
q BP1 port hose (25) (above)
q T1 port (drain) hose (27) (above)
31. Remove boom tube mounting clamp (43).
33. Disconnect 14 control valve hoses and 2

tubes.
q (45): From the top
A-1 port hose (If equipped)
A1 port hose (Bucket head side)
A2 port hose (Swivel joint B port)
A3 port tube (Boom bottom side)
A4 port hose (Swing motor MA port)
A5 port hose (Swivel joint C port)
A6 port hose (Arm head side)
50-500 12 PC200, 200LC, 220, 220LC-8M0

34. Remove mounting bolt, and lift off control valve Installation
assembly (47) to remove. q Installation is done in the reverse order of re-
4 Control valve assembly: 260 kg moval.

5 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
58.8 78.5 Nm {6.0 8.0 kgm}
q Air bleeding
part".
PC200, 200LC, 220, 220LC-8M0 50-500 13

SEN06146-00 Disassembly and assembly of control valve
Disassembly and assembly of Procedures for replacing pressure com-

control valve 1
pensation valve seal
a Since many types of pressure compensation
valves are installed, put a mark on each and
a This section explains only the precautions for
record the installed position when removing
assembling the contol valve assembly.
them.
1. Remove piston (2), plug (3) and spring (4) from
Special tools pressure compensation valve (1).
Necessity
Symbol
Part number Part name 2. Remove seals (5) and (6) from piston (2).
Qty
796-946-1310 Guide f21.8 mm
t 1
(For 723-46-40100)
796-946-1610 Guide f21.4 mm
t 1
(For 723-46-41100)
796-946-1810 Guide f21.2 mm
2 t 1
(For 723-46-43100 and 723-46-43400)
796-946-1910 Guide f21.0 mm
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2210 Guide f20.6 mm
t 1
(For 723-46-45100 and 723-46-45700)
796-946-1320 Guide f21.8 mm a There are many types of pistons.
t 1
(For 723-46-40100)
3. Place tool T2 on piston (2), put seal (5) on the
796-946-1620 Guide f21.4 mm
t 1 tool, and then push the seal down slowly in
(For 723-46-41100) such a way that it expands evenly to install it in
796-946-1820 Guide f21.2 mm position.
t 1 a Put the seal on the tool and push it down
(For 723-46-43100 and 723-46-43400)
3 to the flat part of the tool. Then you may
796-946-1920 Guide f21.0 mm
T t 1 install the tool to the piston to push in the
(For 723-46-46101 and 723-46-46300) seal further.
796-946-2220 Guide f20.6 mm
t 1
(For 723-46-45100)
796-946-1420 Guide f21.6 mm
t 1
(For 723-46-42700)
796-946-1330 Sleeve
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
t 1
(For 723-46-43100 and 723-46-43400)
4
796-946-1930 Sleeve
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)
50-500 14 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of control valve SEN06146-00
4. Repeat the same process to install another a After the installation, push piston (2) by
seal (6). Place tool T3 on the same end of pis- hand and check that the piston returns
ton (2). Slowly push seal (6) down in such a with the spring force alone.
way that it expands evenly to install it in posi-
tion.
a Put the seal on the tool and push it down
to the flat part of the tool. Then you may
install the tool to the piston to push in the
seal further.
5. Install settling tool T4 on piston (2) and keep it

installed for approximately one minute so that
seals (5) and (6) fit in.
a Check that there is no extrusion or cut on
the seal.
6. Fit plug (3) and spring (4) to piston (2), then

install pressure compensation valve (1).
PC200, 200LC, 220, 220LC-8M0 50-500 15

Assembly of control valve a Assemble filter (9) installed to the bottom ports
(PLS1) and (PLS2) in the direction shown in
the figure below. (Pay attention to the position
of caulked portion (10).)
a Apply engine oil to the sliding surfaces before

assembling.
a When installing spool (7) to the valve chamber,
set drilled hole (H1) to the direction shown in
the following figure.
a Do the same with section L-L.
q When installing spool (8) to the valve chamber,

set drilled hole (H2) to the direction shown in
the following figure.
a Do the same with H-H, K-K and M-M shown in
the sectional view.
50-500 16 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of control valve SEN06146-00
PC200, 200LC, 220, 220LC-8M0 50-500 17

q Upper and lower control valve covers q Arm drift prevention valve
2 Mating face of upper and lower control a Tighten the mounting bolts of the arm
valve cover blocks (11): hydraulic drift prevention valve in the
Loctite 222 or equivalent same order as that for the control valve
a Tighten the mounting bolts of the control cover block.
valve upper and bottom cover blocks in 3 Mounting bolt of arm hydraulic drift pre-
the following order. (A D C B) vention valve:
3 Mounting bolts for control valve upper 58.8 73.6 Nm {6 7.5 kgm}
and lower cover blocks: a After assembling, put stoppers to prevent
156.9 176.5 Nm {16 18 kgm} cleaning solvent from entering through f12
holes (13).
q Pressure compensation valve
a Install each pressure compensation valve
paying attention to the matchmark that
was put when removing it.
3 Pressure compensation valve:
372.7 411.9 Nm {38 42 kgm}
q Main relief valve assembly
a After installing to the control valve, check
and adjust them. For details, see Testing
and adjusting, "Measuring and adjusting
oil pressure in work equipment, swing,
and travel circuits".
3 Main relief valve assembly:
q Merge-divider valve 49 58.8 Nm {5 6 kgm}
2 Merge-divider valve mating face (12):
Loctite 222 or Sealend 242 equivalent
a Tighten the mounting bolts of merge-
divider valve in the same order as that for
the control valve cover block.
3 Merge-divider valve mounting bolt:
156.9 176.5 Nm {16 18 kgm}
q Variable back pressure valve
a Tighten the mounting bolts of the variable
back pressure valve in the same order as
that for the control valve cover block.
3 Variable back pressure valve mounting
bolt: 58.8 73.6 Nm {6 7.5 kgm}
q Boom drift prevention valve
a Tighten the mounting bolts of the boom
hydraulic drift prevention valve in the
same order as that for the control valve
cover block.
3 Mounting bolt of boom hydraulic drift
prevention valve:
58.8 73.6 Nm {6 7.5 kgm}
q Arm quick return valve
a Tighten the mounting bolts of the arm
quick return valve in the same order as
that for the control valve cover block.
3 Mounting bolt of arm quick return valve:
58.8 73.6 Nm {6 7.5 kgm}
50-500 18 PC200, 200LC, 220, 220LC-8M0

Removal and installation of hydraulic pump assembly SEN06146-00

hydraulic pump assembly 1
Special tools
Necessity
Symbol
Qty
10 796-460-1210 Oil stopper q 1
A
11 796-770-1320 Adapter q 1
Removal
completely, after the engine is stopped, 4. Temporarily sling engine hood (2).
loosen the hydraulic tank cap gradually to a When slinging the engine hood, take care
reduce the pressure inside, and set the lock not to damage the rubber seal.
k Disconnect the cable from the negative () 5. Remove pins (3) and (4), then remove 2 gas
terminal of the battery. springs (5).
avoid a mistake in the position of installation 6. Lift off engine hood (2) to remove it.
later.
1. Swing to right 45. (For hydraulic tank oil drain)
2. Remove hydraulic tank strainer and stop oil

flow-out using tools A10, A11.
a If tools A10, A11 are not used, remove the
drain plug and drain oil from the hydraulic
tank and piping.
6 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
PC200, 200LC, 220, 220LC-8M0 50-500 19

SEN06146-00 Removal and installation of hydraulic pump assembly
8. Disconnect hose (8a). 14. Disconnect clamp (14).
9. Remove cover (8). 15. Remove filter and bracket assembly (15).
a Put it on hose bracket (HB).

a Cover (13) cannot be removed unless
removing cover (7).
16. Disconnect 6 hoses.

q (16): Rear load pressure input port hose
q (17), (18): EPC basic pressure port hose
q (19): Pump pressure input port hose
(Color band: Blue)
q (20): Front load pressure input port hose
(Color band: Red)
q (21): Drain port hose
50-500 20 PC200, 200LC, 220, 220LC-8M0

Removal and installation of hydraulic pump assembly SEN06146-00
18. Disconnect 4 hoses and 1 tube. 22. Remove clip (32).

q (23): Branch hose
q (24): Rear pump discharge port hose 23. Remove clamp (33).
q (25): Front pump discharge port hose
q (26): Pump suction port tube
24. Remove muffler bracket (34).
19. Drain oil from the damper case.

6 Damper case: 0.65 l
20. Disconnect pump wiring connectors at 4

points.
q (27): V12 PC-EPC R solenoid valve
(Color band: yellow)
q (28): P22 hydraulic oil temperature sensor
(Color band: no color)
q (29): V19 LS-EPC solenoid valve
(Color band: red)
q (30): V11 PC-EPC R solenoid valve
(Color band: white)
25. Lift off hydraulic pump assembly (35) to
a Located behind muffler bracket (31).
remove the mounting bolt. [*1]
a Muffler drain tube (36) is double tightened.
PC200, 200LC, 220, 220LC-8M0 50-500 21

SEN06146-00 Removal and installation of hydraulic pump assembly
26. Lift off hydraulic pump assembly (37) to Installation

remove it. [*1] q Installation is done in the reverse order of
4 Hydraulic pump assembly: 220 kg removal.
[*1]
2 Hydraulic pump involute spline:
Antifriction agent (LM-G)
2 Mating face of the hydraulic pump case:
a Since flywheel housing is made of aluminum,
be careful not to over torque.
a Impact wrench is not applicable to use.
q Refilling with oil (damper case)

the specified level.
5 Damper case: EO30-DH, 0.65 l

5 Hydraulic tank:
237 l (PC200/200LC-8M0)
244 l (PC220/220LC-8M0)
58.8 78.5 Nm {6.0 8.0 kgm}
q Air bleeding
part".
50-500 22 PC200, 200LC, 220, 220LC-8M0

Removal and installation of oil seal in hydraulic pump input SEN06146-00
Removal and installation of oil Installation

seal in hydraulic pump input shaft1 q Installation is done in the reverse order of
removal.
Special tools [*1]

2 Oil seal lip portion: Grease (G2-LI)
Necessity
2
Symbol
Part number Part name Oil seal outer periphery: Grease (G2-LI)
a Coat the oil seal outer circumference thinly
Qty
with grease.
S 796T-467-2410 Push tool t 1 a Press fit oil seal (3) with tool S, [1], [2].
Removal
1. Remove the hydraulic pump assembly refer-
ring to the section of "Removal and installation
of hydraulic pump assembly".
2. Remove snap ring (1) and then remove spacer

(2).
3. Pry off oil seal (3) with a screwdriver. [*1]

a Take care in removing the oil seal so that
the shaft may not be damaged.
PC200, 200LC, 220, 220LC-8M0 50-500 23

SEN06146-00 Disassembly and assembly of work equipment PPC valve
Disassembly and assembly of work equipment PPC valve assembly 1
a Only precautions for assembling the work Assembly

equipment PPC valve assembly are explained a Before assembly, thoroughly clean the parts
below. and check them for dirt, rust, or damage to pre-
vent failure. Assemble the parts with utmost
Disassembly care.
a Spring (6) and spring (7) consist of each one of a Install spring (5) with its small diameter side on
two types of springs with different installed the shim (4) side.
loads in four places, so check the mounting q Diameter of spring (Inside diameter)
position (oil pressure port) and mark with tags Small diameter side: f4.9 mm
to prevent mistakes when installing. Large diameter side: f5.55 mm
a When installing springs (6) and (7), note that
they are different and they must be installed to
different hydraulic ports.
q Installed height: 31.9 mm (Common to
both springs)
q Installed load:
Spring (6) (P1, P2): 35.3 N {3.6 kg}
Spring (7) (P3, P4): 21.6 N {2.2 kg}
a When installing piston (8), apply grease (G2-
LI) to its outside and the inside of the body (1)
hole.
3 Bolt (11):
11.8 14.7 Nm {1.2 1.5 kgm}
50-500 24 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of work equipment PPC valve SEN06146-00
a When installing joint (12) to body (1), apply

LOCTITE as shown below.
1) When installing the joint, apply 1 drop
(approx. 0.02 g) of LOCTITE (No. 262)
each to 2 places of the female screw (A)
of the body. Before installing the joint,
thoroughly degrease and dry its male
screw and the female screw of the body
with DRYSOL.
2) Drop LOCTITE to the following positions.
2 Female screw (A) of body:
LOCTITE No. 262
3 Joint (12): 39 49 Nm {4 5 kgm}
a Apply grease (G2-LI) to the sliding parts of joint

(12) and contact surfaces of disc (13) and pis-
ton (8).
2 Quantity of grease (G2-LI)
The sliding portions of the joint (J portion):
Apply grease (G2-LI) 7 10 ml to entire cir-
cumference.
The sliding portions of the joint (P portion):
Apply gear oil 0.2 0.4 ml to the sliding
portions (4 places) between the joint and
pin.
Contact surfaces of disc and piston:
0.3 0.8 cc/place
a When assembling disc (13), adjust it so that
the end play of the lever will be 0.5 3 mm at
200 mm from the center of revolution.
a See Testing and adjusting, "Adjusting play
of work equipment and swing PPC valve".
a Tighten nut (14) to the following tightening
torque.
3 Nut (14): 69 88 Nm {7 9 kgm}
PC200, 200LC, 220, 220LC-8M0 50-500 25

SEN06146-00 Disassembly and assembly of travel PPC valve
Disassembly and assembly of travel PPC valve 1
Figure of structure
Disassembly
1. Remove screws (19) and remove damper
assemblies (18).
2. Remove mounting bolt (17) and remove case

(16), shafts (15) and levers (13) as a unit.
3. Remove mounting bolts (11) to remove plate

(10).
a Note the thickness and installed position
of washer (12).
a Remove pin (21) from valve body (1).
4. Remove seals (9) and collars (8).
5. Remove pistons (7), and then to remove

retainers (6), springs (5) and (4), and shims
(3).
a Note the installed position, quantity and
thickness of shims (3) and keep them.
6. Remove valves (2) from valve body (1).
50-500 26 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of travel PPC valve SEN06146-00
Assembly
a Only precautions for assembly are described.
a Before assembly, thoroughly clean the parts
and check them for dirt, rust, or damage to pre-
vent failure. Assemble the parts with utmost
care.
a When installing piston (7), apply grease (G2-
LI) to its periphery and the inside of the valve
body hole.
a Install spring (4) with its small diameter end
facing shim (3).
q Diameter of spring (inside diameter)
Small diameter end: f 4.9 mm
Large diameter end: f 5.55 mm
a Apply grease (G2-LI) to the rocking parts of
shaft (15), contact surfaces on lever (13) and
piston (7), and contact surfaces on damper
(18) and pin.
2 Grease (G2-LI)
Rocking parts of shaft (15): 4 to 8 cc/entire
periphery
Contact surfaces on lever (13) and piston
(7): 0.3 to 0.8 cc/part
Contact surfaces on damper (18) and pin:
0.3 to 0.8 cc/part
a For washer (12), install the one 1.6 mm in
thickness (t) first. If the difference in the lever
angle between right and left when the lever is
at full stroke position exceeds 0.7 degree,
change the thickness of the washer to make
the difference 0.7 degree or smaller.
a If the thickness of the washer is reduced by 0.3
mm, the full stroke angle of the lever increases
by 0.39 deg.
q Settings of thickness (t) of washer (12):
1.0, 1.3, 1.6, 1.9, 2.2 mm
a Tighten each part to the following torque.
3 Bolt (11): 27 to 34 Nm {2.8 to 3.5 kgm}
3 Bolt (17): 25 to 31 Nm {2.5 to 3.2 kgm}
3 Screw (19):
0.441 to 0.588 Nm {0.045 to 0.06 kgm}
PC200, 200LC, 220, 220LC-8M0 50-500 27

SEN06146-00 Disassembly and assembly of work equipment cylinder

work equipment cylinder 1 Disconnection of cylinder assembly and piston
rod assembly
1. Remove the piping from the cylinder assembly.
Special tools
2. Remove 12 mounting bolts and disconnect cyl-
Necessity
Symbol
Part number Part name inder head assembly (1).
Qty
3. Pull out piston rod assembly (2).
790-502-1003 Cylinder repair stand q 1
1 a Place a container under the cylinder to
790-101-1102 Pump q 1 collect oil from the cylinder.
790-102-4300 Wrench assembly t 1
2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
Rubber band
796-720-1670 q 1
(for boom and bucket))
07281-01279 Clamp q 1
4
Rubber band
796-720-1680 q 1
(for bucket)
07281-01589 Clamp q 1
U 790-201-1702 Push tool kit t 1
Push tool
790-201-1841 1
5
790-201-1851 Push tool (for arm) 1
790-101-5021 Grip 1 Disassembly of piston rod
01010-50816 Bolt 1 1. Set piston rod assembly (2) on tool U1.
790-201-1500 Push tool kit t 1
Plate (for boom and
790-201-1650 1
bucket)
6
790-201-1660 Plate (for arm) 1
790-101-5021 Grip 1
01010-50816 Bolt 1
50-500 28 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of work equipment cylinder SEN06146-00
2. Using a hexagonal wrench (6 mm), remove 4. Remove plunger (5) and collar (6).
lock screw (3) at the end of piston assembly a Only for the arm and boom cylinders
(4).
a Above operation is common to the boom, 5. Remove cylinder head assembly (7).
arm and bucket cylinder.
q Screw size: M12 x 1.75 mm (16 mm in
length)
6. Remove cap (8) to remove 12 balls (9), and

remove plunger (10).
a Arm cylinder only
a If screw (3) is caulked too firmly to be
loosened, squeeze the screw further once
and then apply tap (T) to the threaded por-
tion to ease the caulking.
Disassembly of piston
1. Remove two rings (11).
3. Using tool U2, remove piston assembly (4). 2. Remove two wear rings (12).
a When not using tool U2, use the drilled
holes (H) (f10 mm, two places) to loosen 3. Remove piston ring (13).
the piston assembly.
4. Remove the O-ring and two backup rings (14).
PC200, 200LC, 220, 220LC-8M0 50-500 29

Disassembly of cylinder head Assembly

1. Remove the O-ring and backup ring (15). a Be careful not to damage the packings, dust
seals, O-rings, etc.
2. Remove snap ring (16), then remove dust seal a Clean each part. After assembling the cylinder,
(17). cover the piping ports and pin holes to prevent
entering of dirt.
3. Remove rod packing (18) and buffer ring (19). a Before installing the backup ring, warm it in hot
water of approximately 50 to 60C. Do not
4. Remove snap ring (30). attempt to force it into position.
5. Remove bushing (20). Assembly of cylinder (only for arm cylinder)

1. Install valve (23) and spring (22).
2. Install plug (21) with O-ring (24).

a Clean, degrease, and dry the thread por-
tion of the plug, and then apply liquid gas-
ket to the entire periphery of the thread
portion.
3 Plug (21):
83.4 102.9 Nm {8.5 10.5 kgm}
2 Plug (21): Liquid gasket (LG-5)
Disassembly of cylinder (arm cylinder only)

1. Remove plug (21).
2. Remove spring (22) and valve (23).
50-500 30 PC200, 200LC, 220, 220LC-8M0

Assembly of cylinder head Assembly of piston

1. Using tool U5, press fit bushing (20). 1. Set piston ring (13) on tool U3. Expand piston
ring (13) by turning the handle 8 to 10 turns.
2. Install snap ring (30).
2. Remove piston ring (13) from tool U3. Install
3. Install buffer ring (19) and rod packing (18). the ring to the piston.
4. Install dust seal (17) using tool U6, and install 3. Using tool U4, compress piston ring (13).
snap ring (16).
5. Install backup ring (15) and the O-ring.
4. Install two backup rings (14) and the O-ring.

a Install the backup rings and O-ring as
shown in the figure below.
5. Install wear rings (12) (2 pieces).
6. Install wear rings (11) (2 pieces).

a Be careful not to open the end gap of the
ring too wide.
PC200, 200LC, 220, 220LC-8M0 50-500 31

Assembly of piston rod 5. Place plunger (10) on piston rod assembly (2).
1. Set piston rod assembly (2) to tool U1. Install 12 balls (9) and cap (8).
a After installing the plunger, check that
there is a little play at its end.
a Arm cylinder only
2. Install cylinder head assembly (7).
3. Install the O-ring and the backup rings to collar

(6) and install the collar to the piston rod. 6. If both of piston rod assembly (2) and piston
a Install the two backup rings, one each in assembly (4) are to be reused, assemble them
the front and rear of the O-ring. according to the following procedure. (If either
a Only the boom and arm cylinders or both of them are to be replaced with new
ones, see Step 7.)
4. Install plunger (5). 1) Using tool U2, install piston assembly (4)
a Only the boom and arm cylinders to piston rod assembly (2).
a Any burrs or sharp edges on threaded
portions must be removed using files
before installation.
50-500 32 PC200, 200LC, 220, 220LC-8M0

a Fully tighten piston assembly (4) until 3 Piston assembly (4):

it contacts with end face (b) of the 294 29.4 Nm {30 3.0 kgm}
rod. Then, at around this position, a For a cylinder with a head cushion,
align screw holes (H) in the piston ensure that there is a little play in
and piston rod end face. plunger (5) with piston assembly (4)
a For a cylinder with a head cushion, installed.
ensure that there is a small play in q Only the boom and arm cylinders
plunger (5) with piston assembly (4)
installed.
q Only the boom and arm cylinders
2) Drill a screw hole across the threads of

piston rod assembly (2) and piston assem-
bly (4).
2) Install screw (3) to lock piston assembly a With a drill aligned with the V groove
(4) and piston rod assembly (2). where the threads of piston assembly
2 Screw (3) thread portion: (4) and piston rod assembly (2) are
Adhesive (Loctite #262) mated, drill a hole straight.
3 Screw (3): a The cylinder with the bottom cushion
58.9 73.6 Nm {6 7.5 kgm} must not be machined in the cushion
a After installing screw (3), caulk the cap machining hole position.
screw at four peripheral places (a). q Dimensions of screw hole (mm):
Tap drill diameter 10.3
Tap drill hole
27
depth
Screw hole size 12 x 1.75
Screw hole depth 20
a After tapping the screw hole, remove
chips and other dirt and thoroughly
clean the area.
7. When replacing either or both of piston rod

assembly (2) and piston assembly (4) with new
ones, assemble the new ones according to the
following procedure.
1) Using tool U2, screw in piston assembly
(4) until it comes into contact with end face
(b) of the rod.
a If the cylinder has the bottom cushion,
put a mark on the rod end face to indi-
cate the tightening position of the ball
cap.
PC200, 200LC, 220, 220LC-8M0 50-500 33

3) Install screw (3) to lock piston assembly 2. Install the cylinder assembly to piston rod
(4) and piston rod assembly (2). assembly (2).
a After installing screw (3), caulk the a Align axial center of the cylinder tube, then
screw at four peripheral places (a). insert.
2 Screw (3) thread portion: a Check that the ring is not broken and has
Adhesive (Loctite #262) not come out, then push in fully.
3 Screw (3):
58.9 73.6 Nm {6 7.5 kgm}
3. Tighten the mounting bolts for cylinder head

assembly (1).
3 Cylinder head assembly (1) mounting
Connection of cylinder assembly and the piston bolt:
rod assembly Boom cylinder: 270 39 Nm {27.5
1. Install piston rod assembly (2) to tool U1. 4.0 kgm}
Arm cylinder: 373 54 Nm {38.0 5.5
kgm}
Bucket cylinder: 270 39 Nm {27.5
4.0 kgm}
4. Install piping.
3 Piping fixing band mounting bolt:
Boom cylinder: 27 7 Nm {2.8 0.7
kgm}
Arm and bucket cylinder: 89 34 Nm
{9.0 3.5 kgm}
50-500 34 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 50-500 35

SEN06146-00

2012 KOMATSU
All Rights Reserved
50-500 36
SEN06147-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
50 Disassembly and assembly1

600 Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
PC200, 200LC, 220, 220LC-8M0 50-600 1

600 Work equipment
SEN06147-00 Removal and installation of work equipment assembly
Removal and installation of work 5. Start the engine and then retract the piston rod.
equipment assembly a Bind the piston rod with wire etc. and put it
down on the blocking tools so that the pis-
ton rod does not slip out, or allot a support
Special tools so that the cylinder doesn't fall down to the
bottom side. If a support is allotted, remove
Essentiality
Symbol
the grease fitting at the bottom side.
Quantity
Part number Part name a Remove the boom cylinder on the other
side in the same manner.
796-900-1200 Remover t 1 a If bumping of the lifting hook against the
work equipment lamp is anticipated in lift-
796-900-1210 Sleeve 1
ing the work equipment, the lamp must be
792-900-1520 Plate 1 removed.
799-900-1230 Screw 1 6. Disconnect 2 pieces of bucket cylinder hose
796-900-1240 Adapter 1 (6) and 2 pieces of arm cylinder hose (7).
V
01643-33080 Washer 1 a Apply the oil restraining plug and then fix
01803-13034 Nut 1 the hoses to the valve side by use of
ropes.
Puller
790-101-4000 t 1 7. Disconnect intermediate connector for work-
(490 kN {50 ton} long)
ing lamp A13 (8).
790-101-1102 Pump (294 kN {30 ton}) t 1
Removal
k Safely lower the work equipment to the
ground by extending the arm and the
bucket completely. Set the lock lever in
the lock position,
k After performing step 5, release the resid-
ual pressure in the hydraulic circuit. Refer
to the "Releasing residual pressure from
hydraulic circuit" section in the Testing
and adjusting chapter of this manual.
1. Disconnect grease hose (1).

2. Sling the boom cylinder assembly (2).
3. Remove lock bolt (3).
4. Remove plate (4) and remove the head pin. [*1]
a Check the number as well as locations of
the shims used.
50-600 2 PC200, 200LC, 220, 220LC-8M0

600 Work equipment
Removal and installation of work equipment assembly SEN06147-00
8. Lift the work equipment assembly, remove Installation

plate (9) and pin (10) at the foot. [*2] q Installation is done in the reverse order of
removal.
[*1]
2 Inside surface of bushing when assembling
pin: Molybdenum disulfide lubricant (LM-
P)
2 Greasing after assembling the pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers into the pin hole.
a st1: resin shim (thickness 1.0 mm)
a Adjust the clearance (b) between cylinder rod
(12) and plate (4) to 1.5 mm or less using
shims: 1.0 and 2.0 mm
q In case to remove using tool V

Remove plate (9) and remove pin (10) at the
foot using tool V.
a Check the number as well as locations of the
shims used.
[*2]
2 Inner surface of bushing as assembling the
pin: Anti-friction compound (LM-P)
2 Feed grease after assembling pin:
Grease (LM-G)
a Adjust the clearance (c) between the foot's end
9. Remove work equipment assembly (11). face of boom (13) and bracket (14) to 1 mm or
4 Work equipment assembly: less by use of shims. Thickness of standard
3,450 kg (PC200/200LC-8M0) shim: 2.0, 2.5, 3.0 and 3.5 mm
4,450 kg (PC220/220LC-8M0)
PC200, 200LC, 220, 220LC-8M0 50-600 3

600 Work equipment
SEN06147-00 Removal and installation of work equipment assembly
q Air bleeding
part".

50-600 4 PC200, 200LC, 220, 220LC-8M0

600 Work equipment
Removal and installation of work equipment assembly SEN06147-00
PC200, 200LC, 220, 220LC-8M0 50-600 5

SEN06147-00

2012 KOMATSU
All Rights Reserved
50-600 6
SEN06148-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
50 Disassembly and assembly

700 Cab and its attachments
Removal and installation of operator's cab assembly ..................................................................................... 2
Removal and installation of operator cab glass (stuck glass) ......................................................................... 5
Removal and installation of front window assembly ..................................................................................... 15
Removal and installation of floor frame assembly ........................................................................................ 22
Removal and installation of air conditioner unit assembly ............................................................................ 26
PC200, 200LC, 220, 220LC-8M0 50-700 1

SEN06148-00 Removal and installation of operator's cab assembly
Removal and installation of 9. Remove rear covers (10) to (13).

operator's cab assembly
Removal
1. Remove front window (1).

2. Remove step plate (2).
3. Remove floor mat (3).
4. Refer to Removal and installation of monitor

assembly, and remove monitor assembly (4).
5. Remove covers (5) and (6). 10. Remove duct (14).

6. Remove cover and duct assembly (7). 11. Remove cover (15).
a Disconnect connector H15 fixed on the
back from the clip.
12. Remove plate (16).
7. Insert key (8), turn it right, and open the out-

side-air filter cover.
8. Remove outside-air filter (9).
13. Remove plate (17).

14. Remove lock pin (18) and remove duct (19).
50-700 2 PC200, 200LC, 220, 220LC-8M0

Removal and installation of operator's cab assembly SEN06148-00
15. Remove duct (20). 23. Remove ducts (32) and (33).
16. Disconnect connector L03 (21). 24. Disconnect wiper motor connector M05 (34).
17. Remove plates (22) and (23) from the operator 25. Remove harness (35) and antenna (36) from
cab. the cab wall.
18. Pass over and disconnect antennas (24) and 26. Remove duct (37) upper and lower.
(24a) from KOMTRAX communication modem 27. Remove duct (38) upper and lower.
(K).
19. Disconnect connectors CK01(25) and CK02
(26).
20. Disconnect connector M10 (27) from the oper-
ator's cab. (If equipped)
21. Disconnect cab wiring intermediate connectors

H09 (28), H08 (29), and H16 (30).
22. Disconnect radio antenna (31).
28. Disconnect window washer hose (39).

29. Disconnect harness clamp (40).
30. Haul in antenna (36).
PC200, 200LC, 220, 220LC-8M0 50-700 3

SEN06148-00 Removal and installation of operator's cab assembly
31. Disconnect harness clamp (41) from the right 35. Lift off and remove operator's cab assembly
back side of cab. (47).
4 Operator's cab assembly: 470 kg
32. Remove bolt (42) under the cab and remove

lock plate (43). [*1]
33. Remove bolt (44). [*2]
Installation
removal.
[*1]
3 Mounting bolt (42) of lock plate (43):
98 123 Nm {10 12.5 kgm}
[*2]
3 Bolt (44):
245 309 Nm {25 31.5 kgm}
34. Remove 6 mounting bolts (45) and 4 mounting

nuts (46).
a Check the bolt length beforehand.
50-700 4 PC200, 200LC, 220, 220LC-8M0

Removal and installation of operator cab glass (stuck SEN06148-00
Removal and installation of operator cab glass (stuck glass)
a Among the panes of window glass on the 4 (1) : Right side window glass
sides of the operator's cab, 5 panes (1) to (4) (2) : Left side rear window glass
and (18) are stuck. (3) : Door lower window glass
a In this section, the procedure for replacing the (4) : Front window glass
stuck glasses is explained. (5) : Front window assembly
a When replacing front window glass (4), remove (Front window glass + Front frame)
front window assembly (5). (It is impossible to (6) : Dam rubber
replace only the front window glass while the (17) : Center trim seal
front window assembly is installed to the opera- (18) : Rear glass
tor's cab.)
a For the procedure for replacing the front win-
dow assembly, see Removal and installation of
front window assembly.
PC200, 200LC, 220, 220LC-8M0 50-700 5

SEN06148-00 Removal and installation of operator cab glass (stuck
Special tools (The figure shows the operator's cab of a wheel

loader.)
Necessity
Symbol
Qty
2 793-498-1210 Lifter (Suction cup) t 2
X
3 20Y-54-13180 Stopper rubber t 2
Removal
a Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator's cab
(metal sheet)(8).
a If the window glass is broken finely, it may

be removed with a knife [4] and a screw-
driver.
a Widening the cut with a flat blade screw-
driver, cut the dam rubber and adhesive
with knife [4].
(The figure shows the operator's cab of a wheel

loader.)
a If a seal cutter is not available, make holes

on the adhesive and dam rubber with a
drill and pass a fine wire (piano wire, etc.)
[2] through the holes. Then, grip the both
ends of the wire with pliers [3], etc. (or
hold them by winding them onto some-
thing) and move the wire to the right and
left to cut the adhesive and dam rubber.
Since the wire may be broken by the fric-
tional heat, apply lubricant to the wire.
2. Remove the window glass.
50-700 6 PC200, 200LC, 220, 220LC-8M0

Installation a Even if the primer is packed again just

1. Using a knife and scraper [5], remove the after it is unpacked, use it within 24 hours
remaining adhesive and dam rubber from the after it is unpacked for the first time.
metal sheets (glass sticking surfaces) of the (Discard the primer 24 hours after it is
operator's cab. unpacked.)
a Remove the adhesive and dam rubber to 1) Stir the primers for both of paint and glass
a degree that they will not affect adhesion sufficiently before using them.
of the new adhesive. Take care not to a If the primer has been stored in a refrig-
scratch the painted surfaces. erator, leave it at the room temperature
(If the painted surfaces are scratched, for at least half a day before stirring it.
adhesion will be lowered.) (If the primer is unpacked just after
taken out of the refrigerator, water will
(The figure shows the operator's cab of a wheel be condensed. Accordingly, leave the
loader.) primer at the room temperature for a
sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.
2. Remove oil, dust, and dirt, etc. form the stick-

ing surfaces of cab (8) and window glass (9)
with white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave 3) Evenly apply the paint primer to the surfaces
them for at lease 5 minutes to dry. to stick dam rubber and its outside surfaces
(The figure shows the operator's cab of a wheel to apply adhesive on operator's cab (8).
loader.) 2 Paint primer:
Sunstar primer for painting plane
580 super or equivalent
a Do not apply the primer more than 2
times.
(If it is applied more than 2 times, its
performance will be lowered.)
3. Apply primer (10).

a The using limit of primer is 4 months after
the date of manufacture. Do not use the
primer after this limit.
a Use the primer within 2 hours after un-
packing it.
PC200, 200LC, 220, 220LC-8M0 50-700 7

a Parts to be coated with primer; Apply the prim- a Never apply the wrong primer.
er all over dimension (a). If the glass primer, etc. is applied by mistake,
q Dimension to apply primer (a): 25 mm wipe it off with white gasoline.
4) Apply the glass primer to the sticking sur-

faces of window glass (9).
2 Glass primer:
Sunstar primer for glass 580
super or equivalent
a Do not apply the primer more than 2
times.
(If it is applied more than 2 times, its
performance will be lowered.)
a In addition to the above parts, additionally

apply the primer to right side window glass (1)
and door lower window glass (3).
q Range to apply primer additionally for right side
window glass (1): (b)
q Range to apply primer additionally for door
lower window glass (3): (c)
a After applying the primer, leave it for at least 5

minutes (within 8 hours) to dry.
a Parts to be coated with primer; Apply
the primer to all around of sticking
surface (d) of window glass (9) for
dam rubber (6) installation position
and operator's cab (8).
a Do not apply the primer to the
boarder about 5mm wide between the
black part and transparent part of the
glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a Never apply the wrong primer.
If the paint primer, etc. is applied by
mistake, wipe it off with white gaso-
line.
50-700 8 PC200, 200LC, 220, 220LC-8M0

4. Stick dam rubber (both-sided adhesive

tape)(6) along the inside edge of the glass
sticking section.
a Do not remove the release tape of dam
rubber on the glass sticking side before
sticking the glass.
a When sticking the dam rubber, do not
touch the cleaned surface to the utmost.
a Care should be taken not to float the dam
rubber of each sticking corner.
2) Stick dam rubber (6) for left side window

glass (2) to the position as shown in the
figure.
a When sticking dam rubber (6) around a

frame, do not lap its finishing end over the
starting end. Or, make clearance of about
5 mm between them (e).
1) Stick dam rubber (6) for right side window
glass (1) to the position as shown in the
figure.
a Stick dam rubber (6a) additionally to

right side window glass (1).
q Positions to stick additional dam rub-
ber to the right side window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm
PC200, 200LC, 220, 220LC-8M0 50-700 9

3) Stick dam rubber (6) for door lower win- a Stick dam rubber (6c) of the lower
dow glass (3) to the position as shown in side of the front window glass along
the figure. the outside edge of the lower line, dif-
ferently from other dam rubbers (6).
(If it is stuck along the inside, it will be
seen through the transparent part of
the glass.)
a Stick dam rubber (6b) additionally to

door lower window glass (3).
q Positions to stick additional dam
rubber to the door lower window
class: 5. Position the new window glass.
(j) : 110 mm 1) Check the clearance between the window
(k) : 90 mm glass and the operator's cab on the right,
(m) : 200 mm left, upper, and lower sides, and then posi-
tion the window glass to be the clearances
evenly.
2) Stick tapes [6] between window glass (9)
and operator's cab (8) and draw position-
ing line (n).
a Stick tapes [6] for positioning to 3
points, that is, right, left and lower
parts of the right side window glass,
left side rear window glass, and door
lower window glass for accurate posi-
tioning.
3) Cut the tape between window glass (9)
and operator's cab (8) with a knife, etc.
and then remove the window glass.
4) Stick dam rubber (6) for front window a Do not remove the tapes left on the
glass (4) to the position as shown in the window glass and the operator's cab
figure. before installing the window glass.
50-700 10 PC200, 200LC, 220, 220LC-8M0

a When positioning front window glass

2) Cut the tip of the adhesive nozzle (14) so
(4), set its horizontal position to the
that dimensions (q) and (r) will be as fol-
frame width.
lows.
And set its vertical position to make
q Dimension (q): 10 mm
the height difference (p) between the
q Dimension (r): 15 mm
frame top and the front window glass
3 mm.
3) Set adhesive cartridge (12) to caulking

6. Apply adhesive. gun [7].
a Use either of two types of adhesives a An electric caulking gun is more effi-
according to the season. cient.
2 Adhesive (Apr. to Oct.):
Sunstar penguine seal 580 super S
or equivalent
2 Adhesive (Oct. to Apr.):
Sunstar penguine seal 580 super W
or equivalent
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25C.
a Never heat the adhesive higher than
30C.
a When reusing the adhesive, remove the
all hardened part form the nozzle tip.
1) Break aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
PC200, 200LC, 220, 220LC-8M0 50-700 11

4) Remove the release tape of dam rubber

on the glass adhesive side.
5) Apply adhesive (15) to the outside of dam
rubber (6) of the operator's cab.
a Apply adhesive (15) with dimensions

(s) and (t) for dam rubber (6) of oper-
ator's cab (8).
q Dimension (s): 10 mm
q Dimension (t): 15 mm
a Apply adhesive (15) higher than dam
rubber (6).
a Apply the adhesive evenly with same
height level.
7. Install the window glass.

1) Install window class (9), matching it to the
lines of the positioning tapes drawn in step
5.
a Since the window glass cannot be
removed and stuck again, stick it with
utmost caution.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking window glass (9), press all
around of it until it sticks to the dam rubber
closely.
a Apply adhesive (15) additionally to
a Press the corners of the window glass
additional dam rubber (6a) of right
firmly.
side window glass and additional dam
rubber (6b) of door lower window
glass.
50-700 12 PC200, 200LC, 220, 220LC-8M0

a You can perform this work efficiently

by pulling window glass (9) from
inside of the operator's cab with suc-
tion cup X2.
a After installing front window glass (4),

fill the clearances between it and cen-
ter trim seal (16) with caulking mate-
rial in range (s) with dimensions (t)
and (u).
After applying the primer to glass (4)
of section A-A, apply the adhesive as
caulking material.
q Caulking dimension (t): 2 mm
q Caulking dimension (u): 5 mm
a When caulking, mask the glass side
and form the adhesive with a rubber
spatula as shown in the figure.
a Wipe off the projected adhesive.
2 Glass primer:
Sunstar primer for glass 580
super or equivalent
2 Adhesive:
SUNSTAR penguine seal 580
super S or W or equivalent
PC200, 200LC, 220, 220LC-8M0 50-700 13

8. Fix the window glass. 9. After installing the window glass, remove any
1) After installing right window glass (1) to excess of the primer and adhesive from the
the operator's cab, insert stopper rubbers operator's cab and window glass.
X3 to 2 places (v) at the bottom of the a By using the white gasoline, wipe off the
glass to fix the glass. adhesive before it is dried up.
a When cleaning the glass, do not give an
impact on it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours.
(at temperature of 20C and humidity of
60%)
2) After removing the stopper rubbers, sty-
rene foam blokes, and rubber bands, wait
at least 14 hours, that is, at least 24 hours
in total, before operating the machine
actually.
2) By using styrene foam blocks [9] and rub-

ber bands [10], fix the window glass and
the dam rubber to fit them completely.
50-700 14 PC200, 200LC, 220, 220LC-8M0

Removal and installation of front window assembly SEN06148-00
Removal and installation of front

window assembly
k Lower the work equipment completely to
the ground and stop the engine.
a To replace the front window glass, the front win-
dow assembly must be removed from the oper-
ator's cab. The procedure for removing and
installing the front window assembly (front
frame and front window glass) is explained
below.
Removal
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides).
2. Remove left corner block (1) and right corner

block (2). [*1]
a Mounting bolt (4) and washer (3) for left

corner block are used to hang the pull-up
assist cable in the following step 6.
6. Remove left lower pin (7). [*2]

a By removing left lower pin (7), plate (8) at
the end of pull-up assist cable (9) comes
off.
a Hang plate (8) on the mounting bolt of left
corner block (use washer) and set in
place.
k The return load of 58.8 N {6 kg} is
applied to the rear of the operator's
3. Release the rear lock of the cab. cab. Accordingly, take care when
removing left lower pin (7) to discon-
4. Lower the front window assembly carefully a nect pull-up assist cable (9).
little. Put out rollers (5) and (6) under the both
sides of the front window through the portion
from which the corner blocks were removed in
the above step 2. (the portion where the rail is
open) and hold them.
5. Remove rollers (5) and (6) under the both

sides of the front window.
PC200, 200LC, 220, 220LC-8M0 50-700 15

SEN06148-00 Removal and installation of front window assembly
9. Twist front window assembly (10) to the right

and left to remove both upper rollers (11) and
(12) from the rails, and then remove front win-
dow assembly (10).
7. Pull out the bottom of front window assembly

(10) though the rail opening portion and lower
it gradually.
8. Lower front window assembly (10) completely.

a Do not let the front window assembly
touch the monitor.
50-700 16 PC200, 200LC, 220, 220LC-8M0

Installation a Install the right corner block so that clear-

q Carry out installation in the reverse order to ance (a) between the rail and right corner
removal. block (2) becomes 0 2.0 mm.
a Install the right corner block so that there
[*1] is no level difference at the rolling surface
q Adjust opening and closing of the front window (R) of the roller.
assembly according to the following proce-
dure.
1. Open and close the front window to check that
it does not interfere with the rails and that the
rollers are not hitched.
2. If there is any problem in opening and closing
of the front window, loosen the mounting bolt of
roller adjustment bracket (13) and adjust the
condition of the front window, and then tighten
the mounting bolt again.
a Make sure that bracket (13) is not
mounted on the angle.
3 Mounting bolt: 34.3 Nm {3.5 kgm}
5. Install left corner block (1).

a Fully tighten the block after adjusting the
Close position in the following step 6.
a Install the left corner block so that clear-
ance (b) between the rail and left corner
block (1) becomes 0 2.0 mm.
a Install the left corner block so that there is
no level difference at the rolling surface
(R) of the roller. (Refer to the above fig-
ure.)
3. Raise the front window assembly and fix it with

the rear locks (on both sides).
a Check that the locks in the rear of the
operator's cab are securely fastened.
4. Install right corner block (2).

a Fully tighten the block after adjusting the
Close position in the following step 6.
PC200, 200LC, 220, 220LC-8M0 50-700 17

6. Adjust the Close position of the front window

assembly lock according to the following pro-
cedure.
1) Tighten left and right corner blocks (1) and
(2) at roughly right positions so that front
window glass (14) is attached firmly to
cab-side trim seal (15).
7. After the adjustment, splash water heavily over

the front window glass and check that the
water does not leak into the cab.
2) Check the working condition of right and

left locks (16) and (17) when opening and
closing the front window assembly.
q If right and left locks (16) and (17) do
not work normally.
1] Loosen lock fitting bolt (18), move
lock (16) forward, and then tighten the
bolt again.
a The same applies to the right
side.
2] After moving the lock, recheck the fit-
ness of front window glass (14) and
cab-side trim seal (15) which was
checked in step 1).
3] Repeat the work in 1] and 2] until the
fitness of the front window glass and
the working condition of locks (16)
and (17) are both acceptable, and
then tighten the mounting bolts of the
right and left corner blocks.
50-700 18 PC200, 200LC, 220, 220LC-8M0

8. Adjust the Open position of the front window 4) Loosen locknut (20) of right and left side of
assembly lock. rubber stoppers (18), and then pull back
1) After adjusting the Close position of the both rubber stoppers (18) so that they
front window assembly lock in steps 6 and won't contact with the front window
7, raise the front window assembly to the assembly when it is in Open position.
ceiling.
2) Set the front window assembly locks at
the both sides of rear of the operator's cab
to the Open position, and then check the
following items.
q Check the working condition of right
a nd left lo cks (1 6) an d ( 17 ) ( as
explained above).
q Front window assembly must be in
contact with the right and left rubber
stoppers (18) and furthermore, must
be pushing them backward for 1.5
3.0 mm.
q The front window assembly must be
pushing the limit switch (19) back- 5) Loosen both sides of locknuts (22), and
ward for 4 7 mm. adjust the position of striker bolt (21).
a The position of limit switch (19) can- a Striker bolt (21): M10
not be adjusted. Therefore, the Inner diameter of plate (23): 14.5
Open position of the front window mm
assembly is decided within the range
where this switch works.
a Limit switch (19) is used to prevent
the windshield wiper from moving
when turning the wiper switch on by
m i s ta k e w h e n t h e f r o n t w i n d o w
assembly is in Open position. If the
wiper operates when there is no glass
in the front, the wiper falls down
inside the cab and causes trouble.
To check whether limit switch (19) is
working, turn the key switch on and
see that, even if the wiper switch is
turned on, the wiper does not operate
when the front window assembly is in 1] Front window assembly (10) must be
Open position. pushing the limit switch (19) back-
ward for 4 7 mm (at Open posi-
tion).
2] Working condition of lock (17).
q After checking the above items, if it

becomes necessary to do the adjust-
ment.
3) Close front window assembly (10).
PC200, 200LC, 220, 220LC-8M0 50-700 19

6) Adjustment of right and left rubber stop- 4] Tighten locknuts (20) of the both
pers (18). sides of rubber stopper (18).
1] Bring front window assembly (10) (the
lock should be in Open position) into
contact with right and left rubber stop-
pers (18).
9. Adjust stopper (24) of the front window assem-

bly.
1) Adjust and lock both sides of stopper (24)
2] Close front window assembly (10). so that when pulling up the front window
3] Turn right and left rubber stoppers assembly (10), surface (d) of stopper (D)
(18) to the left for one and a half of front window assembly (10) is in contact
rotation. with surface (c) of stopper (24).
a One turn of rubber stopper (18)
to the left is equivalent to
squashing the rubber for approxi-
mately 1.5 mm.
a When the front window assembly
is in Open position, the front
window assembly must be push-
ing right and left rubber stoppers
(18) for 1.5 3.0 mm.
50-700 20 PC200, 200LC, 220, 220LC-8M0

10. Check the operating effort of the lock of the

front window assembly.
1) After finishing the adjustment of steps 6
9, check that latching efforts of both right
and left locks (16) and (17) are even.
a Check the latching efforts on both
Close side (in the front of the opera-
tor's cab) and Open side (in the rear
of the operator's cab).
[*2]
3 Left lower pin:
27 34 Nm {2.75 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
PC200, 200LC, 220, 220LC-8M0 50-700 21

SEN06148-00 Removal and installation of floor frame assembly
Removal and installation of floor 5. Disconnect ground (2).

frame assembly
Removal
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill- 6. Disconnect connectors (4a) to (7b) from travel
ing operation of refrigerant (R134a). PPC valve (3).
a Never release the refrigerant (R134a) to the q Connector (4a): L.H. travel reverse oil
atmosphere. pressure sensor (P10)
Connector (4b): L.H. travel forward oil
k
q
If refrigerant gas (R134a) gets in your eyes, pressure sensor (P09)
you may lose your sight. Accordingly, put q Connector (5a): R.H. travel forward oil
on protective goggles while you are collect- pressure sensor (P11)
ing the refrigerant (R134a) or filling the air q Connector (5b): R.H. travel reverse oil
conditioner circuit with the refrigerant pressure sensor (P12)
(R134a). Collecting and filling work must be
conducted by a qualified person. 7. Disconnect hoses (11) to (14) from travel PPC
valve (6).
1. Turn the upper structure by 90. a The hose bands are colored as follows:
q Hose (6a): Red (L.H. travel forward
2. Drain the engine coolant. port (P2))
6 Coolant : 20.3 l (PC200/200LC-8M0) q Hose (6b): Without band (L.H. travel
19.8 l (PC220/220LC-8M0) reverse port (P1))
q Hose (7a): Blue (R.H. travel reverse
3. Remove the operator's cab assembly by refer- port (P3))
ring to Removal and installation of operator's q Hose (7b): Green (R.H. travel forward
cab assembly. port (P4))
50-700 22 PC200, 200LC, 220, 220LC-8M0

Removal and installation of floor frame assembly SEN06148-00
q Step 8 10 is optional (for breaker).

8. Disconnect the following PPC hoses from the
PPC valve. The color of the band is;
q (8): Yellow
q (9): No color
9. Disconnect connectors S11 (10) and S10 (11).
10. Disconnect connectors P13 (12) and V30 (13).
22. Disconnect connectors (27) to (29) from air

conditioner controller assembly (B).
q Connector (27): Machine main harness
(AC01)
(AC02)
q Connector (29): Air conditioner unit har-
ness (AC04)
11. Disconnect ground (14). From the left,
T04, T05, T06, T07, T09, T10
13. Disconnect connector A08 (16) from the clip.
14. Disconnect connector P17 (17) from the air
conditioner tube.
15. Remove the clamp and disconnect spacer
(18).
a Check the connecting point.
a Disconnect the work equipment PPC hose
(P) at joint box side. (See item 30.)
23. Remove cover (31) (3 bolts).

a Disconnect connectors (32) and (33)
located behind cover (31).
q Connector (32): R.H. console intermediate
harness (H14)
harness (H15)

19. Remove mounting bolt (22) and disconnect air
conditioner tube (23). [*1]
20. Remove clamps (24) and (25). [*2]
21. Disconnect clamp (26). (If equipped)
PC200, 200LC, 220, 220LC-8M0 50-700 23

SEN06148-00 Removal and installation of floor frame assembly
24. Remove grommet (34). Green

25. Move wiring harness (35) to the outside of the Red
floor frame. Yellow
a (SP) is made of sponge. a Prepare an oil sump.
26. Disconnect the clamp of wiring harness (35). 31. Pull out PPC hose assembly (41) of the work
27. Move plates (36) and (37) together with wiring equipment.
harness (35) to the boom side.
32. Sling floor frame assembly (42) and remove it.

28. Open the engine hood and remove cover (38). a Make sure that the hoses, connectors,
clamps, and so on are disconnected with-
out fail.
4 Floor frame assembly: 250 kg

30. Disconnect PPC hose (40) of the work equip-
ment. From the top, the color of the band is:
White
Brown
None
Blue
Black
50-700 24 PC200, 200LC, 220, 220LC-8M0

Removal and installation of floor frame assembly SEN06148-00
Installation
removal.
[*1]
a When installing the air conditioner circuit hoses,
take care so that dirt, water, may not enter.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat
the O-ring with compressor oil for new refrig-
erant (R134a) (Denso: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG (PAG 46 or
equivalent)).
3 Mounting bolt: 8 12 Nm {0.8 1.2 kgm}
[*2]
a Make sure that the hoses do not lap over.
q Filling air conditioner circuit with refriger-

ant (R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 725 50 g
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant: 20.3 l (PC200/200LC-8M0)
19.8 l (PC220/220LC-8M0)
PC200, 200LC, 220, 220LC-8M0 50-700 25

SEN06148-00 Removal and installation of air conditioner unit assembly
Removal and installation of air Removal

conditioner unit assembly 1. Collect the refrigerant (R134a) from the air
k Park the machine on a level ground, swing conditioner circuit. [*1]
the upper structure by 90 deg., lower the a Refrigerant to be collected:
work equipment to the ground stably, and 725 50 g
stop the engine.
k Disconnect the cable from the negative () 2. Drain the coolant.
terminal of the battery. 6 Coolant: 20.3 l (PC200/200LC-8M0)
k If you drain the coolant or disconnect the 19.8 l (PC220/220LC-8M0)
heater hose when the coolant temperature
is high, you may be scalded. In this case, 3. Pull up front window assembly (1) to the ceiling
wait until the coolant temperature lowers and lock it.
and then drain the coolant or disconnect a Make sure that the assembly is certainly
the heater hose. locked.
k If refrigerant gas (R134a) gets in your
eyes, you may lose your sight. And if it 4. Remove front lower window (2).
touches your skins, you may suffer from
frostbite. Accordingly, put on the protec- 5. Remove floor mat (3).
tive eyeglasses, gloves and working suits
with long sleeves while you are collecting
or filling the refrigerant (R134a).
a Never release the refrigerant (R134a) to the

atmosphere.
a Ask a qualified person for collecting, adding,
and filling operations of the refrigerant (R134a).
a Note connector numbers and installed positions
before disconnecting wiring and hoses.
a Positions of the controllers are shown below.
q A: Pump controller assembly
q B: Air conditioner controller assembly
q C: KOMTRAX terminal controller assem-
bly 6. Remove box (8) (five bolts).
a Disconnect the hose located under box
(8).
7. Remove box (9) (three bolts).

a Be careful about connectors (10) and (11)
located behind box (9) (for machines
equipped with 12 V power socket).
q Connector (10): 12 V power socket inter-
mediate harness (M13A)
q Connector (11): 12 V power socket inter-
mediate harness (M13B)
50-700 26 PC200, 200LC, 220, 220LC-8M0

Removal and installation of air conditioner unit assembly SEN06148-00
8. Pull up cover (12) (three bolts) to remove. 10. Remove duct (15) (two bolts).
a The connectors and harnesses at the rear
must not be caught. 11. Remove cover (16) (three bolts) and bracket
(41) (two bolts).
a Disconnect connectors (17) and (18)
located behind cover (16) .
harness (H14)
harness (H15)
9. Remove cover (13) (seven bolts).

a Disconnect connector (14) located behind
cover (13).
q Connector (14): Cigarette lighter (M04)
12. Remove plate (19) (two bolts).
13. Pull up lock pin (20) to unlock and remove duct

(21).
PC200, 200LC, 220, 220LC-8M0 50-700 27

14. Remove ducts (24) to (28). [*2] 17. Remove four bolts (29) and remove pump con-
a Cut the cable ties holding the ducts. troller assembly (A). Arrange the assembly
neatly and place it on the floor apart from the
operator's cab.
15. Remove cable tie (39) of the left console wiring

harness.
18. Disconnect connectors (30) to (32) from air
conditioner controller assembly (B).
(AC01)
(AC02)
q Connector (32): Air conditioner unit har-
ness (AC04)
16. Remove cable tie (40) of the floor wiring har-

ness.
50-700 28 PC200, 200LC, 220, 220LC-8M0

19. Disconnect connectors (42) to (45). 24. Remove six mounting bolts (37), then remove
q Connector (42): Communication antenna air conditioner unit assembly (38).
(GPS)
(CK01).
(CK02).
q Connector (45): Communication antenna
20. Remove KOMTRAX terminal (C) (four bolts).
22. Remove bolt (34), then disconnect tubes (35)

of the air conditioner. [*3]
23. Disconnect hoses (36) of the heater core. [*4]
PC200, 200LC, 220, 220LC-8M0 50-700 29

Installation [*3]
a Perform installation in the reverse order to a When installing air conditioner hoses and
removal. tubes, take care so that dust, dirt or water does
not enter them.
[*1] a When connecting the air conditioner hoses and
a Filling air conditioner circuit with refrigerant tubes, check that O-rings are fitted to their
(R134a) joints.
Fill the air conditioner circuit with refrigerant a Do not reuse an O-ring since it is deformed and
(R134a). deteriorated once it is used.
a Filling quantity: a When removing O-rings, use a soft tool to avoid
725 50 g damaging hoses and tubes.
q Refilling of air compressor oil a Check that there is no defect or deterioration on
For details, see Others "Filling compressor oil". the O-ring.
a Apply compressor oil (Denso: ND-OIL8) for
[*2] R134a refrigerant to O-rings.
a Removing cover (48) makes easier to install
ducts (24) and (26) .
a Since the mounting bolts of cover (48) are hid-
den by cover (47), remove cover (47) first.
3 Hose clamp (M6 bolt):

8 to 12 Nm {0.8 to 1.2 kgm}
[*4]
a When installing the hoses of heater core, make
white line (marking) of heater hoses straight to
prevent kink of heater hoses.
q Refilling of coolant (radiator)

Supply the coolant through the coolant filler
port to the specified level. Run the engine to
circulate the coolant through the system. Then,
check the coolant level again.
5 Coolant (radiator):
20.3 l (PC200/200LC-8M0)
19.8 l (PC220/220LC-8M0)
50-700 30 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 50-700 31

SEN06148-00

2012 KOMATSU
All Rights Reserved
50-700 32
SEN06149-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

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

Removal and installation of machine monitor assembly ................................................................................. 2
Removal and installation of engine controller assembly ................................................................................. 4
Removal and installation of pump controller assembly ................................................................................... 6
Removal and installation of KOMTRAX terminal assembly ............................................................................ 8
PC200, 200LC, 220, 220LC-8M0 50-800 1

SEN06149-00 Removal and installation of machine monitor assembly
Removal and installation of 4. Remove three mounting screws of cover (4).

machine monitor assembly 1
a One of the three screws is covered with
cap (5).
the work equipment to the ground, and
stop the engine.
a Note connector numbers and installed posi-
tions before disconnecting wirings and hoses.
Removal
1. Pull up front window assembly (1) to the ceiling
and lock it.
a Check that the front window is securely
locked.
2. Remove front lower window (2). 5. Remove connector (6) and then remove cover
(4).
a Connector (6): Sunlight sensor (P31)
3. Remove rubber panel (3) (two bolts).
6. Remove duct (10) (one bolt).
50-800 2 PC200, 200LC, 220, 220LC-8M0

Removal and installation of machine monitor assembly SEN06149-00
7. Insert a flat-head screwdriver in slit (7) and pull 9. Remove four mounting bolts (11) of machine
it upward to remove cover (9) while releasing monitor (12).
lug (8).
10. Disconnect connectors (13) to (16).

a Hook (17) beneath cover (9) unites cover a Disconnecting connector (15) first makes
(9). easier to disconnect the other connectors.
q Connector (13): Machine monitor (CM01)
q Connector (14): Machine monitor (CM02)
q Connector (15): Machine monitor (not
used) (CM03)
q Connector (16): Machine monitor (for
camera connection) (CM04)
8. Loosen mounting bolts (19) of cover and duct

assembly (18).
a Loosening mounting bolts (19) first makes
easier to remove machine monitor mount-
ing bolts.
Installation
removal.
PC200, 200LC, 220, 220LC-8M0 50-800 3

SEN06149-00 Removal and installation of engine controller assembly

engine controller assembly 1
Removal
Installation
q Carry out installation in the reverse order to re-
moval
[*1]
q Check that there is no sand, dust or water
inside the controller connector (especially on
the bottom). If any of them is found, completely
remove them using a blower, etc. (Sand, dust
or water may cause defective contact in con-
3. Open the engine hood. nectors or defects by entering water.)
4. Disconnect connectors CE02 (2) and (3) from a Reference

the engine controller. [*1] q How to replace the seal of O-ring of power
a The connector is locked with the inside source connector (4).
hexagonal head bolt L6 (4 mm). Seal of O-ring:
1010-074-0406 (NIHON-DEUTSCH Ltd.)
5. Disconnect connector (4) from the engine con- or equivalent
troller by pushing the lock. [*1]
1) Remove cover (6) by nipping the tab with twee-
6. Remove the mounting bolt and engine control- zers [1].
ler (5).
a Ground (E) and harness clamp are tight-
ened together with.
50-800 4 PC200, 200LC, 220, 220LC-8M0

Removal and installation of engine controller assembly SEN06149-00
2) Remove O-ring (7) with tweezers [1].
PC200, 200LC, 220, 220LC-8M0 50-800 5

SEN06149-00 Removal and installation of pump controller assembly
Removal and installation of pump

controller assembly 1
Removal
Installation
moval.
a Reference
1. Procedure for removing connector cover (1)
1) Cut and remove cable tie (2).
2. Disconnect relay R08 (4) from the clip. 2) Move lever (3) up.
3. Disconnect bracket (5) and put it to the right
side.
4. Disconnect wiring connectors C01 (6) and C02

(7) as follows.
q Tilt lock (L2) inside while pressing lock
(L1).
a Bar (B) comes out and the lock is re-
leased.
5. Remove the 4 mounting bolts and pump con-

troller assembly (8).
3) Lightly push part (A) of connector cover

(1) from both sides to unfasten claw (B).
4) Remove connector cover (1) around claw
(C).
50-800 6 PC200, 200LC, 220, 220LC-8M0

Removal and installation of pump controller assembly SEN06149-00
a Connector without connector cover 3) Set claw (C) to the connector and place
(1) connector cover (1).
a Take care that wiring harness (5) will
not be caught.
2. Procedure for installing connector cover

1) Push in right and left sliders (4) as far as
possible. 4) Set claw (B) and install connector cover
(1).
a Right and left sliders (4) pushed in as

far as possible (Left figure) 5) Bind connector cover (1) and wiring har-
2) Move lever (3) of connector cover (1) from ness with a new cable tie. (See 1. 1).)
the upper position to the left position (lock
position) in the figure.
a (B), (C): Claws
a If the sliders and lever are not set as
shown in the following figure, the con-
nector is not disconnected or locked
securely with the lever. Accordingly,
check their positions again.
PC200, 200LC, 220, 220LC-8M0 50-800 7

SEN06149-00 Removal and installation of KOMTRAX terminal assembly
Removal and installation of 4. Remove cover (6) (seven bolts).

KOMTRAX terminal assembly 1
a Be careful about connector (7) located
behind cover (6).
k Park the machine on a level ground, lower q Connector (7): Cigarette lighter (M04)
the work equipment to the ground, and
stop the engine.
a Note connector numbers and installed posi-
tions before disconnecting wiring and hoses.
a The position of the KOMTRAX terminal is
shown below.
q C: KOMTRAX terminal
5. Disconnect connectors (8) to (11).

(GPS)
(CK01).
(CK02).
6. Remove KOMTRAX terminal (C) (four bolts).
Removal
1. Remove box (1) (five bolts).
a Disconnect the hose located under box
(1).
2. Remove box (2) (three bolts).

a Be careful about connectors (3) and (4)
located behind box (2) (for machines
equipped with 12 V power socket).
q Connector (3): 12 V power socket
intermediate harness (M13A)
q Connector (4): 12 V power socket
intermediate harness (M13B)
3. Remove cover (5) (three bolts).

Installation
removal.
50-800 8 PC200, 200LC, 220, 220LC-8M0

Removal and installation of KOMTRAX terminal assembly SEN06149-00
PC200, 200LC, 220, 220LC-8M0 50-800 9

SEN06149-00

2012 KOMATSU
All Rights Reserved
50-800 10
SEN06151-00
SEN06002-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR
Shop Manual
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
PC200-8M0 400001 and up
PC220-8M0 100001 and up
80 Appendix
100 Air conditioner
Precautions for refrigerant .......................................................................................................................... 3

Air conditioner component .......................................................................................................................... 4
Configuration and function of refrigeration cycle......................................................................................... 6
Outline of refrigeration cycle ....................................................................................................................... 7
Air conditioner unit ...................................................................................................................................... 9
Air conditioner controller ............................................................................................................................. 15
Compressor ................................................................................................................................................ 16
Condenser and Modulator .......................................................................................................................... 17
Sensor......................................................................................................................................................... 18
Procedure for testing and troubleshooting .................................................................................................. 20
Circuit diagram and arrangement of connector pins ................................................................................... 22
System diagram .......................................................................................................................................... 24
Parts and connectors layout ....................................................................................................................... 26
Testing air leakage (duct)............................................................................................................................ 29
Testing with self-diagnosis function............................................................................................................. 31
Testing vent (mode) changeover................................................................................................................. 33
Testing FRESH/RECIRC air changeover.................................................................................................... 34
Testing sunlight sensor ............................................................................................................................... 35
Testing (dual) pressure switch for refrigerant.............................................................................................. 36
Testing relays .............................................................................................................................................. 37
PC200, 200LC, 220, 220LC-8M0 80-100 1

100 Air conditioner
SEN06151-00
Troubleshooting chart 1............................................................................................................................... 38

Troubleshooting chart 2............................................................................................................................... 40
Failure code list related to air conditioner ................................................................................................... 43
Failure code [879AKA] A/C Inner sensor Open Circuit ............................................................................... 44
Failure code [879AKB] A/C Inner sensor Short Circuit ............................................................................... 45
Failure code [879BKA] A/C Outer sensor Open Circuit .............................................................................. 46
Failure code [879BKB] A/C Outer sensor Short Circuit............................................................................... 48
Failure code [879CKA] Ventilating sensor Open Circuit.............................................................................. 50
Failure code [879CKB] Ventilating sensor Short Circuit.............................................................................. 51
Failure code [879DKZ] Sunlight sensor Open or Short Circuit.................................................................... 52
Failure code [879EMC] Ventilating Damper Abnormality ............................................................................ 54
Failure code [879FMC] Air Mix Damper Abnormality.................................................................................. 55
Failure code [879GKX] Refrigerant Abnormality ......................................................................................... 56
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate).... 58
Troubleshooting for compressor and refrigerant system (Air is not cooled)................................................ 60
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ................................ 63
Troubleshooting for FRESH/RECIRC air changeover................................................................................. 65
Troubleshooting with gauge pressure ......................................................................................................... 67
Connection of service tool........................................................................................................................... 69
Precautions for disconnecting and connecting air conditioner piping ......................................................... 71
Handling of compressor oil.......................................................................................................................... 73
Desiccant replacement procedure .............................................................................................................. 75
80-100 2 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Precautions for refrigerant SEN06151-00
Precautions for refrigerant
k Collect the refrigerant (Air conditioner gas:

R134a) from air conditioner circuit before
disconnecting air conditioner hose to re-
place air conditioner unit, condenser, air
conditioner compressor or receiver drier and
so on.
a Ask a qualified person for collecting, adding and
filling operations of the refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmo-
sphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches
your skin, you may suffer from frostbite. Put
on protective eyeglasses, gloves and work-
ing cloth with long sleeves while collecting
the refrigerant or filling the air conditioner
circuit with the refrigerant.
PC200, 200LC, 220, 220LC-8M0 80-100 3

100 Air conditioner
SEN06151-00 Air conditioner component
Air conditioner component
80-100 4 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Air conditioner component SEN06151-00
1. Compressor Specifications
2. Condenser Refrigerant R134a
3. Modulator * Refrigerant refilling level (g) 725 50
4. Hot water piping
5. Hot water return piping A. Front vent
6. Refrigerant piping B. Rear vent
7. Dual pressure switch C. Foot vent
8. Sight glass D. Defroster air vent
9. Air conditioner controller E. Recirculation air inlet
10. Air conditioner unit F. Fresh air inlet
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
*: Receiver drier and condenser are integrated on this product. The existing receiver drier unit is called "mod-
ulator" here.
PC200, 200LC, 220, 220LC-8M0 80-100 5

100 Air conditioner
SEN06151-00 Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle

Cycle Compression Condensation Expansion Evaporation
(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator cab In operator cab
Location Engine compartment Front of radiator (Built in air conditioner (Built in air conditioner
unit) unit)
Circulates refrigerant
gas and increases its Lowers temperature and Evaporates refrigerant to
Condenses refrigerant
temperature and pres- pressure of refrigerant liq- absorb heat from air
to discharge heat
sure so that it can be uid and gas for easy evap- around evaporator, and
Function absorbed in evaporator.
liquefied easily in con- oration with throttle. cool the air.
(condensation of refrig-
denser. Controls flow rate, too. (Evaporation of refriger-
erant)
(Compression of (Throttle of refrigerant) ant)
refrigerant)
Gas o Gas Gas o Liquid
Liquid o Liquid and gas Liquid and gas o Gas
State of refriger-
ant Adiabatic compres- Cnstant pressure
Adiabatic expansion Cnstant pressure change
sion change
80-100 6 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Outline of refrigeration cycle SEN06151-00
Outline of refrigeration cycle

The refrigeration cycle is comprised of 4 cycles. The refrigerant is circulated while repeatedly vaporizing and
liquefying.
1. Compression (Compressor) The expansion valve controls the refrigerant

The compressor sucks in the refrigerant that has feed rate so that the optimum quantity of liquid
been vaporized in the evaporator and refrigerant is supplied to the evaporator.
compresses it into a state where it can be easily
liquefied at the ambient temperature. (*1) Throttle action
The gaseous refrigerant sucked into the If there is a narrow section in the passage
compressor cylinder is compressed to a temper- through which liquid is flowing at a constant rate,
ature and pressure at which it can be easily a resistance to the flow will be generated.
liquefied when cooled to the ambient tempera- The liquid expands when it passes through the
ture. narrow section and rushes into the passage
where the sectional area is larger, and conse-
2. Condensation (Condenser) quently, its pressure and temperature are
The condenser cools and liquefies the high pres- reduced.
sure and high-temperature gaseous refrigerant No heat is transferred from or to the outside
sent from the compressor. during the throttle action.
The heat released to the outside from the
condenser is called condensation heat. 4. Evaporation (Evaporator)
The amount of condensation heat is the sum The evaporator evaporates the liquid refrigerant
total of the heat absorbed by the evaporator from (superheated vapor).
the air in the cab and the quantity of the work The refrigerant evaporates, while absorbing an
applied (the value converted into a heat quantity) amount of heat necessary for evaporation (evap-
by compression of the compressor. oration heat) from the air around the cooling fins
The refrigerant liquefied in the condenser is sent (air in the cab).
to the receiver drier, where moisture is removed. After the heat has been removed, the cooled air
In the compression cycle, the gaseous refrig- is sent into the cab by the blower fan, reducing
erant and liquid refrigerant coexist. the temperature inside the cab.
The temperature (condensation temperature) The mist refrigerant that has been sent from the
and the pressure (condensation pressure) at expansion valve coexists with the evaporated
which the gaseous refrigerant is liquefied are refrigerant in the evaporator
proportional to each other. The temperature (evaporation temperature) and
the pressure (evaporation pressure) at which the
Reference: The pressure varies depending on liquid refrigerant is evaporated are proportional
the condensation temperature of the refrigerant. to each other.
The compressor sucks in the evaporated refrig-
3. Expansion (Expansion valve) erant in order to keep the pressure level in the
The expansion valve reduces the liquid refrig- evaporator as low as possible so that the liquid
erant pressure to a level where liquid refrigerant refrigerant can be evaporated at a much lower
can be easily evaporated by the throttle action temperature.
(*1).
The action of reducing the liquid refrigerant pres- Relationship between refrigerant and defective
sure to a level where it can be easily evaporated air conditioning
before it is sent to the evaporator is called q The refrigerant circulates in the refrigeration cir-
expansion. cuit while repeating the refrigeration cycle to ex-
The expansion valve, which reduces the refrig- pel the heat from inside the cab.
erant pressure, also adjusts the refrigerant flow q If there is an insufficient quantity of refrigerant,
rate simultaneously. all of it will be evaporated while it is passing
The quantity of the liquid refrigerant that can be through the evaporator. This causes evaporator
evaporated in the evaporator depends on the efficiency to deteriorate, which will result in de-
amount of heat (refrigeration load) to be fective air conditioning.
removed under the specific evaporation temper-
ature (evaporation pressure).
PC200, 200LC, 220, 220LC-8M0 80-100 7

100 Air conditioner
SEN06151-00 Outline of refrigeration cycle
q If there is excessive refrigerant, not all of it will be

evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the
compressor to compress the liquid and may
damage the components.
q If water gets into the refrigeration circuit, it will
freeze at a small hole in the expansion valve,
lower the refrigerant flow, and may result in de-
fective air conditioning.
80-100 8 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Air conditioner unit SEN06151-00

a This air conditioner unit is auto temperature control type.
PC200, 200LC, 220, 220LC-8M0 80-100 9

100 Air conditioner
SEN06151-00 Air conditioner unit
A: Refrigerant inlet (from condenser) *: See "Parts and connectors layout" for details re-
B: Refrigerant outlet (to compressor) garding the compressor clutch relay.
C: Hot water inlet
D: Hot water outlet Air flow adjustment
E: Recirculation air hole q Whenever an air flow control switch is operated
F: Fresh air hole on the machine monitor, air flow setting data is
G: Front air vents sent to the air conditioner controller. The air con-
H: Rear air vents ditioner controller controls blower motor (4) us-
J: Foot level air vents ing power transistor (13) in order to adjust the air
K: Defroster vents flow.
1. Evaporator Vent (mode) changeover

2. Heater core q Whenever a vent switch is operated on the ma-
3. Expansion valve chine monitor, mode data is sent to the air con-
4. Blower fan, blower motor ditioner controller. The air conditioner controller
5. Air mix servomotor controls mode changeover servomotor (7) to ad-
6. Air mix door just the opening angle of mode changeover
7. Vent (mode) changeover servomotor doors (8) to (10) and thus perform vent change-
8. Rear door over.
9. Foot door
10. Defroster door FRESH/RECIRC air changeover
11. FRESH/RECIRC air changeover servomotor q Whenever a FRESH/RECIRC air changeover
12. FRESH/RECIRC air changeover servomotor switch is operated on the machine monitor,
13.Power transistor FRESH/RECIRC air changeover setting data is
14. Evaporator temperature sensor sent to the air conditioner controller. The air con-
15. Inner sensor (inside air temperature sensor) ditioner controller controls FRESH/RECIRC air
changeover servomotor (11) to open and close
Outline FRESH/RECIRC air changeover door (12).
q The air conditioner unit consists of the evapora-
tor (1) and heater core (2), and is used to cool Automatic air conditioner
down or warm up the air in the cab. q Inside air temperature sensor (15) detects the in-
ternal temperature based on changes in resis-
Temperature control tance. The air conditioner controller detects the
q Whenever a temperature control switch is oper- internal temperature by converting the changes
ated on the machine monitor, temperature set- in the resistance of inside air temperature sensor
ting data is sent to the air conditioner controller, (15) into voltage changes.
which is located behind the operator seat. The The air conditioner controller checks the voltage
air conditioner controller controls the air mix ser- of inside air temperature sensor (15) and
vomotor (5) and changes the angle of the air mix controls the internal temperature so that it
door (6) in order to adjust the temperature. matches the setting made on the machine
monitor.
Over-cooling (Freezing) prevention Data from the sunlight sensor and the outside air
q Evaporator temperature sensor (14) varies its temperature sensor is also taken into consider-
electrical resistance according to temperature. ation when adjusting the internal temperature.
q The air conditioner controller detects the temper-
ature of the evaporator (1) by converting the a The door is the same as the damper.
changes in the resistance of the evaporator tem-
perature sensor (14) into voltage changes.
q The air conditioner controller performs control to
prevent freezing of the evaporator (1) by operat-
ing the compressor clutch relay (*) to stop the
compressor.
80-100 10 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Changeover pattern of the vent (mode) changeover door

Rear door (8) Foot door (9) Defroster door (10)
Opening and Opening and Opening and
Angle Angle Angle
closing door closing door closing door
Front Close 0 Close 0 Close 0
Front and rear Open 25 Close 0 Close 0
Front, rear and
Air vent Open 25 Open 35 Close 0
foot
mode
Foot Open 25 Open 53 Close 0
Foot and defroster Open 25 Open 23 Open 38
Defroster Open 25 Open 0 Open 38
Selection pattern of air mix door (6)

Set temperature Opening and closing door Angle
Max. Cool Close 0
Max. Hot Open 80
PC200, 200LC, 220, 220LC-8M0 80-100 11

100 Air conditioner
Functions of major components q When the door (damper) reaches the position
a For details of the numbers in the following sen- specified by each switch, the air conditioner con-
tence, see "Air conditioner unit". troller stops the supply of current to the servomo-
Evaporator tor, then the corresponding door stops.
q Evaporator (1) is cooled by the low-pressure, q When the potential difference fails to reach a
low-temperature refrigerant gas being sent from predefined voltage for control of the servomotor,
expansion valve (3). the air conditioner controller notifies the machine
q Air from blower motor (4) is cooled and dehumid- monitor of an abnormality. [879EMC] or
ified when passing through the fins of the evap- [879FMC] is displayed in the "Electrical System"
orator (1). (electrical systems abnormality record) screen in
service mode of the machine monitor.
Heater core a FRESH/RECIRC air changeover servo motor
q Heater core (2) is warmed by the hot water (en- does not feature a variable resistance, and
gine coolant) being sent from the engine. therefore, does not have a self-diagnosis
q Air from blower motor (4) is warmed when pass- function.
ing through the fins of the heater core (2). a When attempting to operate a servomotor during
inspecting, do not supply power directly between
Evaporator temperature sensor servomotor terminals (6) and (7).
q Evaporator temperature sensor (14) is installed
on evaporator (1) with the holder. Its resistance
changes in response to the temperature change
of the evaporator (1).
q The air conditioner controller determines the
evaporator temperature from the voltage value
of the evaporator temperature sensor (14) and
turns the compressor on/off to prevent freeze of
the evaporator (1).
Servomotors
a Servomotors are used to adjust the temperature

(air mix) and to perform vent (mode) change-
over.
q Whenever a switch on the machine monitor is
operated, the air conditioner controller delivers
power to the servomotor by raising the voltage
between terminals (6) and (7) to 24 V. (The rota-
tion direction changes based on the supply po-
larity.)
q The servomotor contains a variable resistance,
and its resistance value changes as the motor
turns.
q The air conditioner controller delivers voltage at
5 V to the variable resistance and detects motor
rotation angle based on the potential difference.
80-100 12 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Expansion valve
A: When evaporator outlet temperature is high Structure

B: When evaporator outlet temperature is low q Box-type expansion valve (1) consists of needle
C: From receiver drier (high-pressure refrigerant) valve (1a), spring (1b), etc.
D: To compressor (low-pressure refrigerant) q Refrigerant gas (2) is sealed in the diaphragm
chamber (hatched area) outside diaphragm
1. Expansion valve (1a-1) of needle valve (1a).
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas
3. Evaporator
Outline
q The expansion valve converts high-pressure
and high-temperature liquid refrigerant from the
receiver drier to low-pressure, low-temperature
misty refrigerant through the throttle action.
q It controls the flow rate of refrigerant by changing
the level of throttling depending on the tempera-
ture in the cab.
q The temperature of the air blown out of the air
vent is adjusted depending on the volume of re-
frigerant circulating in the evaporator (3).
PC200, 200LC, 220, 220LC-8M0 80-100 13

100 Air conditioner
Operation Dual pressure switch

q Thermoprobe (1a-2) senses the refrigerant tem- a The dual pressure switch is mounted on the air
perature after it passes through the evaporator conditioner hose under the floor.
(3). q The dual pressure switch turns "OFF" when the
q After the refrigerant passes through evaporator refrigerant circuit pressure becomes abnormally
(3), its temperature is transferred to the refriger- low or abnormally high.
ant gas (2) in the diaphragm chamber (hatched q When the dual pressure switch turns "OFF", the
area) through the thermoprobe (1a-2). air conditioner controller turns the compressor
q The pressure of the refrigerant gas (2) sealed in clutch relay "OFF". As a result, the compressor's
the diaphragm chamber (hatched area) changes magnet clutch is released and air conditioner
in response to the temperature change of the components are protected.
thermoprobe (1a-2), which therefore changes
the force (Fg) pushing the needle valve (1a). Function
q The opening level of the needle valve (1a) is de-
termined based on the balance between the re-
action force exerted by the spring (1b) in a
rightward direction, and the force (Fg) of the re-
frigerant gas (2) pushing the needle valve (1a)
through the diaphragm (1a-1) in a leftward direc-
tion.
q The refrigerant flow rate flowing from the receiv-
er drier to evaporator (3) is determined based on
the opening level of needle valve (1a).
When evaporator (3) outlet temperature is high:

[When not cooled yet: Condition (A) in the fig-
ure]
q The pressure of the refrigerant gas (2) in the di-
a LA or lower: Abnormally low pressure
aphragm chamber is high and the volume is in- a HA or higher: Abnormally high pressure
creased.
q The force (Fg) of the refrigerant gas (2) pushing
LA: 0.20 MPa {2 kg/cm2}
the needle valve (1a) is increased, and the nee- LB: 0.02 MPa {0.2 kg/cm2}
dle valve (1a) moves leftward. HA: 3.14 MPa {32 kg/cm2}
q As a result, the opening level of the needle valve
HB: 0.59 MPa {6 kg/cm2}
(1a) is increased and the refrigerant flow rate to
the evaporator (3) is increased to improve cool-
ing capacity.
When evaporator (3) outlet temperature is low:

[When cooled already: Condition (B) in the fig-
ure]
q The pressure of the refrigerant gas (2) in the di-
aphragm chamber is low and the volume is de-
creased.
q The force (Fg) of the refrigerant gas (2) pushing
the needle valve (1a) is reduced, and the needle
valve (1a) is moved rightward by the spring force
(1b).
q The opening level of the needle valve (1a) is re-
duced and the refrigerant flow rate to the evapo-
rator (3) is reduced to lower the cooling capacity.
80-100 14 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Air conditioner controller SEN06151-00
Air conditioner controller
a See "System Diagrams" for details regarding in-

put/output signals.
PC200, 200LC, 220, 220LC-8M0 80-100 15

100 Air conditioner
SEN06151-00 Compressor
Compressor
A: Refrigerant inlet (from air conditioner unit) Function

B: Refrigerant outlet (to condenser) q The compressor circulates the refrigerant and
compresses the gaseous refrigerant from the
1. Pulley evaporator into a misty refrigerant at high pres-
2. Magnetic clutch sure and high temperature so that it will be easily
3. Relief valve regenerated (liquefied) at the normal tempera-
ture.
q Calling into account of the evaporator tempera-
ture and refrigerant pressure, the air conditioner
controller activates magnetic clutch (2) built in
the compressor.
q When the magnetic clutch is engaged, the power
of the engine rotates the compressor shaft along
with pulley (1) to drive the compressor.
Specifications
Number of cylinder Bore x
Stroke 10 - 32 x 20.8
(mm)
Piston capacity
157.3
(cc/rev)
Allowable maximum speed
6,000
(rpm)
Denso: ND-OIL8 (For
Compressor oil
R134a)
Compressor oil refill capacity
180
(cc)
80-100 16 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Condenser and Modulator SEN06151-00
Condenser and Modulator
A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to air conditioner unit)
1. Condenser
2. Modulator
Function Function
q Condenser (1) q Modulator (2)
It cools and liquefies the high-pressure, a This has desiccant in it. See "Desiccant replace-
high-temperature misty refrigerant from the ment procedure".
compressor. It is used to store liquefied high-pressure,
a If the fin is crushed or is clogged with dust, heat high-temperature misty refrigerant from the
exchange efficiency is reduced and complete liq- condenser. It is capable of completely liquefying
uefaction of refrigerant becomes impossible. As the refrigerant even when bubbles are contained
a result, pressure in refrigerant circulation circuit in the refrigerant due to the condenser condition
is increased, applying extra load to the engine or in heat dissipation.
reducing cooling effect. Take extreme care not It eliminates foreign substances in the circulation
to crush or damage the fins when handling them line and moisuture in the refrigerant by use of the
or checking them in daily inspection. built-in filter and desiccant.
Specification Specification
Fin pitch (mm) 4.0 Weight of desiccating 290
Height x Width x Thickness agent (g)
421 x 540 x 16
(mm)
Weight (kg) 3.2
PC200, 200LC, 220, 220LC-8M0 80-100 17

100 Air conditioner
SEN06151-00 Sensor
Sensor
Sunlight sensor Outside air temperature sensor
1. Connector 1. Connector
2. Sensor 2. Sensor
Outline Outline
q The sunlight sensor is mounted on top of the ma- q The outside (air) temperature sensor is installed
chine monitor. on the bracket in the cooling unit. (See "Parts
q It detects the strength of incident sunlight and and connectors layout".)
sends signals to the air conditioner controller. q The outside air temperature sensor has feature
q When performing automatic air conditioning, the of change in resistance by temperature change,
air conditioner controller controls the blower mo- therefore, can detect the ambient temperature.
tor and the air mix servomotor with the data of q The air conditioner controller detects the ambi-
the sunlight sensor in order to adjust the temper- ent temperature by converting the changes in
ature and air flow. the resistance of the outside air temperature
sensor into voltage changes.
Output characteristics q When performing automatic air conditioning, the
air conditioner controller controls the blower mo-
tor and the air mix servomotor with the data of
the outside (air) temperature sensor in order to
adjust the temperature and air flow.
80-100 18 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Sensor SEN06151-00
PC200, 200LC, 220, 220LC-8M0 80-100 19

100 Air conditioner
SEN06151-00 Procedure for testing and troubleshooting
Procedure for testing and troubleshooting

The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See Check with self-diagnosis).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air condi-
tioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air condi-
tioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic testing and troubleshooting sequence
80-100 20 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Procedure for testing and troubleshooting SEN06151-00
*1: By error display or abnormal display on "Electrical Systems" screen on the machine monitor.
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding
with the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant
or no refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.
S: Sight glass condition

R: Receiver drier internal condition
LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for discon-
necting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
PC200, 200LC, 220, 220LC-8M0 80-100 21

100 Air conditioner
SEN06151-00 Circuit diagram and arrangement of connector pins
Circuit diagram and arrangement of connector pins
80-100 22 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Circuit diagram and arrangement of connector pins SEN06151-00
a Diffuser servomotor means vent (mode) changeover servomotor.

a SERVOMOTOR OF INSIDE/OUTSIDE AIR means FRESH/RECIRC air changeover servomotor.
a Frost sensor means evaporator temperature sensor.
PC200, 200LC, 220, 220LC-8M0 80-100 23

100 Air conditioner
SEN06151-00 System diagram
System diagram
a This air conditioner unit is auto temperature control type.
80-100 24 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
System diagram SEN06151-00
Input and output signals of the air conditioner q Operation of air conditioner controller
controller 1. Performing CAN communication with the
Controller connector: AMP 025 - 32PM machine monitor, the air conditioner controller
Wiring harness connector: ACECU (AMP025 - controls the air conditioner unit by inputting
32PF) switches associated with air conditioning.
AMP025 - 32PF 2. The air conditioner controller controls three
Input/ servomotors located inside the air conditioner
Pin Out- unit in order to adjust the temperature (airmix),
Symbol Signal name perform vent (mode) changeover, and perform
No. put
signal FRESH/RECIRC air changeover.
1 +Bback Backup power supply Input 3. The air conditioner controller controls the
2 (*1) ON/OFF condition of the compressor clutch
3 SS Sunlight sensor Input relay (i.e., a switch for activating the
4 THOUT Outside air temperature sensor Input compressor).
Evaporator temperature sen- 4. The air conditioner controller controls the air flow
5 THF Input
sor volume using the power transistor.
6 THI Inside air temperature sensor Input a The power transistor has an overcurrent pre-
Servomotor potentiometer vention fuse in it.
7 POT5 V Output
power supply (5 V)
5. The air conditioner controller detects the evapo-
8 BWFB Blower feedback signal Input
rator temperature using the evaporator tempera-
9 PTRB Power transistor control signal Output
Input/o
ture sensor.
10 CAN_H CAN communication signal (H) 6. In order to prevent freezing of the evaporator,
utput
Input/o the air conditioner controller controls the
11 CAN_L CAN communication signal (L) compressor by turning the compressor clutch
utput
12 (*1) relay ON and OFF.
Fresh/recirculated air servomo- a When the dual pressure switch detects a
13 MRFA Output
tor terminal A pressure abnormality (i.e., turns OFF), the air
Fresh/recirculated air servomo- conditioner controller turns the compressor
14 MRFB Output
tor terminal B clutch relay OFF, and therefore, the com-
15 MAMA Air mix servomotor terminal A Output pressor stops operating.
16 MAMB Air mix servomotor terminal B Output
7. When performing automatic air conditioning, the
17 +24 V 24 V power supply Input
air conditioner controller controls the inside (air)
18 (*1)
temperature to the set temperature and adjust
Air mix servomotor potentiom-
19 SAM Input the air flow according to the data from the
eter signal
Vent (mode) changeover ser- sunlight sensor, the outside air temperature
20 SVI Input sensor, and the inside air temperature sensor.
vomotor potentiometer signal
PRESS 8. The air conditioner controller has the self-diag-
21 Dual pressure switch Input
SW nosis function. If any abnormality is detected, the
22 (*1) controller notifies it to the machine monitor by
23 (*1) the CAN communication. Then, failure code
24 (*1) [879***] is displayed on the "Electrical Systems"
25 GNDS Sensor GND Input screen of the electrical system on the machine
26 GND GND Input monitor.
27 (*1)
28 (*1)
29 RLCC Compressor clutch relay Output
30 (*1)
Vent (mode) changeover ser-
31 MV1A Output
vomotor terminal A
Vent (mode) changeover ser-
32 MV1B Output
vomotor terminal B
*1: Never connect these pins. Malfunctions or fail-
ures may occur.
PC200, 200LC, 220, 220LC-8M0 80-100 25

100 Air conditioner
SEN06151-00 Parts and connectors layout
Parts and connectors layout
q Three fuses related to the air conditioner are in a Note the connector numbers and installed posi-
the fuse box at the right rear of the operator's tions before disconnecting wiring and hoses.
seat.
q The air conditioner unit is mounted inside the
rear cover of at the rear cover of the operator's
seat.
k Park the machine on a level surface, swing
the upper structure by 90 degrees, lower the
work equipment to the ground so that it is
stable, and stop the engine.
k Turn the battery disconnect switch to the
"OFF" position and pull out the key.
Reference
Connector No. Remarks Location
item
AC01 Intermediate connector Right rear of cab 2.
AC02 Intermediate connector Right rear of cab 2.
AC03 Air conditioner compressor Engine 7.
ACECU Engine controller Rear of cab 2.
CM01* Machine monitor Front of cab 5.
CM02 Machine monitor Front of cab 5.
F01 Fuse box Right rear of cab 1.
Dual pressure switch
P17 Under cab 6.
aSwing upper structure 90 deg.
P18 Outside air temperature sensor Cooling unit 8.
P31 Sunlight sensor Machine monitor 4.
R21 Relay Rear of cab 2.
[2] Power transistor Air conditioner unit 3.
FRESH/RECIRC air changeover
[5]* Air conditioner unit 3.
servomotor
[6]* Inside air temperature sensor Air conditioner unit 3.
Evaporator temperature sensor
[7]* Air conditioner unit 3.
(frost sensor)
*: Connectors that are not involved in the troubleshooting
80-100 26 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Parts and connectors layout SEN06151-00
1. Each fuse in fuse box F01: 2. Air conditioner controller: *1

Open the cover of the fuse box at the right rear q AC01: Intermediate connector
of the operator's cab. q AC02: Intermediate connector
q No. 11 (20 A): Fuse for the power supply of q ACECU: Air conditioner controller connector
blower (fan) and the air conditioner compres- q R21: Connector for air conditioner compres-
sor sor electromagnetic clutch relay
q No. 10 (5 A): Fuse for the primary power sup-
ply of the air conditioner unit, air conditioner
controller, and the air conditioner compres-
sor electromagnetic clutch relay
q No. 18 (5 A): Fuse for the power supply
(backup power supply) of the air conditioner
controller
3. Air conditioner unit

a Connectors [2], [5], [6], and [7] do not have
labels.
a Rear side of air conditioner unit (Only con-
nector [2] can be removed while installed on
machine)
[2]: Power transistor (*2) connector
[5]: FRESH/RECIRC air changeover servo-
motor connector
[6]: Inner sensor (inside air temperature
sensor) connector
[7]: Evaporator temperature sensor
connector
*2: Power transistor
PC200, 200LC, 220, 220LC-8M0 80-100 27

100 Air conditioner
SEN06151-00 Parts and connectors layout
4. Sunlight sensor 7. Air conditioner compressor

P31: Sunlight sensor connector a Open the engine hood.
q AC03: Air conditioner compressor connector
5. Machine monitor
q CM01 to CM04: Machine monitor connector 8. Outside air temperature sensor
a Connector CM03: (Not used) P18: Outside (air) temperature sensor connector
a Connector CM04: (For camera connection)
6. Dual pressure switch

a Rotate cab undercover 90 degrees and re-
move it.
q P17: Dual pressure switch connector
80-100 28 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Testing air leakage (duct) SEN06151-00
Testing air leakage (duct)
k Park the machine on a level surface, lower 8. Remove drink box (8) (five bolts).
the work equipment to the ground so that it is a Disconnect the hose under drink box (8).
stable, and stop the engine. 9. Remove magazine box (9) (three bolts).
k Turn the battery disconnect switch to the a Be careful about connectors (10) and (11)
"OFF" position and pull out the key. behind magazine box (9). (for machines
a Note connector numbers and installed positions equipped with 12 V power socket).
when disconnecting wiring and hoses. q Connector (10): 12 V power socket interme-
diate harness (M13A)
Testing q Connector (11): 12 V power socket interme-
1. Lift front window assembly (1) to the ceiling and diate harness (M13B)
lock it. 10. Pull up cover (12) (three bolts) to remove.
a Check that the front window is securely a The connectors and wiring harnesses at the
locked. rear must not be caught.
2. Remove front lower window (2).
3. Remove floor mat (3).
4. Remove cover (4) first, and remove cover (5).
6. Remove cap (7-1).

a Disconnect the sunlight sensor connector
from the rear of cover (7).
PC200, 200LC, 220, 220LC-8M0 80-100 29

100 Air conditioner
SEN06151-00 Testing air leakage (duct)

a Be careful about connector (14) behind box
(13).
12. Check whether any of the following ducts or pins

are disconnected.
q Front duct (15)
q Defroster duct (16)
q Rear duct (17)
q Fresh air inlet duct (18) and pin (19)
80-100 30 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Testing with self-diagnosis function SEN06151-00
Testing with self-diagnosis function
Testing outline How to enter air conditioner "Electrical Sys-

The air conditioner controller performs various tems" screen in service mode of the machine
self-diagnosis such as sunlight sensor, inside air monitor.
temperature sensor, outside air temperature sen-
sor, evaporator temperature sensor, temperature q Overview of machine monitor operating pro-
control system, vent (mode) changeover system, cedure
and refrigerant pressure with the pressure switch. If Normal screen
an error is detected on the temperature control sys- O While pressing number key (4), press (1), (2),
tem, vent (mode) changeover system, or refrigerant, and (3) in this order.
the machine monitor momentarily shows "L01" (2) Service menu (Mode)
and then "Air conditioner system state monitor" is O Press [F3] twice. Press [F6].
displayed continuously. 03 Abnormality record
a The machine monitor displays the system state O Press [F3] once. Press [F6].
monitor "!" when an error occurs in the commu- 02 Electrical Systems screen
nication between the machine monitor and the
air conditioner controller. q Detailed description of machine monitor op-
erating procedure
1. On the normal operation screen, while pressing
number key (4), press (1), (2), and (3) in this
order.
a Even if the cause of a detected problem is re-

stored to normal, the self-diagnosis failure condi-
tion will not automatically be reset. To reset the
failure condition, the starter switch must be set to
OFF.
a On the "Electrical System" screen in the service
mode of the machine monitor, the system per-
forms self-diagnosis for various sensors. If a
problem is detected, failure information is dis-
played.
a FRESH/RECIRC air changeover servomotor is
not checked with self-diagnosis function.
PC200, 200LC, 220, 220LC-8M0 80-100 31

100 Air conditioner
SEN06151-00 Testing with self-diagnosis function
2. On the service menu screen, press [F3] (R) a For details, see the failure code list related to air
twice, and then select "03 Abnormality Record". conditioner
Failure Failure (Displayed on
Remarks
3. Press [F6] ( ) to confirm. code screen)
A/C Inner Sensor Open
879AKA
Circuit
*
A/C Inner Sensor Short
879AKB
Circuit
A/C Outer Sensor Open
879BKA
Circuit
A/C Outer Sensor Short
879BKB
Circuit
Ventilating Sensor Open
879CKA
Circuit
*
Ventilating Sensor Short
879CKB
Circuit
Sunlight Sensor Open or
879DKZ
Short Circuit
Ventilation Dumper
879EMC *
Abnormality
4. On the Abnormality Record screen, press [F3] Air Mix Dumper Abnor-
879FMC *
(R) once, and then select "02 Electrical mality
Systems". 879GKX Refrigerant Abnormality
A/C Model Selection See Chapter
DAZ9KQ
5. Press [F6] ( ) to confirm. Abnormality 40, "Trouble-
shooting by fail-
CAN2 Discon (Aircon
DAZQKR ure code"
ECU)
**
*: Troubleshooting cannot be performed while the
controller is mounted on the machine since the con-
nector cannot be checked.
**: Troubleshooting is not performed by the air con-
ditioner unit but by the machine monitor.
a The air conditioner inner sensor means the in-

side (air) temperature sensor.
a The air conditioner outer sensor means the out-
side (air) temperature sensor.
a The ventilating sensor means the evaporator
temperature sensor (frost sensor).
a The ventilation damper means the vent (mode)
changeover damper (door).
a The air mix damper means the temperature ad-
justment (air mix) damper (door).
80-100 32 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Testing vent (mode) changeover SEN06151-00
Testing vent (mode) changeover
k Park the machine on a level surface, lower

the work equipment to the ground so that it is
when disconnecting wiring and hoses.
Testing
1. Remove drink box (1) (five bolts).
a Disconnect the hose under drink box (1).
2. Remove magazine box (2) (three bolts).
a Be careful about connectors (3) and (4) be-
hind magazine box (2). (for machines
equipped with 12 V power socket). 5. Remove ducts (8) and (9).
q Connector (3): 12 V power socket intermedi-
ate harness (M13A)
q Connector (4): 12 V power socket intermedi-
ate harness (M13B)
3. Remove cover (5) (three bolts).
6. Turn the battery disconnect switch to the "ON"

position.
7. Start the engine and turn the air conditioner
power "ON".
8. Operate the vent changeover switch on the
machine monitor.
9. Check the opening/closing operation of rear
door (11) and defroster door (12) of air condi-
tioner unit (10).

a Be careful about connector (7) behind box
(6).
10. After finishing the inspection, turn the starting

switch to the OFF position.
PC200, 200LC, 220, 220LC-8M0 80-100 33

100 Air conditioner
SEN06151-00 Testing FRESH/RECIRC air changeover
Testing FRESH/RECIRC air

changeover

q FRESH/RECIRC air is selected by changing the
door (damper) angle in the air conditioner unit
with the servo motor. Check the opening and
closing operations of the door (damper) visually.
a The system does not have self-diagnosis func-
tion for FRESH/RECIRC air changeover servo
motor.
Testing
1. Open outside air filter cover (1) and remove
outside air filter (2).
2. Start the engine and turn the air conditioner

power "ON".
3. Operate the FRESH/RECIRC air selector switch
on the machine monitor.
4. Check the opening/closing operation of
FRESH/RECIRC air changeover rear door (3)
through the fresh air inlet on the left side of the
cab.
5. After finishing the inspection, turn the starting

switch to the OFF position.
80-100 34 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Testing sunlight sensor SEN06151-00
Testing sunlight sensor

when disconnecting wiring and hoses.
Testing
q If [879DKZ] "Sunlight sensor disconnection or
short circuit" is displayed by the self-diagnosis
("Air-conditioning System" screen on the ma-
chine monitor), test sunlight sensor connector
P31.
q To reset the self-diagnosis system (detection of
abnormality), the starting switch must be turned
OFF.
a If the sunlight sensor is measured with the resis-
tance range of the tester, the sunlight sensor
may be destroyed, so do not measure with the
resistance range of the tester.
1. Remove the machine monitor cover. For details,

see "Testing air leakage (duct)", Steps 6 and 7.
2. Check connector P31 at the rear of the sunlight
sensor. (Check whether the connector is coming
off.)
3. Disconnect connector P31, remove the sunlight
sensor, and measure the voltage between the
terminals on the sensor side using a circuit tester
in voltage range.
q Approximate voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoors
PC200, 200LC, 220, 220LC-8M0 80-100 35

100 Air conditioner
SEN06151-00 Testing (dual) pressure switch for refrigerant
Testing (dual) pressure switch for refrigerant
k Park the machine on a level surface, lower 4. Ensure that the resistance between the
the work equipment to the ground so that it is switch-side terminals from connector P17 is
stable, and stop the engine. shorted (ON). (If not shorted (OFF), the dual
k Turn the battery disconnect switch to the pressure switch will detect a refrigerant pressure
"OFF" position and pull out the key. abnormality.)
a Note connector numbers and installed positions a When the dual pressure switch is OFF, con-
when disconnecting wiring and hoses. nect a pressure gauge to the high-pressure
side of the air conditioner compressor and
Testing check the refrigerant pressure. See "Connec-
q If [879GKX] "Refrigerant Abnormality" is dis- tion of service tool" and "Troubleshooting
played by the self-diagnosis (on "03 Electrical with gauge pressure."
System" screen of "Abnormality Record" in the a If the refrigerant pressure is normal, the dual
machine monitor), test the dual pressure switch pressure switch is defective.
connector P17.
q To reset the self-diagnosis system (detection of q (Dual) pressure switch
abnormality), the starting switch must be turned
OFF.
q The dual pressure switch is ON when the refrig-
erant pressure is normal, and OFF when it is ab-
normal.
a As the refrigerant pressure will drop when the
ambient temperature is below 0 C, there is a
possibility that the dual pressure switch is
OFF. In such a case, the dual pressure
switch is actually normal (i.e., not defective).
1. Swing by 90 deg..
2. Remove the cab undercover.
3. Disconnect the dual pressure switch connector
P17.
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
k When replacing the dual pressure switch, re-
frigerant must be collected in advance.
a If resistance between the switch-side terminals
from connector P17 is shorted (ON), perform
"Troubleshooting for compressor and refrigerant
system".
80-100 36 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Testing relays SEN06151-00
Testing relays
a If the air conditioner compressor is normal (air is q Checking relay unit

cooled), omit this test since the relays are nor- a Since no T-adapter is available, it is impossible
mal. to check the relay while the voltage is applied to
q Compressor clutch relay R21: the coil actually.
Turns the air conditioner compressor (clutch)
ON/OFF. Compressor clutch relay (RLCC), connector (R21)
a See Step 2 on "Parts and connectors layout". 1) The coil resistance between terminals (1)
and (2) is approximately 300 to 500 z.
Testing 2) While voltage (DC 20 to 30 V) is not applied
1. Check contact R21 of connector (for disconnec- between terminals (1) (+) and (2), terminals
tion). (3) and (4) are connected.
2. Turn the starting switch ON (do not start the 3) While voltage (DC 20 to 30 V) is applied
engine), turn the main power of the air condi- between terminals (1) (+) and (2), terminals
tioner ON, and turn the air conditioner switch. If (3) and (5) are connected.
the compressor relay is normal, it is turned ON.
Check whether its clicks.
a The air conditioner controller will not turn on
the compressor clutch relay in the following
cases.
1) When the evaporator temperature is below
3 C (depending on the input voltage from
the evaporator temperature sensor).
2) When the dual pressure switch detects
abnormality (it is turned OFF).
PC200, 200LC, 220, 220LC-8M0 80-100 37

100 Air conditioner
SEN06151-00 Troubleshooting chart 1
Troubleshooting chart 1
The numbers in the boxes are the item numbers in the troubleshooting table.
1. Cooling trouble
80-100 38 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting chart 1 SEN06151-00
2. Heating trouble
PC200, 200LC, 220, 220LC-8M0 80-100 39

100 Air conditioner
SEN06151-00 Troubleshooting chart 2
Troubleshooting chart 2
1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
Probable cause Check method Remedy
Repair broken parts
Wire breakage or defective con- Check the connector for disconnection.
and connect cor-
nection See "Parts and connectors layout".
rectly
Operate the fan switches in order and check the fan speed. See
Defective blower fan motor Replace
"Air conditioner unit".
Defective power transistor (PTR) Operate the fan switches in order and check the fan speed. Replace
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Check duct joints.
Air leakage through duct joints Repair
See "Testing air leakage (duct)".
Remove obstruc-
Obstruction at evaporator inlet Check evaporator for stain and obstruction
tion and clean
Evaporator is frozen.
Defective evaporator tempera-
Sensor fixing clip inspection, sensor contaminated
ture sensor, defective contact of
Inspect the air conditioner hose around the dual pressure Repair or replace
evaporator temperature sensor,
switch for frost.
defective expansion valve*
(when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
3. Pressure abnormality (high-pressure/low-pressure) during cooling.

Repair leaking part,
then charge with
Insufficient refrigerant
proper quantity of
Check the refrigerant volume through sight glass.
refrigerant again
Specifically, perform checking with the gauge manifold con-
Collect refrigerant,
nected.
then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2} See Troubleshoot-
Judgment by pressure at
High pressure: Approx. 1.5 - 1.7 MPa {15 17 kg/cm2} ing with gauge pres-
inlet/outlet of compressor
Temperature in operator's cab: 30 to 35 C, Engine speed: sure
Approx. 1,500 rpm
80-100 40 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting chart 2 SEN06151-00
4. During cooling, the compressor will not operate smoothly, or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled part Probable cause Check method Remedy
Deflection of belt is large.
Compressor See "Testing and adjusting of Air conditioner
Slack of belt Adjust tension
belt compressor belt tension" in the "Testing and
adjusting" in Chapter 30 of the shop manual.
Trouble in compressor Slip of clutch Repair or replace
Compressor Insufficient compressor oil See "Handling com-
Heating of compressor
Seizing on compressor pressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with multimeter (10 - 20 z) Replace
Magnet clutch Check ground cable and joints.
Wire breakage or defective con-
See "Troubleshooting for compressor and Repair
nection of ground wire
refrigerant system".
Relay Defective compressor clutch relay See "Testing relays" Replace
Refrigerant Low/high pressure (Operation of See "Troubleshooting
See "Troubleshooting with gauge pressure".
pressure pressure switch) with gauge pressure".
See "Troubleshooting for compressor and
Dual pres- refrigerant system".
Defective dual pressure switch Replace
sure switch See "Testing refrigerant (dual) pressure
switch".
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Check the duct joints by referring to "Testing air leakage
Air leakage through duct joints Repair
(duct)."
Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling

Low engine coolant tempera-
Warm up engine, and then check engine coolant temperature Find out cause
ture
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of engine Check engine coolant piping for clogging.
Bleed air and correct
coolant (Hose, pipe and core)
The connection of IN and OUT
Check the destination of heater hoses Correct
heater hoses is in reverse.
7. Fan speed abnormalities during cooling

See "Testing and adjusting of fan belt and alternator belt ten-
Fan speed is low sion" in "Testing and adjusting" in Chapter 30 of the shop man- Correct
ual.
8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be con-
Select manual mode and change temperature setting.
trolled
Vent (mode) changeover is not Common to cooling and
See "Testing vent (mode) changeover".
possible. heating
FRESH/RECIRC air cannot be
See "Testing FRESH/RECIRC air changeover".
changed over
Excessive compressor oil See "Handling of compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole
PC200, 200LC, 220, 220LC-8M0 80-100 41

100 Air conditioner

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.
Failure Problem on machine
Related information Information related to detected failure or troubleshooting

<Information described>
q Procedure
1 q Measuring location
Probable causes of
failure a "Between A and B" means "Measure voltage or resistance and so on between A and B".
(Perform trouble- q Standard value in normal condition to judge probable causes
shooting according q Remarks required for judgement
to these.)
2 <Notes on troubleshooting>
(1) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus () tester leads as shown below unless
otherwise specified.
q Connect the plus (+) lead to a pin or harness indicated in the front.
q Connect the minus () lead to a pin or harness indicated in the rear.
3 - defective (2) Example of troubleshooting by inspection of multiple items
a Normal in 1 but abnormal in 2
At this time - defective shown at left is applied
a If a wiring harness is burnt, replace it.

<Defective wiring harness>
q Open circuit
Connection of connector is defective or wiring harness is broken.
q Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
q Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit
accidentally.
q Short circuit
An independent wire in the harness abnormally comes into contact with one of another wire. (Defective
insulation in connector or others)
Related circuit diagram

This is the excerpted circuit diagram related to failure
q Indicates connector No., and pin No.
q See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for connector location
q The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb:
Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
q N.C.: Normally closed (Normally ON)
q [1], [2], are numbers of unlabeled connectors.
q Arrow (): Roughly indicates their mounting place on the machine.
80-100 42 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code list related to air conditioner SEN06151-00
Failure code list related to air conditioner

Compo-
Failure (Displayed on Category
Failure code nent in Action level Remarks
screen) of record
charge
A/C Inner Sensor Open Electrical Troubleshooting cannot be
879AKA MON
Circuit system performed while the controller
is mounted on the machine
A/C Inner Sensor Short Electrical
879AKB MON since the connector cannot be
Circuit system
checked.
A/C Outer Sensor Open Electrical
879BKA MON
Circuit system
A/C Outer Sensor Short Electrical
879BKB MON
Circuit system
Ventilating Sensor Open Electrical Troubleshooting cannot be
879CKA MON
Circuit system performed while the controller
Ventilating Sensor Short Electrical
879CKB MON since the connector cannot be
Circuit system
checked.
Sunlight Sensor Open or Electrical
879DKZ MON
Short Circuit system
Ventilation Dumper Abnor- Electrical Troubleshooting cannot be
879EMC MON L01
mality system performed while the controller
Air Mix Dumper Abnormal- Electrical
879FMC MON L01 since the connector cannot be
ity system
checked.
Electrical
879GKX Refrigerant Abnormality MON L01
system
A/C Model Selection Electrical
DAZ9KQ MON
Abnormality system See Chapter 40, "Trouble-
CAN2 Discon (Aircon Electrical shooting by failure code"
DAZQKR MON L01
ECU) system
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The ventilation damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes

q Troubleshooting for power supply system (Air conditioner does not operate)
q Troubleshooting for compressor and refrigerant system (Air is not cooled)
q Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
q Troubleshooting for FRESH/RECIRC air changeover
PC200, 200LC, 220, 220LC-8M0 80-100 43

100 Air conditioner
SEN06151-00 Failure code [879AKA] A/C Inner sensor Open Circuit
Failure code [879AKA] A/C Inner sensor Open Circuit
Action
Failure code Open circuit in air conditioner inside air temperature sensor
level Failure
879AKA
Detail of failure q Air conditioner controller detected open circuit in inside (air) temperature sensor.
q The air conditioner controller sends information about the inside (air) temperature sensor open cir-
Action of con-
cuit to the machine monitor via CAN communication.
troller
q Stops the air conditioner if it is in automatic mode.
q The air conditioner does not operate in automatic mode because of an open circuit in the air con-
Problem on
ditioner inside air temperature sensor.
machine
(The air conditioner can be operated in manual mode)
q Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnor-
Related infor-
mality record) screen in the service mode of the machine monitor.
mation
q Troubleshooting cannot be performed since the connector portion of the air conditioner inside (air)
temperature sensor cannot be checked while the controller is installed on the machine.

If no failures are found by the above checks, the air conditioner controller may
1 Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be per-
formed.)
If no failures are found by the above checks, the air conditioner unit may be
2 Defective air conditioner unit defective. (Since this is an internal defect, troubleshooting cannot be per-
formed.)
80-100 44 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879AKB] A/C Inner sensor Short Circuit SEN06151-00
Failure code [879AKB] A/C Inner sensor Short Circuit
Action
Failure code Short circuit in air conditioner inside air temperature sensor
level Failure
879AKB
Detail of failure q Air conditioner controller detected short circuit in inside (air) temperature sensor.
q The air conditioner controller sends information about the inside (air) temperature sensor short cir-
Action of con-
cuit to the machine monitor via CAN communication.
troller
q Stops the air conditioner if it is in automatic mode.
q The air conditioner does not operate in automatic mode because of a short circuit in the air condi-
Problem on
tioner inside air temperature sensor.
machine
(The air conditioner can be operated in manual mode)
Related infor-
mation
q Troubleshooting cannot be performed since the connector portion of the air conditioner inside (air)
temperature sensor cannot be checked while the controller is installed on the machine.

formed.)
formed.)
PC200, 200LC, 220, 220LC-8M0 80-100 45

100 Air conditioner
SEN06151-00 Failure code [879BKA] A/C Outer sensor Open Circuit
Failure code [879BKA] A/C Outer sensor Open Circuit

Action
Failure code Open circuit in air conditioner outside air temperature sensor
level Failure
879BKA
Detail of failure q An open circuit is detected in the air conditioner controller outside air temperature sensor
q The air conditioner controller sends information about the outside air temperature sensor open cir-
Action of con- cuit to the machine monitor via CAN communication.
troller q Continues control of air conditioner in automatic mode, ignoring data of outside air temperature
sensor.
q Since there is an open circuit in the air conditioner outside temperature sensor, outside tempera-
Problem on
ture is not counted in automatic mode.
machine
(does not have any effect to the air conditioner in manual mode)
q For connectors etc., see "Parts and connectors layout".
Related infor-
q Since connector ACECU of the air conditioner controller has small pins and does not have a
mation
T-adapter, perform troubleshooting by using the intermediate connector (Although the intermediate
connector does not have a T-adapter either, it does have large pins).
q To replace the air conditioner harness between air conditioner controller connector ACECU and
intermediate controller, the air conditioner unit must be replaced.

Defective outside air temperature 2. Disconnect connector P18.
1
sensor Approx.
Resistance Between P18 (male) (1) and (2) 25 C
1.7 kz
2. Disconnect connector AC01.
2 a Same as above, if resistance is normal.
ness
Approx.
Resistance Between AC01 (female) (7) and (8) 25 C
1.7 kz
a If no failure is found by check for cause 2, this check is not required.
2. Disconnect connectors P18 and AC01.
tact of connector) Between AC01 (female) (7) and P18 (female) (1) Max. 1 z
Resistance
Between AC01 (female) (8) and P18 (female) (2) Max. 1 z
formed.)
5 Defective air conditioner unit If no failure is found by above checks, air conditioner unit may be defective.
80-100 46 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879BKA] A/C Outer sensor Open Circuit SEN06151-00
Circuit diagram related to air conditioner outside air temperature sensor
PC200, 200LC, 220, 220LC-8M0 80-100 47

100 Air conditioner
SEN06151-00 Failure code [879BKB] A/C Outer sensor Short Circuit
Failure code [879BKB] A/C Outer sensor Short Circuit

Action
Failure code Short circuit in air conditioner outside air temperature sensor
level Failure
879BKB
Detail of failure q Air conditioner controller detected short circuit in outside air temperature sensor.
q The air conditioner controller sends information about the outside air temperature sensor short cir-
Action of con- cuit to the machine monitor via CAN communication.
troller q Continues control of air conditioner in automatic mode, ignoring data of outside air temperature
sensor.
q Since there is a short circuit in the air conditioner outside air temperature sensor, outside temper-
Problem on
ature is not counted in automatic mode.
machine
(does not have any effect to the air conditioner in manual mode)
Related infor-
mation

Defective outside air temperature 2. Disconnect connector P18.
1
sensor Approx.
Resistance Between P18 (male) (1) and (2) 25 C
1.7 kz
2 a Same as above, if resistance is normal.
ness
Approx.
Resistance Between AC01 (female) (7) and (8) 25 C
1.7 kz
a If no failure is found by check for cause 2, this check is not required.
3 Short circuit in wiring harness 2. Disconnect connectors P18 and AC01.
Between AC01 (female) (7) and (8), or between
P18 (female) (1) and (2)
Ground fault in wiring harness 2. Disconnect connectors P18 and AC01.
4
(contact with ground circuit) Between ground and AC01 (female) (8) or P18
(female) (1)
formed.)
80-100 48 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879BKB] A/C Outer sensor Short Circuit SEN06151-00
Circuit diagram related to air conditioner outside air temperature sensor
PC200, 200LC, 220, 220LC-8M0 80-100 49

100 Air conditioner
SEN06151-00 Failure code [879CKA] Ventilating sensor Open Circuit
Failure code [879CKA] Ventilating sensor Open Circuit
Action
Failure code Open circuit in temperature (frost) sensor
level Failure
879CKA
Detail of failure q Air conditioner controller detected open circuit in evaporator temperature (frost) sensor.
q The air conditioner controller sends information about the evaporator temperature (frost) sensor
Action of con-
open circuit to the machine monitor via CAN communication.
troller
q Stops the air conditioner.
Problem on q The air conditioner does not operate due to an open circuit in the evaporator temperature (frost)
machine sensor.
Related infor-
mation
q Troubleshooting cannot be performed since the connector portion of the evaporator temperature
(frost) sensor cannot be checked while the air conditioner unit is installed on the machine.

formed.)
formed.)
80-100 50 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879CKB] Ventilating sensor Short Circuit SEN06151-00
Failure code [879CKB] Ventilating sensor Short Circuit
Action
Failure code Evaporator temperature (frost) sensor short circuit
level Failure
879CKB
Detail of failure q Air conditioner controller detected short circuit in evaporator temperature (frost) sensor.
q The air conditioner controller sends information about the evaporator temperature (frost) sensor
Action of con-
short circuit to the machine monitor via CAN communication.
troller
q Stops the air conditioner.
Problem on q The air conditioner does not operate due to a short circuit in the evaporator temperature (frost) sen-
machine sor.
Related infor-
mation
q Troubleshooting cannot be performed since the connector portion of the evaporator temperature
(frost) sensor cannot be checked while the air conditioner unit is installed on the machine.

formed.)
formed.)
PC200, 200LC, 220, 220LC-8M0 80-100 51

100 Air conditioner
SEN06151-00 Failure code [879DKZ] Sunlight sensor Open or Short Circuit
Failure code [879DKZ] Sunlight sensor Open or Short Circuit

Action
Failure code Sunlight sensor open or short circuit
level Failure
879DKZ
Detail of failure q Air conditioner controller detected open or short circuit in sunlight sensor.
q The air conditioner controller sends information about the sunlight sensor open or short circuit to
Action of con-
the machine monitor via CAN communication.
troller
q Continues control of air conditioner in automatic mode, ignoring data of sunlight sensor.
Problem on q Since there is an open or short circuit in the air conditioner sunlight sensor, sunlight strength is not
machine counted in automatic mode. (does not have any effect to the air conditioner in manual mode).
Related infor-
mation

1. See "Testing sunlight sensor".
Direct sun- Approx.
Between sunlight sensor terminals
light 0.55 V
1 Defective sunlight sensor Approx.
Voltage Between sunlight sensor terminals Cloudy
0.45 V
Approx. 0.4
Between sunlight sensor terminals Indoors
V
a See "Testing sunlight sensor".
tact of connector) Between P31 (female) (1) and AC01 (female) (10) Max. 1 z
Resistance
Between P31 (female) (2) and AC01 (female) (9) Max. 1 z
formed.)
80-100 52 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879DKZ] Sunlight sensor Open or Short Circuit SEN06151-00
Circuit diagram related to sunlight sensor
PC200, 200LC, 220, 220LC-8M0 80-100 53

100 Air conditioner
SEN06151-00 Failure code [879EMC] Ventilating Damper Abnormality
Failure code [879EMC] Ventilating Damper Abnormality
Action
Failure code Abnormality in vent (mode) changeover damper servomotor
level Failure
L01 879EMC
q Air conditioner controller judged from potentiometer voltage of servomotor that vent (mode)
Detail of failure
changeover damper servomotor is not operating.
Action of con- q The air conditioner controller sends information about the abnormality in vent (mode) changeover
troller damper to the machine monitor via CAN communication.
Problem on
q Vent (mode) cannot be changed but air conditioner can be operated.
machine
Related infor-
mation
q Troubleshooting cannot be performed since the connector portion of vent (mode) changeover
damper servomotor cannot be checked while the air conditioner unit is installed on the machine.

formed.)
formed.)
80-100 54 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879FMC] Air Mix Damper Abnormality SEN06151-00
Failure code [879FMC] Air Mix Damper Abnormality
Action Abnormality in air mix (temperature regulation) damper servomo-

Failure code
level Failure tor
L01 879FMC (Machine monitor system)
q The air conditioner controller judged from the potentiometer voltage of the servomotor that the air
Detail of failure
mix (temperature regulation) damper servomotor is not operating.
Action of con- q The air conditioner controller sends information about the air mix damper abnormality to the ma-
troller chine monitor via CAN communication.
Problem on
q The air conditioner does not operate since temperature cannot be regulated.
machine
Related infor-
mation
q Troubleshooting cannot be performed since the connector portion of the air mix damper servomo-
tor cannot be checked while the air conditioner unit is installed on the machine.

formed.)
formed.)
PC200, 200LC, 220, 220LC-8M0 80-100 55

100 Air conditioner
SEN06151-00 Failure code [879GKX] Refrigerant Abnormality
Failure code [879GKX] Refrigerant Abnormality

Action
Failure code Refrigerant (dual) pressure switch abnormality
level Failure
L01 879GKX
Detail of failure q Air conditioner controller detected that dual pressure switch was OFF (abnormal).
q The air conditioner controller sends information about the refrigerant pressure abnormality to the
machine monitor via CAN communication.
Action of con-
q The air conditioner controller turns OFF compressor clutch relay, since refrigerant pressure is ab-
troller
normal.
(air conditioner compressor stops)
Problem on
q Air conditioner (cooling) does not work
machine
Related infor-
mation

1. See "Testing (dual) pressure switch for refrigerant".
k
Defective refrigerant (dual) pres-
1 When replacing the dual pressure switch, be sure to collect refriger-
sure switch
ant in advance. See "Caution for refrigerant"
2. Disconnect connectors AC01 and AC05.
2 (wire breakage or defective con- Between P17 (female) (1) and AC01 (female) (6) Max. 1 z
tact of connector) Resistance Between P17 (female) (2) and ground
Max. 1 z
a Looseness and rust of T06
formed.)
80-100 56 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Failure code [879GKX] Refrigerant Abnormality SEN06151-00
Circuit diagram related to refrigerant (dual) pressure switch
PC200, 200LC, 220, 220LC-8M0 80-100 57

100 Air conditioner
SEN06151-00 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Troubleshooting for power supply and CAN communication system (Air

conditioner does not operate)
Failure Air conditioner does not operate due to power supply system failure.
Problem on q[DAZQKR] is displayed on the operation screen of machine monitor.
machine qNo air blows out (Blower motor does not rotate).
q If failure code [DAZQKR] is displayed on machine monitor, perform this troubleshooting first.
a The machine monitor, engine controller, pump controller, and air conditioner controller are connect-
ed via CAN communication.
q "DAZQKR" is displayed on operation screen of machine monitor in the following cases. In this sec-
tion, 1) and 2) of the following are explained.
1) The air conditioner controller is receiving no power.
2) The air conditioner controller is malfunctioning.
3) No communication is possible between the air conditioner controller and the machine monitor.
a For 3), see failure code [DAZQKR].
q Turn starting switch to ON position and check whether failure code [DAZQKR] is displayed on ma-
chine monitor and whether CAN communication condition is abnormal. This type of abnormal sta-
Related infor- tus indicates that CAN communication cannot be performed between the air conditioner controller
mation above the air conditioner unit and the machine monitor.
q Referring to "Parts and connectors layout", check fuse No. 10 (5 A) in fuse box F01 for breakage.
q Ground cable of air conditioner is connected in machine wiring harness together with electrical
equipment of machine.
q For each connector, see "Parts and connectors layout".
q In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for compres-
sor and refrigerant system."
q To replace the air conditioner harness between air conditioner controller connector ACECU and in-
termediate controller, the air conditioner unit must be replaced.

2. Turn battery disconnect switch to OFF position.
1 Defective wiring harness (ground) 3. Disconnect connector AC02.
Between (1) (black) on harness side of connector
Resistance Max. 1 z
AC02 and chassis ground
2 Blown fuse 2. Referring to "Parts and connectors layout", check fuse No. 10 (5 A) in fuse
box F01 for breakage.
a If fuse described in related information is blown, replace it.
3 Defective wiring harness
4. Turn battery disconnect switch to ON position.
Between connector AC02 (female) (4) (red) and (1)
Voltage 20 to 30 V
(black)
a If the fuse is blown again during the above test, carry out the following pro-
cedure.
Ground fault in wiring harness 2. Turn battery disconnect switch to OFF position.
4 3. Disconnect connector AC02.
Between ground and connector AC02 (female) (4)
(red) or F01-10
80-100 58 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) SEN06151-00

Between connector AC02 (female) (4) (red) and
F01-10
6 Defective air conditioner controller Replace air conditioner controller.
8 Defective machine monitor If no failure is found by above checks, machine monitor is defective.
Circuit diagram related to power supply
PC200, 200LC, 220, 220LC-8M0 80-100 59

100 Air conditioner
SEN06151-00 Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for compressor and refrigerant system (Air is not

cooled)
Failure Air is not cooled due to compressor or refrigerant system failure.
qWhen engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air is
Problem on
not cooled as displayed on screen.
machine
q Air conditioner compressor does not operate.
q Referring to "Testing with self-diagnosis function", display "Electrical Systems" screen on the machine
monitor and check to see if the refrigerant pressure is abnormal by checking whether failure code
[879GKX] is displayed. If the refrigerant pressure is abnormal, the compressor will not be turned ON
and air will not subsequently not be cooled.
a Abnormal refrigerant pressure indicates that "Signal ((21) of connector ACECU) from the dual pres-
sure switch is not grounded".
q In certain cases, the air conditioner will not turn on at 3 C or lower (normal).
Related infor-
q If no air comes out, see "Troubleshooting for blower motor system".
mation
q For each connector and fuse, see "Parts and connectors layout".
a A T-adapter is provided only for the connector AC03.
q Since connector ACECU of the air conditioner controller has small pins and does not have a T-adapt-
er, perform troubleshooting by using the intermediate connector (Although the intermediate connector
does not have a T-adapter either, it does have large pins).
q To replace the air conditioner harness between air conditioner controller connector ACECU and inter-
mediate controller, the air conditioner unit must be replaced.

a Perform this check when failure code [879GKX] is displayed on "Electrical Sys-
tems" screen of machine monitor.
See failure code [879GKX].
Defective dual pressure a In certain cases, the dual pressure switch may be operating normally and set to
1
switch system OFF, therefore, if abnormality is indicated (i.e., switch OFF), attach a pressure
gauge to the air conditioner compressor and check the refrigerant pressure. (See
"Troubleshooting with gauge pressure.")
k Before replacing pressure switch, collect refrigerant.
2. Disconnect the connector AC03 from the air conditioner compressor and connect a
T-adapter to the male side.
Defective air conditioner a Ensure connection of air conditioner compressor ground cable (E).
2
compressor (See "Parts and connectors layout".)
Between connector AC03 (male) (1) and the chassis
Resistance Approx. 15 z
ground (i.e., air conditioner compressor coil resistance)
q Referring to "Testing relays", check sound when compressor clutch relay is turned
ON.
Click is heard -----------------------------------------A
a When A above is abnormal and B below is abnormal and C is normal (if the relay is
normal), go to cause 4.
2. Disconnect connector R21.
Defective compressor 3. Use a wire to short-circuit (3) (white) and (5) (red on yellow) of connector R21
3 clutch relay (does not turn (wiring harness side) . (This forces the compressor to operate without using the
ON) relay.)
Air is cooled -----------------------------------------B
2. Disconnect connector R21 and troubleshoot in that condition.
Between (1) and (2) of connector R21 300
Resistance C
(male) (i.e., coil resistance) 500 z
80-100 60 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting for compressor and refrigerant system (Air is not cooled) SEN06151-00

2. Disconnect connector R21 and carryout troubleshooting without turning starting
switch ON.
a Ensure that test result for cause 2 (air conditioner compressor is normal) is normal.
Between connector R21 (female) (5) and F01-11
Open circuit in wiring har- Max. 1 z
4 (Dual pressure switch is turned ON)
ness
Between connector R21 (female) (3) and chassis
Resistance ground Approx. 15 z
(Air conditioner compressor coil resistance)
Between F01-10 and AC01 (female) (4)
300 500 z
a Relay coil resistance
a If the fuse is not blown, skip troubleshooting.
5 ness 2. Disconnect connectors AC03 and R21, and connect a T-adapter to the female side
(contact with ground circuit) of AC03.
Resistance Between AC03 (female) (1) and chassis ground Min. 1 Mz
2. Disconnect connectors AC01, AC02, and R21.
Short circuit in wiring har- a Ensure that test result for cause 2 is normal.
6
ness
Between wiring harness side (2) of connector R21 and
AC02 (female) (2), (3), and (4)
2. Disconnect connector R21.
Defective air conditioner 3. Turn starting switch to ON position.
7 4. Display the air conditioner operation screen on the machine monitor and press the
controller
A/C switch.
Voltage Between connector R21 (female) (2) and ground Max. 1 V
Defective machine monitor 2. Display the air conditioner operation screen on the machine monitor.
8
(defective switch)
Press A/C switch. "A/C ON" is displayed
Defective air conditioner
9 If no failure is found by above checks, air conditioner unit may be defective.
unit
PC200, 200LC, 220, 220LC-8M0 80-100 61

100 Air conditioner
SEN06151-00 Troubleshooting for compressor and refrigerant system (Air is not cooled)
Circuit diagram related to compressor and refrigerant system
80-100 62 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) SEN06151-00
Troubleshooting for blower motor system (No air comes out or air flow
is abnormal)
Failure No air comes out or air flow is abnormal due to blower motor system failure.
q LCD of machine monitor on air conditioner operation screen lights up normally but air does not come
Problem on
out.
machine
q Air flow does not match fan switch setting on air conditioner operation screen.
q This failure is not checked with self-diagnosis function.
q In cases where the blown-air volume begins to behave in an unpredictable manner after a certain
while during cooling, freezing of the evaporator is a likely cause.
This may be due to the followings.
1) Defective compressor clutch relay (i.e., stuck in ON position) (see item 3-A from "Trouble-
shooting for compressor and refrigerant system")
2) Detachment of the evaporator temperature sensor's mounting holder (Replace the air condi-
tioner unit)
3) Incorrect adjustment of expansion valve (Replace air conditioner unit)
Related infor- q If air comes out, fuse and motor are normal, and also wiring harness is normal.
mation q For each connector and power transistor, see "Parts and connectors layout".
a The power transistor is on the rear side of the air conditioner unit.
q If air comes out but its flow is abnormal in heating mode, replace power transistor. (When no air
comes out, the power transistor may also be defective.)
a The blower motor cannot be replaced unless the air conditioner unit is removed once.
q To replace the air conditioner harness between air conditioner controller connector ACECU and in-
termediate controller, the air conditioner unit must be replaced.
Defective fuse No. 11 in
1 If fuse is blown, circuit probably has ground fault.
fuse box F01
2. Replace power transistor.
2 Defective power transistor
a If air comes out and air flow can be adjusted, the original power transistor is de-
fective.
ness 2. Disconnect connector AC02.
3 3. Remove fuse No. 11 of fuse box F01.
contact of connector) Resistance Between AC02 (female) (2) and F01-11 Max. 1 z
Ground fault in wiring har- 2. Disconnect connectors AC02 and R21.
4 ness 3. Remove fuse No. 11 of F01.
Resistance Between AC02 (female) (2) or F01-11 and ground Max. 1 z
Defective air conditioner If no failures are found by the above checks, the air conditioner controller may be
5
controller defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Defective air conditioner
6 If no failure is found by above checks, air conditioner unit may be defective.
unit
PC200, 200LC, 220, 220LC-8M0 80-100 63

100 Air conditioner
SEN06151-00 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Circuit diagram related to blower motor system
80-100 64 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting for FRESH/RECIRC air changeover SEN06151-00
Troubleshooting for FRESH/RECIRC air changeover

Failure FRESH/RECIRC air cannot be changed over
qWhen FRESH/RECIRC air selector switch of machine monitor is operated, recirculated or fresh air
Problem on
does not change over.
machine
(FRESH/RECIRC air changeover door (damper) does not rotate)
q FRESH/RECIRC air changeover is not checked with self-diagnosis function.
q Referring to "Testing FRESH/RECIRC air changeover", operate the FRESH/RECIRC air selector
switch and check operation of FRESH/RECIRC air changeover door (damper).
q For each connector, see "Parts and connectors layout".
a The T-adapter is not prepared for the connector.
Related infor-
mation
q Troubleshooting cannot be performed since the connector portion of the servomotor cannot be
checked while it is installed on machine.

Defective fuse No. 18 in fuse box
1 If fuse is blown, circuit probably has ground fault.
F01
a Connector [5] installed on machine cannot be disconnected since it is on
the rear side of the air conditioner unit.
2 (wire breakage or defective con- 2. Disconnect connector AC02.
tact of connector) 3. Remove fuse No. 18 of F01.
Resistance Between F01-18 and AC02 (female) (3) Max. 1 z
3 3. Remove fuse No. 18 of F01.
Between F01-18 and ground, or between AC02
Resistance Max. 1 z
formed.)
formed.)
Defective machine monitor 2. Display the air conditioner operation screen on the machine monitor.
6
(defective switch) Display of Recirc/Fresh
Press FRESH/RECIRC air selector switch.
changes.
PC200, 200LC, 220, 220LC-8M0 80-100 65

100 Air conditioner
SEN06151-00 Troubleshooting for FRESH/RECIRC air changeover
Circuit diagram related to FRESH/RECIRC air changeover
80-100 66 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Troubleshooting with gauge pressure SEN06151-00
Troubleshooting with gauge pressure

Perform troubleshooting according to the high and <Measurement condition for pressure>
low gauge pressures of the cooling cycle. For de- Item Condition value
tails, see "Connection of service tool". Ambient temperature 25 to 50 C
a The gauge pressure varies largely with the Engine speed 1,500 rpm
weather condition and operating condition of the Air conditioner switch ON
Fan switch HI
machine. Check the gauge pressure under the
Set temperature Full cool
pressure measurement conditions.
q High-pressure line pressure is too high: Above q Dual pressure switch
approx. 2.5 MPa {25 kg/cm2} a The swiths is normally "ON", and becomes
q High-pressure line pressure is too low: Below
"OFF" when it detects abnormal pressure for
compressor operation.
approx. 1 MPa {10 kg/cm2}
q Low-pressure line pressure is too high: Above
approx. 0.3 MPa {3 kg/cm2}

q Low-pressure line pressure is too low: Below ap-
prox. 0.05 MPa {0.5 kg/cm2}

a Dual pressure switch turns "OFF" to protect the
air conditioner circuit if the pressure of the
high-pressure or low-pressure line is abnormal.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
PC200, 200LC, 220, 220LC-8M0 80-100 67

100 Air conditioner
SEN06151-00 Troubleshooting with gauge pressure
Indicated gauge
Cause Check method Remedy
pressure
Air conditioner cycle is operating normally.
If there is any trouble (cooling trouble), there is another cause.
Pressure is normal
High-pressure: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2}
2
Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm }
Collect refrigerant, then
Bubble can be seen through sight glass. *1, fill up with proper quan-
Insufficient refrigerant
*3 tity of refrigerant again
*2
There is a temperature difference between
Replace
Clogging of receiver drier inlet and outlet pipes of receiver drier.
*2
Tank is frosty
Clean or replace
<Both high-pres- Clogging of expansion valve Expansion valve is frosted
*2
sure and low-pres-
Gas leakage at thermoprobe of expan- Replace
sure are too low> Low-pressure gauge reads vacuum
sion valve *2
Repair or replace
Low-pressure gauge Evaporator is frozen
Replace receiver drier
reads vacuum Defective evaporator temperature sensor Flow rate of refrigerant is reduced due to
or defective contact of sensor (coming off freezing.
fill up with proper quan-
of mounting clip) (At Cool Max. and HI speed of fan, later it
tity of refrigerant again
becomes not to cold.)
*2
Piping between receiver drier and com-
pressor is clogged or crushed. Clean or replace
Clogged or crushed piping
If clogged completely, low-pressure gauge *2
reads vacuum
fill up with proper quan-
Filling too much with refrigerant Connect gauge manifold
tity of refrigerant again
*2
Clean, repair fins, or
Dirty condenser, clogging or crushing of repair or replace con-
<Both high-pres- Defective cooling of condenser
fins, or defective rotation of cooling fan denser
sure and low-pres-
*2
sure are too high>
Improper adjustment of expansion valve Replace
Bubble can be seen through sight glass. *3
(Valve is opened too wide) *2
Evacuate and then fill up
with proper quantity of
Air in cycle parts Bubble can be seen through sight glass. *3
refrigerant again
*2
<High-pressure is Clean inside of cycle or
Clogged or crushed piping between com- There is a remarkable temperature differ-
too high and low- replace
pressor and condenser ence across clogged part
pressure is too low> *2
<High-pressure is Both high-pressure and low-pressure are
too low and Defective compressor (Compression balanced while compressor is in operation. Replace
low-pressure is too trouble of compressor) Compressor has seized and is extremely *2
high> hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2:
k When replacing a cooling cycle part, see Caution about refrigerant and collect refrigerant. After
replacing it, fill up the air conditioner system with refrigerant again.
*3: Sight glass is on the air conditioner hose near condenser.
80-100 68 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Connection of service tool SEN06151-00
Connection of service tool

Sym- Connect the gauge manifold, hoses and other ser-
bol vice tools according to the following procedure.
X 799-703-1200 Service tool kit 1. Close high-pressure valve (6) and low-pressure
valve (7) of gauge manifold (1).
a Use the service tool kit for R134a. 2. Connect the red charging hose (2) to the HI side
Service tool kit X of the gauge manifold and the blue charging
(1): Gauge manifold hose (3) to the LO side.
(2): Red high-pressure charging hose (red) 3. Connect quick joints (4) and (5) to each hose.
(3): Blue low pressure charging hose (blue) 4. Connect quick joints (4) and (5) to service valves
(4): Quick joint for HI side (large diameter) (8) and (9) of high- and low-pressure piping
(5): Quick joint for LO side (small diameter) respectively.
(a): As the thread is coarse, care should be taken

with regard to loosening.
PC200, 200LC, 220, 220LC-8M0 80-100 69

100 Air conditioner
SEN06151-00 Connection of service tool
A: From Cab
B: To Condenser
80-100 70 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Precautions for disconnecting and connecting air conditioner piping SEN06151-00
Precautions for disconnecting and connecting air conditioner piping
Precautions for disconnecting Precautions for connecting

k Collect the refrigerant (Air conditioner gas: q Once an O-ring is used, it is deformed and dete-
R134a) from air conditioner circuit before riorated. Accordingly, do not reuse it. When re-
disconnecting air conditioner hose to removing it, use a soft tool (such as a toothpick) so
place air conditioner unit, condenser air con- that the piping will not be damaged.
ditioner compressor or receiver drier and so q When connecting piping check that there is no
on. damage and deterioration.
a Ask a qualified person for collecting, adding and q Apply compressor oil (ND-OIL8) for R134a to its
filling operation of refrigerant (R134a). O-rings. (See item 4 of "Handling compressor
a Never release the refrigerant (R134a) to the at- oil")
mosphere. a Do not apply oil to the threads of a bolt, nut or
k If refrigerant gas (R134a) gets in your eyes, union, however.
you may lose your sight. And if it touches q Push in each pipe to the stopper and tighten the
your skin, you may suffer from frostbite. Put bolt or nut fully with your fingers.
on protective eyeglasses, gloves and work- q Be sure to use two wrenches to tighten each nut.
ing cloth with long sleeves while collecting Use one wrench to fix and tighten the nut with
the refrigerant or filling the air conditioner the other wrench to the specified torque (Use a
circuit with the refrigerant. torque wrench for tightening).
q When loosening the air conditioner hose nuts af- a Example of O-ring installation
ter collecting the refrigerant, be sure to use 2 q There are O-rings at all the connections of the air
wrenches. Use one wrench to fix and use the conditioner piping.
other one to loosen the nuts.
q Cover the air conditioner piping connections not
to enter dust, water or moisture.
PC200, 200LC, 220, 220LC-8M0 80-100 71

100 Air conditioner
SEN06151-00 Precautions for disconnecting and connecting air conditioner piping
Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque Nm {kgm}
M6 x 1.0 8 12 {0.8 1.2}
1. Engine
2. Compressor
3. Condenser
4. Modulator
5. Air conditioner unit
80-100 72 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Handling of compressor oil SEN06151-00
Handling of compressor oil
1. Compressor oil management (DENSO: Quantity to

ND-OIL8 for R134a) Air conditioner part be added
(cc)
Although compressor oil differs from engine oil in Air conditioner unit, evaporator Approx. 40
that it does not need regular checking or filling, the Condenser (including modulator) Approx. 60
following types of problem can occur if the amount
Modulator (desiccant) only Approx. 20
in the system is too high or too low.
Condition Content Hose (between compressor and cab) Approx. 35
Insufficiency of Lubrication trouble and seizure of com- Hose (between compressor and con-
Approx. 30
oil pressor denser)
Cooling trouble Hose
Approx. 10
Excess of oil (Excessive oil stick to parts and lower (between condenser and cab)
heat exchange performance)
Accordingly, compressor oil must be filled to the
specified level, similarly to refrigerant.
2. Filling compressor oil
k Refrigerant is potentially hazardous to health

and to the environment. Before disconnect-
ing air conditioner hoses, therefore, refriger-
ant should be collected in accordance with
"Precautions for connecting air conditioner
piping."
a If oil for CFC-12 (R-12) is used, lubrication trou-
ble will occur and the compressor may be broken
or seized.
Be sure to use an oil suitable for R134a
(DENSO: ND-OIL8).
a Oil for use with R134a is extremely hygroscopic,
and therefore, the cap must be immediately
closed after use to limit contact with air.
Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow oil for use with R134a to come into
contact with acrylic plastic or polystyrene
surfaces (except a baked finish) as it may
dissolve these plastics.
Check compressor oil in the following cases, and
then add new oil if necessary.
q When much refrigerant is discharged because of
leakage.
q When the compressor is troubled and replaced.
(See 3 below)
q When a cycle parts such as condenser, receiver
drier, evaporator unit, etc. is replaced.
q Quantity of oil to be added when cycle part is re-
placed
PC200, 200LC, 220, 220LC-8M0 80-100 73

100 Air conditioner
SEN06151-00 Handling of compressor oil
3. Replacement of compressor 4. Applying compressor oil to O-rings
q In case of compressor seizure or breakage. Whenever connecting piping or hoses, the com-
Metal chips will circulate through the air condi- pressor oil (ND-OIL8) must be applied to O-rings in
tioner circuit and contaminate the compressor oil order to prevent the leakage of refrigerant.
extremely.
In this case, flush the air conditioner circuit and
replace the compressor and receiver drier.
The compressor oil is removed from the air
conditioner circuit by flushing. Accordingly,
install a new compressor with the oil of the spec-
ified quantity (180 cc) filled in it.
q Other cases
a New compressor contains compressor oil of 180
cc in it.
1) Prepare an oil container and drain oil from
the old compressor.
2) Measure the quantity of the drained oil with a
measuring cylinder, and note the quantity or
mark the level.
3) Drain below-mentioned quantity of oil from

the new compressor.
Quantity to be drained = 180 cc - "Noted
quantity"
Example: If 30 cc was drained from the
removed compressor, the quantity to be
drained from the new compressor would be
150 cc (i.e., 180 - 30 cc).
80-100 74 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Desiccant replacement procedure SEN06151-00
Desiccant replacement procedure

a Prepare desiccant replacement kit Taking out desiccant (D)
(20Y-810-1250). 1. Remove snap ring (SR) from receiver drier (2).
2. Remove cap (C) from receiver drier (2).
Hold boss (B) of cap (C) with pliers etc. to
remove.
a Cap (C) may be hard to remove. When re-
moving it, take care not to damage or deform
the seal or receiver drier (2).
3. Remove filter (F) from receiver drier (2)
4. Take desiccant (D) out of receiver drier (2).
a Removed snap ring (SR), cap (C), filter (F),
desiccant (D) will be replaced with the parts
of the drier (desiccant replacement kit) and
will not be necessary any more.
k When replacing the desiccant, be sure to col-

lect the refrigerant from the air conditioning
cycle. If the desiccant is replaced without
collecting the refrigerant, the refrigerant may
blind you or cap (C) may fly out and injure
you because of the refrigerant pressure in
the cycle.
1. Condenser
2. Receiver drier
a The desiccant is in receiver drier (2).
PC200, 200LC, 220, 220LC-8M0 80-100 75

100 Air conditioner
SEN06151-00 Desiccant replacement procedure
Installing new desiccant (D)

1. Apply ND-OIL 8 to the periphery of O-ring (OR)
of cap (C).
2. Install filter (F) to cap (C).
3. Insert desiccant (D) in receiver drier (2).

4. Install cap (C) with filter (F) to receiver drier (2).
5. Install snap ring (SR) to receiver drier (2).
a Install snap ring (SR) to the groove in receiv-
er drier (2) securely. If it is not installed se-
curely, cap (C) may come off.
80-100 76 PC200, 200LC, 220, 220LC-8M0

100 Air conditioner
Desiccant replacement procedure SEN06151-00
PC200, 200LC, 220, 220LC-8M0 80-100 77

SEN06151-00
2012 KOMATSU
All Rights Reserved
80-100 78
SEN06153-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
90 Diagrams and drawings 1

100 Hydraulic diagrams and drawings
Symbols in hydraulic circuit diagram............................................................................................................... 2
Hydraulic circuit diagram................................................................................................................................. 5
PC200, 200LC, 220, 220LC-8M0 90-100 1

SEN06153-00 Symbols in hydraulic circuit diagram
Symbols in hydraulic circuit diagram 1
90-100 2 PC200, 200LC, 220, 220LC-8M0

Symbols in hydraulic circuit diagram SEN06153-00
PC200, 200LC, 220, 220LC-8M0 90-100 3

SEN06153-00 Symbols in hydraulic circuit diagram
90-100 4 PC200, 200LC, 220, 220LC-8M0

Hydraulic circuit diagram
Hydraulic circuit diagram PC200, 200LC, 220, 220LC-8M0
1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN06153-00
PC200, 200LC, 220, 220LC-8M0 5
Symbols in hydraulic circuit diagram SEN06153-00
PC200, 200LC, 220, 220LC-8M0 90-100 7

SEN06153-00
2012 KOMATSU
All Rights Reserved
90-100 8
SEN06154-00
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0

PC200-8M0 400001 and up
PC220-8M0 100001 and up
90 Diagrams and drawings 1

200 Electrical diagrams and drawings
Symbols in electric circuit diagram.................................................................................................................. 2
Electrical circuit diagram ................................................................................................................................. 5
PC200, 200LC, 220, 220LC-8M0 90-200 1

SEN06154-00 Symbols in electric circuit diagram
Symbols in electric circuit diagram 1
90-200 2 PC200, 200LC, 220, 220LC-8M0

Symbols in electric circuit diagram SEN06154-00
PC200, 200LC, 220, 220LC-8M0 90-200 3

SEN06154-00 Symbols in electric circuit diagram
90-200 4 PC200, 200LC, 220, 220LC-8M0

Electrical circuit diagram (1/5) Electrical circuit diagram
PC200, 200LC, 220, 220LC-8M0
PC200-8M0,PC200LC-8M0, PC220-8M0, PC220LC-8M0
This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN06154-00
PC200, 200LC, 220, 220LC-8M0 5
PC200, 200LC, 220, 220LC-8M0
SEN06154-00
PC200, 200LC, 220, 220LC-8M0 7
PC200, 200LC, 220, 220LC-8M0
SEN06154-00
PC200, 200LC, 220, 220LC-8M0 9
PC200, 200LC, 220, 220LC-8M0
SEN06154-00
PC200, 200LC, 220, 220LC-8M0 11
PC200, 200LC, 220, 220LC-8M0
SEN06154-00
PC200, 200LC, 220, 220LC-8M0 13
Symbols in electric circuit diagram SEN06154-00
PC200, 200LC, 220, 220LC-8M0 90-200 15

5
SEN06154-00
2012 KOMATSU
All Rights Reserved
90-200 16
6

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SEN06109-00

HYDRAULIC PC200 -8M0

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

PC200, 200LC, 220, 220LC-8M0 00-100 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN06109-00

00 Index and foreword SEN06110-00

10 Structure, function and maintenance standard SEN06115-00

20 Standard value table SEN06124-00

30 Testing and adjusting SEN06126-00

00-100 2 PC200, 200LC, 220, 220LC-8M0

50 Disassembly and assembly SEN06141-00

90 Diagrams and drawings SEN06152-00

PC200, 200LC, 220, 220LC-8M0 00-100 3

10 Structure, function and maintenance standard

00-100 4 PC200, 200LC, 220, 220LC-8M0

Center swivel joint ................................................................................................................... 10

20 Standard value table

30 Testing and adjusting

PC200, 200LC, 220, 220LC-8M0 00-100 5

Releasing remaining pressure from hydraulic circuit ............................................................... 54

00-100 6 PC200, 200LC, 220, 220LC-8M0

Failure code [CA144] Coolant Temp Sens High Error ............................................................. 28

PC200, 200LC, 220, 220LC-8M0 00-100 7

Failure code [DAF8KB] Camera Power Supply Short Circuit .................................................. 28

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

400 Troubleshooting of electrical system (E-mode) SEN06138-00

PC200, 200LC, 220, 220LC-8M0 00-100 9

H-14 In combined operation of work equipment,

50 Disassembly and assembly

00-100 10 PC200, 200LC, 220, 220LC-8M0

Disassembly and assembly of swing motor and swing machinery assembly.......................... 24

PC200, 200LC, 220, 220LC-8M0 00-100 11

Testing (dual) pressure switch for refrigerant .............................................................................. 36

90 Diagrams and drawings

00-100 12 PC200, 200LC, 220, 220LC-8M0

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

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

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

PC200, 200LC, 220, 220LC-8M0 00-200 1

Foreword, safety and general information 1

General precautions q If welding repairs is required, always have a

00-200 2 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 00-200 3

Precautions for slinging work and making sig-

00-200 4 PC200, 200LC, 220, 220LC-8M0

PC200, 200LC, 220, 220LC-8M0 00-200 5

q When loosening the nuts fixing air conditioner

q When tightening nuts of the air conditioner

00-200 6 PC200, 200LC, 220, 220LC-8M0

Fire prevention q When performing grinding or welding work

PC200, 200LC, 220, 220LC-8M0 00-200 7

q Fire caused by piping Dispose of waste materials

00-200 8 PC200, 200LC, 220, 220LC-8M0

How to read the shop manual 1

Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard