SM PC200, PC200LC-7

SEBM024312
MACHINE MODEL SERIAL NUMBER

PC200-7 200001 and up
PC200LC-7 200001 and up
PC220-7 60001 and up
PC220LC-7 60001 and up
This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
PC200, 200LC, PC220, 220LC-7 mount the SAA6D102E-2 engine.

For details of the engine, see the 102 Series Engine Shop Manual.
2005
All Rights Reserved
Printed in Japan 10-05 (01) 00-1
(12)
GENERAL
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD............................................ 10-1
20 TESTING AND ADJUSTING ........................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
90 OTHERS ................................................................................................................................ 90-1
00-2 PC200/220(LC)-7
(2)
LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.

Time of Time of Time of Time of Time of
Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
q 00-1 (12) 01-1 10-15 10-45 (11) 10-77
00-2 (2) 01-2 10-16 10-46 (11) 10-78
q 00-2-1 (12) 01-3 (11) 10-17 10-47 10-79 (4)
q 00-2-2 (12) 01-4 (11) 10-18 (4) 10-48 10-79-1 (4)
q 00-2-3 (12) 01-5 (11) 10-19 10-50 10-80 (4)
q 00-2-4 (12) 01-6 10-20 10-51 (11) 10-81 (4)
q 00-2-5 (12) 01-7 (11) 10-21 10-52 10-82 (4)
00-3 01-8 10-22 10-53 10-83 (4)
00-4 01-9 (11) 10-23 (9) 10-54 10-84 (4)
00-5 01-10 10-24 (11) 10-55 10-85
00-6 01-11 10-25 10-56 10-86
00-7 01-12 10-26 10-57 10-87
00-8 01-13 10-28 10-58 10-88
00-9 01-14 (4) 10-29 10-60 10-89
00-10 10-30 10-61 10-90
00-11 10-31 10-62 10-91
00-12 10-1 (4) 10-32 10-63 10-92
00-13 10-2 (6) 10-33 10-64 10-93
00-14 10-3 10-34 10-65 10-94
00-15 10-4 10-35 (11) 10-66 10-95
00-16 10-6 10-36 (11) 10-67 10-96
00-17 10-7 (4) 10-37 (11) 10-68 10-97 (11)
00-18 10-8 (4) 10-38 (11) 10-69 10-98 (11)
00-19 10-9 (4) 10-39 (11) 10-70 (11) 10-99
00-20 10-10 (4) 10-40 (11) 10-71 10-100
00-21 10-11 (4) 10-41 (4) 10-72 10-101
00-22 10-12 10-42 (11) 10-74 (11) 10-102
10-13 10-43 10-75 10-103 (4)
10-14 10-44 (11) 10-76 10-104 (4)
PC200/220(LC)-7 00-2-1
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10-105 (4) 10-148 10-193 (4) q 20-103 (12) 20-144 (1)
10-106 (4) 10-149 10-194 (4) q 20-104 (12) 20-145 (1)
10-107 10-150 10-195 20-105 (5) 20-146 (10)
10-108 10-152 10-196 (4) 20-106 (1) 20-147 (1)
10-109 10-153 (10) 10-197 (3) q 20-107 (12) 20-148 (11)
10-110 (11) 10-155 (11) 10-198 (3) q 20-108 (12) 20-149 (1)
10-111 (11) 10-156 (4) 10-199 (9) 20-109 (11) 20-150 (1)
10-112 (11) 10-157 (11) 10-200 (3) 20-110 (1) 20-151 (1)
10-113 10-158 10-201 (11) q 20-111 (12) 20-152 (1)
10-114 10-159 (4) 10-202 (3) 20-112 (5) 20-153 (1)
10-115 (11) 10-160 10-203 (3) 20-113 (11) 20-154 (1)
10-116 (11) 10-161 (4) 10-204 (3) 20-114 (1) q 20-155 (12)
10-117 (11) 10-162 10-205 (3) 20-115 (11) 20-156 (1)
10-118 (11) 10-163 (11) 10-206 (3) 20-116 (11) 20-157 (1)
10-119 (11) 10-164 (4) 10-207 (3) 20-117 (11) 20-158 (1)
10-120 (11) 10-165 (11) 10-208 (3) 20-118 (5) 20-159 (1)
10-121 10-166 (4) 10-209 (3) 20-119 (8) 20-160 (1)
10-122 (11) 10-167 20-120 (11) 20-161 (1)
10-123 (11) 10-168 20-121 (11) 20-162 (11)
10-124 (11) 10-169 (11) 20-1 (11) 20-122 (11) 20-163 (11)
10-125 (11) 10-170 (11) 20-2 (11) 20-123 (11) 20-163-1 (11)
10-126 10-171 (11) 20-3 (1) 20-124 (11) 20-164 (10)
10-127 10-172 20-4 (11) 20-125 (11) 20-165 (10)
10-128 10-173 (11) 20-5 (1) q 20-126 (12) 20-166 (10)
10-129 (9) 10-174 (4) 20-6 (11) 20-127 (11) 20-167 (10)
10-130 10-175 (11) 20-7 (5) 20-127-1 (5) 20-168 (10)
10-131 (11) 10-176 20-8 (11) 20-128 (11) 20-169 (10)
10-132 (11) 10-177 20-9 (1) q 20-129 (12) 20-170 (10)
10-133 (4) 10-178 20-10 (11) q 20-130 (12) 20-171 (10)
10-134 10-180 (11) 20-11 (1) q 20-131 (12) 20-172 (10)
10-135 10-181 20-12 (11) 20-132 (10) 20-173 (10)
10-136 10-182 (11) 20-13 (1) 20-133 (11) 20-174 (10)
10-137 10-183 (11) 20-14 (11) 20-134 (11) 20-175 (11)
10-138 10-184 (11) 20-15 (1) 20-135 (11) 20-176 (10)
10-139 10-185 (11) 20-16 (11) 20-136 (11) 20-176-1 (10)
10-140 10-186 (11) 20-17 (11) 20-137 (11) 20-176-2 (10)
10-142 10-187 20-18 (11) 20-138 (11) 20-176-3 (10)
10-143 10-188 q 20-139 (12) 20-176-4 (10)
10-144 10-189 q 20-101 (12) 20-140 (1) 20-177 (7)
10-145 10-190 q 20-101-1 (12) 20-141 (11) 20-177-1 (7)
10-146 10-191 20-101-2 (11) 20-142 (1) 20-178 (1)
10-147 10-192 q 20-102 (12) 20-143 (1) 20-179 (1)
00-2-2 PC200/220(LC)-7
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20-180 (1) 20-229-3 (5) 20-264 (5) 20-327-1 (7) 20-358 (5)
20-181 (11) 20-229-4 (5) 20-265 (5) 20-327-2 (5) 20-359 (1)
20-182 (1) 20-229-5 (5) 20-266 (11) 20-328 (7) 20-360 (5)
20-183 (1) 20-230 (7) 20-267 (5) 20-329 (1) 20-361 (5)
20-184 (1) 20-231 (5) 20-268 (5) 20-329-1 (7) 20-362 (1)
20-185 (11) 20-231-1 (7) 20-329-2 (5) 20-364 (11)
20-231-2 (5) 20-301 (5) 20-330 (7) 20-365 (1)
20-201 (1) 20-232 (7) 20-302 (11) 20-331 (5) 20-366 (11)
20-202 (1) 20-233 (5) 20-304 (1) 20-331-1 (7) 20-367 (1)
20-203 (1) 20-233-1 (7) 20-305 (1) 20-331-2 (5) 20-368 (5)
20-204 (1) 20-233-2 (5) 20-306 (5) 20-332 (7) 20-369 (1)
20-205 (1) 20-234 (7) 20-307 (1) 20-333 (1) 20-370 (1)
20-206 (1) 20-235 (5) 20-308 (1) 20-333-1 (7) 20-372 (11)
20-207 (3) 20-235-1 (9) 20-309 (1) 20-333-2 (5) 20-373 (1)
20-208 (1) 20-235-2 (9) 20-310 (1) 20-334 (7) 20-374 (11)
20-209 (1) 20-236 (1) 20-311 (1) 20-335 (1) 20-375 (1)
20-210 (1) 20-237 (1) 20-312 (7) 20-335-1 (7) 20-376 (1)
20-211 (1) 20-238 (1) 20-313 (1) 20-335-2 (5) 20-377 (1)
20-212 (11) 20-239 (5) 20-313-1 (11) 20-336 (7) 20-378 (11)
20-213 (5) 20-240 (1) 20-313-2 (5) 20-337 (1) 20-379 (5)
20-214 (11) 20-241 (1) 20-314 (5) 20-337-1 (7) 20-380 (5)
20-215 (11) 20-242 (1) 20-315 (1) 20-337-2 (5) 20-381 (7)
20-216 (11) 20-243 (1) 20-316 (1) 20-338 (5) 20-381-1 (8)
20-218 (11) 20-244 (1) 20-317 (1) 20-339 (5) 20-382 (5)
20-219 (11) q 20-245 (12) 20-318 (7) 20-340 (5) 20-383 (5)
20-220 (11) 20-246 (1) 20-319 (1) 20-341 (1) 20-384 (11)
20-221 (11) 20-247 (1) 20-319-1 (7) 20-342 (1) 20-385 (11)
20-222 (1) 20-248 (1) 20-319-2 (5) 20-343 (1) 20-386 (5)
20-223 (5) 20-249 (1) 20-320 (7) 20-344 (5)
20-223-1 (11) 20-250 (1) 20-321 (1) 20-345 (5) 20-501 (11)
20-223-2 (11) 20-251 (1) 20-321-1 (7) 20-346 (5) 20-502 (1)
20-223-3 (5) 20-252 (1) 20-321-2 (5) 20-347 (1) 20-502-1 (11)
20-223-4 (11) 20-253 (5) 20-322 (7) 20-348 (5) 20-503 (11)
20-223-5 (5) 20-254 (1) 20-323 (1) 20-349 (1) 20-504 (5)
20-223-6 (5) 20-255 (1) 20-323-1 (7) 20-350 (5) 20-505 (7)
20-224 (7) 20-256 (5) 20-323-2 (5) 20-351 (1) 20-506 (7)
20-225 (9) 20-257 (1) 20-324 (7) 20-352 (5) 20-507 (5)
20-226 (1) 20-258 (7) 20-325 (1) 20-353 (5) 20-508 (11)
20-227 (1) 20-259 (1) 20-325-1 (7) 20-354 (5) 20-509 (7)
20-228 (1) 20-260 (5) 20-325-2 (5) 20-355 (1) 20-509-1 (7)
20-229-1 (7) 20-262 (5) 20-326 (7) 20-356 (5) 20-510 (5)
20-229-2 (9) 20-263 (5) 20-327 (1) 20-357 (1) 20-511 (7)
PC200/220(LC)-7 00-2-3
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20-511-1 (7) 20-556 (5) 20-712 (5) 30-22 (11) 30-49 (2)
20-512 (5) 20-557 (5) 20-713 (11) 30-23 (11) 30-50 (2)
20-513 (11) 20-558 (5) 20-714 (11) 30-24 (2) 30-51 (2)
20-514 (11) 20-559 (5) 20-715 (5) 30-25 (2) 30-52 (11)
20-515 (1) 20-560 (5) 20-716 (11) 30-26 (11) 30-53 (2)
20-516 (11) 20-717 (5) 30-27 (11) 30-54 (2)
20-517 (11) 20-601 (11) 20-718 (11) 30-28 (2) 30-55 (2)
20-518 (11) 20-602 (11) 20-719 (11) 30-29 (2) 30-56 (2)
20-519 (5) 20-603 (1) 20-720 (5) 30-30 (2) 30-57 (2)
20-520 (1) 20-604 (1) 20-721 (11) 30-31 (11) 30-58 (2)
20-521 (5) 20-605 (11) 20-722 (11) 30-32 (2) 30-59 (2)
20-522 (11) 20-606 (11) 20-723 (5) 30-33 (2) 30-60 (2)
20-523 (11) 20-607 (11) 20-724 (11) 30-34 (2) q 30-61 (12)
20-524 (5) 20-608 (11) 30-35 (2) q 30-62 (12)
20-526 (5) 20-609 (11) 30-36 (2) 30-63 (2)
20-527 (1) 20-610 (11) q 30-1 (12) 30-37 (2) 30-64 (2)
20-528 (1) 20-611 (11) 30-2 (5) 30-38 (2) 30-65 (2)
20-530 (5) 20-612 (11) 30-3 (2) q 30-39 (12) 30-66 (2)
20-531 (1) 20-613 (11) 30-4 (2) (30-40) 30-67 (2)
20-532 (5) 20-614 (1) 30-5 (3) q 30-41 (12) q 30-68 (12)
20-533 (5) 20-615 (11) 30-6 (2) Q 30-41-1 (12) 30-69 (11)
20-534 (5) 20-616 (11) q 30-6-1 (12) q 30-42 (12) 30-70 (2)
20-535 (5) 20-617 (11) q 30-6-2 (12) q 30-43 (12) 30-71 (2)
20-536 (5) 20-618 (11) 30-6-3 (8) q 30-44 (12) 30-72 (2)
20-537 (5) 20-619 (11) q 30-6-4 (12) q 30-45 (12) 30-73 (2)
20-538 (5) 20-620 (11) Q 30-6-5 (12) q 30-46 (12) 30-74 (2)
20-540 (5) 20-621 (11) Q 30-6-6 (12) q 30-47 (12) 30-75 (2)
20-541 (1) 20-622 (11) 30-7 (2) q 30-48 (12) 30-76 (2)
20-542 (5) 20-623 (11) 30-8 (2) q 30-48-1 (12) q 30-77 (12)
20-543 (1) 20-624 (11) 30-9 (2) q 30-48-2 (12) 30-78 (2)
20-544 (5) 30-10 (2) q 30-48-3 (12) q 30-79 (12)
20-545 (1) 20-701 (11) q 30-11 (12) q 30-48-4 (12) q 30-79-1 (12)
20-546 (5) 20-702 (5) q 30-12 (12) q 30-48-5 (12) Q 30-79-2 (12)
20-547 (5) 20-703 (5) q 30-13 (12) q 30-48-6 (12) q 30-80 (12)
20-548 (7) 20-704 (5) q 30-14 (12) q 30-48-7 (12) q 30-81 (12)
20-549 (11) 20-705 (5) 30-15 (2) Q 30-48-8 (12) q 30-82 (12)
20-550 (5) 20-706 (5) 30-16 (2) Q 30-48-9 (12) q 30-83 (12)
20-551 (11) 20-707 (5) 30-17 (11) Q 30-48-10 (12) q 30-84 (12)
20-552 (5) 20-708 (5) 30-18 (2) Q 30-48-11 (12) q 30-85 (12)
20-553 (5) 20-709 (5) 30-19 (2) Q 30-48-12 (12) 30-86 (2)
20-554 (5) 20-710 (5) 30-20 (2) Q 30-48-13 (12) 30-87 (11)
20-555 (5) 20-711 (11) 30-21 (11) Q 30-48-14 (12) 30-88 (11)
00-2-4 PC200/220(LC)-7
(12)

q 30-89 (12) 90-17-6 (9)
q 30-90 (12) 90-17-8 (9)
q 30-91 (12) 90-17-10 (9)
q 30-92 (12) 90-17-12 (9)
q 30-92-1 (12) 90-19 (6)
q 30-92-2 (12) 90-21 (6)
30-93 (2)
30-94 (5)
30-95 (5)
30-96 (5)
30-97 (5)
30-98 (5)
30-99 (5)
30-100 (5)
30-101 (5)
30-102 (5)
30-103 (5)
30-104 (5)
30-105 (5)
30-106 (5)
30-107 (5)
30-108 (5)
q 30-109 (12)
30-110 (5)
q 30-111 (12)
q 30-112 (12)
q 30-113 (12)
30-114 (8)
30-115 (5)
90-1 (9)
90-3
90-5
90-7 (6)
90-9 (6)
90-11 (6)
90-13 (6)
90-15 (9)
90-17 (9)
90-17-2 (9)
90-17-4 (9)
PC200/220(LC)-7 00-2-5
(12)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive () terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120 hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150.
The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
The adapter can be pushed in about 3.5
mm.
Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
Hold the mouthpiece of the tightening portion Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Qty Container Main applications, features
Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
Quick hardening type adhesive
Three bond Polyethylene Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container Used mainly for adhesion of metals,
rubbers, plastics and woods.
Quick hardening type adhesive
Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
Used mainly for adhesion of rubbers,
plastics and metals.
Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc Used at joint portions subject to high
648-50 container
temperatures.
Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube Used as sealant for flange surface, tread.
Used as sealant for oil pan, final drive
Gasket case, etc.
sealant Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
Used as sealing material for transfer case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Qty Container Main applications, features
Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
Used as lubricant for linkage, bearings,
etc.
SYG2-400LI General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum Used for heavy load portion
SYG2-400M 400 g 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR S is used for high-temperature
PENGUINE season (April - October) and W for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER S or April) as adhesive for glass.
W (Using limit: 4 months)
Sika Japan, Polyethylene Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 14.7 1.2 1.5

8 13 27 34 2.8 3.5
10 17 59 74 6 7.5
12 19 98 123 10 12.5
14 22 153 190 15.5 19.5
16 24 235 285 23.5 29.5

18 27 320 400 33 41
20 30 455 565 46.5 58
22 32 610 765 62.5 78
24 36 785 980 80 100
27 41 1150 1440 118 147

30 46 1520 1910 155 195
33 50 1960 2450 200 250
36 55 2450 3040 250 310
39 60 2890 3630 295 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 9.8 0.6 1.0

8 13 13.7 23.5 1.4 2.4
10 14 34.3 46.1 3.5 4.7
12 27 74.5 90.2 7.6 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 4.9 2.5 0.5

18 24 49 19.6 52
22 27 78.5 19.6 82
24 32 137.3 29.4 14 3
30 36 176.5 29.4 18 3
33 41 196.1 49 20 5
36 46 245.2 49 25 5
42 55 294.2 49 30 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 74 6 7.5
12 17 98 123 10 12.5
16 22 235 285 23.5 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 63 {3.5 6.5} 44 {4.5}

03, 04 20 Varies depending 84 132 {8.5 13.5} 103 {10.5}
05, 06 24 on type of 128 186 {13.0 19.0} 157 {16.0}
10, 12 33 connector. 363 480 {37.0 49.0} 422 {43.0}
14 42 746 1010 {76.0 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}

10 10 17 9.8 12.74 {1.0 1.3} 11.27 {1.15}
12 12 19 14.7 19.6 {1.5 2.0} 17.64 {1.8}
14 14 22 19.6 24.5 {2.0 2.5} 22.54 {2.3}
16 16 24 24.5 34.3 {2.5 3.5} 29.4 {3.0}
18 18 27 34.3 44.1 {3.5 4.5} 39.2 {4.0}
20 20 30 44.1 53.9 {4.5 5.5} 49.0 {5.0}
24 24 32 58.8 78.4 {6.0 8.0} 68.6 {7.0}
30 30 32 93.1 122.5 {9.5 12.5} 107.8 {11.0}
33 33 107.8 147.0 {11.0 15.0} 124.4 {13.0}
36 36 36 127.4 176.4 {13.0 18.0} 151.9 {15.5}
42 42 181.3 240.1 {18.5 24.5} 210.7 {21.5}
52 52 274.4 367.5 {28.0 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.20
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 54 {3.5 5.5} 44 {4.5} 18UN 14.3
02 19 16
34 63 {3.5 6.5} 44 {4.5} 14
11
22 54 93 {5.5 9.5} 74 {7.5} 16UN 17.5
03 16
24 59 98 {6.0 10.0} 78 {8.0} 18
13
04 27 84 132 {8.5 13.5} 103 {10.5} 22 16UN 20.6
16
05 32 128 186 {13.0 19.0} 157 {16.0} 24 1 14UNS 25.4
3
06 36 177 245 {18.0 25.0} 216 {22.0} 30 1 12UN 30.2
16
(10) 41 177 245 {18.0 25.0} 216 {22.0} 33
(12) 46 197 294 {20.0 30.0} 245 {25.0} 36
(14) 55 246 343 {25.0 35.0} 294 {30.0} 42
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR BW RW YR GW LW
2
Color White & Red White & Black Red & White Rellow & Red Green & White Blue & White
Code WB BY RB YB GR LR
3
Color White & Black Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG RG YL GB LB
5
Color White & Green Red & Green Yellow & Blue Green & Black Blue & Black
Code RL YW GL n
6
Color Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), 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 perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(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 return to the original value. This gives 550 mm = 21.65 inches.
(B)
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
(C)
(A) 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
00-16
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
00-17
Liter to U.S. Gallon

1l = 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
Liter to U.K. Gallon

1l = 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 7.969 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
00-18
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
00-19
kg/cm2 to lb/in2
1kg/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 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade 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 81 117.8

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 0 140.0 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
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
Specification Dimension Drawings

PC200-7, PC200LC-7 . . . . . . . . . . . 01-2
PC220-7, PC220LC-7 . . . . . . . . . . . 01-4
Specifications
PC200-7, PC200LC-7 . . . . . . . . . . . 01-6
PC220-7, PC220LC-7 . . . . . . . . . . . 01-8
Weight Table
PC200-7, PC200LC-7 . . . . . . . . . . 01-10
PC220-7, PC220LC-7 . . . . . . . . . . 01-12
Fuel, Coolant, And Lubricants. . . . . . . 01-14
PC200-7 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
SPECIFICATION DIMENSION DRAWINGS
PC200-7, PC200LC-7
DIMENSIONS
WORKING RANGES
01-2 PC200-7
12
DIMENSIONS
Item Unit PC200-7 PC200LC-7
A Overall length mm 9,425 9,425
B Overall height mm 3,000 3,000
C Overall width mm 2,800 3,080
D Track shoe width mm 600 700
E Height of cab mm 3,000 3,000
F Tail swing radius mm 2,750 2,750
G Track overall length mm 4,080 4,450
H Length of track on ground mm 3,270 3,640
Min. ground clearance mm 440 440
WORKING RANGES
A Max. digging reach mm 9,875 9,875
B Max. digging depth mm 6,620 6,620
C Max. digging height mm 10,000 10,000
D Max. vertical wall depth mm 5,980 5,980
E Max. dumping height mm 7,110 7,110
F Min. dumping height mm 2,645 2,645
G Max. reach at ground level mm 9,700 9,700
PC200/220(LC)-7 01-3
(11)
PC220-7, PC220LC-7
DIMENSIONS
WORKING RANGES
01-4 PC200/220(LC)-7
(11)
12
DIMENSIONS
A Overall length mm 9,885 9,885
B Overall height mm 3,160 3,160
C Overall width mm 2,980 3,280
D Track shoe width mm 600 700
E Height of cab mm 3,015 3,015
F Tail swing radius mm 2,940 2,940
G Track overall length mm 4,250 4,640
H Length of track on ground mm 3,460 3,845
WORKING RANGES
A Max. digging reach mm 10,180 10,180
B Max. digging depth mm 6,920 6,920
C Max. digging height mm 10,000 10,000
D Max. vertical wall depth mm 6,010 6,010
E Max. dumping height mm 7,035 7,035
F Min. dumping height mm 2,530 2,530
G Max. reach at ground level mm 10,020 10,020
PC200/220(LC)-7 01-5
(11)
GENERAL SPECIFICATIONS
SPECIFICATIONS
PC200-7, PC200LC-7
Machine model PC200-7 PC200LC-7
Serial Number 200001 and up
Bucket capacity m 0.8 0.8
Operating weight kg 19,300 20,700
Max. digging depth mm 6,620 6,620

Working ranges
Max. vertical wall depth mm 5,980 5,980

Max. digging reach mm 9,875 9,875
Max. reach at ground level mm 9,700 9,700
Max. digging height mm 10,000 10,000
Max. dumping height mm 7,110 7,110
Max. digging force kN {kg} 138.3 {14,100} 138.3 {14,100}

Performance
(using power max. function) (149.1 {15,200}) (149.1 {15,200})
Swing speed rpm 12.4 12.4

Swing max. slope angle deg. 20 20
Travel speed km/h Lo: 3.0 ( Mi: 4.1) Lo: 3.0 ( Mi: 4.1)
Hi: 5.5 Hi: 5.5
Gradeability deg. 35 35
Ground pressure kPa {kg/cm} 44.1 {0.45} 36.3 {0.37}

[standard shoe width] [mm] [600] [700]
Overall length (for transport) mm 9,425 9,425

Overall width mm 2,800 3,080
Overall width of track mm 2,800 3,080
Overall height (for transport) mm 3,000 3,000
Overall height to chassis mm 3,000 3,000
Dimensions
Ground clearance to bottom of upper structure mm 1,085 1,085

Tail swing radius mm 2,750 2,750
Min. swing radius of work equipment mm 3,040 3,040
Height of work equipment at min. swing radius mm 8,005 8,005
Length of track on ground mm 3,270 3,640
Track gauge mm 2,200 2,380
Height of machine cab mm 2,335 2,335
: The "Mi" mode is on the multi-monitor specification machine only.
01-6 PC200-7
12
Model SAA6D102E-2-A
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.883 {5,883}
Flywheel horsepower kW/rpm {HP/rpm} 106.7/1,950 {143/1,950}

Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 610.0/1,500 {62.2/1,500}

High idle rpm 2,150
Low idle rpm 1,030
Min. fuel consumption g/kWh {g/HPh} 215 {160}
Starting motor 24V, 4.5 kW

Alternator 24V, 35 A
Battery 12V, 110 Ah x 2
Radiator core type Corrugated CWX-4
Carrier roller 2 on each side
Track roller 7 on each side 9 on each side

carriage
Under-
Assembly-type triple Assembly-type triple

Track shoe grouser, 45 on each grouser, 49 on each
side side
HPV95+95, variable displacement

Hydraulic
Type x No.
pump
Delivery
l/min Piston type: 214 x 2
Set pressure
MPa (kg/cm) Piston type: 37.2 {380}
Control
Type x No. 6-spool type x 1

valve
Control method Hydraulic
Travel motor HMV110ADT-2, Piston type

Hydraulic
motor
(with brake valve, parking brake): x 2

Hydraulic system
Swing motor KMF125ABE-5, Piston type

(with safety valve, holding brake): x 1
Type Boom Arm Bucket

Hydraulic culinder
Double act- Double act- Double act-

ing piston ing piston ing piston
Inside diameter of cylinder mm 120 135 115

Diameter of piston rod 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
Hrdraulic tank Closed box type

Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)
PC200/220(LC)-7 01-7
(11)
PC220-7, PC220LC-7
Bucket capacity m 1.0 1.0
Operating weight kg 22,700 24,130
Max. digging depth mm 6,920 6,920

Working ranges
Max. vertical wall depth mm 6,010 6,010

Max. digging reach mm 10,180 10,180
Max. reach at ground level mm 10,020 10,020
Max. digging height mm 10,000 10,000
Max. dumping height mm 7,035 7,035
Max. digging force kN {kg} 158.9 {16,200} 158.9 {16,200}

Performance
(using power max. function) (171.6 {17,500}) (171.6 {17,500})
Swing speed rpm 11.7 11.7
Swing max. slope angle deg. 25 25
Travel speed km/h Lo: 3.1 ( Mi: 4.2) Lo: 3.1 ( Mi: 4.2)
Hi: 5.5 Hi: 5.5
Gradeability deg. 35 35
Ground pressure kPa {kg/cm} 50.0 {0.51} 41.2 {0.42}

[standard shoe width] [mm] [600] [700]
Overall length (for transport) mm 9,885 9,885

Overall width mm 2,980 3,280
Overall width of track mm 2,980 3,280
Overall height (for transport) mm 3,160 3,160
Overall height to chassis mm 3,015 3,015
Dimensions
Ground clearance to bottom of upper structure mm 1,110 1,110

Tail swing radius mm 2,940 2,940
Min. swing radius of work equipment mm 3,450 3,450
Height of work equipment at min. swing radius mm 8,110 8,110
Length of track on ground mm 3,460 3,845
Track gauge mm 2,380 2,580
Height of machine cab mm 2,390 2,390
01-8 PC200-7
Model SAA6D102E-2-C
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.883 {5,883}
Flywheel horsepower kW/rpm {HP/rpm} 125/2,000 {167/2,000}

Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 686/1,500 {70/1,500}

High idle rpm 2,260
Low idle rpm 1,060
Min. fuel consumption g/kWh {g/HPh} 212 {153}
Starting motor 24V, 4.5 kW

Alternator 24V, 35 A
Battery 12V, 110 Ah x 2
Radiator core type Corrugated CF19-5
Carrier roller 2 on each side
Track roller 8 on each side 10 on each side

carriage
Under-
Assembly-type triple Assembly-type triple

Track shoe grouser, 47 on each grouser, 51 on each
side side
HPV95+95, variable displacement

Hydraulic
Type x No.
pump
Delivery
l/min Piston type: 214 x 2
Set pressure
MPa (kg/cm) Piston type: 37.2 {380}
Control
Type x No. 6-spool type x 1

valve
Control method Hydraulic
Travel motor HMV110ADT-2, Piston type

Hydraulic
motor
(with brake valve, parking brake): x 2

Hydraulic system
Swing motor KMF125ABE-5, Piston type

(with safety valve, holding brake): x 1
Boom Arm Bucket

Type
Hydraulic culinder
Double act- Double act- Double act-

ing piston ing piston ing piston
Inside diameter of cylinder mm 130 140 130

Diameter of piston rod mm 90 100 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
Hrdraulic tank Closed box type

Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)
PC200/220(LC)-7 01-9
(11)
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
PC200-7, PC200LC-7
This weight table is for use when handling components or when transporting the machine.
Unit: kg
Serial Number 200001 and up 200001 and up
Engine assembly 749 749
Engine 598 598
Damper 6 6
Hydraulic pump 145 145

Radiator oil cooler assembly 110 110
Hydraulic tank, filter assembly (excluding hydraulic oil) 123 123
Fuel tank (excluding fuel) 121 121
Revolving frame 1,729 1,729
Operators cab 278 278
Operators seat 35 35
Counterweight 3,735 3,735
Swing machinery 160 160
Control valve 263 263
Swing motor 60 60
Travel motor 98 x 2 98 x 2
Center swivel joint 36 36
Track frame assembly 4,194 4,712
Track frame 2,179 2,534
Swing circle 273 273
Idler 99 x 2 99 x 2
Idler cushion 130 x 2 135 x 2
Carrier roller 16 x 4 16 x 4
Track roller 36 x 14 36 x 18
Final drive (including travel motor) 343 x 2 343 x 2
01-10 PC200-7
12
Unit: kg
Track shoe assembly
Standard triple grouser shoe (600 mm) 1,215 x 2 1,325 x 2
Wide triple grouser 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
Boom assembly 1,408 1,408
Arm assembly 653 653
Bucket assembly 628 628
Boom cylinder assembly 172 x 2 172 x 2
Arm cylinder assembly 226 226
Bucket cylinder assembly 136 136
Link assembly (large) 81 81
Link assembly (small) 22 x 2 22 x 2
Boom pin 48 + 8 x 2 + 31 + 10 + 26 48 + 8 x 2 + 31 + 10 + 26
Arm pin 11 + 8 11 + 8
Bucket pin 20 x 2 20 x 2
Link pin 13 x 2 13 x 2
PC200-7 01-11
PC220-7, PC220LC-7
Unit: kg
Engine assembly 749 749
Engine 598 598
Damper 6 6
Hydraulic pump 145 145

Radiator oil cooler assembly 119 119
Hydraulic tank, filter assembly (excluding hydraulic oil) 123 123
Fuel tank (excluding fuel) 121 121
Revolving frame 2,048 2,048
Operators cab 278 278
Operators seat 35 35
Counterweight 5,056 5,056
Swing machinery 237 237
Control valve 263 263
Swing motor 60 60
Travel motor 98 x 2 98 x 2
Center swivel joint 36 36
Track frame assembly 4,828 5,460
Track frame 2,558 3,046
Swing circle 293 293
Idler 99 x 2 99 x 2
Idler cushion 135 x 2 135 x 2
Carrier roller 16 x 4 16 x 4
Track roller 36 x 16 36 x 20
Final drive (including travel motor) 362 x 2 362 x 2
01-12 PC200-7
12
Unit: kg
Track shoe assembly
Wide triple grouser shoe (800 mm) 1,600 x 2 1,735 x 2
Road liner (rubber pad type) (600 mm) 1,535 x 2 1,665 x 2
Boom assembly 1,825 1,825
Arm assembly 1,213 1,213
Bucket assembly 722 722
Boom cylinder assembly 195 x 2 195 x 2
Arm cylinder assembly 262 262
Bucket cylinder assembly 161 161
Link assembly (large) 82 82
Link assembly (small) 22 x 2 22 x 2
Boom pin 50 + 10 x 2 + 31 + 10 + 26 50 + 10 x 2 + 31 + 10 + 26
Arm pin 11 + 10 11 + 10
Bucket pin 20 x 2 20 x 2
Link pin 17 x 2 17 x 2
PC200-7 01-13
GENERAL FUEL, COOLANT, AND LUBRICANTs
12
FUEL, COOLANT, AND LUBRICANTS
KIND AMBIENT TEMPERATURE CAPACITY (l)

RESERVOIR OF -22 -4 14 32 50 68 86 104F
FLUID Specified Refill
-30 -20 -10 0 10 20 30 40C
SAE 30
SAE 10W
Engine oil pan 26.3 24
SAE 10W-30
SAE 15W-40
Damper case 0.75

Swing machinery case 6.6 6.6
Engine
Final drive case (each side) SAE 30 4.7 4.5
oil
Idler (1 each) 0.07-0.08 0.07-0.08
Track roller (1 each) 0.19-0.20 0.19-0.20
Carrier roller (1 each) 0.075-0.085 0.075-0.085
PC200-7
SAE 10W
PC200LC-7
SAE 10W-30
240
Hydraulic system 143
SAE 15W-40 PC220-7
PC220LC-7
Hydraulic
HO46-HM (a)
oil 247
ASTM D975 No. 2

Diesel
Fuel tank 400
fuel ASTM D975A
No.1
PC200, PC200,
PC200LC-7 PC200LC-7
22.8 22.4
Cooling system Coolant Add antifreeze
PC220, PC220,
PC220LC-7 PC220LC-7
30.9 30.9
a For the HO46-HM, use the oil recommended by Komatsu.
01-14 PC200/220(LC)-7
(4)
10 STRUCTURE, FUNCTION, AND
MAINTENANCE STANDARD
1252
Engine Related Parts . . . . . . . . . . . . . .10-2 Hydraulic Cylinder
Radiator Oil Cooler Aftercooler . . .10-3 PC200-7, PC200LC-7 . . . . . . . . . 10-134
Power Train . . . . . . . . . . . . . . . . . . . . .10-4 PC220-7, PC220LC-7 . . . . . . . . . 10-136
Final Drive . . . . . . . . . . . . . . . . . . . . . .10-6 Work Equipment. . . . . . . . . . . . . . . 10-138
Swing Machinery Air Conditioner . . . . . . . . . . . . . . . . 10-146
PC200-7, PC200LC-7 . . . . . . . . . . . .10-8 Engine Control . . . . . . . . . . . . . . . . 10-147
PC220-7, PC220LC-7 . . . . . . . . . . .10-10 Electronic Control System . . . . . . . 10-155
Swing Circle Multi Monitor System . . . . . . . . . . 10-180
PC200-7, PC200LC-7 . . . . . . . . . . .10-12 7-Segment Monitor System . . . . . 10-200
PC220-7, PC220LC-7 . . . . . . . . . . .10-13 Sensor . . . . . . . . . . . . . . . . . . . . . . . 10-207
Track Frame Recoil Spring . . . . . . .10-14
Idler. . . . . . . . . . . . . . . . . . . . . . . . . . .10-16
Carrier roller. . . . . . . . . . . . . . . . . . . .10-18
Track roller . . . . . . . . . . . . . . . . . . . . .10-19
Track Shoe . . . . . . . . . . . . . . . . . . . . .10-20
Hydraulic Equipment Layout Drawing
10-24
Hydraulic Tank . . . . . . . . . . . . . . . . . .10-26
Hydraulic Pump . . . . . . . . . . . . . . . . .10-28
Control Valve
PC200-7, PC200LC-7 . . . . . . . . . . .10-50
PC220-7, PC220LC-7 . . . . . . . . . . .10-64
CLSS . . . . . . . . . . . . . . . . . . . . . . . . . .10-80
Self Pressure Reducing Valve. . . . . .10-83
Swing Motor . . . . . . . . . . . . . . . . . . .10-86
Reverse Prevention Valve . . . . . . . . .10-91
Center Swivel Joint . . . . . . . . . . . . . .10-93
Travel Motor . . . . . . . . . . . . . . . . . . .10-94
Travel Junction Valve . . . . . . . . . . .10-103
Stroke Regulation when Travelling
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-105
Valve Control . . . . . . . . . . . . . . . . . .10-107
Work Equipment Swing PPC Valve
10-108
Travel PPC Valve . . . . . . . . . . . . . . .10-112
Service PPC Valve . . . . . . . . . . . . . .10-121
Solenoid Valve. . . . . . . . . . . . . . . . .10-124
PPC Accumulator. . . . . . . . . . . . . . .10-126
Return Oil Filter . . . . . . . . . . . . . . . .10-127
Boom Hydraulic Drift Prevention Valve
10-128
Lift Check Valve . . . . . . . . . . . . . . . .10-131
Attachment Circuit Selector Valve .10-132
PC200/220(LC)-7 10-1
(4)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE RELATED PARTS
12
ENGINE RELATED PARTS
: PC200-7, PC200LC-7 Serial No. 250001 and up

PC220-7, PC220LC-7 Serial No. 65001 and up
1. Drive plate 5. Damper assembly OUTLINE

2. Torsion spring 6. Muffler
3. Stopper pin 7. Rear engine mount The damper assembly is a wet type.
4. Friction plate 8. Front engine mount Oil capacity: 0.75 l
10-2 PC200/220(LC)-7
(6)
RADIATOR OIL COOLER
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AFTERCOOLER
12
RADIATOR OIL COOLER AFTERCOOLER
SWP08671
1. Reservoir tank SPECIFICATIONS

2. Oil cooler
3. Radiator Radiator : CWX-4 (PC200-7, PC200LC-7)
4. Fan : CF19-5 (PC220-7, PC220LC-7)
5. Radiator inlet hose Oil cooler : CF40-1
6. Radiator outlet hose
7. Radiator cap
8. Net
9. Shroud
10. Aftercooler
PC200-7 10-3
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN
1. Idler 7. Engine (SAA6D102E-2)

2. Center swivel joint 8. Travel speed solenoid valve
3. Control valve 9. Swing brake solenoid valve
4. Final drive 10. Swing motor (KMF125ABE-5)
5. Travel motor (HMV 110ADT-2) 11. Swing machinery
6. Hydraulic pump (HPV95+95) 12. Swing circle
10-4 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE
12
FINAL DRIVE
10-6 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE
12
1. Level plug
2. Drain plug
3. No. 2 sun gear (No. of teeth: 21)
4. No. 1 sun gear (No. of teeth: 10)
5. No. 1 planetary carrier
6. Cover
8. Sprocket
9. Floating seal
10. Travel motor
11. Hub
12. No. 2 planetary gear (No. of teeth: 36)
13. Ring gear (No. of teeth: 95)
14. No. 1 planetary gear (No. of teeth: 42)
SPECIFICATIONS
Reduction ratio:
10 + 95 21+ 95
+ 1 = 57.00
10 21
Unit: mm
No. Check item Criteria Remedy
Backlash between No. 2 sun gear and Standard clearance Clearance limit
15
No. 2 planetary gear 0.15 - 0.49 1.00
Backlash between No. 1 planetary gear

16 0.17 - 0.57 1.10
and ring gear
Backlash between No. 2 planetary car-

17 0.06 - 0.25
rier and motor
Backlash between No. 1 sun gear and Replace

18 0.14 - 0.46 1.00
No. 1 planetary gear
Backlash between No. 2 planetary gear

19 0.17 - 0.57 1.10
and ring gear
Backlash between No. 1 planetary car-

20 0.38 - 0.66 1.00
rier and No. 2 sun gear
21 End play of sprocket shaft 0.00 - 0.10
22 Amount of wear on sprocket tooth Repair limit: 6

Rebuild or
Standard size Repair limit
23 Width of sprocket tooth replace
71 68
PC200/220(LC)-7 10-7
(4)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY
12
SWING MACHINERY
PC200-7, PC200LC-7
10-8 PC200/220(LC)-7
(4)
12
1. Swing pinion (No. of teeth: 15)

2. Spacer
3. Case
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear
13. Drain plug
SPECIFICATIONS
Reduction ratio:
17 + 58 18 + 58
= 18.627
17 18
Unit: mm
Backlash between swing motor shaft and Standard clearance Clearance limit
14
No. 1 sun gear 0.18 - 0.28
Backlash between No. 1 sun gear and No. 1
15 0.16 - 0.50 1.00
planetary gear
Backlash between No. 1 planetary gear and
16 0.18 - 0.59 1.10
ring gear
Backlash between No. 1 planetary carrier
17 0.39 - 0.71 1.20
and No. 2 sun gear
18 0.16 - 0.50 0.90
planetary gear Replace
19 0.18 - 0.59 1.00
ring gear
20 0.07 - 0.23
and swing pinion
Backlash between swing pinion and swing
21 0.22 - 1.32 2.00
circle
Clearance between plate and No. 2 plane-
22 0.66 - 1.14
tary carrier
23 Clearance between No. 2 sun gear and plate 1.66 - 2.94
Standard size Repair limit Apply hard chrome
Wear of swing pinion surface contacting
24 plating, recondi-
with oil seal 115 00.100 tion, or replace
PC200/220(LC)-7 10-9
(4)
PC220-7, PC220LC-7
10-10 PC200/220(LC)-7
(4)
12
1. Swing pinion (No. of teeth: 13)

2. Spacer
3. Case
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
13. Drain plug
SPECIFICATIONS
Reduction ratio:
17 + 58 14 + 58
= 22.689
17 14
Unit: mm
Backlash between swing motor shaft and Standard clearance Clearance limit
14
No. 1 sun gear 0.18 - 0.28
15 0.16 - 0.59 1.00
planetary gear
16 0.18 - 0.50 1.10
ring gear
17 0.39 - 0.64 1.20
and No. 2 sun gear
18 0.16 - 0.44 0.90
planetary gear Replace
19 0.18 - 0.56 1.00
ring gear
20 0.08 - 0.23
and swing pinion
Backlash between swing pinion and swing
21 0.23 - 1.37 2.00
circle
Clearance between plate and No. 2 plane-
22 0.58 - 0.62
tary carrier
23 Clearance between No. 2 sun gear and plate 2.56 - 3.84
Standard size Repair limit Apply hard chrome
Wear of swing pinion surface contacting
24 plating, recondi-
with oil seal 125 00.100 tion, or replace
PC200/220(LC)-7 10-11
(4)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
PC200-7, PC200LC-7
1. Swing circle inner race (No. of teeth: 110) SPECIFICATIONS

2. Ball
3. Swing circle outer race
Reduction ratio:
110
a. Inner race soft zone S position = 7.333
15
b. Outer race soft zone S position
Amount of grease: 14.6 l (G2-LI)
Unit: mm
Axial clearance of bearing Standard clearance Clearance limit

4 Replace
(when mounted on chassis) 0.5 - 1.6 3.2
10-12 PC200/220(LC)-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
12
PC220-7, PC220LC-7
S*P09097
1. Swing circle inner race (No. of teeth: 92) SPECIFICATIONS

2. Ball
3. Swing circle outer race
Reduction ratio: = 7.077

92
a. Inner race soft zone S position
13
b. Outer race soft zone S position
Amount of grease: 15.8 l (G2-LI)

Unit: mm
Axial clearance of bearing Standard clearance Clearance limit

4 Replace
(when mounted on chassis) 0.5 - 1.6 3.2
PC200-7 10-13
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME RECOIL SPRING
12
TRACK FRAME RECOIL SPRING
1 Idler The dimensions and the number of track rollers depend

2 Track frame on the model, but the basic structure is not different.
3 Carrier roller Number of track rollers
4 Final drive
5 Track roller Model Qty
6 Track shoe
7 Center guard PC200-7 7
8 Recoil spring
9 Front guard PC200LC-7 9
PC220-7 8
PC220LC-7 10
10-14 PC200-7
12
Standard shoe
Model
PC200-7 PC200LC-7 PC220-7 PC220LC-7
Item
Shoe width 600 mm 700 mm 600 mm 700 mm
Link pitch 190 mm 190 mm 190 mm 190 mm
No. on track (one side) 45 (pieces) 49 (pieces) 47 (pieces) 51 (pieces)
Unit: mm
Standard
Tolerance Repair limit
size
10 Vertical width of idler guide
Track frame 107 Rebuild
or
Idler support 105
replace
Horizontal width of idler Track frame 250
11
guide Idler support 247.4
Free length Installation Installation Free Installation

Recoil spring x O.D. length load length load
12 108.8 kN 87.3 kN Replace

PC200-7 558 X 238 437 534
(11,100 kg) (8,900 kg)
PC200LC-7
126.5 kN 100.9 kN
PC220-7 603.5 X 239 466 576
(12,900 kg) (10,300 kg)
PC22LC-7
PC200-7 10-15
12
IDLER
10-16 PC200-7
12
Unit: mm

1 Outside diameter of protruding
538
2 Outside diameter of tread 500 488 Rebuild

or
3 Thickness of tread 26 20 replace
4 Total width 159
5 Width of tread 37.5 43.5
Standard Tolerance Standard Clearance

Clearance between shaft and size Shaft Hole clearance limit
6
bushing
-0.250 +0.074
65 0.214 - 0.424 1.5
-0.350 -0.036 Replace
Tolerance bushing
Standard Standard Interference
Interference between idler and size Shaft Hole interference limit
7
bushing
+0.089 -0.006
72 0.065 - 0.161
+0.059 -0.072
PC200-7 10-17
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CARRIER ROLLER
12
CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
145
2 Outside diameter of tread 120 106
3 Width of tread 43
4 Thickness of tread 36.5 29.5
5 Width of flange 14

6 Replace
bushing
-0.179 +0.284
40 0.339 - 0.474
-0.190 +0.169
Standard Tolerance Standard Interference

Interference between roller size Shaft Hole interference limit
7
and bushing
+0.061 0
47 0.036 - 0.101
+0.036 -0.040
Standard clearance Clearance limit

8 Axial clearance of roller
0.44 - 0.76
10-18 PC200/220(LC)-7
(4)
12
TRACK ROLLER
Unit: mm

1 Outside diameter of flange
188
2 Outside diameter of tread 156 144
3 Thickness of tread 44.5 38.5 Rebuild

or
4 Overall width 225 replace
5 Inside width 85
6 Width of tread 44.5
7 Width of flange 25.5

8
bushing
-0.215 +0.195
60 0.215 - 0.510 1.5
-0.315 0 Replace
Tolerance bushing
Standard Standard Interference
Interference between roller size Shaft Hole interference limit
9
and bushing
-0.153 +0.030
67 0.023 - 0.153
-0.053 0
PC200-7 10-19
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE
12
TRACK SHOE
TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE
P portion shows the link of bushing press fitting end.
1.Triple-grouser shoe 3.Swamp shoe

2.Road liner 4.Flat shoe
10-20 PC200-7
12
Unit: mm
No
Check item Criteria Remedy
.
1 Link pitch
190.25 194.25
Reverse
When turned or
Standard size replace
2 Bushing outside diameter Normal load Impact load
59.3 54.3

3 Link height
105 97 Repair or
replace
Thickness of link metal
4 28.5 20.5
(bushing press-fitting portion)
5 160.4
6 Shoe bolt pitch 62
7 18
8 Inside width 84.8
9 Link Overall width 45.4
10 Tread width 39.6
Regular 2.5 Adjust or

11 Protrusion of pin
Master 2.5 replace
Protrusion of Regular 4.85

12
bushing Master 0.0
Overall length of Regular 212

13
pin Master 212
Overall length of Regular 138.5

14
bushing Master 128.7
Standard 10.4 Reverse

Thickness of
15 When turned / or
bushing metal 5.4
Impact Load replace
16 Thickness of spacer
17 Bushing 88.2 - 245 kN {9 - 25 ton}
18 Press-fitting Regular pin 127.4 - 274.4 kN {13 - 28 ton}

force
Master pin 78.4 - 147 kN {8 - 15 ton}
19
: Dry type track link
PC200-7 10-21
12
Unit: mm
Tightening torque Additional tightening

(Nm {kgm}) angle (deg.)
490 49
a. Regular link Triple shoe 120 10
{50 5}
Road liner 549 59 Retighten

Shoe bolt
20 (Rubber pad type) {56 6}
Tightening torque Additional tightening Lower limit torque

b. Master link (Nm {kgm}) angle (deg.) (Nm {kgm})
PC200-7: 45, PC200LC-7: 49

No. of shoes (each side)
PC220-7: 47, PC220LC-7: 51
Standard Tolerance Standard

Interference between size Shaft Hole interference
21
bushing and link
+0.304 +0.074
59 0.320 - 0.434
+0.394 0
Interference between +0.222 -0.138

22 38 0.300 - 0.422
regular pin and link +0.162 -0.200

Clearance between regular pin size Shaft Hole clearance
23
and bushing
+0.222 +0.902 Adjust or
38 0.180 - 0.740
+0.162 +0.402 replace

Interference between master size Shaft Hole interference
24 pin and bushing
+0.280 +0.062
37.8 0.188 - 0.280
+0.250 0

Clearance between master pin size Shaft Hole clearance
25 and bushing
-0.150 +0.902
38 0.552 - 1.252
-0.350 +0.402
Standard size Repair limit Lug welding,

Height of Triple-grouser rebuild or
26 16 replace
grouser
Road liner 70 25 Replace
: Dry type track link
10-22 PC200-7
12
TRIPLE GROUSER SHOE
SWAMP SHOE
Unit: mm

1 Height
26 16
10
2 Thickness
( ) 8.5
3 26
Length of base
4 19
5 20
Rebuild or replace
6 Length at tip 14
7 19
8 Thickness 36 26
( ) 34.5 24.5
9 Height 102.5 90.5
10 Thickness 17 5
( ) PC200-7, PC200LC-7: 600 mm width shoe
PC200/220(LC)-7 10-23
(9)
HYDRAULIC EQUIPMENT LAYOUT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD DRAWING
12
HYDRAULIC EQUIPMENT LAYOUT DRAWING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
6. R.H. travel motor
7. Swing motor
8. Hydraulic pump
9. Control valve
10. Oil cooler
11. L.H. travel motor
12. Multi-pattern selector valve
13. L.H. PPC valve
14. Lock lever (electric type)
15. Center swivel joint
16. R.H. PPC valve
17. Travel PPC valve
18. Attachment circuit selector valve
19. Holding valve
20. Accumulator
21. Solenoid valve assembly
21A PPC lock solenoid
21B Travel junction solenoid
21C Pump merge/divider solenoid
21D Travel speed solenoid
21E Swing brake solenoid
21F 2-stage relief solenoid
10-24 PC200/220(LC)-7
(11)
HYDRAULIC EQUIPMENT LAYOUT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD DRAWING
12
PC200-7 10-25
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC TANK
12
HYDRAULIC TANK
1. Sight gauge SPECIFICATIONS

2. Hydraulic tank Tank capacity: 200 l
3. Oil filler cap Amount of oil inside tank: 143 l
4. Filter element Pressure valve
5. Strainer Relief cracking pressure:
6. Bypass valve 16.7 6.9 kPa
7. Suction strainer {0.17 0.07 kg/cm}
Suction cracking pressure:
0 - 0.49 kPa
{0 - 0.005 kg/cm}
Bypass Valve set pressure:
150 30 kPa
{1.5 0.3 kg/cm}
10-26 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
HYDRAULIC PUMP
HPV95 + 95
1. Front main pump IM : PC mode selector current PENR : Rear pump control pressure detec-
2. Rear main pump ISIG : LS set selector current tion port
3. LS valve PAF : Front pump delivery port PLSF : Front load pressure input port
4. PC valve PFC : Front pump delivery pres- PLSFC: Front load pressure detection port
5. LS-EPC valve sure detection port PLSR : Rear load pressure input port
6. PC-EPC valve PAR : Rear pump delivery port PLSRC: Rear load pressure detection port
PRC : Rear pump delivery pressure PS : Pump suction port
detection port PSIG : LS set selector pressure detection
PBF : Pump pressure input port port
PD1F: Case drain port PM : PC set selector pressure detection
PENF: Front pump control pressure port
detection port PEPC : EPC basic pressure input port
Outline
This pump consists of 2 variable capacity swash plate
piston pumps, PC valve, LS valve, and EPC valve.
10-28 PC200-7
12
1. Shaft (Front) 7. Cylinder block

2. Cradle 8. Valve plate
3. Case (Front) 9. End cap
4. Rocker cam 10. Shaft (Rear)
5. Shoe 11. Case (Rear)
6. Piston 12. Servo piston
PC200-7 10-29
12
Function
The rotation and torque transmitted to the Rocker cam (4) has flat surface A, and shoe
pump shaft are converted into hydraulic (5) is always pressed against this surface
energy, and pressurized oil is discharged while sliding in a circular movement.
according to the load. Rocker cam (4) brings high pressure oil at cyl-
It is possible to change the discharge amount inder surface B with cradle (2), which is
by changing the swash plate angle. secured to the case, and forms a static pres-
Structure sure bearing when it slides.
Cylinder block (7) is supported to shaft (1) by Piston (6) carries out relative movement in
a spline, and shaft (1) is supported by the the axial direction inside each cylinder cham-
front and rear bearings. ber of cylinder block (7).
The tip of piston (6) is a concave ball, and The cylinder block seals the pressure oil to
shoe (5) is caulked to it to form one unit. Pis- valve plate (8) and carries out relative rota-
ton (6) and shoe (5) form a spherical bearing. tion. This surface is designed so that the oil
pressure balance is maintained at a suitable
level. The oil inside each cylinder chamber of
cylinder block (7) is sucked in and discharged
through valve plate (8).
10-30 PC200-7
12
Operation
1) Operation of pump
i Cylinder block (7) rotates together with
shaft (1), and shoe (5) slides on flat surface
A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle is called the swash plate
angle.)
ii Center line X of rocker cam (4) maintains
swash plate angle in relation to the axial
direction of cylinder block (7), and flat sur-
face A moves as a cam in relation to shoe
(5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (7). The suction and discharge is car-
ried out by this difference F - E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged dur-
ing that stroke. On the other hand, the vol-
ume of chamber F becomes larger, and as
the volume becomes bigger, the oil is
sucked in.
iii If center line X of rocker cam (4) is in line
with the axial direction of cylinder block (7)
(swash plate angle = 0), the difference
between volumes E and F inside cylinder
block (7) becomes 0, so the pump does not
carry out any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
PC200-7 10-31
12
2) Control of discharge amount
If the swash plate angle becomes larger,
the difference between volumes E and F
becomes larger and discharge amount Q
increases.
Swash plate angle is changed by servo
piston (12).
Servo piston (12) moves in a reciprocal
movement () according to the signal
pressure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and
rocker cam (4), which is supported by the
cylindrical surface to cradle (2), slides in a
rotating movement in direction of arrow.
With servo piston (12), the area receiving
the pressure is different on the left and
the right, so main pump discharge pres-
sure (self pressure) PP is always brought
to the chamber receiving the pressure at
the small diameter piston end.
Output pressure Pen of the LS valve is
brought to the chamber receiving the
pressure at the large diameter end. The
relationship in the size of pressure PP at
the small diameter piston end and pres-
sure Pen at the large diameter end, and
the ratio between the area receiving the
pressure of the small diameter piston and
the large diameter piston controls the
movement of servo piston (12).
10-32 PC200-7
12
LS VALVE
1. Plug PP : Pump port

2. Locknut PDP : Drain port
3. Sleeve PLP : LS control pressure output port
4. Spring PLS : LS pressure input port
5. Seat PPL : PC control pressure input port
6. Spool PSIG : LS mode selection pilot port
7. Piston
8. Sleeve
PC VALVE
PP1 : Pump port

1. Servo piston assembly
PP2 : Pump pressure pilot port
2. Plug
PT : Drain port
3. Pin
PM : PC mode selector pressure pilot port
4. Spool
PPL : PC control pressure output port
5. Retainer
PLP : LS control pressure output port
6. Seat
7. Cover
8. Wiring
PC200-7 10-33
12
Function
(1) LS valve
The LS valve detects the load and controls the
discharge amount.
This valve controls main pump discharge
amount Q according to differential pressure
PLS (=PP - PLS) [called the LS differential
pressure] (the difference between main pump
pressure PP and control valve outlet port
pressure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control
valve output, and pressure Psig {called the
LS selector pressure} from the proportional
solenoid valve enter this valve. The relation-
ship between discharge amount Q and differ-
ential pressure PLS, (the difference between
main pump pressure PP and LS pressure
PLS) (= PP - PLS) changes as shown in the
diagram at the right according to LS pressure
selector current isig of the LS-EPC valve.
When isig changes between 0 and 1A, the set
pressure of the spring changes according to
this, and the selector point for the pump dis-
charge amount changes at the rated central
valve between 0.69 2.2 MPa {7 22 kg/
cm}.
(2) PC valve
When the pump discharge pressure PP1
(self-pressure) and PP2 (other pump pres-
sure) are high, the PC valve controls the
pump so that no more oil than the constant
flow (in accordance with the discharge pres-
sure) flows even if the stroke of the control
valve becomes larger. In this way, it carries
out equal horsepower control so that the
horsepower absorbed by the pump does not
exceed the engine horsepower.
In other words, If the load during the opera-
tion becomes larger and the pump discharge
pressure rises, it reduces the discharge
amount from the pump; and if the pump dis-
charge pressure drops, it increases the dis-
charge amount from the pump. The
relationship between the average of the front
and rear pump discharge pressures (average
discharge amount of F, R pumps (PP1 +
PP2)/2) and pump discharge amount Q is
shown on the right, with the current given to
the PC-EPC valve solenoid shown as a param-
eter. The controller senses the actual speed of
the engine, and if the speed drops because of
an increase in the load, it reduces the pump the set value, the command current to the PC-
discharge amount to allow the speed to EPC valve solenoid from the controller
recover. In other words, when the load increases according to the drop in the engine
increases and the engine speed drops below speed to reduce the pump swash plate angle.
10-34 PC200-7
12
OPERATION
SDP08884
(1) LS valve At this point, spool (6) is pushed to the left,

1) When control valve is at neutral position and port C and port D are connected. Pump
The LS valve is a three-way selector valve, pressure PP enters the large diameter end of
with pressure PLS (LS pressure) from the the piston from port K and the same pump
outlet port of the control valve brought to pressure PP also enters port J at the small
spring chamber B, and main pump discharge diameter end of the piston, so the swash plate
pressure PP brought to port H of sleeve (8). is moved to the minimum angle by the differ-
The size of this LS pressure PLS + force Z of ence in the area of the piston (12).
spring (4) and the main pump pressure (self
pressure) PP determines the position of
spool (6). However, the size of the output
pressure PSIG (the LS selection pressure) of
the EPC valve for the LS valve entering port G
also changes the position of spool (6). (The
set pressure of the spring changes).
Before the engine is started, servo piston (12)
is pushed to the right. (See the diagram on
the right)
When the engine is started and the control
lever is at the neutral position, LS pressure
PLS is 0 MPa {0 kg/cm}. (It is interconnected
with the drain circuit through the control
valve spool.)
PC200/220(LC)-7 10-35
(11)
12
SDP08885
2) Operation in increase direction for pump For this reason, the pressure at the large
discharge amount diameter end of servo piston (12) becomes
When the difference between the main pump drain pressure PT, and pump pressure PP
pressure PP and LS pressure PLS, in other enters port J at the small diameter end, so
words, LS differential pressure PLS, servo piston (12) is pushed to the right. There-
becomes smaller (for example, when the area fore, the swash plate moves in the direction
of opening of the control valve becomes to make the discharge amount larger. If the
larger and pump PP drops), spool (6) is output pressure of the EPC valve for the LS
pushed to the right by the combined force of valve enters port G, this pressure creates a
LS pressure PLS and the force of spring (4). force to move piston (7) to the left. If piston
When spool (6) moves, port D and port E are (7) is pushed to the left, it acts to make the set
joined and connected to the PC valve. When pressure of spring (4) weaker, and the differ-
this happens, the PC valve is connected to the ence between PLS and PP changes when
drain port, so circuit D - K becomes drain ports D and E of spool (6) are connected.
pressure PT. (The operation of the PC valve is
explained later).
10-36 PC200/220(LC)-7
(11)
12
SDP08886
3) Operation in decrease direction for

pump discharge amount
The following explains the situation if the Main pump pressure PP also enters port J at
servo piston (12) moves to the left (the dis- the small diameter end of the piston, but
charge amount becomes smaller). When LS because of the difference in area between the
differential pressure PLS becomes larger large diameter end and the small diameter
(for example, when the area of opening of the end of servo piston (12), servo piston (12) is
control valve becomes smaller and pump pushed to the left.
pressure PP rises), pump pressure PP As a result, the swash plate moves in the
pushes spool (6) to the left. direction to make angle smaller.
When spool (6) moves, main port pressure If LS selection pressure PSIG enters port G, it
PP flows from port C and port D and from acts to make the set pressure of spring (4)
port K, it enters the large diameter end of the weaker.
piston.
PC200/220(LC)-7 10-37
(11)
12
SDP08887
4) When servo piston is balanced

Let us take the area receiving the pressure at At this point, the relationship between the
the large diameter end of the piston as A1, area receiving the pressure at both ends of
the area receiving the pressure at the small piston (12) is A0 : A1 = 3:5, so the pressure
diameter end as A0, and the pressure flowing applied to both ends of the piston when it is
into the large diameter end of the piston as balanced becomes PP : Pen = 5:3.
Pen. If the main pump pressure PP of the LS The position where spool (6) is balanced and
valve and the combined force of force Z of stopped is the standard center, and the force
spring (4) and LS pressure PLS are balanced, of spring (4) is adjusted so that it is deter-
and the relationship is A0 x PP = A1 x Pen, mined when PP - PLS = 2.2 MPa {22 kg/cm}.
servo piston (12) will stop in that position, However, if PSIG (the output pressure of 0
and the swash plate will be kept at an inter- 2.9 MPa {0 30 kg/cm} of the EPC valve of
mediate position. (It will stop at a position the LS valve) is applied to port G, the balance
where the opening of the throttle from port D stop position will change in proportion to
to port E and from port C to port D of spool pressure PSIG between PP - PLS = 2.2
(6) is approximately the same.) 0.69 MPa {22 7 kg/cm}.
10-38 PC200/220(LC)-7
(11)
12
(2) PC Valve
1) When pump controller is normal
a. When the load on the actuator is small
and pump pressures PP1 and PP2 are
low
1 Movement of PC-EPC solenoid (1)
The command current from the pump the pressure (pressure of port C) output
controller flows to PC-EPC solenoid from the PC valve changes according to
(1).This command current acts on the PC- this position.
EPC valve and outputs the signal pres- The size of command current X is deter-
sure. When this signal pressure is mined by the nature of the operation
received, the force pushing piston (2) is (lever operation), the selection of the
changed. working mode, and the set value and
On the opposite side to the force pushing actual value for the engine speed.
this piston (2) is the spring set pressure of a Other pump pressure
springs (4) and (6) and pump pressure This is the pressure of the pump at the
PP1 (self pressure) and PP2 (other pump opposite end.
pressure) pushing spool (3). Piston (2) For the F pump, it is the R pump pressure
stops at a position where the combined For the R pump, it is the F pump pressure
force pushing spool (3) is balanced, and
PC200/220(LC)-7 10-39
(11)
12
SDP08889
2 Action of spring
The spring load of springs (4) and (6) in the If the command circuit input to PC-EPC valve
PC valve is determined by the swash plate solenoid (1) changes further, the force push-
position. ing piston (2) changes, and the spring load of
If piston (9) moves to the left, spring (6) is springs (4) and (6) also changes according to
compressed, and if it moves further to the left, the value of the PC-EPC valve solenoid com-
spring (6) contacts seat (5) and is fixed in mand current.
position. In other words, the spring load is
changed by piston (9) extending or compress-
ing springs (4) and (6).
10-40 PC200/220(LC)-7
(11)
12
Port C of the PC valve is connected to port E

of the LS valve (see (1) LS valve). Self pres-
sure PP1 enters port B and the small diame-
ter end of servo piston (9), and other pump
pressure PP2 enters port A.
When pump pressures PP1 and PP2 are
small, spool (3) is on the right. At this point,
port C and D are connected, and the pressure
entering the LS valve becomes drain pressure
PT. If port E and port G of the LS valve are
connected (see (1) LS valve), the pressure
entering the large diameter end of the piston
from port J becomes drain pressure PT, and
servo piston (9) moves to the right. In this
way, the pump discharge amount moves in
the direction of increase.
As servo piston (9) moves further, springs (4)
and (6) expand and the spring force becomes
weaker. When the spring force becomes
weaker, spool (3) moves to the left, so the
connection between port C and port D is cut,
and the pump discharge pressure ports B and
C are connected. As a result, the pressure at
port C rises, and the pressure at the large
diameter end of the piston also rises, so the
movement of piston (9) to the right is
stopped.
In other words, the stop position for piston (9)
(= pump discharge amount) is decided at the
point where the force of springs (4) and (6)
and the pushing force from the PC-EPC valve
solenoid and the pushing force created by the
pressures PP1 and PP2 acting on the spool
(3) are in balance.
PC200/220(LC)-7 10-41
(4)
12
b. When load on actuator is large and

pump discharge pressure is high
When the load is large and pump dis- If main pump pressure PP increases fur-
charge pressures PP1 and PP2 are high, ther and spool (3) moves further to the
the force pushing spool (3) to the left left, main pump pressure PP1 flows to
becomes larger and spool (3) moves to port C and acts to make the discharge
the position in the diagram above. When amount the minimum. When piston (9)
this happens, as shown in the diagram moves to the left, springs (4) and (6) are
above, part of the pressurized oil from compressed and push back spool (3).
port B flows out through port C where the When spool (3) moves to the left, the
LS valve is actuated to port D, and the opening of port C and port D becomes
pressurized oil flowing from port C to the larger. As a result, the pressure at port C
LS valve becomes approximately half of (= J) drops, and piston (9) stops moving
main pump pressure PP. to the left.
When port E and port G of the LS valve The position in which piston (9) stops
are connected (see (1) LS valve), the pres- when this happens is further to the left
sure from port J enters the large diameter than the position when pump pressures
end of servo piston (9), and servo piston PP1 and PP2 are low.
(9) stops.
10-42 PC200/220(LC)-7
(11)
12
The relation of average pump pressure

(PP1 + PP2)/2 and the position of servo
piston (9) forms a bent line because of
the double-spring effect of springs (4)
and (6). The relationship between aver-
age pump pressure (PP1 + PP2)/2 and
pump discharge amount Q is shown in
the figure at the right.
If command voltage X sent to PC-EPC

valve solenoid (1) increases further, the
relationship between average pump
pressure (PP1 + PP2)/2, and pump dis-
charge amount Q is proportional to the
pushing force of the PC-EPC valve sole-
noid and moves in parallel. In other
words, the pushing force of PC-EPC
solenoid (1) is added to the force push-
ing to the left because of the pump pres-
sure applied to the spool (3), so the
relationship between the average pump
pressure (PP1 + PP2)/2 and Q moves
from 1 to 2 in accordance with the
increase in X.
PC200/220(LC)-7 10-43
12
2) When pump controller is abnormal and

PC prolix switch is ON
a. When load on main pump is light
If there is a failure in the pump controller, At this point, port C is connected to the
turn emergency pump drive switch ON to drain pressure of port D, and the large
switch to the resistor side. In this case, the diameter end of the piston of servo piston
power source is taken directly from the (9) also becomes the drain pressure PT
battery. But if the current is used as it is, it through the LS valve. When this happens,
is too large, so use the resistor to control the pressure at the small diameter end of
the current flowing to PC-EPC valve sole- the piston is large, so servo piston (9)
noid (1). moves in the direction to make the dis-
When this is done, the current becomes charge amount larger.
constant, so the force pushing piston (2)
is also constant.
If the main pump pressure PP1 and PP2
are low, the combined force of the pump
pressure and the force of PC-EPC valve
solenoid (1) is weaker than the spring set
force, so spool (3) is balanced at a posi-
tion to the left.
10-44 PC200/220(LC)-7
(11)
12
b. When main pump load is heavy

In the same way as in the previous item, and discharge amount Q is determined as
when the emergency pump drive switch shown in the diagram for the valve of the
is ON, the command current sent to PC- current sent to the PC-EPC valve solenoid
EPC valve solenoid (1) becomes constant. through the resistor.
For this reason, the force of piston (2) The curve when the PC prolix switch is
pushing spool (3) is constant. ON is curve 2, which is to the left of
If main pump pressures PP1 and PP2 curve 1 for when the pump controller is
increase, spool (3) moves further to the normal.
left than when the main pump load is
light, and is balanced at the position in
the diagram above.
In this case, the pressure from port A
flows to port C, so servo piston (9) moves
to the left (to make the discharge amount
smaller) by the same mechanism as
explained in item 2)-b, and stops at a
position to the left of the position when
the load on the pump is light. In other
words, even when the emergency pump
drive switch is ON, the curve for the
pump pressure PP
PC200/220(LC)-7 10-45
(11)
12
LS(PC)-EPC VALVE
1. Body 5. Coil PSIG(PM) : To LS(PC) valve

2. Spool 6. Plunger PT : To tank
3. Spring 7. Connector PEPC : From self pressure reducing valve
4. Rod
10-46 PC200/220(LC)-7
(11)
12O
FUNCTION
The EPC valve consists of the proportional

solenoid portion and the hydraulic valve
portion.
When it receives signal current i from the
pump controller, it generates the EPC out-
put pressure in proportion to the size of the
signal, and outputs it to the LS valve.
OPERATION
1. When signal current is 0 (coil deener-

gized)
When there is no signal current flowing
from the controller to coil (5), coil (5) is
generalized.
For this reason, spool (2) is pushed to the
right in the direction of the arrow by spring
(3).
As a result, port PEPC closes and the pres-
surized oil from the main pump does not
flow to the LS valve.
At the same time, the pressurized oil from 08890
the LS valve passes from port PSIG(PM)
through port PT and is drained to the tank.
PC200-7 10-47
2. When signal current is very small (coil

energized)
When a very small signal current flows to
coil (5), coil (5) is energized, and a propul-
sion force is generated which pushes
plunger (6) to the left.
Push pin (4) pushes spool (2) to the left,
and pressurized oil flows from port PEPC
to port PSIG(PM).
When the pressure at port PSIG(PM) rises
and the load of spring (3) + the force acting
on surface a of spool (2) becomes greater
than the propulsion force of plunger (6), 08891
spool (2) is pushed to the right. The circuit
between port PEPC and port PSIG(PM) is
shut off, and at the same time, port
PSIG(PM) and port PT are connected.
As a result, spool (2) is moved up or down
until the propulsion force of plunger (6) is
balanced with the load of spring (3) + pres-
sure of port PSIG(PM).
Therefore, the circuit pressure between the
EPC valve and the LS valve is controlled in
proportion to the size of the signal current.
3. When signal current is maximum (coil

energized)
When the signal current flows to coil (5),
coil (5) is energized.
When this happens, the signal current is at
its maximum, so the propulsion force of 08892
plunger (6) is also at its maximum.
For this reason, spool (2) is pushed fully to
the left by push pin (4).
As a result, the maximum flow of pressur-
ized oil from port PEPC flows to port
PSIG(PM), and the circuit pressure
between the EPC valve and LS valve
becomes the maximum.
At the same time, port PT closes and stops
the oil from flowing to the tank.
10-48 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
CONTROL VALVE
PC200-7, PC200LC-7
1. 6-spool valve OUTLINE
2. Cover 1
3. Cover 2 This control valve consists of a 6-spool
4. Pump merge-divider valve valve (unit type), 1 service valves, a pump
5. Back pressure valve merge-divider valve, a back pressure valve,
6. Boom lock valve and a boom hydraulic drift prevention
7. Service valve valve.
Since all the valves are assembled together
with connecting bolts and their passes are
connected to each other inside the assem-
bly, the assembly is small in size and easy
to maintain.
Since one spool of this control valve is
used for one work equipment unit, its struc-
ture is simple.
A1 : To bucket cylinder head P9 : From right travel PPC valve

A2 : To left travel motor P10 : From right travel PPC valve
A3 : To boom cylinder bottom P11 : From arm PPC valve
A4 : To swing motor P12 : From arm PPC valve
A5 : To right travel motor P-1 : From service PPC valve
A6 : To arm cylinder head P-2 : From service PPC valve
A-1 : To attachment BP1 : Boom RAISE PPC output pressure
B1 : To bucket cylinder bottom BP5 : From attachment circuit selector solenoid
B2 : To left travel motor valve
B3 : To bottom cylinder head PLS1 : To rear pump control
B4 : To swing motor PLS2 : To front pump control
B5 : To right travel motor PP1 : From rear main pump
B6 : To arm cylinder bottom PP2 : From front main pump
B-1 : To attachment PR : To solenoid valve, PPC valve, EPC valve
P1 : From bucket PPC valve PS : From pump merge-divider solenoid valve
P2 : From bucket PPC valve PST : From travel junction valve
P3 : From left travel PPC valve PX1 : From 2-stage solenoid valve
P5 : From boom PPC valve SA : Pressure sensor fitting port
P6 : From boom PPC valve SB : Pressure sensor fitting port
P7 : From swing PPC valve T : To tank
P8 : From swing PPC valve TS : To tank
TSW : To swing motor
10-50 PC200-7
12
7-spool valve
(6-spool valve + 1 service valve)
(1/9)
PC200/220(LC)-7 10-51
(11)
12
(2/9)
S*P09099
10-52 PC200-7
12
(3/9)
1. Unload valve 9. Pressure compensation valve (Service)

2. Pressure compensation valve (Arm OUT) 10. Pressure compensation valve (Bucket CURL)
3. Pressure compensation valve (Right travel 11. Pressure compensation valve (Left travel for-
Reverse) ward)
4. Pressure compensation valve (Left swing) 12. Pressure compensation valve (Boom LOWER)
5. Pressure compensation valve (Boom RAISE) 13. Pressure compensation valve (Right swing)
6. Pressure compensation valve (Left travel 14. Pressure compensation valve (Right travel
reverse) forward)
7. Pressure compensation valve (Bucket DUMP) 15. Pressure compensation valve (Arm IN)
8. Pressure compensation valve (Service) 16. Main relief valve
PC200-7 10-53
12
(4/9)
1. Spool (Arm) 6. Spool (Bucket)

2. Spool (Right travel) 7. Spool (Service)
3. Spool (Swing) 8. Unload valve
4. Spool (Boom) 9. Main relief valve
5. Spool (Left travel) 10. Spool return spring
Unit: mm

Free length x Installed Installed Free Installed
11 Spool return spring Outside diameter length load length load
416.5 N 333.2 N If damaged or
54.2 x 34.8 51.2
{42.5 kg} {34 kg} deformed, replace
spring
429.9 N 336.1 N
12 Spool return spring 54.6 x 34.8 51.2
{43.9 kg} {34.3 kg}
393 N 314.6 N
{40.1 kg} {32.1 kg}
10-54 PC200-7
12
(5/9)
1. Safety-suction valve (Arm OUT) 12. Safety-suction valve (Arm IN)

2. Suction valve (Right travel reverse) 13. LS shuttle valve (Arm)
3. Suction valve (Boom RAISE) 14. LS shuttle valve (Right travel)
4. Suction valve (Left travel reverse) 15. LS select valve
5. Safety-suction valve (Bucket DUMP) 16. LS shuttle valve (Boom)
6. Safety-suction valve (Service) 17. LS shuttle valve (Left travel)
7. Safety-suction valve (2-stage) (Service) 18. LS shuttle valve (Bucket)
8. Safety-suction valve (Bucket CURL) 19. LS shuttle valve (Service)
9. Suction valve (Left travel forward) 20. LS check valve
10. Safety-suction valve (Boom LOWER) 21. Pressure relief plug
11. Suction valve (Right travel forward)
Unit: mm

Free length x Installed Installed Free Installed If damaged or
22 Check valve spring Outside diameter length load length load deformed, replace
spring
1.5 N 1.2 N
11.5 x 4.6 8.5
{0.15 kg} {0.12 kg}
PC200-7 10-55
12
(6/9)
ARM CONTROL VALVE R. H. TRAVEL CONTROL

VALVE
1. Unload valve 5. Safety-suction valve
2. Main relief valve 6. Spool 12. Suction valve
3. Safety valve (Boom 7. Pressure compensation valve 13. Spool
RAISE) (OUT) 14. Pressure compensation valve
4. Lift check valve 8. LS shuttle valve (Reverse)
15. LS shuttle valve
9. Pressure compensation valve
(IN)
(Forward)
10. Safety-suction valve 17. Suction valve
11. Check valve for regeneration cir-
cuit
10-56 PC200-7
Unit: mm

18 Relief spring Outside diameter length load length load
406.7 N 325.6 N
30.7 x 9.6 25.9
{41.5 kg} {33.2 kg}
69.6 N 55.7 N
19 Valve spring 24.3 x 8 19.5
{7.1 kg} {5.7 kg}
20 Unload spring 31.5 x 10.2 26.9
{7.2 kg} {5.8 kg} deformed, replace
spring
Regeneration valve 6.2 N 4.9 N
21 31.5 x 10.3 19
spring {0.6 kg} {0.5 kg}
17.5 N 14.0 N
22 Piston return spring 48.1 x 10.8 28
{1.8 kg} {1.4 kg}
79.4 N 63.5 N
{8.1 kg} {6.5 kg}
29.4 N 23.5 N
{3 kg} {2.4 kg}
PC200-7 10-57
(7/9)
BUCKET CONTROL VALVE SERVICE VALVE
1. Safety-suction valve 7. Safety-suction valve

2. Spool 8. Spool
3. Pressure compensation valve (DUMP) 9. Pressure compensation valve
4. LS shuttle valve 10. LS shuttle valve
5. Pressure compensation valve (CURL) 11. Pressure compensation valve
Unit: mm

13 Piston return spring Outside diameter length load length load If damaged or
17.5 N 14.0 N deformed, replace
48.1 x 10.8 28 spring
{1.8 kg} {1.4 kg}
29.4 N 23.5 N
{3 kg} {2.4 kg}
10-58 PC200-7
12
(8/9)
SWING CONTROL VALVE BOOM CONTROL VALVE L. H. TRAVEL CONTROL

VALVE
1. Spool 5. Suction valve
2. Pressure compensation 6. Spool 13. Pump merge-divider valve
valve (Left) 7. Pressure compensation (Travel junction valve)
3. LS select valve valve (RAISE) 14. Return spring
4. Pressure compensation 8. Hydraulic drift prevention 15. Suction valve
valve (Right) valve 16. Spool
9. LS shuttle valve 17. Pressure compensation
10. Pressure compensation valve (Reverse)
valve (Lower) 18. LS shuttle valve
11. Safety-suction valve 19. Pressure compensation
12. Check valve for regeneration valve (Forward)
circuit 20. Suction valve
10-60 PC200-7
Unit: mm

21 Regeneration valve spring Outside diameter length load length load
6.2 N 4.9 N
31.5 x 10.3 19
{0.6 kg} {0.5 kg}
17.5 N 14.0 N
{1.8 kg} {1.4 kg}
29.4 N 23.5 N
{3 kg} {2.4 kg} If damaged or
428.3 N 343 N deformed, replace
24 Load spring 30.4 x 16.7 27 spring
{43.7 kg} {35.0 kg}
3.0 N 2.4 N
25 Check valve spring 13.6 x 5.5 10
{0.3 kg} {0.25 kg}
35.3 N 28.2 N
{3.6 kg} {2.9 kg}
13.7 N 11.0 N
27 Check valve spring 16.4 x 8.9 11.5
{1.4 kg} {1.1 kg}
50.0 N 40.0 N
28 Spool return spring 30.7 x 20.5 23
{5.1 kg} {4.1 kg}
PC200-7 10-61
12
(9/9)
1. Unload valve 9. LS bypass plug

2. Main relief valve 10. Screw
3. Pump merge-divider valve (Main) 11. Poppet
4. Return spring 12. Spring (Pressure reducing valve pilot)
5. Pump merge-divider valve (For LS) 13. Spring (Pressure reducing valve main)
6. Return spring 14. Valve (Pressure reducing valve)
7. Valve (Sequence valve) 15. Spring (Safety valve)
8. Spring (Sequence valve) 16. Ball
10-62 PC200-7
Unit: mm

17 Valve spring Outside diameter length load length load
69.6 N 55.7 N
24.3 x 8 19.5
{7.1 kg} {5.7 kg}
83.4 N 66.7 N
18 Unload spring 31.5 x 10.2 26
{8.5 kg} {6.8 kg}
1.5 N 1.2 N
{0.15 kg} {0.12 kg} If damaged or
20 Spool return spring 46.6 x 21.8 3.3 spring
{16.0 kg} {12.8 kg}
177.5 N 142.0 N
{18.1 kg} {14.5 kg}
199.8 N 160.0 N
22 Sequence valve spring 70.9 x 18.0 59
{20.4 kg} {16.3 kg}
10.4 N 8.3 N
{1.1 kg} {0.8 kg}
430.2 N 344.2 N
24 Relief spring 34.7 x 10.4 32.3
{43.9 kg) {35.1 kg}
PC200-7 10-63
CONTROL VALVE
PC220-7, PC220LC-7
1. 6-spool valve OUTLINE
2. Cover 1
3. Cover 2 This control valve consists of a 6-spool
4. Pump merge-divider valve valve (unit type), 1 service valves, a pump
5. Back pressure valve merge-divider valve, a back pressure valve,
6. Boom lock valve and a boom hydraulic drift prevention
7. Service valve valve.
Since all the valves are assembled together
with connecting bolts and their passes are
connected to each other inside the assem-
bly, the assembly is small in size and easy
to maintain.
Since one spool of this control valve is
used for one work equipment unit, its struc-
ture is simple.
A1 : To bucket cylinder head P9 : From right travel PPC valve

A2 : To left travel motor P10 : From right travel PPC valve
A3 : To boom cylinder bottom P11 : From arm PPC valve
A4 : To swing motor P12 : From arm PPC valve
A5 : To right travel motor P-1 : From service PPC valve
A6 : To arm cylinder head P-2 : From service PPC valve
A-1 : To attachment BP1 : Boom RAISE PPC output pressure
B1 : To bucket cylinder bottom BP5 : From attachment circuit selector solenoid
B2 : To left travel motor valve
B3 : To bottom cylinder head PLS1 : To rear pump control
B4 : To swing motor PLS2 : To front pump control
B5 : To right travel motor PP1 : From rear main pump
B6 : To arm cylinder bottom PP2 : From front main pump
B-1 : To attachment PR : To solenoid valve, PPC valve, EPC valve
P1 : From bucket PPC valve PS : From pump merge-divider solenoid valve
P2 : From bucket PPC valve PST : From travel junction valve
P5 : From boom PPC valve SA : Pressure sensor fitting port
P6 : From boom PPC valve SB : Pressure sensor fitting port
P7 : From swing PPC valve T : To tank
P8 : From swing PPC valve TS : To tank
TSW : To swing motor
10-64 PC200-7
12
7-spool valve
(6-spool valve + 1 service valves)
(1/9)
PC200-7 10-65
12
(2/9)
S*P09102
10-66 PC200-7
12
(3/9)
1. Unload valve 9. Pressure compensation valve (Service)

2. Pressure compensation valve (Arm OUT) 10. Pressure compensation valve (Bucket CURL)
3. Pressure compensation valve (Right travel 11. Pressure compensation valve (Left travel for-
Reverse) ward)
4. Pressure compensation valve (Left swing) 12. Pressure compensation valve (Boom LOWER)
5. Pressure compensation valve (Boom RAISE) 13. Pressure compensation valve (Right swing)
6. Pressure compensation valve (Left travel 14. Pressure compensation valve (Right travel
reverse) forward)
7. Pressure compensation valve (Bucket DUMP) 15. Pressure compensation valve (Arm IN)
8. Pressure compensation valve (Service) 16. Main relief valve
PC200-7 10-67
12
(4/9)
S*P09104
1. Spool (Arm) 6. Spool (Bucket)

2. Spool (Right travel) 7. Spool (Service)
3. Spool (Swing) 8. Unload valve
4. Spool (Boom) 9. Main relief valve
5. Spool (Left travel) 10. Spool return spring
Unit: mm

11 Spool return spring Outside diameter length load length load
54.2 x 34.8 51.2
{42.5 kg} {34 kg} deformed, replace
spring
429.9 N 336.1 N
{43.9 kg} {34.3 kg}
393 N 314.6 N
{40.1 kg} {32.1 kg}
10-68 PC200-7
12
(5/9)
1. Safety-suction valve (Arm OUT) 12. Safety-suction valve (Arm IN)

2. Suction valve (Right travel reverse) 13. LS shuttle valve (Arm)
3. Suction valve (Boom RAISE) 14. LS shuttle valve (Right travel)
4. Suction valve (Left travel reverse) 15. LS select valve
5. Safety-suction valve (Bucket DUMP) 16. LS shuttle valve (Boom)
6. Safety-suction valve (Service) 17. LS shuttle valve (Left travel)
7. Safety-suction valve (2-stage) (Service) 18. LS shuttle valve (Bucket)
8. Safety-suction valve (Bucket CURL) 19. LS shuttle valve (Service)
9. Suction valve (Left travel forward) 20. LS check valve
10. Safety-suction valve (Boom LOWER) 21. Pressure relief plug
11. Suction valve (Right travel forward)
Unit: mm

Free length x Installed Installed Free Installed If damaged or
22 Check valve spring Outside diameter length load length load deformed, replace
spring
1.5 N 1.2 N
11.5 x 4.6 8.5
{0.15 kg} {0.12 kg}
PC200-7 10-69
12
(6/9)
ARM CONTROL VALVE R. H. TRAVEL CONTROL

VALVE
1. Unload valve 5. Safety-suction valve
2. Main relief valve 6. Spool 12. Suction valve
3. Safety valve (Boom 7. Pressure compensation valve 13. Spool
RAISE) (OUT) 14. Pressure compensation valve
4. Lift check valve 8. LS shuttle valve (Reverse)
15. LS shuttle valve
(IN)
(Forward)
10. Safety-suction valve 17. Suction valve
11. Check valve for regeneration cir-
cuit
10-70 PC200/220(LC)-7
(11)
Unit: mm

18 Relief spring Outside diameter length load length load
430.2 N 344.2 N
34.7 x 10.4 32.3
{43.9 kg} {35.1 kg}
3.1 N 2.5 N
19 Valve spring 10.45 x 7 4.8
{0.32 kg} {0.26 kg}
20 Unload spring 31.5 x 10.2 26.9
{7.2 kg} {5.8 kg} deformed, replace
spring
Regeneration valve 6.2 N 4.9 N
21 31.5 x 10.3 19
spring {0.6 kg} {0.5 kg}
17.5 N 14.0 N
{1.8 kg} {1.4 kg}
79.4 N 63.5 N
{8.1 kg} {6.5 kg}
29.4 N 23.5 N
{3 kg} {2.4 kg}
PC200-7 10-71
(7/9)
BUCKET CONTROL VALVE SERVICE VALVE

2. Spool 8. Spool
3. Pressure compensation valve (DUMP) 9. Pressure compensation valve
4. LS shuttle valve 10. LS shuttle valve
5. Pressure compensation valve (CURL) 11. Pressure compensation valve
Unit: mm

13 Piston return spring Outside diameter length load length load If damaged or
48.1 x 10.8 28 spring
{1.8 kg} {1.4 kg}
29.4 N 23.5 N
{3 kg} {2.4 kg}
10-72 PC200-7
12
(8/9)
SWING CONTROL VALVE BOOM CONTROL VALVE L. H. TRAVEL CONTROL

VALVE
1. Spool 5. Suction valve
2. Pressure compensation 6. Spool 13. Distributor and confluence
valve (Left) 7. Pressure compensation valve (Travel junction valve)
3. LS select valve valve (RAISE) 14. Return spring
4. Pressure compensation 8. Hydraulic drift prevention 15. Suction valve
valve (Right) valve 16. Spool
9. LS shuttle valve 17. Pressure compensation
10. Pressure compensation valve (Reverse)
valve (Lower) 18. LS shuttle valve
11. Safety-suction valve 19. Pressure compensation
12. Check valve for regeneration valve (Forward)
circuit 20. Suction valve
10-74 PC200/220(LC)-7
(11)
Unit: mm

21 Regeneration valve spring Outside diameter length load length load
6.2 N 4.9 N
31.5 x 10.3 19
{0.6 kg} {0.5 kg}
17.5 N 14.0 N
{1.8 kg} {1.4 kg}
29.4 N 23.5 N
{3 kg} {2.4 kg} If damaged or
428.3 N 343 N deformed, replace
24 Load spring 30.4 x 16.7 27 spring
{43.7 kg} {35.0 kg}
3.0 N 2.4 N
{0.3 kg} {0.25 kg}
35.3 N 28.2 N
{3.6 kg} {2.9 kg}
13.7 N 11.0 N
{1.4 kg} {1.1 kg}
50.0 N 40.0 N
{5.1 kg} {4.1 kg}
PC200-7 10-75
12
(9/9)
1. Unload valve 9. LS bypass plug

2. Main relief valve 10. Screw
3. Pump merge-divider valve (Main) 11. Poppet
4. Return spring 12. Spring (Pressure reducing valve pilot)
5. Pump merge-divider valve (For LS) 13. Spring (Pressure reducing valve main)
6. Return spring 14. Valve (Pressure reducing valve)
7. Valve (Sequence valve) 15. Spring (Safety valve)
8. Spring (Sequence valve) 16. Ball
10-76 PC200-7
Unit: mm

17 Valve spring Outside diameter length load length load
3.1 N 2.5 N
10.45 x 7 4.8
{0.32 kg} {0.26 kg}
70.6 N 56.4 N
18 Unload spring 31.5 x 10.2 26.8
{7.2 kg} {5.8 kg}
1.5 N 1.2 N
{0.15 kg} {0.12 kg} If damaged or
20 Spool return spring 46.6 x 21.8 3.3 spring
{16.0 kg} {12.8 kg}
177.5 N 142.0 N
{18.1 kg} {14.5 kg}
199.8 N 160.0 N
22 Sequence valve spring 70.9 x 18.0 59
{20.4 kg} {16.3 kg}
10.4 N 8.3 N
{1.1 kg} {0.8 kg}
430.2 N 344.2 N
24 Relief spring 34.7 x 10.4 32.3
{43.9 kg) {35.1 kg}
PC200-7 10-77
MAIN RELIEF VALVE
1. Spring
2. Poppet
FUNCTION
The relief valve set pressure is set to 2 stages.

When power is needed, pilot pressure P is turned ON and the pressure is set to high pressure.
OPERATION
The relief valve set pressure is determined by the installed load of spring (1). (First stage)
It is unnecessary to set the first and second stage individually.
The second stage is set when the first stage is set.
1. When pilot pressure P is OFF: Low-pressure setting

The set pressure is determined by the installed load of spring (1).
2. When pilot pressure P is ON: High-pressure setting

In addition to the installed load of spring (1), pilot pressure P is applied to poppet diameter d1, so the
set pressure becomes higher.
10-78 PC200-7
12
VARIABLE TYPE PRESSURE COMPENSATION VALVE

(FOR SERVICE VALVE)
1. Valve FUNCTION
2. Spring
3. Sleeve It is possible to adjust the division of the oil
4. Poppet flow to the service valve when the service
5. Spring valve (for attachment) is operated together
6. Screw with the main control valve (boom RAISE,
7. Locknut etc.).
8. Plastic cap (Variable in proportion to surface area)
The pump pressure leaving the service valve
SS. From service valve spool spool acts on the left end of valve (1), and at
CP. Cylinder port the same time passes through throttle a and
LS. Load pressure from other work equipment enters chamber g.
The maximum LS pressure passes through
throttle d and enters chamber e. At the same
time, the cylinder port pressure passes
through passage c and throttle f, and goes to
chamber h.
In addition, the force of spring (2) acts on
valve (1), and the force of spring (5) acts on
poppet (4). The force of spring (5) can be
adjusted with screw (6).
PC200/220(LC)-7 10-79
(4)
OPERATION
Simultaneous operation with work equip-

ment under heavy load (boom RAISE, etc.)
1. The pump pressure and LS pressure are
determined by the pressure of the other work
equipment, but the cylinder port pressure
becomes the actuating pressure of the attach-
ment.
When the difference between the pump pres-
sure and the cylinder pressure is less than the
force of spring (5), then balance of the force
acting on valve (1) is as follows:
P x A1 = P x A2 + LS (A2 A1) + F
A1: Cross-sectional area of diameter D1
A2: Cross-sectional area of diameter D2
F: Force of spring
2. If the difference between pump pressure P

and the cylinder pressure becomes greater
than the force of spring (5), poppet (4) is
pushed to the right and the passage opens,
so the pump passage is connected to the cyl-
inder port through throttle a, chamber g, and
passages b and c, and the oil flows to the cyl-
inder port. When this happens, a differential
pressure is formed between the upstream
and downstream sides of throttle a, and the
pressure in chamber g goes down, so the
force pushing valve (1) to the left is reduced.
In other words, the area ratio becomes
smaller, so valve (1) moves to the right and
increases the flow from the pump to the cylin-
der.
10-79-1 PC200/220(LC)-7
(4)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
12
CLSS
OUTLINE OF CLSS
FEATURES STRUCTURE
CLSS stands for Closed center Load Sensing The CLSS consists of a main pump (2
System, and has the following features. pumps), control valve, and actuators for the
work equipment.
1) Fine control not influenced by load The main pump body consists of the pump
2) Control enabling digging even with fine con- itself, the PC valve and LS valve.
trol
3) Ease of compound operation ensured by flow
divider function using area of opening of
spool during compound operations
4) Energy saving using variable pump control
10-80 PC200/220(LC)-7
(4)
Basic principle
1) Control of pump swash plate
The pump swash plate angle (pump dis-
charge amount) is controlled so that LS dif-
ferential pressure PLS (the difference
between pump pressure PP and control
valve outlet port LS pressure PLS) (load
pressure of actuator) is constant.
(LS pressure PLS = Pump discharge pres-
sure PP LS pressure PLS)
If LS differential pressure PLS becomes

lower than the set pressure of the LS valve
(when the actuator load pressure is high),
the pump swash plate moves towards the
maximum position; if it becomes higher
than the set pressure of the LS valve (when
the actuator load pressure is low), the
pump swash plate moves towards the min-
imum position.
PC200/220(LC)-7 10-81
(4)
2) Pressure compensation
A pressure compensation valve is installed to In this way, the flow of oil from the pump is
the outlet port side of the control valve to bal- divided (compensated) in proportion to the
ance the load. area of opening S1 and S2 of each valve.
When two actuators are operated together,
this valve acts to make pressure difference P
between the upstream (inlet port) and down-
stream (outlet port) of the spool of each valve
the same regardless of the size of the load
(pressure).
10-82 PC200/220(LC)-7
(4)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE
SELF PRESSURE REDUCING VALVE

FUNCTION
This valve reduces the discharge pressure of

the main pump and supplies it as control
pressure for the solenoid valves, PPC valves,
etc..
OPERATION
1. When engine is stopped

Poppet (11) is pressed by spring (12) against
the seat and port PR is not connected to TS.
Valve (14) is pressed by spring (13) against
the left side and port P2 is connected to PR.
Valve (7) is pressed by spring (8) against the
left side and port P2 is not connected to A2.
(See Fig. 1.)
PC200/220(LC)-7 10-83
(4)
2. When in neutral or load pressure P2 is

low (When boom is lowered and arm is in IN
position and they are moving down under
own weight)
Note: When load pressure A2 is lower than self-pres-
sure reducing valve output pressure PR.
Valve (7) receives the force of spring (8) and
PR pressure (which is 0 MPa {0 kg/cm} when
the engine is stopped) in the direction to
close the circuit between ports P2 and A2. If
the hydraulic oil flows in port P2, the dx P2
pressure becomes equal to the total of the
force of spring (8) and the value of area of d
x PR pressure, then the area of the pass
between ports P2 and A2 is so adjusted that
the P2 pressure will be kept constant above
the PR pressure.
If the PR pressure rises above the set level,
poppet (11) opens and the hydraulic oil flows
from the PR port through orifice "a" in spool
(14) and open part of poppet (11) to seal drain
port TS.
Accordingly, differential pressure is gener-
ated between before and after orifice "a" in
spool (14) and then spool (14) moves to close
the pass between port P2 and PR. The P2
pressure is controlled constant (at the set
pressure) by the area of the oil pass at this
time and supplied as the PR pressure. (See
Fig. 2.)
3. When load pressure P2 is high

If load pressure A2 rises and the pump dis-
charge increases because of operation of the
work equipment, the dx P2 pressure rises
higher than the total of the force of spring (8)
and the value of d x PR pressure, and then
valve (7) moves to the right stroke end.
As a result, the area of the pass between
ports P2 and A2 increases and the pass resis-
tance lowers and the loss of the engine power
is reduced.
If the PR pressure rises above the set pres-
sure, poppet (11) opens and the hydraulic oil
flows from the PR port through orifice "a" in
spool (14) and open part of poppet (11) to seal
drain port TS.
Accordingly, differential pressure is gener-
ated between before and after orifice "a" in
spool (14) and then spool (14) moves to close
the pass between port P2 and PR. The P2
pressure is controlled constant (at the set
pressure) by the area of the oil pass at this
time and supplied as the PR pressure. (See
Fig. 3.)
10-84 PC200/220(LC)-7
(4)
12
4. When abnormally high pressure is

generated
If the PR pressure on the self-pressure
reducing valve rises high abnormally, ball
(16) separates from the seat against the
force of spring (15) and the hydraulic oil
flows from output port PR to TS. Accord-
ingly, the PR pressure lowers. By this oper-
ation, the hydraulic devices (PPC valves,
solenoid valves, etc.) are protected from
abnormal pressure. (See Fig. 4.)
PC200-7 10-85
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
SWING MOTOR
KMF125ABE-5
B : From swing lock solenoid valve SPECIFICATIONS

S : From control valve
T : To tank
MA : From control valve PC200-7 PC220-7
MB : From control valve
Model KMF125ABE-5
Theoretical displacement 125.0 cm/rev
Safety valve set pressure 28.4 MPa {290 kg/cm}

Rated revolving speed 1,694 rpm 1,879 rpm
Brake release pressure 1.9 MPa {19 kg/cm}
10-86 PC200-7
12
1. Brake spring 8. Housing 15. Safety valve

2. Drive shaft 9. Piston 16. Check valve
3. Spacer 10. Cylinder block 17. Check valve spring
4. Case 11. Valve plate 18. Shuttle valve
5. Disc 12. Reverse prevention valve 19. Shuttle valve spring
6. Plate 13. Center shaft
7. Brake piston 14. Center spring
PC200-7 10-87
12
Unit: mm

1 Check valve spring Outside diameter length load length load If damaged or
62.5 x 20.0 35 spring
{0.36 kg} {0.29 kg}
13.7 N 10.8 N
2 Shuttle valve spring 16.4 x 8.9 11.5
{1.4 kg} {1.1 kg}
10-88 PC200-7
12
Operation of swing lock

1. When swing lock solenoid valve is deacti-
vated
When the swing lock solenoid valve is deacti-
vated, the pressurized oil from the main pump is
shut off and port B is connected to the tank cir-
cuit.
As a result, brake piston (7) is pushed down by
brake spring (1), discs (5) and plates (6) are
pushed together, and the brake is applied.
2. When swing lock solenoid valve is excited

When the swing lock solenoid valve is excited,
the valve is switched and the pressure oil from
the main pump enters port B and flows to brake
chamber a.
The pressure oil entering chamber a overcomes
brake spring (1) and pushes brake piston (7) up.
As a result, discs (5) and plates (6) are separated
and the brake is released.
PC200-7 10-89
12
RELIEF VALVE PORTION
1) Outline
The relief portion consists of check valves
(2) and (3), shuttle valves (4) and (5), and
relief valve (1).
2. Function
When the swing is stopped, the outlet port
circuit of the motor from the control valve
is closed, but the motor continues to rotate
under inertia, so the pressure at the output
side of the motor becomes abnormally
high, and this may damage the motor.
To prevent this, the abnormally high pres-
sure oil is relieved to port S from the outlet
port of the motor (high-pressure side) to
prevent any damage.
3. Operation
1) When starting swing
When the swing control lever is operated
to swing right, the pressure oil from the
pump passes through the control valve and
is supplied to port MA. As a result, the
pressure at port MA rises, the starting
torque is generated in the motor, and the
motor starts to rotate. The oil from the out-
let port of the motor passes from port MA
through the control valve and returns to
the tank. (Fig. 1)
2) When stopping swing
When the swing control lever is returned to
neutral, the supply of pressure oil from the
pump to port MA is stopped. With the oil
from the outlet port of the motor, the return
circuit to the tank is closed by the control
valve , so the pressure at port MB rises. As
a result, rotation resistance is generated in
the motor, so the braking effect starts.
If the pressure at port MB becomes higher
than the pressure at port MA, it pushes
shuttle valve A (4) and chamber C
becomes the same pressure as port MB.
The oil pressure rises further until it
reaches the set pressure of relief valve (1).
As a result, a high braking torque acts on
the motor and stops the motor. (Fig.2)
When relief valve (1) is being actuated, the
relief oil and oil from port S passes
through check valve B (3) and is supplied to
port MA. This prevents cavitation at port
MA.
10-90 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE
12
REVERSE PREVENTION VALVE
Operation diagram
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug
5. Spool (MB side)
6. Spring (MB side)
7. Plug
Explanation of effect
PC200-7 10-91
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE
12
Outline
This valve reduces the swing back genera-
tion in the swing body by the inertia of the
swing body, the backlash and rigidity of the
machinery system, and the compression of
the hydraulic oil when the swing is
stopped. This is effective in preventing
spillage of the load and reducing the cycle
time when stopping the swing (the posi-
tioning ability is good and it is possible to
move swiftly to the next job.
Operation
1) When brake pressure is being gener-
ated at port MB
Pressure MB passes through the notch and
goes to chamber d, spool (5) pushes spring
(6) according to the difference in area D1 >
D2, moves to the left, and MB is connected
to e.
When this happens, pressure MA is below
the set pressure of spring (3), so spool (2)
does not move. For this reason, the pres-
sure oil is closed by spool (2), and the brak-
ing force is ensured.
2) After motor stops

The motor is reversed by the closing pres-
sure generated at port MB. (1st reversal)
When this happens, reversal pressure is
generated at port MA. Pressure MA goes
to chamber a, so spool (2) pushes spring (3)
and moves to the right, and MA is con-
nected to B. At the same time, b is con-
nected to f through the drill hole in spool
(5), so the reversal pressure at port MA is
bypassed to port T to prevent the 2nd
reversal.
10-92 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CENTER SWIVEL JOINT
12
CENTER SWIVEL JOINT
1. Cover A1. To L.H. travel motor port PB T2. To tank

2. Body A2. From control valve port A5 T1. From L.H. and R.H. travel motors port T
3. Slipper seal C1. To R.H. travel motor port PA D2. From control valve port B2
4. O-ring B2. From control valve port B5 B1. To L.H. travel motor port PA
5. Shaft D1. To R.H. travel motor port PB C2. From control valve port A2
E. To L.H. and R.H. travel motors port P
Unit: mm
No. Check Item Criteria Remedy
Clearance between rotor Standard Size Standard clearance Repair limit

6 Replace
and shaft 80
PC200-7 10-93
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
HMV110-2
P : From travel speed solenoid valve SPECIFICATIONS

T : To tank Model
PA : From control valve PC200-7 PC220-7
Item
PB : From control valve
MA: MA pressure pickup port Type HMV110-2
MB: MB pressure pickup port Theoretical Min. 78.6 cm/rev 74 cm/rev
Delivery Max. 106.2 cm/rev 110.7 cm/rev
Set pressure 37.3 MPa {380 kg/cm}
Min.
2,805 rpm 3,046 rpm
Capacity
Rated speed
Max.
1,842 rpm 1,588 rpm
capacity
Brake releasing pressure 1.2 MPa {12 kg/cm}
Travel speed
Differential
switching 0.8 MPa {8 kg/cm}
pressure
pressure
10-94 PC200-7
12
1. Regulator piston 9. Check valve spring 17. Valve plate

2. Spring 10. Output shaft 18. Counterbalance valve
3. Regulator valve 11. Rocker cam 19. Ring
4. Spring 12. Retainer guide 20. Spool return spring
5. Motor case 13. Pin 21. Brake piston
6. Suction safety valve spring 14. Piston 22. Plate
7. Suction safety valve 15. Retainer 23. Disc
8. Check valve 16. Cylinder 24. Ball
PC200-7 10-95
12
Unit: mm

Outside diameter length load length load
Check valve
1 2.55 N 1.96 N
spring PC200-7 31.6 x 6.5 24.2
{0.26 kg} {0.2 kg}
PC220-7 31.6 x 6.5 24.2
{0.73 kg} {0.58 kg} deformed,
replace spring
1.96 N 1.57 N
{0.2 kg} {0.16 kg}
411 N 329 N
3 Return spring 58.43 x 30 42.6
{41.9 kg} {33.5 kg}
55 N 44 N
4 Regulator valve spring 21.5 x 11.1 17.1
{5.6 kg} {4.5 kg}
10-96 PC200-7
OPERATION OF MOTOR
1) Motor swash plate angle at maximum
SJP08742
OR
08893
The solenoid valve is deactivated, so the pilot At the same time, the pressurized oil at regu-
pressure oil from the main pump does not lator piston (15) passes through orifice c in
flow to port P. regulator valve (9) and is drained to the motor
For this reason, regulator valve (9) is pushed case.
to the right in the direction of the arrow by As a result, rocker cam (4) moves in the maxi-
spring (10). mum swash plate angle direction, the motor
Because of this, it pushes check valve (22), capacity becomes maximum.
and the main pressure oil from the control
valve going to end cover (8) is shut off by reg-
ulator valve (9).
Fulcrum a of rocker cam (4) is eccentric to
point of force b of the combined force of the
propulsion force of cylinder (6), so the com-
bined force of the piston propulsion force acts
as a moment to angle rocker cam (4) in the
direction of the maximum swash plate angle.
PC200/220(LC)-7 10-97
(11)
12
2) Motor swash plate angle at minimum
SJP08743
OR
08894
When the solenoid valve is excited, the pilot

pressure oil from the main pump flows to
port P, and pushes regulator valve (9) to the
left direction of the arrow.
Because of this, the main pressure oil from
the control valve passes through passage d in
regulator valve (9), enters regulator piston
(15) at the bottom, and pushes regulator pis-
ton (15) to the right in the direction of the
arrow.
As a result, rocker cam (4) moves in the mini-
mum swash plate angle direction, the motor
capacity becomes minimum.
10-98 PC200/220(LC)-7
(11)
12
OPERATION OF PARKING BRAKE

1) When starting to travel
When the travel lever is operated, the pres-
surized oil from the pump actuates coun-
terbalance valve spool (19), opens the
circuit to the parking brake, and flows into
chamber A of the brake piston (12).
It overcomes the force of spring (11), and SJP08744
pushes piston (12) to the left in the direc-
tion of the arrow. OR
When this happens, the force pushing plate
(13) and disc (14) together is lost, so plate 08895
(13) and disc (14) separate and the brake is
released.
1. When stopping travel

When the travel lever is placed in neutral,
counterbalance valve spool (19) returns to
the neutral position and the circuit to the
parking brake is closed.
The pressurized oil in chamber A of brake
piston (12) is drained to the case from the
orifice in the brake piston, and brake piston SJP08745
(12) is pushed to the right in the direction
of the arrow by spring (11). OR
As a result, plate (13) and disc (14) are
pushed together, and the brake is applied. 08896
A time delay is provided by having the
pressurized oil pass through a throttle in
slow return valve (22) when the brake pis-
ton returns, and this ensures that the brake
is still effective after the machine stops.
PC200-7 10-99
OPERATION OF BRAKE VALVE

The brake valve consists of a suction safety
valve (18A), counterbalance valve (18) in a
circuit as shown in the diagram on the
right. (Fig. 1)
The function and operation of each compo-
nent is as given below.
1) Counterbalance valve, check valve SAP03482

Function
When traveling downhill, the weight of the OR
machine makes it try to travel faster than
the speed of the motor. 08897
As a result, if the machine travels with the
engine at low speed, the motor will rotate
without load and the machine will run
away, which is extremely dangerous.
To prevent this these valves act to make the
machine travel according to the engine
speed (pump discharge amount).
Operation when pressure oil is supplied

surized oil from the control valve is sup-
plied to port PA. It pushes open suction
safety valve (18A) and flows from motor
inlet port MA to motor outlet port MB.
However, the motor outlet port is closed by
suction safety valve (18B) and spool (19),
so the pressure at the supply side rises.
(Fig. 2)
The pressurized oil at the supply side flows

from orifice E1 and E2 in spool (19) to
chamber S1. When the pressure in cham-
ber S1 goes above the spool switching
pressure, spool (19) is pushed to the right
in the direction of the arrow.
As a result, port MB and port PB are con-
nected, the outlet port side of the motor is
opened, and the motor starts to rotate. (Fig.
3)
10-100 PC200-7
Operation of brake when traveling downhill

If the machine tries to run away when travel-
ing downhill, the motor will turn under no
load, so the pressure at the motor inlet port
will drop, and the pressure in chamber S1
through orifices E1 and E2 will also drop.
When the pressure in chamber S1 drops
below the spool switching pressure, spool
(19) is returned to the left, in the direction of
the arrow by spring (20), and outlet port MB
is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the rota-
tion of the motor, and this prevents the
machine from running away.
In other words, the spool moves to a position
where the pressure at the outlet port MB bal-
ances the pressure at the inlet port and the
force generated by the weight of the
machine. It throttles the outlet port circuit
and controls the travel speed according to
the amount of oil discharged from the pump.
(Fig. 4)
2) Safety valve
Function
When travel is stopped (or when traveling
downhill), the circuits at the inlet and outlet
ports of the motor are closed by the counter-
balance valve, but the motor is rotated by
inertia, so the pressure at the outlet port of
the motor will become abnormally high and
damage the motor or piping. The safety
valve acts to release this abnormal pressure
and send it to the inlet port side of the motor
to prevent damage to the equipment.
Operation
1. When travel is stopped (or when travel-
ing downhill, rotating to right)
When the motor inlet port pressure (pressure
PA) goes down, the pressure in chamber S1
also goes down. When it goes below the
switching pressure of the spool, spool is
returned to the left by spring (20), and outlet
port passage B1 is throttled. When this hap-
pens, the motor continues to rotate under
inertia, so the outlet pressure (pressure MB)
rises. (Fig. 5)
If the pressure goes above the set pressure
of suction-safety valve (18A), the poppet
opens. The oil then passes through large
notch A1 in counterbalance valve spool (19)
and flows to chamber MA in the circuit on
the opposite side. (Fig. 6)
2. When rotating to left
The operation is the reverse of when rotating
to the right.
PC200-7 10-101
2) When starting travel (or during normal

travel)
sure oil from the pump moves counterbal-
ance valve spool (19) to the right. When
this happens, the passage to the suction-
safety valve becomes the circuit flowing
through the small notch B2 in the counter-
balance valve spool. As a result, a big dif-
ference in pressure is created, and the
pump pressure rises to provide a powerful
drawbar pull. (Fig. 7)
10-102 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL JUNCTION VALVE
TRAVEL JUNCTION VALVE
Function Operation
This valve connects both travel circuits to each When pilot pressure is turned ON
other so that the hydraulic oil will be supplied If the pilot pressure from the travel junction sole-
evenly to both travel motors and the machine will noid valve becomes higher than the force of
travel straight. spring (14), travel junction spool (13) moves to the
When the machine is steered, outside pilot pres- left stroke end and the junction circuit between
sure PST closes the travel junction valve to secure port PTL (Left travel circuit) and PTR (Right travel
high steering performance. circuit) is closed.
SU(V)P08730
OR
08898
PC200/220(LC)-7 10-103
(4)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL JUNCTION VALVE
When pilot pressure is turned OFF

If pilot pressure PST from the sole- If the oil flow rates in both travel motors
noid valve is 0, travel junction spool become different from each other, the oil
(13) is pressed by the force of spring flows through the route between port PTL,
(14) against the right side and the travel junction spool (13), and port PTR so
pass between ports PTL and PTR is that the oil flow rates will be equalized again.
open.
SU(V)P08731
OR
08899
10-104 PC200/220(LC)-7
(4)
STROKE REGULATION WHEN
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVELLING
STROKE REGULATION WHEN TRAVELLING

Function Operation
If the boom lever is set to the "RAISE" position 1 When travel lever is in neutral
or the arm lever is set in the "IN" or "OUT" The oil in stroke regulation signal chamber
position or the bucket lever is set in the "a" is drained through orifices (5) and (6) of
"CURL" or "DUMP" position while the machine pistons (3) and (4) in the travel spring case
is travelling up a sharp slope, the travel PPC and the travel PPC valve.If the boom lever is
shuttle valve regulates the spool strokes of the set to the "RAISE" position (or the arm lever is
boom, arm, and bucket control valves with the set in the "IN" or "OUT" position or the bucket
travel PPC pressure to limit the flow of the oil lever is set in the "CURL" or "DUMP" posi-
into the boom, arm, and bucket cylinders. tion), spool (1) moves to the left until it
When the strokes of the boom, arm, and reaches the end of spring case (2) (st0).
bucket are regulated, the travel PPC pressure
is applied through the circuit in the control
valve.
PC200/220(LC)-7 10-105
(4)
STROKE REGULATION WHEN
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVELLING
12
2. When travel lever is operated
If the right travel lever is set in the reverse (or At this time, the right travel reverse (or for-
forward) direction, the right travel reverse (or ward) PPC pressure is applied through orifice
forward) PPC pressure pushes spool (7) to the (6) of piston (4) to the left end of piston (8) to
left (or right). push piston (8) to the right.
Spool (7) pushes piston (3) to close orifice (5) When boom RAISE, arm IN, OUT, bucket
and shut off stroke regulation signal chamber CURL, DUMP are operated, spool (1) moves
"a" from the drain circuit of the travel PPC to the left, but the maximum stroke of the
valve. spool is limited to st1, the amount of move-
ment (st2) of piston (8).
10-106 PC200/220(LC)-7
(4)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD VALVE CONTROL
VALVE CONTROL
Lever positions
1. Travel PPC valve 8. Solenoid valve (1) Hold (9) Swing "RIGHT"
2. Service PPC valve 9. Accumulator (2) Boom "RAISE" (10) Swing "LEFT"
3. Service pedal 10. Control valve (3) Boom "LOWER" (11) Neutral
4. L.H. travel lever 11. Hydraulic pump (4) Bucket "DUMP" (12) Travel "REVERSE"
5. R.H. travel lever 12. Junction box (5) Bucket "CURL" (13) Travel "FORWARD"
6. R.H. PPC valve 13. L.H. work equip- (6) Hold
7. R.H. work equipment con- ment control lever (7) Arm "IN"
trol lever 14. L.H. PPC valve (8) Arm "OUT"
PC200-7 10-107
WORK EQUIPMENT SWING PPC
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD VALVE
WORK EQUIPMENT SWING PPC VALVE
P: From main pump P1: Left: Arm OUT / Right: Boom LOWER
T: To tank P2: Left: Arm IN / Right: Boom RAISE
P3: Left: Swing RIGHT / Right: Bucket CURL
P4: Left: SwingLEFT / Right: Bucket DUMP
10-108 PC200-7
12
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connection of lever)
Unit: mm

Centering spring
12 Outside diameter length load length load
(For P3 and P4)
42.5 x 15.5 34
replace spring
Centering spring 29.4 N 23.5 N
13 44.5 x 15.5 34
(For P3 and P4) {3.0 kg} {2.4 kg}
16.7 N 13.7 N
14 Metering spring 26.5 x 8.2 24.9
{1.7 kg} {1.4 kg}
PC200-7 10-109
OPERATION
1) At neutral
Ports A and B of the control valve and
ports P1 and P2 of the PPC valve are con-
nected to drain chamber D through fine
control hole f in spool (1). (Fig. 1)
2) During fine control (neutral fine

control)
When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed; spool (1) is also
pushed by metering spring (2), and moves
down.
When this happens, fine control hole f is
shut off from drain chamber D, and at
almost the same time, it is connected to
pump pressure chamber PP, so pilot pres-
sure oil from the main pump passes
through fine control hole f and goes from
port P1 to port A.
When the pressure at port P1 becomes
higher, spool (1) is pushed back and fine
control hole f is shut off from pump pres-
sure chamber PP. At almost the same time,
it is connected to drain chamber D to
release the pressure at port P1. When this
happens, spool (1) moves up or down so
that the force of metering spring (2) is bal-
anced with the pressure at port P1. The
relationship in the position of spool (1) and
body (10) (fine control hole f is at a point
midway between drain hole D and pump
pressure chamber PP) does not change
until retainer (9) contacts spool (1).
Therefore, metering spring (2) is com-
pressed proportionally to the amount of
movement of the control lever, so the pres-
sure at port P1 also rises in proportion to
the travel of the control lever. In this way,
the control valve spool moves to a position
where the pressure in chamber A (the
same as the pressure at port P1) and the
force of the control valve spool return
spring are balanced. (Fig. 2)
10-110 PC200/220(LC)-7
(11)
12
3) During fine control (when control

lever is returned)
When disc (5) starts to be returned, spool
(1) is pushed up by the force of centering
spring (3) and the pressure at port P1.
connected to drain chamber D and the
pressure oil at port P1 is released.
If the pressure at port P1 drops too far,
spool (1) is pushed down by metering
spring (2), and fine control hole f is shut off
from drain chamber D. At almost the same
time, it is connected to pump pressure
chamber PP, and the pump pressure is sup-
plied until the pressure at port P1 recovers
to a pressure that corresponds to the lever
position.
When the spool of the control valve
returns, 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
fill the chamber with oil. (Fig. 3)
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine
control hole f is shut off from drain cham-
ber D, and is connected with pump pres-
sure chamber PP. Therefore, the pilot
pressure oil from the main pump passes
through fine control hole f and flows to
chamber A from port P1, and pushes the
control valve spool.
The oil returning from chamber B passes
from port P2 through fine control hole f
and flows to drain chamber D. (Fig. 4)
PC200/220(LC)-7 10-111
(11)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
P : From main pump P3 : Right reverse

T : To tank P4 : Right forward
P1 : Left reverse P5 : Travel signal
P2 : Left forward P6 : Steering signal
10-112 PC200/220(LC)-7
(11)
12
1. Plate 6. Centering spring

2. Body 7. Valve
3. Piston 8. Damper
4. Collar 9. Steering signal
5. Metering spring 10. Steering signal valve spring
PC200-7 10-113
12
Unit: mm

1 Metering spring Outside diameter length load length load
26.5 x 8.15 24.7
replace spring
108 N 86.3 N
2 Centering spring 48.1 x 15.5 32.5
{11 kg} {8.8 kg}
8.8 N 7.1 N
3 Steering signal spring 12.8 x 7.3 8.5
{0.9 kg} {0.72 kg}
10-114 PC200-7
12
OPERATION
1) At neutral
ports P1 and P2 of the PPC valve are con-
nected to drain chamber D through fine
control hole f in spool (1). (Fig. 1)
2) Fine control (neutral fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (1) is also
pushed by metering spring (2), and moves
down.
shut off from drain chamber D. At almost
the same time, it is connected to pump
pressure chamber PP, and the pilot pres-
sure of the main pump is sent from port A
through fine control hole f to port P1.
When the pressure at port P1 rises, spool
(1) is pushed back. Fine control hole f is
shut off from pump pressure chamber PP.
At almost the same time, it is connected to
drain chamber D, so the pressure at port
P1 escapes.
As a result, spool (1) moves up and down
until the force of metering spool (2) is bal-
anced with the pressure at port P1.
The relationship of the position of spool (1)
and body (10) (fine control hole f is in the
middle between drain hole D and pump
pressure chamber PP) does not change
until retainer (9) contacts spool (1).
pressed in proportion to the travel of the
control lever, so the pressure at port P1
also rises in proportion to the travel of the
control lever. In this way, the spool of 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. (Fig. 2)
PC200/220(LC)-7 10-115
(11)
12
3) Fine control (control lever returned)
When lever (5) starts to be returned, spool (1)
is pushed up by the force of centering spring
(3) and the pressure at port P1.
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressur-
ized oil at port P1 is released.
If the pressure at port P1 drops too much,
spool (1) is pushed up by metering spring (2),
so fine control hole f is shut off from drain
chamber D. At almost the same time, it is
connected to pump pressure chamber PP, so
the pressure at port P1 supplies the pump
pressure until the pressure recovers to a pres-
sure equivalent to the position of the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole f'
of the valve on the side that is not moving.
It passes through port P2 and goes to cham-
ber B to charge the oil. (Fig. 3)
4) At full stroke
Lever (5) pushes down piston (4), and retainer
(9) pushes down on spool (1). Fine control
hole f is shut off from drain chamber D, and is
connected to pump pressure chamber PP.
Therefore, the pilot pressure oil from the
main pump passes through fine control hole f
and flows to chamber A from port P1 to push
the control valve spool. The return oil from
chamber B passes from port P2 through fine
control hole f' and flows to drain chamber D.
(Fig. 4)
10-116 PC200/220(LC)-7
(11)
2. Travel signal/Steering function

Travel signal
If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as
the travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5.
Steering signal
If the operation quantities of both levers are different from each other as in the steering operation, the
higher one of the PPC output pressures on both sides is output as the steering signal.
Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in
neutral.
Accordingly, if the machine is being steered is judged by the signal of port P6.
Operation
1) While in NEUTRAL
The signals of the output ports (P1 - P4), travel signal (Port P5), and steering signal (Port P6) are not out-
put.
PC200/220(LC)-7 10-117
(11)
2) While travelling straight

(The following drawing shows the circuit for traveling straight forward.)
While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor
is also operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber
(k) and right spring chamber (l) of steering signal valve (j) are set high. Accordingly, the steering signal
valve is kept in neutral and the steering signal (Port P6) is not output.
10-118 PC200/220(LC)-7
(11)
12
3) When steered or pivot-turned
(The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.)
If the operation quantities of both levers are different from each other as in the steering operation (If the
difference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is
output as the steering signal.
In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is
P2. The pressure in right spring chamber (l) is P4.
If (P4 - P2) x (Sectional area of spool) > Set spring load, the spool is changed to the direction of the
arrow and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is out-
put as the steering signal to port P6.
PC200/220(LC)-7 10-119
(11)
12
4) When pivot-turned
(The following drawing shows the circuit for left reverse and right forward operation.)
While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is
operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber
(l) of steering signal valve (j) is set high. Accordingly, the steering signal valve moves to the left and
outputs the steering signal (port P6).
10-120 PC200/220(LC)-7
(11)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE PPC VALVE
SERVICE PPC VALVE
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
T : To tank
P : From main pump
P1 : Port
P2 : Port
Unit: mm

9 Centering spring Outside diameter length load length load If damaged or
124.5 N 100 N deformed,
33.9 x 15.3 28.4 replace spring
{12.7 kg} {10.2 kg}
16.7 N 13.7 N
10 Metering spring 22.7 x 8.1 22
{1.7 kg} {1.4 kg}
PC200-7 10-121
OPERATION
At neutral
The pressurized oil from the main pump
enters from port P and is blocked by spool
(1).
ports a and b of the PPC valve are con-
nected to drain port T through fine control
hole X of spool (1).
WHEN OPERATED
When lever (5) is moved, metering spring

(2) is pushed by piston (4) and retainer (7),
and spool (1) is pushed down by this.
As a result, fine control portion Y is con-
nected with port a, and the pressurized oil
from port P flows from port a to port A of
the control valve.
10-122 PC200/220(LC)-7
(11)
When the pressure at port a becomes

higher, spool (1) is pushed back by the
force acting on the end of the spool, and
fine control portion Y closes.
As a result, spool (1) moves up and down
to balance the force at port a and the force
at metering spring (2).
pressed in proportion to the amount the
control lever is moved. The spring force
becomes larger, so the pressure at port a
also increases in proportion to the amount
the control lever is operated.
In this way, the control valve spool moves
to a position where the pressure of port A
(the same as the pressure at port a) is bal-
anced with the force of the return spring of
the control valve spool.
PC200/220(LC)-7 10-123
(11)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
PPC lock, travel junction, merge-divider, travel speed, swing brake, 2-stage relief solenoid valves
1. PPC lock solenoid valve T : To tank A6 : To main valve (2-stage relief

2. Travel junction solenoid A1 : To PPC valve valve)
valve A2 : To main valve (Travel junc- P1 : From main pump
3. Merge-divider solenoid valve tion valve) ACC: To accumulator
4. Travel speed solenoid valve A3 . To main valve (Merge-
5. Swing brake solenoid valve divider valve)
6. 2-stage relief solenoid valve A4 : To both travel motors
A5 : To swing motor
10-124 PC200/220(LC)-7
(11)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE
12
1. Connector
2. Moving core
3. Coil
4. Spool
5. Block
6. Spring
OPERATION
WHEN SOLENOID IS TURNED OFF
Since the signal current does not flow from

the controller, solenoid (3) is turned off.
Accordingly, spool (4) is pressed by spring
(6) against the left side.
By this operation, the pass from P to A is
closed and the hydraulic oil from the main
pump does not flow into the actuator.
At this time, the oil from the actuator is
drained through ports A and T into the
tank.
WHEN SOLENOID IS TURNED ON
The signal current flows from the controller

to solenoid (3), and the latter is turned on.
Accordingly, spool (4) is pressed against to
the right side.
By this operation, the hydraulic oil from the
main pump flows through port P and spool
(4) to port A, then flows into the actuator.
At this time, port T is closed and the oil
does not flow into the tank.
PC200/220(LC)-7 10-125
(11)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PPC ACCUMULATOR
PPC ACCUMULATOR
1 1. Gas plug
2. Shell
3. Poppet
4. Holder
2 5. Bladder
6. Oil port
3 SPECIFICATIONS
Gas capacity:300 cc (for PPC)
SBP00290
10-126 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD RETURN OIL FILTER
RETURN OIL FILTER
FOR BREAKER
SPECIFICATIONS
1. Drain plug Rated pressure: 6.9 MPa {70 kg/cm2}

2. Element Flow : 200 l/min
3. Case Relief valve cracking pressure:
4. Head cover 0.34 0.05 MPa
5. Relief valve {3.5 0.5 kg/cm2}
Filter mesh size: 6 m
Filtering area : 4,570 cm2
PC200-7 10-127
BOOM HYDRAULIC DRIFT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PREVENTION VALVE
BOOM HYDRAULIC DRIFT PREVENTION VALVE

When boom control valve is at RAISE
08900
When boom control valve is at NEUTRAL
10-128 PC200-7
The main hydraulic oil is shut off from the

Function
holding pressure on the boom cylinder bot-
This valve prevents the oil in the boom cylin- tom side.
der bottom from leaking through spool (1) At this time, the holding pressure on the
and the boom from lowering under its weight boom cylinder bottom side is applied toward
while the boom lever is not operated. the right to area "A" of the ring formed by the
difference between outside diameter d1 of
Operation
poppet (5) and seat diameter d2 (= Area of
d1 - Area of d2). The total of this pressure
1. When boom lever is in "RAISE" position
If the boom lever is set in the "RAISE" posi- and the force of spring (4) closes poppet (5) to
tion, the pressure of the main hydraulic oil is shut off the main hydraulic oil from the hold-
applied toward the left to area "A" of the ring ing pressure on the boom cylinder bottom.
formed by the difference between outside Accordingly, the boom is held.
diameter d1 of poppet (5) and seat diameter 3. When boom lever is in "LOWER" position
d2 (= Area of d1 - Area of d2). At this time, If the boom lever is set in the "LOWER" posi-
if this pressure is higher than the force of tion, pilot spool (2) is pushed by the pilot
spring (4), poppet (5) moves to the left. By this pressure from the PPC valve and the hydrau-
operation, the main hydraulic oil from the lic oil in chamber "b" in the poppet is drained
control valve flows through the open part of through orifice "c".
poppet (5) to the boom cylinder bottom. The oil on the boom bottom side flows from
2. When boom lever is in neutral orifice "a" through chamber "b" and orifice "c"
If the control lever is returned to the neutral to the drain hole, and the oil pressure in
position while the boom is raised, the oil in chamber "b" lowers.
poppet (5) which has flowed through orifice If the pressure in chamber "b" lowers below
"a" is sealed by pilot piston (2). the pressure at port B, poppet (5) opens and
the hydraulic oil from port B flows through
port A to the control valve.
PC200/220(LC)-7 10-129
(9)
If the hydraulic drift prevention valve for the

4. When abnormally high pressure is gener- arm cylinder head circuit is installed
ated (optional), the hydraulic oil in the boom cylin-
If abnormally high pressure is generated in der bottom circuit or that in the arm cylinder
the boom cylinder bottom circuit, the hydrau- head circuit, having higher pressure, pushes
lic oil in port B pushes check valve (6) open, check valve (6 or 6A) open, then safety valve
then safety valve (3) operates. (3) operates.
10-130 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD LIFT CHECK VALVE
LIFT CHECK VALVE
Function
This valve applies back pressure to the drain

circuit to prevent generation of negative pres-
sure on the hydraulic devices for the work
equipment (motors, cylinders, etc.)
Operation
1. While engine is stopped

Any oil is not supplied from the pump to
the self-pressure reducing valve and valve
(1) is pressed by only the force of spring (2)
toward the right and drain circuit "a" of the
control valve is connected through orifice
"b" of valve (1) to port T.
2. While engine is running

Output pressure PR of the self-pressure
reducing valve is applied through the con-
trol valve to spring chamber "c" of the back
pressure valve.
Output pressure PR applied to spring
chamber "c" is applied to the left end of
valve (1) (area of d) to push valve (1) to
the right.
At this time, pressure PA of drain circuit "a"
of the control valve is applied to the right
end of valve (1) (area of d1) to push valve
(1) to the left.
Valve (1) is balanced so that the back pres-
sure PA will be as follows.
PA = {(Area of d) x PR + Force of spring
(2)} / (Area of d1)
PC200/220(LC)-7 10-131
(11)
ATTACHMENT CIRCUIT SELECTOR
ATTACHMENT CIRCUIT SELECTOR VALVE
1. Spool V : To control valve

2. Spring T : To hydraulic tank
ATT: To attachment
ACC: To accumulator
P1 : From attachment circuit selector solenoid valve
TS : To hydraulic tank
Unit: mm

Replace spring if
Free length x Installed Installed Installed
Spool return Free length any damages or
3 Outside Dia. length load load
spring deformations are
833 N 666 N found
132.0 x 29 114.5
{85.0 Kg} {68.0 Kg}
10-132 PC200/220(LC)-7
(11)
ATTACHMENT CIRCUIT SELECTOR
Function
When a breaker is installed, the return oil from

the breaker does not pass through the main
valve, but returns directly to the hydraulic tank.
When other attachments (crusher, etc.) are
installed, the attachment and the main valve are
interconnected.
Operation
1. When attachment other than breaker is

installed
Spool (1) is pushed fully to the left by the
force of spring (2), ATT port and port V are
interconnected, and ATT port and port T are
shut off, so the attachment and main valve are
interconnected.
2. When breaker is installed

When the pilot pressure from the attachment
circuit selector solenoid valve overcomes the
force of spring (2), the spool (1) moves fully to
the right. ATT port and port V are shut off and
ATT port and port T are interconnected, so the
oil returning from the breaker does not pass
through the main valve, but passes through
port T and returns directly to the hydraulic
tank.
PC200/220(LC)-7 10-133
(4)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
PC200-7, PC200LC-7
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-134 PC200-7
12
100 HOURS GREASING
Unit: mm
Standard Tolerance Standard clear- Clearance

Cylinder
size Shaft Hole ance limit
-0.036 +0.222
Clearance between Boom 85 0.083 ~ 0.312 0.412
-0.090 +0.047 Replace bush-
1 piston rod and bush-
ing
ing -0.036 +0.222
Arm 95 0.083 ~ 0.312 0.412
-0.090 +0.047
-0.030 +0.258
Bucket 80 0.078 ~ 0.334 0.434
-0.076 +0.048
-0.030 +0.457
Boom 80 0.400 ~ 0.517 1.0
-0.060 +0.370
Clearance between
-0.030 +0.457
2 piston rod support Arm 80 0.400 ~ 0.533 1.0
-0.076 +0.370
pin and bushing
-0.030 +0.424
Bucket 70 0.380 ~ 0.500 1.0
-0.076 +0.350 Replace pin or
-0.030 +0.424 bushing
Boom 70 0.380 ~ 0.484 1.0
-0.060 +0.350
Clearance between
cylinder bottom -0.030 +0.457
3 Arm 80 0.400 ~ 0.523 1.0
support pin and -0.076 +0.370
bushing
-0.030 +0.424
Bucket 70 0.380 ~ 0.500 1.0
-0.076 +0.350
500 HOURS GREASING

Unit: mm
Tolerance
Standard Standard clear- Clearance
Cylinder
-0.036 +0.222
ing
ing -0.036 +0.222
Arm 95 0.083 ~ 0.312 0.412
-0.090 +0.047
-0.030 +0.257
Bucket 80 0.078 ~ 0.334 0.447
-0.076 +0.048
-0.030 +0.190
Boom 80 0.100 ~ 0.250 ---
-0.060 +0.070
Clearance between
-0.030 +0.175
2 piston rod support Arm 80 0.105 ~ 0.251 ---
-0.076 +0.075
pin and bushing
-0.030 +0.170
Bucket 70 0.100 ~ 0.246 ---
-0.076 +0.070
Replace pin or
-0.030 +0.165 bushing
Boom 70 0.075 ~ 0.225 ---
-0.060 +0.045
Clearance between
3 Arm 80 0.105 ~ 0.251 ---
bushing
-0.030 +0.170
Bucket 70 0.100 ~ 0.230 ---
-0.060 +0.070
PC200-7 10-135
PC220-7, PC220LC-7
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-136 PC200-7
12
100 HOURS GREASING
Unit: mm

Cylinder
size ance limit
Shaft Hole
-0.036 +0.257
ing
ing -0.036 +0.257
Arm 100 0.083 ~ 0.347 0.447
-0.090 +0.047
-0.030 +0.257
Bucket 90 0.084 ~ 0.347 0.447
-0.090 +0.048
-0.030 +0.457
Boom 80 0.400 ~ 0.517 1.0
-0.060 +0.370
Clearance between
-0.030 +0.457
2 piston rod support Arm 80 0.400 ~ 0.533 1.0
-0.076 +0.370
pin and bushing
-0.030 +0.457
Bucket 80 0.400 ~ 0.533 1.0
bushing
-0.030 +0.457
Boom 80 0.400 ~ 0.533 1.0
-0.076 +0.370
Clearance between
3 Arm 80 0.400 ~ 0.533 1.0
bushing
-0.030 +0.457
Bucket 80 0.400 ~ 0.533 1.0
-0.076 +0.370
500 HOURS GREASING

Unit: mm

Cylinder
-0.036 +0.257
ing
ing -0.036 +0.257
Arm 100 0.083 ~ 0.347 0.447
-0.090 +0.047
-0.036 +0.257
Bucket 90 0.084 ~ 0.347 0.447
-0.090 +0.048
-0.030 +0.190
Boom 80 0.100 ~ 0.250 ---
-0.060 +0.070
Clearance between
-0.030 +0.175
2 piston rod support Arm 80 0.105 ~ 0.251 ---
-0.076 +0.075
pin and bushing
-0.030 +0.175
Bucket 80 0.105 ~ 0.251 ---
-0.030 +0.190 bushing
Boom 80 0.100 ~ 0.250 ---
-0.060 +0.070
Clearance between
3 Arm 80 0.105 ~ 0.251 ---
bushing
-0.030 +0.175
Bucket 80 0.105 ~ 0.251 ---
-0.076 +0.075
PC200-7 10-137
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
10-138 PC200-7
PC200-7, PC200LC-7
100 HOURS GREASING
Unit: mm

Clearance between connecting size ance limit
Shaft Hole
1 pin and bushing of revolving
frame and boom -0.036 +0.342
90 0.305 ~ 0.412 1.0
-0.071 +0.269
Clearance between connecting -0.036 +0.153

2 90 0.133 ~ 0.224 1.0
pin and bushing of boom and arm -0.071 +0.097

3 70 0.305 ~ 0.411 1.0
pin and bushing of arm and link -0.076 +0.275 Replace
Clearance between connecting

-0.030 +0.337
4 pin and bushing of arm and 80 0.303 ~ 0.413 1.0
-0.076 +0.273
bucket

-0.030 +0.337
5 pin and bushing of link and 80 0.303 ~ 0.413 1.0
-0.076 +0.273
bucket

6 70 0.303 ~ 0.411 1.0
pin and bushing of link and link -0.076 +0.275
500 HOURS GREASING

Unit: mm

Shaft Hole
90 0.110 ~ 0.202 1.0
-0.071 +0.074

2 90 0.110 ~ 0.237 1.0

3 70 0.108 ~ 0.234 1.0

-0.030 +0.137
-0.076 +0.074
bucket

-0.030 +0.166
-0.076 +0.086
bucket

6 80 0.104 ~ 0.230 1.0
PC200-7 10-139
PC220-7, PC220LC-7
100 HOURS GREASING
Unit: mm

Shaft Hole
90 0.305 ~ 0.412 1.0
-0.071 +0.269

2 90 0.133 ~ 0.224 1.0

3 80 0.305 ~ 0.411 1.0

-0.030 +0.337
-0.076 +0.273
bucket

-0.030 +0.337
-0.076 +0.273
bucket

6 80 0.303 ~ 0.411 1.0
500 HOURS GREASING

Unit: mm

Shaft Hole
100 0.110 ~ 0.239 1.0
-0.071 +0.074

2 90 0.110 ~ 0.237 1.0

3 80 0.116 ~ 0.242 1.0

-0.030 +0.137
-0.076 +0.074
bucket

-0.030 +0.166
-0.076 +0.086
bucket

6 80 0.096 ~ 0.232 1.0
10-140 PC200-7
1. DIMENSION OF ARM
10-142 PC200-7
12
Unit: mm
Model
PC200-7, PC200LC-7 PC220-7, PC220LC-7
No.
1 80 +0.1
0 80 +0.1
0
2 109.3 +1.5
0 109.3 +1.5
0
3 0
305.5 -0.5 0
305.5 -0.5
4 90 -0.036
-0.071 90 -0.036
-0.071
5 402.1 1 419.9 1
6 187.2 0.5 206.1 0.5
7 829.1 1 918.6 1
8 2,919 3,037.6
9 2,630.5 1 2,562.8 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 1,551.7
15 80 80
16 326.5 1 326.5 1
17 80 80
Arm as individual part 0

311-0.5 0
311-0.5
18
When pressfitting bushing 325 325
Min. 1,680 1,605
19
Max. 2,800 2,625
PC200-7 10-143
12
2.DIMENSION OF BUCKET
10-144 PC200-7
12
Unit: mm
Model
PC200-7, PC200LC-7 PC220-7, PC220LC-7
No.
1 457.6 0.5 442.4 0.5
2 22 0.5 59.2 0.5
3 92 48 96 52
4 458.1 446.3
5 1,477.3 1,540.5
6 158.6 185.7
7
8 0 7 37
9 +0.1
80 0 80 +0.2
0
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
17 132 155
18 129 135
19 107 107
20 85 82
21 358.5 +2
0 358.5 +2
0
22 38 37
PC200-7 10-145
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Hot water pickup piping A. Fresh air

2. Air conditioner compressor B. Recirculated air
3. Refrigerant piping C. Hot air/cold air
4. Condenser
5. Receiver tank
6. Hot water return piping
7. Air conditioner unit
8. Duct
10-146 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
OUTLINE
1. Battery relay
2. Battery The engine can be started and stopped with
3. Starting switch only starting switch (3).
4. Fuel control dial The engine throttle and pump controller(7)
5. Linkage reveives the signal of fuel control dial (4) and
6. Starting motor transmits the drive signal to governor motor
7. Engine throttle and pump controller (9) to control the governor lever angle of fuel
8. Fuel injection pump injection pump (8) and control the engine
9. Governor motor speed.
PC200-7 10-147
12
1. OPERATION OF SYSTEM
Starting engine
When the starting switch is turned to the
START position, the starting signal flows to
the starting motor, and the starting motor
turns to start the engine. 08903
When this happens, the engine throttle and
pump controller checks the signal from the
fuel control dial and sets the engine speed
to the speed set by the fuel control dial.
Engine speed control

The fuel control dial sends a signal to the
engine throttle and pump controller
according to the position of the dial. The
engine throttle and pump controller calcu-
lates the angle of the governor motor
according to this signal, and sends a signal 08904
to drive the governor motor so that it is at
that angle.
When this happens, the operating angle of
the governor motor is detected by the
potentiometer, and feedback is sent to the
engine throttle and pump controller, so
that it can observe the operation of the
governor motor.
Stopping engine
When the starting switch is turned to the
STOP position, the engine throttle and
pump controller drives the governor motor
so that the governor lever is set to the NO 08905
INJECTION position.
When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle and pump
controller itself drives the battery relay.
10-148 PC200-7
12
1. COMPONENT
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
The fuel control dial is installed under the
monitor panel, and a potentiometer is
installed under the knob. The potentiome-
ter shaft is turned by turning the knob.
As the potentiometer shaft is turned, the
resistance of the variable resistor in the
potentiometer changes and a throttle sig-
nal is sent to the engine throttle and pump
controller.
The hatched area in the graph shown at
right is the abnormality detection area.
PC200-7 10-149
Governor motor
1. Potentiometer A potentiometer for feedback is installed to

2. Cover monitor the operation of the motor.
3. Shaft Revolution of the motor is transmitted
4. Dust seal through the gear to the potentiometer.
5. Bearing
6. Motor Operation
7. Gear While motor is stopped
8. Connector
Electric power is applied to both phases A
and B of the motor.
Function
The motor is turned according to the drive
While motor is running
signal from the engine throttle and pump
controller to control the governor lever of the The engine throttle and pump controller sup-
fuel injection pump. plies a pulse current to phases A and B, and
the motor revolves, synchronizing to the
This motor used as the motive power source
pulse.
is a stepping motor.
10-150 PC200-7
Engine throttle and pump controller
10-152 PC200-7
12
Input and output signals
CN-1 CN-2 CN-3

Pin Signal name Input/ Pin Signal name Input/ Pin Signal name Input/
No. output No. output No. output
1 Boom bottom pressure sensor Input 1 NC Output 1 VB (controller power) Input
2 R pump pressure sensor Input 2 Swing emergency switch Input 2 VIS (solenoid power) Input
3 Arm angle potentiometer Input 3 NC Input 3 SOL_COM (solenoid common gnd)
4 Signal GND Input 4 232C_RxD Input 4 Battery relay drive Output
Abnormality in auto-greasing con- 5 Overload sensor (ON/OFF) Input 5 Governor motor A phase (+) Output
5 Input
troller 6 Overload alarm valid switch Input 6 LS-EPC Output
6 NC Input 7 Model selection 4 Input 7 Travel junction SOL Output
7 Overload sensor (analog) Input 8 Attachment circuit selector signal Output 8 NC Output
8 F boom pressure sensor Input 9 NC Output 9 Bucket CURL pressure SW Input
9 Boom angle potentiometer Input 10 NC Input 10 Boom RAISE pressure SW Input
10 Signal GND Input 11 NC Output 11 VB (controller power) Input
11 Knob SW Input 12 CAN shield 12 VIS (solenoid power) Input
12 NC Input 13 Model selection 5 Input 13 SOL_COM (solenoid common gnd)
13 Governor motor FB potentiometer Input 14 232C_TxD Output 14 KEY_SIG Input
14 Boom head pressure sensor Input 15 NC Input 15 Governor motor A phase (-) Output
15 NC Input 16 Travel steering signal pressure SW Input 16 PC-EPC Output
16 SENS_PWR Output 17 Model selection 3 Input 17 Pump merge/divider solenoid Output
17 Key Switch (Terminal C) Input 18 Relay drive signal for arm crane Output 18 Heater relay drive Output
18 NC Input 19 NC Output 19 Bucket DUMP pressure switch Input
19 Throttle potentiometer Input 20 NC Input 20 Boom LOWER pressure switch Input
20 NC Input Input/ 21 GND (controller GND)
21 S_NET
21 GND (analog GND) output 22 VIS (solenoid PWR) Input
22 POT_PWR Output Input/ 23 SOL_COM (solenoid common gnd)
22 CAN0_L
23 Key switch (terminal ACC) Input output 24 KEY_SIG Input
Arm crane relay actuation observa- Input/ 25 Governor motor B phase (+) Output
24 Input 23 CAN1_L
tion output 26 Service flow adjustment EPC (1) Output
Flash memory write permission sig- 27 Travel Hi/Lo selector solenoid Output
24 Input
nal 28 2-stage relief solenoid Output
25 NC Input 29 Swing pressure switch Input
26 NC Input 30 Arm IN pressure switch Input
27 Model selection 2 Input 31 GND (controller GND)
28 NC Input 32 GND (controller GND)
29 GND (pulse GND) 33 GND (controller GND)
30 NC Input 34 NC
31 GND (S_NET GND) 35 Governor motor B phase (-) Output
Input/ 36 NC Output
32 CAN0_H
output 37 Swing parking brake solenoid Output
Input/ 38 NC Output
33 CAN1_H
output 39 Travel pressure switch Input
40 Arm OUT pressure switch Input
34 GND (232C GND)
35 Service valve pressure switch Input

36 NC Input
37 Model selection switch 1 Input
38 Swing lock switch Input
39 GND (pulse GND)
40 Engine speed sensor Input
PC200/220(LC)-7 10-153
(10)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
ELECTRONIC CONTROL SYSTEM
Control function 1
Engine/Pump composite control function
Pump/Valve control function
3
One-touch power maximizing function
4
Auto-deceleration function
5
Auto-warm-up/Overheat prevention function
Electronic control system
6
Swing control function
Travel control function
8
ATT flow control, circuit selector function (if equipped)
Self-diagnosis function
a For the self-diagnosis function, see "TROUBLE SHOOTING".
PC200/220(LC)-7 10-155
(11)
MACHINE CONTROL SYSTEM DIAGRAM
10-156 PC200/220(LC)-7
(4)
PC200/220(LC)-7 10-157
(11)
1. Engine and Pump control function
SJP08754
OR
08908
10-158 PC200-7
FUNCTION
The operator can set the work mode switch

on the monitor panel to mode A, E, or B (or
L) and select proper engine torque and
pump absorption torque according to the
type of work.
The engine throttle and pump controller
detects the speed of the engine governor set
with the fuel control dial and the actual
engine speed and controls them so that the
pump will absorb all the torque at each out-
put point of the engine, according to the
pump absorption torque set in each mode.
: The L mode is on the multi-monitor specifica-
tion machine only.
PC200/220(LC)-7 10-159
(4)
12
1) Control method in each mode

Mode A
Matching point in mode A: Rated speed
Model PC200-7, PC220-7 SJP08758
Mode A 106.6 kW/1,900 rpm {143 HP/1,900 rpm} OR
08912
If the pump load increases and the pressure
rises, the engine speed lowers.
At this time, the controller lowers the pump
discharge so that the engine speed will be
near the full output point. If the pressure low-
ers, the controller increases the pump dis-
charge so that the engine speed will be near
the full output point. SJP08759
By repeating these operations, the controller
OR
constantly uses the engine near the full out-
put point. 08913
SJP08760
OR
08914
10-160 PC200/220(LC)-7
12
Mode E / Mode B / (Mode L)
Mode Digging Breaker Finishing
Partial output point 85% 75% 70%
Model PC200-7, PC220-7
Mode E 123 HP / 1,750 RPM
Mode B 108 HP / 1,650 RPM
(Mode L) 99 HP / 1,800 RPM
At this time, the controller keeps the pump

absorption torque along the constant horse-
power curve and lower the engine speed by
the composite control of the engine and
pump.
By this method, the engine is used in the low
fuel consumption area.
: The L mode is on the multi-monitor specifica-
tion machine only.
PC200/220(LC)-7 10-161
(4)
12
2) Function to control pump during

travel
If the machine travels in mode A, either of
engine speed and pump absorption torque
does not change.
SJP08764
If the machine travels in mode E or B, the
working mode does not change, but the OR
engine speed and pump absorption torque
rise to the same value as in mode A. 08920
If the machine travels in mode L, the work-

ing mode and engine speed do not change,
but the pump absorption torque is
increased.
: The L mode is on the multi-monitor specifi-
cation machine only.
3) Function to control when emergency

pump drive switch is turned ON
Even if the controller or a sensor has a
trouble, the functions of the machine can
be secured with pump absorption torque
almost equivalent to mode E by turning on
emergency pump drive switch (10).
In this case, a constant current flows from
the battery to the EPC valve for PC and the
oil pressure is sensed by only the EPC
valve for PC.
10-162 PC200/220(LC)-7
12
2. Pump/Valve control function
SJP08765
OR
08921
Function
The machine is matched to various types of
work properly with the 2-stage relief function
to increase the digging force, etc.
PC200/220(LC)-7 10-163
(11)
12
1) LS control function
The change point (LS set differential pressure)
of the pump discharge in the LS valve is
changed by changing the output pressure
from the LS-EPC valve to the LS valve accord-
ing to the operating condition of the actuator.
By this operation, the start-up time of the 08922
pump discharge is optimized and the com-
posite operation and fine control perfor-
mance is improved.
2) Cut-off function
When the cut-off function is turned on, the
PC-EPC current is increased to near the maxi-
mum value.
By this operation, the flow rate in the relief
state is lowered to reduce fuel consumption.
Operating condition for turning on cut-off
function
Condition
The average value of the front and rear

pressure sensors is above 27.9 MPa {285
kg/cm} and the one-touch power maximiz-
ing function is not turned on
The cut-off function does not work, however,

while the machine is travelling in mode A, the
arm crane operation, or swing lock switch is
turned on.
1. 2-stage relief function
The relief pressure in the normal work is 34.8
MPa {355 kg/cm}. If the 2-stage relief func-
tion is turned on, however, the relief pressure
rises to about 37.2 MPa {380 kg/cm}.
By this operation, the hydraulic force is
increased further.
Operating condition for turning on 2-stage
relief function
Condition Relief pressure
During travel
When swing lock switch is 34.8 MPa
turned on {355 kg/cm}
When boom is lowered
When one-touch power maxi- 37.2 MPa
mizing function is turned on {380 kg/cm}
When L mode is operated
10-164 PC200/220(LC)-7
(4)
12
3. One-touch power maximizing function
SJP08766
OR
08923
FUNCTION
Power can be increased for a certain time by

operating the left knob switch.
PC200/220(LC)-7 10-165
(11)
12
1) One-touch power maximizing function

When the operator needs more digging force
to dig up a large rock, etc., if the left knob
switch is pressed, the hydraulic force is
increased about 7% to increase the digging
force.
If the left knob switch is turned on in working
mode "A" or "E", each function is set automat-
ically as shown below.

Working mode Engine/Pump control 2-stage relief function Operation time Software cut-off function
34.8 MPa {355 kg/cm}
Matching at rated out- Automatically
A, E Cancel
put point reset at 8.5 sec
37.2 MPa {380 kg/cm}
10-166 PC200/220(LC)-7
(4)
12
4. Auto-deceleration function
SJP08767
OR
08924
FUNCTION
If the all control levers are set in NEUTRAL

while waiting for a dump truck or work, the
engine speed is lowered to the medium level
automatically to reduce the fuel consumption
and noise.
If any lever is operated, the engine speed
rises to the set level instantly.
PC200-7 10-167
12
OPERATION
WHEN CONTROL LEVERS ARE SET IN NEU-

TRAL
If all the control levers are set in NEUTRAL

while the engine speed is above the decelera-
tor operation level (about 1,400 rpm), the
engine speed lowers instantly to the first
deceleration level about 100 rpm lower than
the set speed.
If 4 more seconds pass, the engine speed
lowers to the second deceleration level
(about 1,400 rpm) and keeps at that level until
any lever is operated again.
WHEN ANY CONTROL LEVER IS OPERATED
If any control lever is operated while the

engine speed is kept at the second decelera-
tion level, the engine speed rises instantly to
the level set with the fuel control dial.
10-168 PC200-7
12
1. Auto-warm-up/Overheat prevention
function
SJP08768
OR
08925
FUNCTION
After the engine is started, if the engine cool-

ant temperature is low, the engine speed is
raised automatically to warm up the engine.
If the engine coolant temperature rises too
high during work, the pump load is reduced
to prevent overheating.
PC200/220(LC)-7 10-169
(11)
12
1) Auto-warm-up function
After the engine is started, if the engine cool-
ant temperature is low, the engine speed is
raised automatically to warm up the engine.
Operating condition (All) Operated
Coolant temperature: Below 30C.

Engine speed: Max. 1,200 rpm Engine speed: Max. 1,200 rpm

Resetting condition (Any one) Reset

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

If the engine coolant temperature rises too temperature rises above 95C.
high during work, the pump load and engine
speed are reduced to prevent overheating.
Operating condition Operation/Remedy Resetting condition

Coolant temperature: Below 105C

Work mode: Any mode Fuel control dial: Return to low idle
Coolant tempera- Engine speed: Low idle position once.
ture: Above 105C Monitor alarm lamp: Lights up Under above condition, controller
Alarm buzzer: Sounds is set to condition before operation
of function. (Manual reset)

Work mode: Mode A, E, OR B Coolant temperature: Below 102C
Coolant tempera- Engine speed: Keep as is. Under above condition, controller
ture: Above 102C Monitor alarm lamp: Lights up. is set to condition before operation
Lower pump discharge. of function. (Automatic reset)

Work mode: Mode A
Coolant tempera- Under above condition, controller
Engine speed: Keep as is.
ture: Above 100C is set to condition before operation
Lower pump discharge.
of function. (Automatic reset)

Work mode: Travel
Coolant tempera- Under above condition, controller
Engine speed: Keep as is.
ture: Above 95C is set to condition before operation
Lower travel speed.
of function. (Automatic reset)
10-170 PC200/220(LC)-7
(11)
12
6. Swing control function
SJP08769
OR
08926
FUNCTION
The swing lock and swing holding brake func-

tions are installed.
PC200/220(LC)-7 10-171
(11)
12
1) Swing lock and swing holding brake 2) Quick hydraulic oil warm-up function
functions when swing lock switch is turned on
The swing lock function (manual) is used to If swing lock switch (4) is turned on, the
lock machine from swinging at any position. pump-cut function is cancelled and the relief
The swing holding brake function (automatic) pressure rises from 34.8 MPa {355 kg/cm} to
is used to prevent hydraulic drift after the 37.2 MPa {380 kg/cm}. If the work equipment
machine stops swinging. is relieved under this condition, the hydraulic
Swing lock switch and swing lock/holding oil temperature rises quickly and the warm-up
brake time can be shortened.
Lock Lock
Function Operation
switch lamp
If swing lever is set in neu-

tral, swing brake operates in
Swing
about 5 sec. If swing lever is
OFF OFF holding
operated, brake is released
brake
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.
Operation of swing holding brake release

switch
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 release
switch.
Swing hold- ON OFF

ing brake (When control has (When controller is
release switch trouble) normal)
Swing lock
ON OFF ON OFF
switch
Swing
Swing lock Swing lock Swing lock
holding
Swing brake is turned is can- is turned
brake is
on. celed. on.
turned on.
a Even if the swing holding brake release

switch is turned on, if the swing lock switch is
turned on, the swing brake is not released.
a If the swing lock is reset, swinging is stopped
by only the hydraulic brake of the safety
valve. Accordingly, if swinging is stopped on
a slope, the upper structure may drift hydrau-
lically.
10-172 PC200/220(LC)-7
12
7. Travel control function
SJP08770
OR
08927
FUNCTION
The pumps are controlled and the travel

speed is changed manually or automatically,
to secure proper travel performance matched
to the type of work and jobsite during travel.
PC200/220(LC)-7 10-173
(11)
12
1) Pump control function during travel
If the machine travels in a work mode other
than mode A, the work mode and the engine
speed are kept as they are and the pump
absorption torque is increased.
a For details, see ENGINE/PUMP COMPOSITE
CONTROL FUNCTION.
2) Travel speed change function

i) Manual change with travel speed switch
If the travel speed switch is changed
between Lo, ( Mi), and Hi, the engine
throttle and pump controller controls the
pump capacity and motor capacity at each
gear speed as shown at right to change
the travel speed.
Travel speed Lo (Low ( Mi) (Mid- Hi (High

switch speed) dle Speed) speed)
Pump capac-
60 90 100
ity (%)
Motor capacity Max. Max. Min.
Travel speed
3.0 4.1 5.5
(km/h)
ii) Automatic change by engine speed

If the engine speed is lowered to 1,500
rpm or less with the fuel control dial dur-
ing travel;
the travel speed does not change even if
the travel speed switch is changed from
Lo, ( Mi) to Hi,
the travel speed changes to Mi level auto-
matically if the travel speed has been Hi.
iii) Automatic change by pump discharge
pressure
While the machine is traveling with the
travel speed switch at Hi, if the load is
increased because of an upslope ground,
etc. and the travel pressure keeps above
24.5 MPa {250 kg/cm} for 0.5 seconds, the
travel motor capacity is changed automat-
ically and the travel speed is lowered (to
the Mi level) (The travel speed switch is
kept at Hi, however).
While the machine is travelling at Mi
level, if the load is reduced on a flat or
08928
downslope ground, etc. and the travel
pressure keeps below 14.7 MPa {150 kg/
cm} for 0.5 seconds, the travel motor
capacity is changed automatically and the
travel speed is set to Hi again.
: The "Mi" mode is on the multi-monitor specifi-
cation machine only.
10-174 PC200/220(LC)-7
(4)
8. ATT flow control, circuit selector function (option)
FUNCTION
This function is available only with the ATT speci-

fication. The function acts as follows according to
the flow command and working mode from the
monitor.
1) It throttles the ATT PPC pressure and controls
the flow when the pedal is depressed fully.
2) In mode B and the other modes, it switches to
ATT single acting (B) or double acting (other
modes).
: The ATT flow control adjustment function is
on the multi-monitor specification machine
only.
PC200/220(LC)-7 10-175
(11)
9. System component parts

1) Engine revolution sensor
1. Sensor
2. Locknut
3. Wiring harness
4. Connector
FUNCTION
The engine revolution sensor is installed to

the ring gear of the engine flywheel. It electri-
cally calculates the number of the gear teeth
which pass in front of it and transmits the
result to the engine throttle and pump con-
troller.
A magnet is used to sense the gear teeth.
Each time a gear tooth passes in front of the
magnet, a current is generated.
10-176 PC200/220(LC)-7
12
2) 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/cm}
Resetting (OFF) Pressure: 0.3 0.5 MPa
{3.0 0.5 kg/cm}
FUNCTION
The junction block has 9 pressure switches,

which check the operating condition of each
actuator by the PPC pressure and transmit it
to the governor/pump controller.
PC200-7 10-177
12
3) Pump pressure sensor
1. Sensor
2. Connector
FUNCTION
The pump pressure sensor is installed to the

inlet circuit of the control valve. It converts
the pump discharge pressure into a voltage
and transmits it to the governor/pump con-
troller.
OPERATION
The oil pressure applied from the pressure

intake part presses the diaphragm of the oil
pressure sensor, the diaphragm is deformed.
The gauge layer facing the diaphragm mea-
sures the deformation of the diaphragm by
the change of its resistance, then converts the SJP08774
change of the resistance into a voltage and
transmits it to the amplifier (voltage ampli- OR
fier).
The amplifier amplifies the received voltage 08930
and transmits it to the governor/pump con-
troller.
Relationship between pressure P (MPa {kg/
cm}) and output voltage (V) is as follows.
V = 0.08 [0.008] x P + 0.5
10-178 PC200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
MULTI MONITOR SYSTEM
SJP08775
OR
08931
The monitor system monitors the condition The monitor panel also has various mode
of the machine with sensors installed on vari- selector switches and functions to operate the
ous parts of the machine. It processes and machine control system.
immediately displays the obtained informa-
tion on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, hydrau-
lic oil temperature, fuel level, etc.)
10-180 PC200/220(LC)-7
(11)
12
1. Monitor panel
OUTLINE
The monitor panel has the functions to dis-

play various items and the functions to
select modes and electric parts.
The monitor panel has a CPU (Central Pro-
cessing Unit) in it to process, display, and
output the information.
The monitor display unit consists of LCD
(Liquid Crystal Display). The switches are
flat sheet switches.
PC200-7 10-181
Input and output signals
CN-1 CN-2 CN-3

Pin Signal name Input/ Pin Signal name Input/ Pin Signal name Input/
No. output No. output No. output
1 Key ON Input 1 Engine coolant temperature Input 1 NC Input
2 Key ON Input 2 Fuel level Input 2 NC Input
3 Washer motor output Output 3 Radiator coolant level Input 3 NC Input
4 Starting signal Input 4 (Hydraulic oil level) Input 4 NC Input
5 Limit switch (W) Input 5 Air cleaner clogging Input 5 NC Input
6 GND 6 NC Input 6 NC Input
7 GND 7 Engine oil pressure Input 7 RS230C CTS Input
8 VB + Input 8 Engine oil level Input 8 RS230C RXD Input
9 Wiper motor (+) Output Input/ Input/
9 N/W signal 9 RS230C RXD
10 Wiper motor (-) Output Output Output
11 Buzzer ON signal Input Input/ Input/
10 N/W signal 10 RS230C RXD
12 Limit switch (P) Input Output Output
11 Battery charge Input 11 BOOTSW Input
12 Hydraulic oil temperature (analog) Input 12 NC Input
13 GND (for analog signal) 13 GND
14 Buzzer drive Input 14 CAN (SHIELD) Input
15 Limit SW (window) Input 15 CAN (+) Input
16 Buzzer cancel Input 16 CAN (-) Input
17 Swing lock Input
18 Preheat Input
19 Light switch Input
20 N/W GND
10-182 PC200/220(LC)-7
(11)
MONITOR CONTROL, DISPLAY PORTION
MONITOR PORTION
08932
1. Wiper motor 11. Fuel level monitor

2. Preheating monitor 12. Hydraulic oil temperature monitor
3. Swing lock monitor 13. Power max. monitor
4. Engine coolant temperature monitor 14. Auto-deceleration monitor
5. Hydraulic oil temperature gauge 15. Radiator coolant level caution
6. Engine coolant temperature gauge 16. Battery charge caution
7. Working mode monitor 17. Engine oil pressure caution
8. Service monitor 18. Engine oil level caution
9. Travel speed monitor 19. Air cleaner clogging
10. Fuel gauge 20. Maintenance time warning caution
PC200/220(LC)-7 10-183
(11)
MONITOR ITEMS AND DISPLAY
Symbol Display item Display method
Swing holding brake

Swing lock switch Swing lock monitor
release switch
OFF OFF OFF

Swing lock
ON OFF ON
SAT00098
OFF ON Flashes
ON ON ON
Continuous set time Preheating monitor status
Up to 30 sec. ON
Preheating
SAP00526 From 30 sec. to 40 sec. Flashes
More than 40 sec. OFF
Power Max. switch status Power max. monitor status
Lights up but goes out after

Power Max. Being pressed
approx. 9 sec. when kept pressed
Not being pressed Flashes
Engine
coolant
temperature
See gauge display on the next page
Hydraulic oil
temperature
Fuel level
10-184 PC200/220(LC)-7
(11)
Temperature, vol-
Gauge Range Indicator Buzzer sound
ume
A1 105 Red
A2 102 Red
Engine coolant tem- A3 100 Green

perature (C) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
Hydraulic oil tem- B3 100 Green

perature (C) B4 80 Green
B5 40 Green
B6 20 White
C1 289 Green
C2 244.5 Green
C3 200 Green
Fuel level (L)
C4 100 Green
C5 60 Green
C6 41 Red
PC200/220(LC)-7 10-185
(11)
hydraulic oil temperature gauge and the hydrau-

Checks before starting (caution lamps all light lic oil temperature monitor are stopped, and the
up), when maintenance interval is exceeded. following cautions are displayed.
If the checks before starting or maintenance inter-
val is exceeded items light up, the display of the
Check before When engine is When engine is run-
Symbol Display item
starting item stopped ning
When abnormal,
Engine oil pressure -- lights up and buzzer
sounds
Lights up when abnor-

Battery charge --
mal
When abnormal,
Radiator coolant Lights up when abnor-
lights up and buzzer
level mal
sounds

Engine oil level --
SAP00523
mal

Air cleaner clogging --
mal
SAP00521
Lights up when there is a warning. Lights up for

Maintenance only 30 sec. after key is turned ON, then goes
out.
When the above cautions are displayed, if the

The problems that have occurred are displayed in hydraulic oil temperature is high or low, only the
order from the left. symbol is displayed.
Condition of hydraulic oil Color of symbol

Low temperature (below B6) Black on white background
Normal (B6 - B2) No display

High temperature (B1 or up) White on red letters
10-186 PC200/220(LC)-7
(11)
Display category Symbol Display item Display range Display method
ON INT OFF
Displays set con-
Wiper
dition
Working Displays set

mode mode
Monitor
Displays set
Travel speed
speed
Auto-deceler- Displays actua-

ON OFF
ation tion status
Service Lights up when

Service meter meter indica- When service meter is working service meter is
tor working
PC200-7 10-187
SWITCHES
1. Working mode selector switch

2. Selector switch
3. Display brightness, contrast adjustment switch
4. Control switch
5. Window washer switch
6. Wiper switch
7. Maintenance switch
8. Travel speed selector switch
9. Auto-deceleration switch
10-188 PC200-7
Working mode selector switch

The condition of the machine changes accord- Switch that is Working mode sta-
ing to the switch that is pressed (A, E, L, B). It Display
pressed tus after setting
is possible to check the condition on the work-
ing mode monitor display. The relationship [A] A A mode (default)
between each working mode and the monitor [E] E E mode
display is shown in the table on the right.
[L] L L mode
Selector switch [B] B B mode
This is used when making detailed settings in
each working mode. (For details, see ATTACH-
MENT FLOW CONTROL FUNCTION for modes
A and E.)
Maintenance switch
Check the condition of the maintenance
items. (For details, see MAINTENANCE FUNC-
TION.)
Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON/OFF.
Use the auto-deceleration monitor display to
check the present condition.
When the working mode switch is operated to
switch the working mode, it is automatically
set to ON.
Travel speed selector switch

Each time the travel speed selector switch is Display Setting
pressed, the travel speed changes.
Crawler symbol + Lo Low speed (default)
Lo Mi Hi Lo . . . . . .
Use the travel speed monitor display to check Crawler symbol + Mi Medium speed
the present condition.
Crawler symbol + Hi High speed
The relationship between the set speed and
the monitor display in the table on the right.
Wiper switch
Each time the wiper switch is pressed, the
wiper setting changes OFF INT ON Wiper actuation
OFF . . . . . . Display Setting
status
Use the wiper monitor display to check the
Stowing stopped
present condition. None OFF
or now stowing
The relationship between the wiper setting
and the monitor display is as shown in the Intermittent actu-
Wiper symbol + INT INT
table on the right. ation
Continuous actu-
Wiper symbol + ON ON
ation
PC200-7 10-189
Window washer switch

While the switch is being pressed, window
washer liquid is sprayed out. There is a time
delay before the wiper starts.
Control switch
This is used for control when using the main-
tenance function or select function.
(For details, see each function.)
Display brightness, contrast adjustment

switch
Use this switch when adjusting the display
brightness and contrast.
(For details, see each function.)
10-190 PC200-7
SELECT MODE FUNCTION
This is used when setting the flow in each

working mode. It is possible to make the set-
ting when genuine attachment piping is
installed and the initial value setting function
on the service menu has been used to set to
ATTACHMENT INSTALLED.
It is possible to check on the working mode
monitor if this function can be set.
Working mode Monitor display
A mode [A] + crusher symbol
E mode [E] + crusher symbol
B mode [B] + flow symbol
METHOD OF USE
a Carry out the setting on the normal screen

1. A mode, E mode
1) Press select switch (1) on the monitor to
move to the adjustment screen.
2) Press control switch (2) to select the flow
level.
Control switch Actuation
Flow level bar graph

extends to the right

retracts to the left
3) After completing the level selection, press

input confirmation switch (3).
The selection flow level is confirmed and
Flow level Flow (l/min.) Remarks
the screen moves to the normal screen.
From the moment that the flow level is 8 430 Default
selected, the content of the selection is
7 350
reflected for the attachment flow.
H Before the input confirmation switch 6 250
is pressed, the flow level is not con-
5 170
firmed, so press return switch (4) to
return to the normal screen. This func- 4 140
tion can be used to return to the previ-
ously set flow. 3 115
The relationship between the set flow 2 90
level and the flow value is as shown in
the table on the right. 1 30
PC200/220(LC)-7 10-191
(11)
2. B mode
1) Press select switch (1) on the monitor to
move to the screen for selecting the 3-
stage flow level.
2) Press control switch (2), or input [01] - [03]
with the numeral 10-key pad to choose
one on the three flow levels.
No. 10-key pad operation
01
02
03

input confirmation switch (3).
The selected flow level is selected.
a Before the input confirmation switch
is pressed, the flow level is not con-
return to the operator screen. This
No. Flow level (l/min.) Remarks
function can be used to return to the
previously set flow. 01 180 Default
4) After the flow level is confirmed, the 02 140
screen changes to the screen shown in
the diagram on the right. 03 100
With this screen, it is possible to make
fine adjustment to the flow.
5) Press control switch (2) and select the
flow level.


10-192 PC200/220(LC)-7
(11)

input confirmation switch (3). When When When
Flow flow is flow is flow is
The selected flow level is confirmed and Remarks
level 100 L/ 140 L/ 180 L/
the screen moves to the operator screen.
min. min. min.
From the moment that the flow level is
selected, the content of the selection is 7 130 170 210
reflected for the attachment flow.
6 120 160 200
a Before the input confirmation switch
is pressed, the flow level is not con- 5 110 150 190
4 100 140 180 Default
return to the normal screen. This func-
tion can be used to return to the previ- 3 90 130 170
ously set flow.
2 80 120 160
The relationship between the set flow
level and the flow value is as shown in 1 70 110 150
the table on the right.
7) Check the set value with the working
mode monitor. Display level Set value (l/min.)
The relationship between the display
level and the set value is as shown in the 8 200 or 210
table on the right, and it is possible to
7 180 or 190
check the level of the flow that can be set.
6 160 or 170
5 140 or 150
4 120 or 130
3 100 or 110
2 80 or 90
1 70
PC200/220(LC)-7 10-193
(4)
MAINTENANCE FUNCTION
When the maintenance time for replacement,

inspection, or filling has approached for the 10
maintenance items, press maintenance switch (1)
and the caution display (yellow or red) appears
on the monitor display for 30 seconds after the
key is turned ON to remind the operator to carry
out lubrication maintenance.
a Maintenance items
Replacement
No. Item
interval (hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel filter 500
04 Hydraulic filter 1000
05 Hydraulic tank breather 500
06 Corrosion resistor (1000)
07 Damper case oil 1000
08 Final case oil 2000
09 Machinery case oil 1000
10 Hydraulic oil 5000
Option, so not set
a The above replacement intervals are set for

each item, and the time remaining to mainte-
nance is reduced as the machine is operated.
The content of the caution display differs
according to the ramaining time. The relation-
ship is as shown in the table below.
Display Condition
Remaining time for

maintenance for all
None
items is more than 30
hours
There is one or more

Notice display (black
items with less than 30
symbol displayed on
hours remaining time
yellow background)
for maintenance
There is one or more

Warning display (wiper
items with less than 0
symbol displayed on red
hours remaining time
background)
for maintenance
10-194 PC200/220(LC)-7
(4)
METHOD OF CHECKING STATUS

MAINTENANCE ITEMS
a Operate as follows when on the operator

screen.
1. Press maintenance switch (1) and switch to
the maintenance list display screen.
a The maintencance items are displayed as
symbols on the screen.
2. Press control switch (2), or use the 10-key pad
to input the number (01 - 10) of the mainte-
nance item to select the item.
a The cursor moves and the item is high-
lighted.
a The display method is the same as
described on the previous page (relation-
ship between remaining time and caution
display). If the remaining time is less than
30 hours, the item is displayed in yellow,
and if it is less than 0 hours, it is displayed
in red.
MAINTENANCE OPERATION
1. After completing the selection, press input

confirmation switch (3).
The screen will change to the maintenance
reset screen.
2. Use the maintenance reset screen to check
the content, and if there is any problem, press
input confirmation switch (3) to move to the
check screen.
If the wrong item is selected, press return
switch (4) to return to the maintenance list
screen.
3. Check the content on the check screen, and if
there is no problem, press input confirmation
switch (3) to reset the maintenance time.
After the reset is completed, the screen
returns to the maintenance list display
screen. To check the remaining time, or if the
wrong item is selected, press return switch (4)
to return to the maintenance list screen.
a The check screen shows the symbol for
the maintenance item and the set time in
large letters.
a The background color of the symbol for
the item where the maintenance tiem was
reset is the same as the background of the
screen, so it is possible to check that it has
been reset.
PC200/220(LC)-7 10-195
BRIGHTNESS, CONTRAST ADJUSTMENT

FUNCTION
This function is used to adjust the brightness and

contrast of the display.
ADJUSTMENT METHOD
a Operate as follows when on the operator

screen.
1. Press display brightness/contrast adjustment
switch (1) and switch to the adjustment
screen.
a Relationship between menu symbol and con-
tent.
No. Symbol Content
00 Return mark Return
01 Contrast
02 Brightness
2. Press control switch (2), or use the 10-key pad

to input the number (00 - 02) to select either
contrast or brightness.
After completing the selection, press input
confirmation switch (3) and return to the
adjustment screen.
Then press return switch (4) or use the 10-key
pad to set to [00] and press input confirma-
tion switch (3) to return to the normal screen.
3. Press control switch (2) and adjust the bright-
ness and contrast as desired.

Flow level bar graph 08937

10-196 PC200/220(LC)-7
(4)
SERVICE METER CHECK FUNCTION
When the starting switch is at the OFF posi-

tion, keep return switch (1) and control switch
(2) of the monitor pressed at the same time,
and the service meter is shown on the dis-
play.
This display is shown only while the two
switches are being pressed. When the
switches are released, the display goes out.
Note that it takes 3 - 5 seconds after the
switches are pressed for the service meter
display to appear.
DISPLAY LCD CHECK FUNCTION
On the password input screen or on the nor-

mal screen, if monitor return switch (1) and
working mode (A) switch are kept pressed at
the same time, all the LCD display will light 08943
up and the whole screen will become white,
so the display can be checked.
If any part of the display is black, the LCD is
broken.
PC200-7 10-197
3
USER CODE DISPLAY FUNCTION
If there is any problem in operating the

machine, the user code is displayed on the
monitor to advise the operator of the steps to
take.
This code display appears on the operator
screen.
On the operator screen, the user code is dis-
played on the portion for the hydraulic oil
temperature gauge.
If more than one user code is generated at the

same time, the user codes are displayed in
turn for 2 seconds each to display all the user
codes.
08945
10-198 PC200-7
3
While the user code is being displayed, if the

input confirmation switch is pressed, the ser-
vice code and failure code can be displayed.
If there is more than one service code or fail-

ure code, the display switches every 2 sec-
onds and displays all the service codes/failure
codes that caused the user code to be dis-
played.
Even if service codes/failure codes have
occurred, if they did not cause the user code
to be displayed, this function does not display
them.
If the telephone number has been set using

the telephone number input on the service
menu, it is possible to switch on the service
code/failure code and display the telephone
symbol and telephone number.
For details of inputting and setting the tele-
phone number, see SPECIAL FUNCTIONS OF
MONITOR PANEL in the TESTING AND
ADJUSTING section.
PC200/220(LC)-7 10-199
(9)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
7-SEGMENT MONITOR SYSTEM
SJP08775
OR
08931
The monitor system monitors the condition The monitor panel also has various mode
of the machine with sensors installed on vari- selector switches and functions to operate the
ous parts of the machine. It processes and machine control system.
immediately displays the obtained informa-
tion on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, hydrau-
lic oil temperature, fuel level, etc.)
10-200 PC200-7
3
12
1. Monitor panel
OUTLINE INPUT AND OUTPUT SIGNALS

CN-P01 CN-P02
The monitor panel has the functions to dis-
play various items and the functions to select Pin Pin
Signal neme Signal Name
No. No.
modes and electric parts.
1 Key switch (Battery) 1 Engine coolant temperature
The monitor panel has a CPU (Central Pro- 2 Key switch (Battery) 2 Fuel
cessing Unit) in it to process, display, and out-
3 Washer motor output 3 Radiator coolant level
put the information.
4 Key switch (Terminal C) 4 NC
The monitor display unit consists of LCD (Liq-
5 Wiper contact W 5 Air cleaner clogging sensor
uid Crystal Display) and LED (Light Emitting
6 GND 6 NC
Diode). The switches are flat sheet switches.
7 GND 7 Engine oil pressure sensor
8 VB + (24 V) 8 Engine oil level sensor
9 Wiper motor (+) 9 Network signal
10 Wiper motor (-) 10 Network signal
11 (Buzzer ON signal input) 11 Charge level
12 Wiper contact P 12 NC
13 GND (For analog signal)
14 NC
15 Wind limit switch
16 Buzzer cancel
17 Swing lock
18 Preheating
19 Limit switch
20 Network (GND)
PC200/220(LC)-7 10-201
(11)
Display section of monitor
1. Service meter display

2. Coolant temperature gauge
3. Coolant temperature caution
4. Digital meter display (Service code and user
code are displayed when trouble occurs
5. Fuel level caution
6. Fuel level gauge
7. Engine oil level caution lamp
8. Preheating pilot lamp
9. Swing holding brake pilot lamp
10. Oil maintenance pilot lamp
11. Battery charge caution lamp
12. Air cleaner clogging caution lamp
13. Engine oil pressure caution lamp
10-202 PC200-7
3
Monitored items and display

When engine is
Symbol Displayed item Display range While engine is running
stopped
Max. 1,500 rpm Lights when normal.
Max. 0.05 MPa (Goes off when
{0.5 kg/cm} engine is started.) Flashes and buzzer
Engine oil pressure
Min. 1,500 rpm sounds when abnormal.
Max. 0.15 MPa
{1.5 kg/cm}
Air cleaner clogging When clogged Goes off. Flashes when abnormal.
SAP00521
Lights when normal.

When charge is (Goes off when
Charge level engine is started.) Flashes when abnormal.
abnormal
Flashes when abnor-

Engine oil level Below low level Goes off.
SAP00523
mal.
When swing is Lights up when swing is locked. Flashes when

Packing (Swing lock)
locked swing holding brake release switch is turned on.
SAT00098
Oil maintenance See "OIL MAINTENANCE FUNCTION" on next page.
Lights up for 30 sec. when starting switch is set

Preheating When preheated to HEAT. Then, flashes for 10 sec. to indicated
SAP00526 completion of preheating.
Flashes at 102C or higher. Flashes and

Coolant temperature
buzzer sounds at 105C or higher.
Fuel level Flashes when below low level.
PC200-7 10-203
3
12
Oil maintenance function
1. Function and operation

At a set time after the engine oil is replaced, the
oil maintenance function is turned on to notify
the operator by the LED lamp on the monitor
panel that it is time to replace the oil. The func-
tion to indicate the phone number of the place to
make contact for service on the LCD unit is
installed, too.
1) Check of elapsed time

Nothing is displayed normally until point
B shown in the figure at right after this
function is reset. If the key is turned on
with the buzzer cancel switch processed
(for 2.5 seconds), however, the elapsed
time is displayed on the service meter
section.
2) Display of replacement of oil
If time passes point B after this function is
reset, the elapsed time is displayed on the
service meter section and the LED flashes
when the key is turned on.
2. Setting of time interval

1) The time interval is set in the interval set-
ting mode. It can be set to "125h", "250h",
"500h", "Not set", or "Demo-mode". The
default is "Not set".
2) To enter the interval setting mode, press
and hold the clock switch for 2.5 seconds.
3) If the buzzer cancel switch is pressed in
the interval setting mode, the clock dis-
play section changes to "" "125"
"250" "500" " d" in order. ("" corre-
sponds to "Not set" and " d" corresponds
to "Demo-mode".)
4) To save the time interval, set a desired
time (mode) on the monitor panel and
press and hold the clock switch for 2.5
seconds.
10-204 PC200-7
3
12
3. Timing and contents of display

1) When replacement of oil is displayed
The elapsed time is displayed for 10 sec-
onds after all segments are turned on.
Phone number is displayed for the next 10
seconds.
If the phone number has not been input,
however, the elapsed time is displayed for
20 seconds after all segments are turned
on.
2) When elapsed time is checked
The elapsed time is displayed for 10 sec-
onds after all segments are turned on.
4. Resetting elapsed time

1) When the replacement of oil and elapsed
time are displayed, press the buzzer can-
cel switch 10 seconds after all segments
are turned on (while the elapsed time is
displayed) and hold for 3 seconds. The
elapsed time is reset. After this operation,
"0h" is displayed for 1 second.
2) When the set time is changed, the elapsed
time is reset to "0h".
5. Demo-mode
1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and
replacement of oil is displayed when the
key is turned on. The elapsed time does
not increase, however. The time can be
reset in this mode. Turn on the key 3
times in this mode, and the time interval
is automatically set to "Not set" at the 4th
time and after. The elapsed time is set to
"0h" and counting of elapsed time is
started.
PC200-7 10-205
3
12
Mode selector switches
1. Travel speed switch

2. Auto-deceleration switch
3. Wiper switch
4. Work mode selector switch
(Including setting switch)
There are 4 sets of the mode selector Operations table of switch section
switches on the switch section. Each time one
switch is pressed, the machine condition The bold letters are the positions of the
changes. The current condition is indicated switches reset when the starting switch is
by the lighting of the LED above the switch. turned on.
The initial setting of only the work mode after Item Operation
the starting switch is turned on can be
changed. Work mode AEB
For how to change the setting, see "Work Auto-deceleration ONOFF
mode default setting mode" in TROUBLE-
SHOOTING-Display and special functions of Wiper OFFIntermittentON
monitor panel.
Travel speed HiLo
10-206 PC200-7
3
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
SENSOR
The signals from the sensors are input to the
panel directly. Either side of a sensor of con-
tact type is always connected to the chassis
ground.
Sensor When When

Type of sensor
name normal abnormal
Engine oil ON OFF

Contact
level (Closed) (Open)
Engine oil OFF ON

Contact
pressure (Open) (Closed)
Hydraulic
oil tempera- Resistance
ture
Coolant
Resistance
temperature
Fuel level Resistance
Air cleaner OFF ON

Contact
clogging (Closed) (Open)
PC200-7 10-207
3
12
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Engine oil pressure sensor (For low pressure)
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
Coolant temperature sensor

Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
10-208 PC200-7
3
12
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor
PC200-7 10-209
3
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS ................................................................. 20- 2

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS................................................................. 20- 4
TESTING AND ADJUSTING ...................................................................................................................... 20-101
TROUBLESHOOTING ................................................................................................................................ 20-201
Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
k When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is removed
when the coolant is still hot, the coolant will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
PC200/220(LC)-7 20-1
(11)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Applicable model PC200, 200LC-7
Engine SAA6D102E-2
Standard value Service limit

Item Measurement condition Unit
for new machine value
High idle 2,15070 2,15070
Engine speed Low idle rpm 1,03050 1,03050
Rated speed 1,950 1,950
At sudden acceleration Bosch Max. 1.0 Max. 2.0

Exhaust gas color
At high idle index Max. 0.5 Max. 1.5
Valve clearance Intake valve 0.25

mm
(Normal temperature) Exhaust valve 0.51
Difference
Oil temperature: 4060C MPa Min. 2.4 between cyinders
Compression pressure
Engine speed: 250rpm {kg/cm2} {Min. 24.6} Min. 1.0
{Min. 10.3}
(Coolant temperature: operating range) kPa Max. 1.2 5.1

Blow-by pressure
At rated output {mmH2O} {Max. 123} {520}
(Coolant temperature: operating range)

At high idle 0.390.64 0.25
Oil pressure MPa
{4.06.5} {2.6}
(SAE15W-40) {kg/cm2}
At low idle Min. 0.15 0.09
{Min. 1.5} {0.9}
Oil temperature Whole speed range (inside oil pan) C 80110 120
Fuel injection timing Before Top Dead Center (degree) 111 111
Fan belt tension mm 8 Min. 6, Max. 10

Deflection when pressed with finger
Air conditioner force of approx. 58.8 N{6 kg} mm 58 58
compressor belt tension
20-2 PC200/220(LC)-7
(11)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
PC220, 220LC-7
SAA6D102E-2
Standard value Service limit

for new machine value
2,20070 2,20070
1,03050 1,03050
2,000 2,000
Max. 1.0 Max. 2.0
Max. 0.5 Max. 1.5
0.25
0.51
Difference
Min. 2.4 between cyinders
{Min. 24.6} Min. 1.0
{Min. 10.3}
Max. 1.2 5.1

{Max. 123} {520}
0.390.64 0.25
{4.06.5} {2.6}
Min. 0.15 0.09
{Min. 1.5} {0.9}
80110 120
111 111
8 Min. 6, Max. 10
58 58
PC200/220(LC)-7 20-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Cate-
Item Measurement Condition Unit Standard value Permissible value
gory
Engine coolant temperature:
Within operation range
Hydraulic oil temperature: Within
2 pumps at relief 2,000100 2,000100
operation range
Engine at high idle
Arm in relief condition
Engine coolant temperature:
Engine speed
Within operation range

At 2-pump relief + one rpm
operation range 1,900100 1,900100
touch power up
Engine at high idle
Arm relief + One-touch power
max. switch in ON condition
Engine at high idle
Auto-deceleration switch in ON
Speed when auto-
condition 1,400100 1,400100
deceleration is operated
All control levers in NEUTRAL
condition
Boom control valve
Spool stroke
Arm control valve

Bucket control valve mm 9.50.5 9.50.5
Swing control valve
Travel control valve
Boom control lever 8510 8510
Travel of control
Arm control lever Engine stopped 8510 8510

Bucket control lever Control lever grip at center 8510 8510
levers
Max. reading up to stroke end mm

Swing control lever (exception lever play in NEU- 8510 8510
Travel control lever TRAL position) 11512 11512
Play of control lever Max. 10 Max. 15
15.73.9 Max. 24.5
Boom control lever
{1.60.4} {Max. 2.5}
15.73.9 Max. 24.5
Arm control lever
Hydraulic oil temperature: Within {1.60.4} {Max. 2.5}
of control levers
Operating force
operation range 12.72.9 Max. 21.6

Bucket control lever
Engine at high idle {1.30.3} {Max. 2.2}
N{kg}
Control lever grip at center 12.72.9 Max. 21.6
Swing control lever Pedal at tip {1.30.3} {Max. 2.2}
Max. reading up to stroke end
24.55.9 Max. 39.2
Lever
{2.50.6} {Max. 4.0}
Travel control lever
74.518.6 Max. 107.6
Papel
{7.61.9} {Max. 11}
20-4 PC200/220(LC)-7
(11)
PC220, 220LC-7
Standard value Permissible value
2,050100 2,050100
1,950100 1,950100
1,400100 1,400100
9.50.5 9.50.5
8510 8510
8510 8510
8510 8510
8510 8510
11512 11512
Max. 10 Max. 15
15.73.9 Max. 24.5
{1.60.4} {Max. 2.5}
15.73.9 Max. 24.5
{1.60.4} {Max. 2.5}
12.72.9 Max. 21.6
{1.30.3} {Max. 2.2}
12.72.9 Max. 21.6
{1.30.3} {Max. 2.2}
24.55.9 Max. 39.2
{2.50.6} {Max. 4.0}
74.518.6 Max. 107.6
{7.61.9} {Max. 11}
PC200/220(LC)-7 20-5
(1)

Cate-
gory
Hydraulic oil temperature: Within opera-
tion range
Engine at high idle 3.91.0 3.91.0
Unload pressure
Working mode: A mode {4010} {4010}
Hydraulic pump output pressure with all
control levers in NEUTRAL position
Boom Hydraulic oil temperature: Within opera- 34.81.0 33.336.8
Arm tion range {35510} {340375}
Engine at high idle
Bucket Working mode: A mode
Hydraulic pump output pressure with all
( 37.31.0
{38010} ) ( 36.339.2
{370400} )
measurement circuits relieved 30.91.5 28.932.9
Swing
Hydraulic pressure
Values inside parenthesis: Hydraulic oil {31515} {295335}

pressure with one-touch power max. 38.21.0 37.340.2
Travel MPa
switch in ON mode (reference only) {39010} {380410}
{kg/cm2}
Hydraulic oil temperature: Within opera-
tion range
Control circuit Engine running at high idle 3.230.2 2.843.43
source pressure Self pressure reducing valve output pres- {332} {2935}
sure with all control levers in NEUTRAL
position
Hydraulic oil tempera- When all con-
ture: Within operation trol levers in 3.91.0 3.91.0
range NEUTRAL {4010} {4010}
Self pressure Engine at high idle position
reducing valve Working mode: A mode When
Traveling speed: Hi traveling at 2.20.1 2.20.1
Hydraulic oil pump pres- half stroke {221} {221}
sure - LS pressure (without load)
deg. Max. 100 Max. 130

Swing brake angle Hydraulic oil temperature: Within operation (mm) () ()
range
Engine running at high idle
Working mode: A mode
Swing circle misalignment amount when
stopping after one turn
Swing
90 3.10.3 Max. 3.7
Hydraulic oil temperature:

Time taken to start Within operation range
sec.
swing Engine running at high
idle
Time required for passing 180 4.40.4 Max. 5.5
points 90 and 180 degrees
from starting point
20-6 PC200/220(LC)-7
(11)
PC220, 220LC-7
3.91.0 3.91.0
{4010} {4010}
34.81.0 33.336.8
{35510} {340375}
( 37.31.0
{38010} ) ( 36.339.2
{370400} )
30.91.5 28.932.9
{31515} {295335}
38.71.0 37.340.2
{39510} {380410}
3.230.2 2.843.43
{332} {2935}
3.91.0 3.91.0
{4010} {4010}
2.20.1 2.20.1
{221} {221}
Max. 165 Max. 200

() ()
2.90.3 Max. 3.5
4.30.4 Max. 5.4
PC200/220(LC)-7 20-7
(5)

Cate-
gory
Time taken to
Hydraulic oil temperature: Within operation sec. 24.22.5 Max. 30
swing
range
Time required for 5 more turns after making
initial one turn
15
Swing
BKP00103
Hydraulic drift of Hydraulic oil temperature: Within operation

range mm 0 0
swing
Engine stopped
Keeping upper structure transverse on
slope of 15 degrees
Notching a mating mark on inner and outer
races of swing circle
Mating mark misalignment amount during 5
minutes
Hydraulic oil temperature: Within operation
range
l/min
Leakage from Engine running at high idle
Max. 5 Max. 10
swing motor Swing lock switch: ON
Leakage amount for one minute during
swing relief
PC200: 46.260.4
PC200: 51.35.1
Lo PC200LC:
PC200LC: 55.95.6
50.365.5
PC200: 33.745.3
BKP00104
PC200: 37.53.8
Travel speed (1) Hydraulic oil temperature: Within ( Mi) PC200LC:
PC200LC: 40.84.1
operation range 36.748.9
Working mode: A mode PC200: 26.631.4
Time required for track shoes to PC200: 28.01.4
Hi PC200LC:
make 5 turns after making one ini- PC200LC: 30.51.5
29.034.0
tial idle turn
Travel
sec.
45
Lo 242.5 21.527.5
BKP00105
Travel speed (2) Hydraulic oil temperature: Within ( Mi) 172.5 14.520.5
operation range
Flat ground Hi 131.0 12.015.0
Time required for traveling 20 m
after 10 m trial run
: The Mi mode is on the multi-monitor specification machine only.
20-8 PC200/220(LC)-7
(11)
PC220, 220LC-7
25.7 +2.8
2.4
Max. 31
0 0
Max. 5 Max. 10
PC220: 53.6 +6.0

4.9 PC220: 48.763.6
PC220LC: PC220LC:
+6.5
58.1 5.3 52.868.6
PC220: 39.2 +4.4

3.6 PC220: 35.647.6
PC220LC: PC220LC:
+4.7
42.5 3.9 38.651.2
+1.5
PC220: 28.0 1.3 PC220: 26.731.5
PC220LC: PC220LC:
30.3 +1.6 28.933.9
1.4
242.5 21.527.5
172.0 15.020.0
131.0 12.015.0
PC200/220(LC)-7 20-9
(1)

Cate-
gory
45
BKP00105
operation range
Engine at high idle
Travel deviation Travel speed: Lo mm Max. 150 Max. 250
Solid and flat ground
Swerving amount while traveling
20 m (X) after initial 10 m trial run
20m
10m
Travel
BKP00107
12
BKP00108
Hydraulic drift of travel Hydraulic oil temperature: Within mm 0 0

operation range
Engine stopped
Parking machine on slope of 12
degrees with sprocket facing
upslope
Sliding distance for 5 minutes
operation range
Engine at high idle
Leakage of travel motor Traveling with sprocket locked l/min 13.6 27.2
Oil leakage amount for one
minute with traveling in relief con-
dition
Whole work equip-

ment (tooth tip fall Max. 600 Max. 900
amount)
Hydraulic drift of work equipment
BKP00110
Boom cylinder (cylin-
Work equipment
Hydraulic oil temperature: Within Max. 18 Max. 27

der retraction amount)
operation range
Flat and level ground mm
Work equipment in measurement
Arm cylinder (cylinder posture as illustrated above
Engine stopped Max. 160 Max. 240
extension amount)
Work equipment control lever in
NEUTRAL position
Fall amount for 15 minutes as
Bucket cylinder (cylin- measured every 5 minutes start- Max. 40 Max. 58
der retraction amount) ing immediately after initial set-
ting
20-10 PC200/220(LC)-7
(11)
PC220, 220LC-7
Max. 150 Max. 250
0 0
13.6 27.2
Max. 600 Max. 900
Max. 18 Max. 27
Max. 160 Max. 240
Max. 40 Max. 58
PC200/220(LC)-7 20-11
(1)

Cate-
gory
RAISE
3.30.4 Max. 4.7
Boom Hydraulic oil temperature: Within

operation range
LOWER
2.40.3 Max. 3.7
Time required from raise stroke
end till bucket touches ground
3.50.3 Max. 4.5
IN
Work equipment speed
Arm
sec.
operation range
OUT
Engine running at high idle 2.70.3 Max. 3.5

Time required from dumping stroke
Work equipment
end to digging stroke end

CURL
2.60.3 Max. 3.3
Bucket
operation range
DUMP
Engine running at high idle 1.90.2 Max. 2.7

Time required from dumping stroke
end to digging stroke end
Time lag
BKP00114
Boom sec. Max. 1.0 Max. 1.2
range
Engine running at low idle
Time required from raise stroke end till
bucket touches ground and pushes up
machine front
20-12 PC200/220(LC)-7
(11)
PC220, 220LC-7
+0.5 Max. 4.9

3.4 0.3
2.70.3 Max. 4.4
3.80.4 Max. 4.5
+0.4 Max. 3.5

2.9 0.2
2.90.3 Max. 3.3
2.20.3 Max. 2.7
Max. 1.0 Max. 1.2
PC200/220(LC)-7 20-13
(1)

Cate-
gory
BKP00115
Arm Hydraulic oil temperature: Within operation Max. 2.0 Max. 2.8
range
Time required from dumping stroke end till
bucket stops momentarily after control
lever is tilted to digging and starts to move
Time lag
again sec.
Work equipment
BKP00116
Bucket Hydraulic oil temperature: Within operation Max. 1.0 Max. 3.6
range
Time required from dumping stroke end till
bucket stops momentarily after control
lever is tilted to digging and starts to move
again
Cylinders range 4.5 20
leackage
Internal

cc/min
Leakage amount for one minute with cylin-
Center
der or travel to be measured in relief condi- 10 50
swivel joint
tion
Performance in compound operation
range
Engine at high idle
Traveling speed: Lo
Swerving amount Flat and level ground
in simultaneous Swerving amount (X) when traveling 20 m
operation of work after initial trial run of 10 m mm Max. 200 Max. 220
equipment and 20m
travel
10m BKP00107
Performance of
hydraulic pump
Hydraulic pump
See next page /min See next page
delivery
20-14 PC200/220(LC)-7
(11)
PC220, 220LC-7
Max. 2.0 Max. 2.8
Max. 1.0 Max. 3.6
4.5 20
10 50
Max. 200 Max. 220
See next page
PC200/220(LC)-7 20-15
(1)

Cate-
gory
Discharge amount of hydraulic pump (A mode)
Performance of hydraulic pump
Pump speed: At 1,950 rpm, PC current 310 mA
Test pump Discharge Average Standard value Judgement

discharge pressure of pressure for discharge standard lower
Check point
pressure other pump amount Q limit Q
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2}) (/min) (/min)
As desired P1 P2 P1+P2 See graph See graph

2
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the spec-
ified 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.
20-16 PC200/220(LC)-7
(11)

Cate-
gory
Discharge amount of hydraulic pump (A mode)
Performance of hydraulic pump
Pump speed: At 2,050 rpm, PC current 310 mA
Test pump Discharge Average Standard value Judgement

discharge pressure of pressure for discharge standard lower
Check point
pressure other pump amount Q limit Q
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2}) (/min) (/min)
As desired P1 P2 P1+P2 See graph See graph

2
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the spec-
ified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of
measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
PC200/220(LC)-7 20-17
(11)
Flow control characteristic of PC valve (STD)

The values in this table are used as reference values when carrying out troubleshooting.

Category Item Measurement Condition Unit Reference Value
Time required for turn-

Characteristics of
ing from 0 to 90 Hydraulic oil temperature: Within operation
PC flow control sec. 4.20.4
degrees with boom range
valve
raised Engine at high idle
Rated load applied to bucket
Time required till passing spot of 90 degrees
starting from illustrated posture and with boom
raised

Category Item Measurement Condition Unit Reference Value
Time required for turn-

Characteristics of
ing from 0 to 90 Hydraulic oil temperature: Within operation
PC flow control sec. 4.30.4
degrees with boom range
valve
raised Engine at high idle
Rated load applied to bucket
Time required till passing spot of 90 degrees
starting from illustrated posture and with boom
raised
20-18 PC200/220(LC)-7
(11)
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING ........................................................ 20-101-1

INSPECTION AND ADJUSTMENT OF ENGINE SPEED .......................................................................... 20-102
MEASUREMENT OF EXHAUST GAS COLOR.......................................................................................... 20-104
ADJUSTMENT OF VALVE CLEARANCE................................................................................................... 20-105
MEASUREMENT OF COMPRESSION PRESSURE ................................................................................. 20-107
MEASUREMENT OF BLOW-BY PRESSURE............................................................................................ 20-108
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING........................................................... 20-109
MEASUREMENT OF ENGINE OIL PRESSURE........................................................................................ 20- 111
ADJUSTMENT OF ENGINE SPEED SENSOR.......................................................................................... 20- 112
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION.......................................... 20- 112
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM............................................... 20- 113
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS........................................................ 20- 114
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION ............................................................. 20- 115
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE
IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL .................................... 20- 116
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE......................................... 20-120
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE ....................... 20-121
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE........................ 20-124
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE .............................................................. 20-128
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE ......................................................................... 20-131
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE ......................................................... 20-132
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT................................... 20-133
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT ......................................................... 20-134
MEASUREMENT OF OIL LEAKAGE AMOUNT ......................................................................................... 20-135
AIR BLEEDING OF VARIOUS PARTS ....................................................................................................... 20-137
INSPECTION PROCEDURES FOR DIODE............................................................................................... 20-139
SPECIAL FUNCTION OF MULTI-MONITOR PANEL ................................................................................. 20-140
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL .................................................................. 20-164
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM.................................................... 20-177
PC200/220(LC)-7 20-101
(12)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Qty
Test, measurement item Part No. Part name Remarks
1 799-205-1100 Tachometer kit 1 Digital indication: 6 99,999.9 rpm

Engine speed A
2 795-790-2500 Take off drive 1
Handy smoke
1 799-201-9001 1
checker
Exhaust gas color B Bosch index: 0 9
Commercially
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Engine valve clearance C Commercially
2 Thickness gauge 1
available
Compression
1 795-502-1205 1
Compression pressure D gauge
2 795-502-1700 Adapter 1
1 799-201-1504 Blow-by kit 1 0 4.9 kPa {0 500 mmH2O}
Blow-by pressure E
2 795-790-1950 Tool (Nozzle) 1
1 795-799-1131 Gear 1
Fuel injection timing F 2 795-799-1900 Pin assembly 1
3 795-799-1950 Lock pin 1
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 1
kit (analog type) {25, 60, 400, 600 kg/cm2}
1
Engine oil pressure G Oil pressure gauge
790-261-1204 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
kit (digital type)
2 799-401-2320 Oil pressure gauge 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
Swing circle bearing Commercially
H Dial gauge 1
clearance available
Hydraulic oil pressure of Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 1
work equipment, swing kit (analog type) {25, 60, 400, 600 kg/cm2}
and travel circuit 1
Oil pressure gauge
Control circuit oil pres- J 790-261-1204 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
kit (digital type)
sure
799-101-5220 Nipple 1 10 x 1.25 mm
Pump PC control circuit 2
oil pressure 07002-11023 O-ring 1
799-101-5002 1
1
Oil pressure gauge
790-261-1204 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Pump LS control circuit kit (digital type)
K
oil pressure 799-101-5220 Nipple 1 10 x 1.25 mm
2
07002-11023 O-ring 1
Differential pres-
3 799-401-2701 1
sure gauge
799-101-5002 1
Solenoid valve output 1
L Oil pressure gauge
pressure 790-261-1204 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
kit (digital type)
2 799-401-3100 Adapter 1 02 size
20-101-1 PC200/220(LC)-7
(12)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Qty
Test, measurement item Part No. Part name Remarks
799-101-5002 1
PPC valve output pres- kit (analog type) {25, 60, 400, 600 kg/cm2}
M
sure Oil pressure gauge
799-261-1204 1 Pressure gauge: 58.8MPa {600 kg/cm2}
kit (digital type)
Oil leakage inside Commercially
N Cylinder 1
hydraulic cylinder available
Coolant temperature,
P 799-101-1502 Digital thermometer 1 99.9 1,299C
oil temperature
79A-264-0021 Push-pull scale 1 0 294 N {0 30 kg}
Operating force Q
79A-264-0091 Push-pull scale 1 0 490 N {0 50 kg}
Commercially
Stroke, hydraulic drift R Scale 1
available
Commercially
Work equipment speed S Stopwatch 1
available
Commercially
Voltage, resistance T Tester 1
available
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor
panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connec-
tors and electric circuit diagram of each system.
PC200/220(LC)-7 20-101-2
(11)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE SPEED
INSPECTION AND ADJUSTMENT OF ENGINE SPEED

a Engine inspection and maintenance tools 2. Fit take off drive A2, and connect pickup set [1]
and meter [2] of tachometer kit A1.
Mark Part No. Part name
1 799-205-1100 Tachometer kit
A
2 795-790-2500 Take off drive
a Engine speed may be detected using a monitor-

ing function in the monitor panel (special function
furnished to the monitor panel).
3. Measure the engine speed after setting each

measurement condition.
1) Engine speed at low idle:
i) Set the fuel dial at low idle (MIN).
ii) Move all the control levers of work
equipment, swing and travel to the
NEUTRAL position.
k Be careful not to touch the strongly heated por-
2) Engine speed at high idle:
i) Turn the auto-decelerator OFF.
tion of the engine by accident while installing a
ii) Set the fuel dial at high idle (MAX).
measurement equipment.
iii) Move all the control levers of work
Inspection
NEUTRAL position.
1. Open up the engine hood and take off cover (1).
3) Engine speed at fuel pump relief
a Use a filter wrench to take off the cover.
i) Set the fuel dial at high idle (MAX)
ii) Put the arm in the digging relief position.
4) Engine speed when 2 pump relief and one-
touch power max. switch are set (near rated
engine speed)
i) Set the fuel dial at high idle (MAX).
ii) Put the arm in digging relief position and
keep the one-touch power max. switch
depressed.
a The one-touch power max. function is
automatically released in 8.5 seconds,
even if the knob switch is kept de-
pressed. Take measurement during the
period.
20-102 PC200/220(LC)-7
(12)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE SPEED
5) Engine speed when auto-decelerator is set

i) Turn the auto-decelerator ON.
ii) Set the fuel dial at high idle (MAX).
iii) Move all the control levers of work
NEUTRAL position.
a Approx. 5 seconds after all the control le-
vers are moved to the NEUTRAL posi-
tion, the rpm falls automatically. That is
when the rpm with the auto-decelerator
in motion should be measured.
4. Detach all the measurement tools after the

inspection, and make sure that the machine is
back to normal condition.
Adjustment
1. Adjustment of engine speed at low idle
a If the rpm at low idle deviates from the stand-
ard value, make adjustment using the adjust-
ment function provided in the monitor panel.
a For the adjustment procedures, refer to the
section, "Special function of monitor panel"
2. Adjustment of governor spring

a If the rpm at high idle deviates from the
standard value, or it is unsteady (hunting),
adjust the governor spring securing dimen-
sions, using the adjustment function in the
monitor panel.
a For the adjustment procedures, refer to the
section, "Special function of monitor panel"
PC200/220(LC)-7 20-103
(12)
TESTING AND ADJUSTING MEASUREMENT OF EXHAUST GAS COLOR
MEASUREMENT OF EXHAUST GAS COLOR

a Exhaust gas color measurement tool

1 799-201-9001 Handy smoke checker
B
2 Commercial product Smoke meter
k Be careful not to touch the highly heated parts,

while fitting and detaching a measurement tool.
a If no compressed air or power is not available in
the field, use Handy Smoke Checker B1. For re-
cording official data, use Smoke Meter B2.
1. Measurement with Handy Smoke Checker B1

1) Fit a filtering paper to Handy Smoke Checker 2) Connect the probe hose, accelerator switch
B1. outlet and air hose to the Smoke Meter B2.
2) Insert the exhaust gas intake pipe into the a Keep the pressure of the supplied com-
exhaust pipe. pressed air below 1.5 MPa {15 kg/cm2}.
3) Start the engine and keep it running until the 3) Connect the power cable to an outlet of AC
engine coolant temperature comes within socket.
the operating range. a Confirm that the Smoke Meter power
4) Let the exhaust gas stay on the filtering switch is in the OFF position, before con-
paper by operating a handle of Handy necting the power cable to an outlet.
Smoke Checker B1, when the engine speed 4) Fit a filtering paper by loosening the suction
is suddenly accelerated or kept at high idle. pump cap nut.
a Fit the filtering paper securely so that air
may not leak.
5) Move the Smoke Meter B2 power switch to
the ON position.
5) Take out the filtering paper and compare it

with the attached scale for judgement.
6) Detach the measurement tool after the
measurement, and make sure the machine
is back to normal condition. 6) Start the engine and keep it running until the
engine coolant temperature rises to the
2. Measurement with Smoke Meter B2 operating range.
1) Insert probe [1] of the Smoke Meter B2 into 7) Let the exhaust gas stay on the filtering
the exhaust gas pipe outlet, and fasten it to paper by depressing the accelerator pedal of
the outlet with a clip. Smoke Meter B2, when the engine speed is
suddenly accelerated or kept at high idle.
8) Put the polluted filtering paper on non-pol-
luted filtering paper (more than 10 sheets) in
the filtering paper holder, and read the indi-
cated value.
9) Detach the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
20-104 PC200/220(LC)-7
(12)
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE
ADJUSTMENT OF VALVE CLEARANCE

a Valve clearance adjustment tools
Mark Part No. Part Name

1 795-799-1131 Gear
C
2 Commercial product Filler Gauge
1. Open up the engine hood, and remove the fan

guard on the counterweight side.
2. Remove all cylinder head covers (1).
5. When No. 1 cylinder is at the top dead center,

adjust valve clearances indicated with a black
bullet mark (q) in the chart below in the follow-
ing manner.
a Chart of valve
3. Take off cap (2) and fit gear C1.
1) Insert filler gauge C2 in between rocker arm

(4) and valve stem (5), and adjust the valve
clearance with adjusting screw (6).
a For the adjustment, turn the adjusting
screw with filler gauge C2 inserted to the
extent that filler gauge C2 can be lightly
moved.
4. Turn the crankshaft clockwise with gear C1, 2) Fix adjusting screw (6) and then tighten lock
then match 1.6 TOP notch "a" of the crank pul-
3 Lock nut: 244 Nm{2.450.41kgm}
nut (7).
ley with pointer (3), and bring up No.1 cylinder to
the top dead center. a Check the valve clearance again after
a When No. 1 cylinder is at the top dead cent- tightening lock nut (7).
er, its rocker arm can be manually moved as a Proceed to the next step once all the adjust-
much as the valve clearance. If it cannot be ments of valve clearance indicated with a
moved, that means that No. 1 cylinder is not black bullet mark (q) have been completed.
yet at the top dead center. In that case, ro-
tate it by one more turn.
PC200/220(LC)-7 20-105
(5)
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE
6. Turn the crankshaft clockwise with gear C1,

then match 1.6 TOP notch "a" of the crank pul-
ley with pointer (3), and bring up No. 6 cylinder
to the top dead center.
7. When No. 6 cylinder is at the top dead center,

adjust valve clearances indicated with a white
bullet mark () in the chart.
a The adjustment procedures are the same as
introduced in Item 5 above.
8. After the adjustment, make sure that the
3 Cylinder head cover securing bolt:

244 Nm{2.450.41 kgm}
20-106 PC200/220(LC)-7
(1)
TESTING AND ADJUSTING MEASUREMENT OF COMPRESSION PRESSURE
MEASUREMENT OF COMPRESSION PRESSURE

a Compression pressure measurement tools

1 795-502-1205 Compression gauge
D
2 795-502-1700 Adapter
k Be careful not to get burnt by touching the ex-

haust manifold or muffler, or get caught with a
rotating parts, while taking measurement of
compression pressure.
1. Adjust the valve clearances.

a For the adjustment, refer to the section, "Ad-
justment of Valve Clearance". 6. Take off governor spring (2).
2. Make preparations for measuring the engine 7. Fasten governor lever (3) of the fuel injection
speed. pump, as it is in contact with the stopper on the
a For the preparations, refer to the section, "In- STOP side.
spection and adjustment of engine speed".
3. Warm up the engine until the engine oil temper-

ature rises up to 40 60 C.
4. Detach nozzle holder (1) of a cylinder to be

measured.
8. Crank up the engine with the engine starting

motor, and measure the compression pressure.
a Read off the value, when the needle of the
compression gauge steadies itself.
a When taking measurement of the compres-
sion pressure, be sure to measure the en-
gine rpm, too, so that it stays within the range
5. Fit Adapter D2 to the nozzle holder mounting, of designated measurement conditions.
and connect with gauge assembly [1] of com-
9. Detach the measurement tools after the mea-
3 Adapter: 60 9 Nm {6.12 0.92 kgm}
pression gauge D1.
surement, and make sure that the machine is
2 Nozzle holder:
3 Nozzle holder:
Seizure preventive (Molycoat 1000)
60 9 Nm {6.12 0.92 kgm}
PC200/220(LC)-7 20-107
(12)
TESTING AND ADJUSTING MEASUREMENT OF BLOW-BY PRESSURE
MEASUREMENT OF BLOW-BY PRESSURE

a Blow-by pressure measurement tools a Read off the blow-by pressure value, when
the needle of the gauge steadies itself.
1 799-201-1504 Blow-by kit
E
2 795-790-1950 Tool (Nozzle)
1. Fit tool E2 to blow-by hose (1) and connect it

with gauge [1] of blow-by kit E1.

2. Start the engine, and lock the travel.
k Insert pin [2] in between the sprocket and

the track frame to make sure to block the
travel.
3. Start the engine and keep it running until the

engine coolant temperature rises to the operat-
ing range.
4. Measure the blow-by pressure at high idle and

under the following conditions.
Work equipment, swing and travel:
Travel relief
20-108 PC200/220(LC)-7
(12)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING

a Fuel injection timing inspection and adjustment 4. Fix the fuel injection pump drive gear to match
tools injection timing by pushing drive gear timing pin
(3) in the direction of the front cover.
Mark Part No. Part Name a Injection timing requires adjustment of high
1 795-799-1131 Gear precision. Be sure to fix the drive gear with
F 2 795-799-1900 Pin Assembly timing pin (3) so as to match injection timing.
3 795-799-1950 Lock Pin a Push-in depth: 8 mm
a If timing pin (3) cannot be pushed in, turn the
crankshaft a bit fore or aft with gear F1.
Inspection a If it is found difficult to confirm the push-in
1. Open up the engine hood, and then detach the depth with timing pin (3) as installed in the
fan guard on the counterweight side. engine, metallic pin ass'y F2 may well be
2. Take off cover (1) and fit gear F1. used instead.
3. Turn the crankshaft clockwise with gear F1, then

5. Disconnect plug (4) of the fuel injection pump.
match 1.6 TOP notch "a" of the crank pulley with
pointer (2), and bring up No.1 cylinder to the top
6. Reverse and push in timing pin (5) of the fuel
dead center.
injection pump, and confirm its cut-out portion
a Take off the cylinder head cover for No.1 cyl-
matches with protruding portion b inside the
inder, and confirm that its rocker arm can be
pump.
manually moved as much as the valve clear-
a If timing pin (5) can be pushed in smoothly,
ance. If it cannot be moved, that means that
then injection timing is correct.
No.1 cylinder is not yet at the top dead cent- a If timing pin (5) cannot be pushed in smooth-
er. In that case, rotate it by one more turn. ly, injection timing is incorrect and requires
adjustment.
a If it is found difficult to confirm the push-in
depth with timing pin (5) as installed in the
engine, metallic pin ass'y F3 may well be
used instead.
PC200/220(LC)-7 20-109
(11)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
7. Detach the measurement tools after the mea- 3. Reverse and push in timing pin (5) of the fuel
surement, and make sure that the machine is injection pump, then match the pin cut-out por-
3 Cylinder head cover securing bolt:

back to normal condition. tion and protruding portion "b" inside the fuel
injection pump by turning the shaft.
k Do not forget to bring driving gear timing pin

244 Nm{2.450.45 kgm} a After fuel timing has been set, fix it by fitting
plug (4).
(3) and injection pump timing pin (5) back to
the pre-inspection condition.
a In case the adjustment follows, leave gear
F1 and timing pin (3) as they are.
Adjustment
a If fuel injection timing is found incorrect, adjust it
in the following manner.
1. Confirm that drive gear injection timing is fixed
with driving gear timing pin (3).
a If timing pin (3) was pulled back after the in-
spection had been completed, push it in
again following the foregoing inspection pro-
cedures.
4. Mount the fuel injection pump.
a For mounting the pump, refer to the same
section mentioned in Item 2 above.
5. Detach the measurement tools after the adjust-

ment, and make sure that the machine is back
k Before starting the engine again, check that

to normal condition.
driving gear timing pin (3) and fuel injection

pump timing pin (5) have been brought back
to the pre-adjustment condition.
2. Dismantle the fuel injection pump.

a For dismantling the fuel injection pump, refer
to the section, "FUEL INJECTION PUMP
ASSEMBLY" in the chapter of "DISASSEM-
BLY AND ASSEMBLY".
20-110 PC200/220(LC)-7
(1)
TESTING AND ADJUSTING MEASUREMENT OF ENGINE OIL PRESSURE
MEASUREMENT OF ENGINE OIL PRESSURE

a Engine oil pressure measurement tools 4. Measure engine oil pressure at low idle as well
as at high idle.
799-101-5002 Hydraulic tester
1 Digital type
790-261-1204
G hydraulic tester
Hydraulic tester
2 799-401-2320
(1.0 MPa {10 kg/cm2})
1. Take off engine oil pressure measurement plug

(1) on top of the engine filter.

2. Install nipple [1] of the hydraulic tester G1, and

connect it to hydraulic tester G2.

engine coolant temperature rises to the operat-
ing range.
PC200/220(LC)-7 20-111
(12)
ADJUSTMENT OF ENGINE SPEED SENSOR
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION
ADJUSTMENT OF ENGINE INSPECTION AND ADJUST-

SPEED SENSOR MENT OF AIR COMPRESSOR
BELT TENSION
a Detach engine speed sensor (1) before the ad-
justment, then check that there is no metal dust Inspection
stuck or damage at the tip and fit it again. Check belt deflection amount a when depressing the
mid point between the fan pulley and the compres-
sor with a thumb.
Belt depressing force: Equivalent to 58.8 N{6 kg}
1. Screw in sensor (1) until its tip comes to contact
3 Threaded portion:
with the tip of flywheel ring gear teeth (2).
Gasket sealant (LG-6)

Adjustment
2. Screw back sensor (1) from that position by the a If the belt deflection amount is not proper, adjust
prescribed angle. it in the following manner.
a Screw-back angle: 11/6 turn 1. Loosen two compressor bracket securing bolts
a Adjust clearance "a" between the sensor tip (1) (upper and lower).
and gear tooth tip to be 1.251.75 mm. 2. Loosen lock nut (2), and adjust the belt tension
by shifting the position of compressor bracket
3 Nut: 49.068.6 Nm{57 kgm}

3. Fasten sensor (1) with nut (3). (1) with adjust bolt (3).
3. Tighten lock nut (2).
4. Tighten two compressor bracket (1) securing
bolts.
a Check the belt tension again after the adjust-
ment.
4. After the adjustment, confirm that correct engine

speed is displayed in the monitor panel, using
the special monitoring function.
a For monitoring engine speed, refer to the
section, "Special Function of Monitor Panel".
20-112 PC200/220(LC)-7
(5)
TESTING AND ADJUSTING EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL

SYSTEM
a If a failure occurs on any of the engine control de- 3. Remove bolt (4), connect governor spring (3)
vices like fuel dial, governor pump controller or and fix it at the original position.
governor motor potentiometer, and the engine a Tilt the governor motor lever to the fuel injec-
gets out of control, first fix the engine rpm and tion pump side, but stop short of the gover-
take the following steps to avoid the immediate nor spring.
danger. a The governor lever of the fuel injection pump
a The suggested steps are provisional ones. Iden- is fixed at a near-idle position.
tify the cause for the failure and carry out repairs
promptly thereafter.
1. Disconnect E11 connector (1) of the governor

motor from E10 connector (2) of the governor
potentiometer.
k If the governor motor connector is left con-
nected, the governor motor will be suddenly
activated while the engine is running, caus-
ing a mechanical damage. Be sure to dis-
connect it.
a The following arrangement of wiring varies
partly from machine model to machine mod-
el.
4. Start the engine again and travel the machine to
a safe place.
5. Disconnect governor spring (3) and stop the

engine.
k Operation of stopping the engine is to be
carried out while the engine is running at
high speed. Be careful not to touch the parts
of high temperature or get caught in rotating
parts.
a If the governor spring is tilted all the way to
the fuel injection pump, the pump stops with
no more injection.
a Hold the governor spring until the engine
2. Detach governor spring (3) on the governor comes to a complete stop. Otherwise the
motor side. fuel injection pump automatically returns to
the low idle position, and the engine does not
stop.
PC200/220(LC)-7 20-113
(11)
TESTING AND ADJUSTING MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS

a Swing circle bearing clearance measurement 4. Hold the arm nearly perpendicular to the
tools ground, and lower the boom until the track
shoes will be lifted at the machine front.
Mark Part No. Part Name a The upper structure is raised at the front and
H Commercial Product Dial Gauge lowered at the rear at that time.
a Follow the steps explained below, when measur- 5. Read off the value in dial gauge H in this condi-
ing clearance in the swing circle bearing in the tion.
a The value indicated in dial gauge H express-
k Be careful not to put a hand or foot under the un-
actual machine.
es clearance in the bearings.
dercarriage, while taking measurement.
1. Fasten dial gauge H to swing circle outer race

(1) or inner race (2), and contact the probe with
the end surface of inner race (2) or outer race
(1) on the opposite side.
a Set dial gauge H at the machine front or rear.
6. Return the machine to the posture in Item 2

above, and confirm reading of dial gauge H is
zero.
a If zero value is not indicated, repeat the
steps in Items 3 through 5.
2. Keep the work equipment in the max. reach pos-

ture and keep the height of the bucket teeth tip
level with the lower height of the revolving
frame.
a The upper structure is lowered at the front
and raised at the rear at that time.
3. Set dial gauge H at zero point.
20-114 PC200/220(LC)-7
(1)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION

Inspection Adjustment
1. Travel the machine forward by the length of a If the track shoe tension is not proper, adjust it in
track on ground, keeping the engine at low idle, the following manner.
and stop the machine slowly.
1. When the tension is too strong
2. Place straight bar [1] on the track shoe between Discharge grease by loosening valve (1).
the idler and the 1st carrier roller. k Do not loosen valve (1) by more than one
a L beam is recommended for bar [1], because turn, because grease will spurt out due to its
of its deflection-free nature. internal high pressure.
3. Measure max. clearance a between bar [1] and 2. When the tension is too weak
the track shoe. Add grease through grease fitting (2).
Max. standard clearance a: 10 30 mm a If the normal track shoe tension is not re-
stored even after greasing, move the ma-
chine slowly back and forth.
PC200/220(LC)-7 20-115
(11)
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
TESTING AND ADJUSTING HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRES-

SURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING
AND TRAVEL
a Inspection and adjustment tools for hydraulic oil 2) Fit nipple J2 and connect it to oil pressure
pressure in hydraulic circuit for work equipment, gauge [1] of hydraulic tester J1.
swing and travel a Use an oil pressure gauge with the ca-
pacity of 58 MPa{600 kg/cm2}.
799-101-5002 Hydraulic Tester
1 Digital Type
790-261-1204
Hydraulic Tester
J
Nipple
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring
a Hydraulic oil pressure in the hydraulic circuit for

work equipment, swing and travel (hydraulic
pump output pressure) may be also confirmed
with a monitoring function in the monitor panel
(special function of monitor panel).
3) Start the engine and keep it running until the
Measurement hydraulic oil temperature rises to the operat-
1. Pre-measurement work ing range.
k Lower the work equipment to the ground,
then release the remaining pressure in the
piping by operating the control lever several
times after stopping the engine, and release
the pressure inside the hydraulic tank by
gradually loosening the oil filler cap.
1) Remove hydraulic oil pressure measuring
plugs (1) and (2).
Plug (1): For the circuit of front hydraulic
pump
Plug (2): For the circuit of rear hydraulic
pump
20-116 PC200/220(LC)-7
(11)
2. Combination of pump, actuator, and valve a Hydraulic oil pressure when the main relief
a When the oil from the pumps is divided, the valve is in relief condition is displayed.
front pump and rear pump act independently a If one-touch power max. switch is de-
on each actuator. Note that different actua- pressed, the oil pressure is turned to high re-
tors relieve different valves. lief pressure, and if released, it is turned to
a When the work equipment circuit or swing low relief pressure.
circuit is relieved singly, the oils of the pumps a Keep the swing lock switch in the OFF posi-
are merged. When the travel circuit is re- tion during the inspection. If it is moved to the
lieved singly, the oils of the pumps are divid- ON position, hydraulic oil pressure is turned to
ed. high relief pressure, as the constant 2-stage
a The actuators in the table are arranged in the relief valve is moved to the ON position.
order when the control valve is seen from the
front of the machine (and an attachment is 5. Measurement of swing relief pressure
installed to the service valve). 1) Start the engine and move the swing lock
switch to the ON position.
Pump Actuator Valve relieved 2) Measure hydraulic oil pressure when the
(R unload valve) (R main relief valve) engine is running at high idle and the swing
Service Safety valve circuit is relieved.
Rear Bucket R main relief valve a Hydraulic oil pressure when the swing motor
safety valve is relieved is displayed.
Left travel R main relief valve
a The swing motor relief pressure is lower than
Boom R main relief valve
the main relief pressure.
(Pump merge-divider valve) (Travel junction valve)
(Self-pressure reducing valve) 6. Measurement of travel circuit relief pressure
Swing Swing motor safety valve 1) Start the engine and lock travel.
Front Right travel F main relief valve k Put pin [2] in between the sprocket and the
Arm F main relief valve track frame to make sure locking travel.
(F unload valve) (F main relief valve)
(Centralized safety valve) (Back pressure valve)
3. Measurement of Unload Pressure

1) Start the engine.
2) Measure hydraulic oil pressure, when the
engine is running at high idle and all the
control levers are moved to the NEUTRAL
position.
a Hydraulic oil pressure when the unload valve
unloads is displayed.
4. Measurement of work equipment relief pres-

sure 2) Measure hydraulic oil pressure when the
1) Start the engine and move the cylinder to be engine is running at high idle and the travel
measured to its stroke end. circuit is relieved.
2) Measure hydraulic oil pressure, when the a Hydraulic oil pressure with the main relief
engine is running at high idle and the cylin- valve in relief condition is displayed. In the
der is in relief condition. travel circuit relief, the pressure is high pres-
sure relief all the time.
PC200/220(LC)-7 20-117
(11)
ADJUSTMENT OF ENGINE SPEED SENSOR
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HY-
Adjustment 6) Check the pressure again after the adjust-

a The unload valve and the safety valve for boom ment, following the aforementioned steps
LOWER cannot be adjusted. for measurement.
1. Adjustment of main relief pressure a If high pressure setting side is adjusted,
(high pressure setting side) low pressure setting side is also affect-
a If relief pressure of the high pressure in the ed, so adjust it, too.
work equipment and travel circuits is not nor-
mal, adjust the high pressure setting side of 2. Adjustment of main relief pressure (low
main relief valves (3) and (4) in the following pressure setting side)
manner. a When low pressure relief pressure of the
Main relief valve (3): Front main relief work equipment is not normal, or when ad-
valve justment is made of the high pressure setting
Main relief valve (4): Rear main relief side, adjust the low pressure side of the main
valve relief valve, too.
a The relief pressure at high pressure indi- a The relief pressure at high pressure indi-
cates that when the 2- stage relief valve is cates that when the 2-stage relief valve is
ON and pilot pressure is applied to the OFF and pilot pressure is not applied to the
switching port. switching port.
1) Disconnect pilot hose.
2) Fixing holder (8), loosen locknut (7).
3) Turn holder (8) to adjust the pressure.
a If the holder is
turned to the right, the pressure rises.
turned to the left, the pressure lowers.
a Quantity of adjustment per turn of hold-
er: Approx. 12.5 MPa {128 kg/cm2}
3 Lock nut:
4) Fixing holder (8), tighten locknut (7).
53.5 4.9 Nm {5.5 0.5 kgm}
1) Disconnect the pilot hose.

2) Fixing holder (6), loosen locknut (5).
3) Turn holder (6) to adjust the pressure.
a If the holder is
a Quantity of adjustment per turn of hold-
er: Approx. 12.5 MPa {128 kg/cm2}
3 Locknut:
4) Fixing holder (6), tighten locknut (5).
53.5 4.9 Nm {5.5 0.5 kgm}

5) Connect the pilot hose.
6) Check the pressure again after the adjust-
ment, following the aforementioned steps
for measurement.
5) Connect the pilot hose.
20-118 PC200/220(LC)-7
(5)
3. Adjustment of swing relief pressure

a If the swing relief pressure is not normal, ad-
just it with swing motor safety valve (9) in the
following manner.
1) Fixing adjustment screw (11), loosen lock-

nut (10).
2) Turn adjustment screw (11) to adjust the
pressure.
a If the adjustment screw is
a Quantity of adjustment per turn of adjust-
ment screw:
Approx. 6.71 MPa {Approx. 68.4 kg/cm2}
3) Fixing adjustment screw (11), tighten lock-
3 Locknut:
nut (10).
78 103 Nm {8.0 10.5 kgm}
4) Check the pressure again after the adjust-

ment, following the aforementioned steps
for measurement.
PC200/220(LC)-7 20-119
(8)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL

PRESSURE
a Control circuit oil pressure inspection and adjust- 3. Start the engine and keep it running until the
ment tools hydraulic oil temperature rises to the operating
range.
799-101-5002 Hydraulic Tester 4. Measure oil pressure with the engine running at
1 Digital Type high idle and all the control levers in the NEU-
790-261-1204
Hydraulic Tester TRAL position.
J
Nipple
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring
Measurement
k Lower the work equipment to the ground and
stop the engine. After the engine stops, operate
the control lever several times to release the re-
maining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hy-
draulic tank.
1. Remove oil pressure measurement plug (1).

5. Detach all the measurement tools after the mea-
a The relief valve of the control circuit basic pres-
sure is not adjustable.
2. Fit nipple J2 and connect it to oil pressure

gauge [1] of hydraulic tester J1.
a Use an oil pressure gauge with the capacity
of 5.9 MPa {60 kg/cm2}.
20-120 PC200/220(LC)-7
(11)
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL
TESTING AND ADJUSTING PRESSURE
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL

CIRCUIT OIL PRESSURE
a Pump PC control circuit oil pressure inspection Plug (3): For measuring the front PC
and adjustment tools valve delivery pressure
Plug (4): For measuring the rear PC
Mark Part No. Part Name valve delivery pressure
1 Digital Type
790-261-1204
Hydraulic Tester
J
Nipple
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring
Measurement
a Implement measuring the pump PC control cir-
cuit oil pressure after confirming that the work
equipment, swing and travel circuit oil pressure
as well as the control circuit original oil pressure

are normal.
2) Fit nipple J2 and connect to oil pressure
stop the engine. After the engine stops, operate gauge [1] of hydraulic tester J1.
the control lever several times to release the re- a Use an oil pressure gauge with the ca-
maining pressure in the piping. Then loosen the pacity of 58.8 MPa {600 kg/cm2}.
oil filler cap to release the pressure inside the hy- Photo shows pump delivery pressure
draulic tank. side
1. Measurement of PC valve output pressure

(servo piston inlet pressure)
a Measure PC valve output pressure (servo
piston inlet pressure) and pump delivery
pressure together, and compare the two
pressures.
1) Remove oil pressure measurement plugs
(1), (2), (3) and (4).
Plug (1): For measuring the front pump
delivery pressure
Plug (2): For measuring the rear pump
delivery pressure
Photo shows PC valve output pressure

side
PC200/220(LC)-7 20-121
(11)
3) Start the engine and keep it running until the 2. Measurement of PC-EPC output pressure
hydraulic oil temperature rises to the operat- 1) Remove oil pressure measurement plug (5).
ing range.
2) Fit nipple J2 and connect it to oil pressure

4) Measure the pump delivery pressure and gauge [1] of hydraulic tester J1.
PC valve output pressure (servo piston inlet a Use an oil pressure gauge with the ca-
pressure) together with the engine running pacity of 5.9 MPa {60 kg/cm2}.
at high idle, after setting the machine at the
following conditions.
Swing lock switch: ON (switched to high
pressure relief with 2-stage relief turned
ON)
Work equipment, swing and travel cir-
cuit: Arm digging relief
a Judgement method:
When the ratio between the pump deliv-
ery pressure and PC valve output pres-
sure (servo piston output pressure)
reaches the following values, both pres-
sures are judged normal.
Pressure to be hydraulic oil pressure rises to the operating
Pressure ratio
measured range.
Pump delivery
1
pressure
PC valve outlet
Approx. 0.6 (3/5)
pressure
a If there is any abnormality with PC valve

or servo piston, the PC valve output
pressure (servo piston output pressure)
equals to the pump delivery pressure, or
approximates to 0 pressure.
20-122 PC200/220(LC)-7
(11)
4) Measure the hydraulic oil pressure with all 1. Loosen locknut (8).
the control levers kept in the NEUTRAL a Before loosening the locknut, make match
position and the engine running at high idle marks at the adjustment screw end so that
and at low idle. you can see the position of the locknut be-
a If PC-EPC valve output pressure chang- fore the adjustment (and you can return the
es to the following values, it is judged locknut to its original position after turning it
normal. in reverse).
Engine Control Hydraulic oil 2. Turn adjustment screw (9) to the right or left to
speed lever pressure adjust.
2.9 MPa a Turn the adjustment screw in the following
Low idle
{30 kg/cm2} directions.
Neutral If the work equipment speed is low, turn
0 MPa
High idle the adjustment screw to the right (to in-
{0 kg/cm2}
crease the pump absorption torque).
If the engine speed lowers, turn the ad-
justment screw to the left (to decrease
Adjustment
the pump absorption torque).
a If any of the phenomena mentioned below oc-
curs and PC valve malfunctioning is suspected,
3 Locknut:
3. Tighten locknut (8).
adjust PC valves (6) and (7) in the following man-
ner.
27.5 34.3 Nm {2.8 3.5 kgm}
As workload increases, the engine rpm
sharply drops.
While the engine rpm is normal, the work
equipment moves slowly.
(6): Front pump PC valve
(7): Rear pump PC valve
a The width across flats of the locknut for the PC
valve is 13 mm and that of the adjustment screw
(inside width) is 4 mm. Do not turn any other
locknut or adjustment screw since it has effects
on the performance of the hydraulic pumps.
4. Confirm that the PC valve output pressure

(servo piston inlet pressure) is normal after the
adjustment, following the measurement steps
explained earlier.
PC200/220(LC)-7 20-123
(11)
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL

CIRCUIT OIL PRESSURE
a Pump LS control circuit oil pressure inspection Plug (3): For measuring the front LS
and adjustment tools valve delivery pressure
Plug (4): For measuring the rear LS
Mark Part No. Part Name valve delivery pressure
1 Digital Type
790-261-1204
Hydraulic Tester
Nipple
K 799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring
Differential Pressure
3 799-401-2701
Gauge
Measurement
a Measure pump LS control circuit oil pressure af-
ter confirming that the work equipment, swing
and travel circuit oil pressure as well as control

circuit original pressure are normal. 2) Fit nipple K2 and connect it to oil pressure
gauge [1] of hydraulic tester K1.
stop the engine. After the engine stops, operate a Use an oil pressure gauge with the ca-
the control lever several times to release the re- pacity of 58.5 MPa {600 kg/cm2}.
maining pressure in the piping. Then loosen the Photo shows pump delivery pressure
oil filler cap to release the pressure inside the hy- side
draulic tank.
1. Measurement of LS valve output pressure

(servo piston inlet pressure)
a Measure LS valve output pressure (servo
piston inlet pressure) and pump delivery
pressure together, and compare both pres-
sures thereafter.
(1), (2), (3) and (4).
delivery pressure
delivery pressure
Photo shows LS valve output pressure
side
20-124 PC200/220(LC)-7
(11)
3) Run the engine and raise the hydraulic oil 5) Detach all the measurement tools after the
temperature to the operating range and measurement and make sure that the
push up the track shoe on the side to be machine is back to normal condition.
measured with the work equipment.
For measuring oil pressure in front cir- 2. Measurement of LS differential pressure
cuit: Right track shoe a LS differential pressure can be obtained by
For measuring oil pressure in rear cir- measuring pump delivery pressure and LS
k Provide a working area of sufficient space,

cuit: Left track shoe pressure (actuator loaded pressure) at the
same time and computing the difference of
as the raised track shoe will be idly rotated. both pressures.
(1), (2), (3) and (4).
delivery pressure
delivery pressure
4) Measure pump delivery pressure and PC

valve output pressure (servo piston inlet
pressure) together with the machine set at
the following conditions and the engine run-
ning at high idle.
All the control levers of the work equip- Plug (3): For measuring the front pump
ment, swing and travel are kept in the LS pressure
NEUTRAL position and the travel control Plug (4): For measuring the rear pump
lever is kept at half stroke (one side of LS pressure
the track shoes idly rotates).
a Let the raised track shoe idly rotate, pay-
ing enough attention to the surroundings
for safety.
a Judgement method:
When the ratio between the pump deliv-
ery pressure and LS valve output pres-
sure (servo piston output pressure)
reaches the following values, both pres-
sures are judged normal.
Oil pressure ratio

Oil pressure to be
All control levers Travel at half
measured
in NEUTRAL stroke
Pump delivery
1
pressure Nearly equal
LS valve delivery pressure Approx.
pressure 0.6 (3/5)
PC200/220(LC)-7 20-125
(11)
2) Fit nipple K2 and connect it to oil pressure kProvide a working area of sufficient
gauge [1] of hydraulic tester K1 or differen- space, as the raised track shoe will be
tial pressure gauge K3. idly rotated.
a When using a differential pressure
gauge:
Connect pump delivery pressure to the
high pressure side and LS pressure to
the low pressure side.
A differential pressure gauge requires
DC 12V power. Connect it with one bat-
tery.
a When using an oil pressure gauge:
Use an oil pressure gauge with the ca-
pacity of 58.5 MPa {600 kg/cm2}.
The max. differential pressure is no
more than approx. 40 MPa {408 kg/cm2}.
The same gauge may be used through-
out the measurement. 4) Measure pump delivery pressure and LS
Photo shows pump delivery pressure pressure (actuator loaded pressure)
side together with the machine set at the follow-
ing conditions and the engine running at
high idle.
Traveling speed: Hi
All the control levers of the work equip-
ment, swing and travel are kept in the
NEUTRAL position and the travel control
lever is kept at half stroke (one side of
the track shoes idly rotates).
a Let the raised track shoe idly rotate, pay-
ing enough attention to the surroundings
for safety.
a Calculation of LS differential pressure:
LS differential pressure = Pump delivery
Photo shows LS pressure side pressure LS pressure
a If LS differential pressure is in the follow-
ing conditions, it is judged normal.
Control lever position LS differential pressure

All levers in Unload pressure
NEUTRAL (see standard value table)
Travel lever at Standard LS differential
half stroke pressure
(Run track idle) (See standard values table)
5) Detach all the measurement tools after the

measurement, and make sure that the
3) Run the engine and raise the hydraulic oil
temperature to the operating range and
push up the track shoe on the side to be
measured with the work equipment.
For measuring oil pressure in front cir-
cuit: Right track shoe
For measuring oil pressure in rear cir-
cuit: Left track shoe
20-126 PC200/220(LC)-7
(12)
3. Measurement of LS-EPC valve output pres- 4) Measure the oil pressure when the engine is
sure running at high idle and the travel speed
1) Remove oil pressure measurement plug (5). switch and travel lever are operated.
a If LS-EPC valve output pressure chang-
es to the following values, the pressure
is normal.
Travel Travel Control Hydraulic

Speed Lever Pressure
Approx. 2.9 MPa
Lo Neutral
{approx. 30 kg/cm2}
Hi Fine control (Note) 0 MPa {0 kg/cm2}
Note: Operate the travel control lever

slightly to the extent that the PPC
hydraulic oil pressure is turned ON.
(Stop the operation short of starting
2) Fit nipple K2 and connect it with oil pressure the machine)
gauge [1] of hydraulic tester K1. 5) Detach all the measurement tools after the
a Use an oil pressure gauge with the ca- measurement, and make sure that the
pacity of 5.9 MPa {60 kg/cm2}. machine is back to normal condition.
Adjustment
a When LS differential pressure is not normal, ad-
just it with LS valves (6) and (7).
(6): Front pump LS valve
(7): Rear pump LS valve

hydraulic oil temperature rises to the operat-
ing range.
1. Fixing adjustment screw (9), loosen locknut (8).
2. Turn adjustment screw (9) to adjust the differen-

tial pressure.
a If the adjustment screw is
turned to the right, the differential pres-
sure rises.
turned to the left, the differential pres-
sure lowers.
a Quantity of adjustment per turn of adjust-
ment screw (LS differential pressure):
Approx. 1.3 MPa {Approx. 13.3 kg/cm2}
PC200/220(LC)-7 20-127
(11)
3 Lock nut: 49 64 Nm {5 7 kgm}

3. Fixing adjustment screw (9), tighten locknut (8).
4. After the adjustment, confirm that LS differential

pressure is normal, following the steps for mea-
surement explained earlier.
20-127-1 PC200/220(LC)-7
(5)
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE

a Solenoid valve output pressure measurement
tools

1 Digital Type
790-261-1204
L Hydraulic Tester
799-401-3100 Adapter (Size 02)
2
02896-11008 O-ring
a Measure solenoid valve output pressure after

confirming that control circuit original pressure is

normal.
2. Fit adapter L2 and connect hoses (1) through
stop the engine. After the engine stops, operate (6) again.
the control lever several times to release the re-
maining pressure in the piping. Then loosen the 3. Fit nipple [1] of hydraulic tester L1 and connect
oil filler cap to release the pressure inside the hy- it to oil pressure gauge [2].
draulic tank. a Use an oil pressure gauge with the capacity
of 5.9 MPa {60 kg/cm2}.
1. Disconnect the hoses of solenoid valve to be

measured at the outlet side.
No. Solenoid valve to be measured
1 PPC lock solenoid valve
2 Travel interconnection solenoid valve
3 Merge/divide solenoid valve
4 Travel speed shifting solenoid valve
5 Swing and parking brake solenoid valve
6 2-stage relief solenoid valve
a Hose (1) is installed at the rear of operator's

cab, and hoses (2) through (6) are installed 4. Start the engine and keep it running until the
at the center of revolving frame. hydraulic oil temperature rises to the operating
range.
20-128 PC200/220(LC)-7
(11)
5. Run the engine at full throttle, then turn each

solenoid valve ON or OFF by operating the con-
trol lever switch, and measure the pressure.
a For conditions for turning each solenoid
valve ON or OFF, refer to the ensuing "Table
for Functioning Conditions" for each sole-
noid valve.
a How each solenoid valve functions can be
confirmed with monitoring function in the
monitor panel. (Special Function of Machine
Monitor)
a When each output pressure shows the fol-
lowing values, it is judged normal.
Solenoid valve Output pressure
OFF (Demagnetization) 0 MPa {0 kg/cm2}
ON (Excitation) 3 MPa {30 kg/cm2}
6. Detach all the measurement tools after the mea-

Table for Functioning Conditions - PPC lock Table for Functioning Conditions - Swing and
solenoid valve parking brake solenoid
Functioning condition Functioning Functioning condition Functioning
Locked OFF When all of them
Safety lock lever Work equipment, OFF
Released ON is OFF
swing, travel,
When any of them
signaling ON
is ON
Table for Functioning Conditions - Travel interconnection solenoid valve

Functioning condition Functioning
When the travel steering signal is ON ON
If front or rear pump pressure
Traveling operation only ON
When the travel steering signal is OFF is over 24.5 MPa {250 kg/cm2}
In conditions other than above OFF
Table for Functioning Conditions - Travel speed shifting solenoid valve

When overheat setting of the 2nd stage is ON
When the fuel dial indicates less than 1500 rpm
When the travel speed switch is at Lo (or Mi (*1))
OFF
The travel signal is OFF
If front or rear pump pressure is
When the travel speed switch is at Hi The travel 24.5 MPa{250 kg/cm2}
signal is ON If front or rear pump pressure is
14.7 MPa {150 kg/cm2} ON
In conditions other than above
*1: The "Mi" mode is on the multi-monitor specification machine only.
PC200/220(LC)-7 20-129
(12)
Table for Functioning Conditions - 2-stage relief solenoid valve

When overheat setting of the 1st stage is ON
When overheat setting of the 2nd stage is ON OFF
When all the signals for work equipment, swing and travel are OFF
When swing lock switch is ON
When travel signal is ON
When working mode is L mode (*1) ON
When boom LOWER signal is ON
When working mode is A or E When left knob If signals other than swing operation only is ON
mode switch is ON If swing operation only is ON
OFF
In conditions other than above
Table for Functioning Conditions - Merge/divide solenoid valve

When working mode is B mode When service signal is ON
When working mode is L mode
When boom RAISE and swing signals are ON
(*1)
ON
When travel signal only is ON
When compound travel marks When steering sig- If front or rear pump pressure is over
are ON nal is OFF 19.6 MPa {200 kg/cm2}
When swing lock switch is ON
When working mode is A mode OFF
When swing signal is ON
When travel signal is OFF
When service and If front or rear pump
When swing signal
arm dumping pressure is over ON
is OFF
signal are ON 19.6 MPa {200 kg/cm2}
In conditions other than above OFF
*1: The "L" mode is on the multi-monitor specification machine only.
20-130 PC200/220(LC)-7
(12)
TESTING AND ADJUSTING MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE

a PPC valve output pressure measurement tools 2. Fit nipple [1] of hydraulic tester M and connect
oil pressure gauge [2].
Mark Part No. Part name a Use an oil pressure gauge with the capacity
799-101-5002 Hydraulic tester of 5.9 MPa {60 kg/cm2}.
M Digital type
790-261-1204
hydraulic tester
a Measure PPC valve output pressure after con-

firming that control circuit original pressure is
normal.
1. Remove PPC oil pressure switches (1) through

(10) in the hydraulic circuits to be measured.
Circuit to be Circuit to be
No. No.
measured measured
1 Boom, RAISE(S06) 7 Swing, left(S03)
2 Boom, LOWER(S02) 8 Swing, right(S07)
3 Arm, DIGGING(S04) 9 Travel (black)(S30)
hydraulic oil temperature rises to the operating
4 Arm, DUMPING(S08) 10 Steering (red)(S31) range.
5 Bucket, DIGGING(S01)
6 Bucket, DUMPING(S05)
a Oil pressure switches (1) through (8) are in-

stalled in the PPC relay block, and (9) and (10)
are installed at the rear of operator's cab.
4. Measure the pressure when the engine is run-

ning at high idle and the control lever of the cir-
cuit to be measured is kept in the NEUTRAL
position and at the full stroke.
a If PPC valve output pressure is at the level
shown below, it is judged normal.
Lever control Hydraulic pressure
In NEUTRAL 0 MPa {0 kg/cm2}
Nearly equal to control
At full stroke original pressure
(See standard value table)
5. Detach all the measurement tools, and make

sure that the machine is back to normal condi-
tion.
PC200/220(LC)-7 20-131
(12)
TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE
a If there is excessive play in the work equipment

or swing lever, adjust it in the following manner.
1. Remove work equipment and swing PPC valve

ass'y.
2. Take off boot (1).
3. Loosen lock nut (2) and screw in disc (3) until it

contacts the heads of four pistons (4).
a Do not move the piston while doing this work.
4. Keep disc (3) in place and tighten lock nut (2) to
3 Lock nut: 98 127 Nm {10 13 kgm}

the specified tightening torque.
5. Install boot (1).
6. Install work equipment and swing PPC valve

ass'y.
20-132 PC200/220(LC)-7
(10)
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK
TESTING AND ADJUSTING EQUIPMENT
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK

EQUIPMENT
a If there is any hydraulic drift in the work equip- 2. Inspection of arm cylinder
ment (cylinders), check in the following manner 1) Operate the arm cylinder to move the arm to
to determine if the cause is in the cylinder pack- the position 100 mm before the digging
ing or in the control valve. stroke end, and stop the engine.
1. Inspection of boom and bucket cylinders

1) Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
a Fill the bucket with earth or apply the rat-
ed load to the bucket.
2) Operate the arm control lever to move the

arm to the digging side.
If the lowering speed increases, the cyl-
inder packing is defective.
If there is no change, the control valve is
defective.
a Operate the control lever with the engine
2) Operate the control lever to the RAISE posi- starting switch in the ON position.
tion or the bucket control lever to the CURL a If pressure in the accumulator has
position. dropped, run the engine for approx. 10
If the lowering speed increases, the cyl- seconds to charge the accumulator again.
inder packing is defective. [Reference]If the cause of the hydraulic drift is in the
If there is no change, the control valve is defective packing, and the above opera-
defective. tion is carried out, downward movement
a Operate the control lever with the engine is accelerated for the following reasons.
starting switch in the ON position. 1) If the work equipment is set to the above pos-
a If pressure in the accumulator has ture (holding pressure applied to the bottom
dropped, run the engine for approx. 10 end), the oil at the bottom end leaks to the head
seconds to charge the accumulator end. However, the volume at the head end is
again. small than the volume at the bottom end by the
volume of the rod end, so the internal pressure
at the head end increases because of the oil
flowing in from the bottom end.
2) When the internal pressure at the head end
increases, the pressure at the bottom end also
rises in proportion to this. The balance is main-
tained at a certain pressure (this differs accord-
ing to the amount of leakage) by repeating this
procedure.
3) When the pressure is balanced, the downward
movement becomes slower. If the lever is then
operated according to the procedure given
above, the circuit at the head end is opened to
the drain circuit (the bottom end is closed by the
check valve), so the oil at the head end flows to
the drain circuit and the downward movement
becomes faster.
PC200/220(LC)-7 20-133
(11)
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT
TESTING AND ADJUSTING RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASE OF REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
3. Inspection of boom lock valve k If the piping between the hydraulic cylinders or
1) Set the work equipment at the maximum the hydraulic motor and control valves is to be
reach and the boom top horizontal. Then disconnected, release the remaining pressure in
k Lock the work equipment control levers and

stop the engine. the following manner.
a There is no pressure remaining in the swing mo-
release the pressure inside the hydraulic tor circuit and travel motor circuit, but the internal
k Do not allow anyone to come under the

tank. pressure in the hydraulic tank affects them. So
open the oil filler cap of the hydraulic tank.
work equipment during the work.
2) Disconnect drain hose (1) of the control 1. Stop the engine, and loosen the oil filler cap
valve, and install a blind plug in the hose. gradually to release the pressure inside the
Part No. for the blind hose: 07376-70210 tank.
a Leave the control valve end open.
a If any oil leaks out from the port that is 2. Turn the engine starting switch to the ON posi-
left open, following hydraulic drift of the tion and operate the control levers several
work equipment, the boom lock valve is times.
defective (loose contact). a There must be power supply to the PPC lock
valve. Be sure to operate the control levers
with the engine starting switch in the ON po-
sition.
a When the levers are operated 2-3 times, the
pressure stored in the accumulator is re-
moved.
3. Start the engine, run at low idle for approx. 10

seconds to accumulate pressure in the accumu-
lator, then stop the engine.
4. Repeat the steps in Item 2 to 3 above several

times.
4. Inspection of PPC valve

Measure the amount of hydraulic drift of the
work equipment when the accumulator is
charged with pressure and the lock lever is put
to the LOCK and FREE positions.
a Operate the control lever with the engine
starting switch in the ON position.
a If pressure in the accumulator has dropped,
run the engine for approx. 10 seconds to
charge the accumulator again.
a If there is any difference in the hydraulic drift
between LOCK and FREE positions, the
PPC valve is defective (some internal fail-
ure).
20-134 PC200/220(LC)-7
(11)
TESTING AND ADJUSTING MEASUREMENT OF OIL LEAKAGE AMOUNT
MEASUREMENT OF OIL LEAKAGE AMOUNT

1. Measurement of oil leakage amount from 4) Continue this condition for 30 seconds, then
boom cylinder measure the oil leakage amount for one
1) Start the engine and keep it running until the minute.
ing range. Then extend the boom cylinder to
k Release the pressure remaining in the pip-

the stroke end.
ing, referring to the foregoing section of

"Release of Remaining Pressure in Hydrau-
lic Circuit".
2) Disconnect hose (1) at the cylinder head
k Be careful not to disconnect the hose at the

end and block the hose end with a plate.
cylinder bottom end.

3) Start the engine and apply the relief pres-
sure to the bottom end of the cylinder with
the engine running at high idle.
4) Continue this condition for 30 seconds, then 5) After the measurement, make sure that the
measure the oil leakage amount for one machine is back to normal condition.
minute.
3. Measurement of oil leakage amount from
bucket cylinder
ing range. Then extend the bucket cylinder

to the digging stroke end.

lic Circuit".
2) Disconnect hose (3) at the cylinder head

end block the hose end with a plate.

5) After the measurement, make sure that the 3) Start the engine and apply the relief pres-
machine is back to normal condition. sure to the bottom end of the cylinder with
2. Measurement of oil leakage amount from 4) Continue this condition for 30 seconds, then
arm cylinder measure the oil leakage amount for one
1) Start the engine and keep it running until the minute.
ing range. Then extend the arm cylinder to

the digging stroke end.

lic Circuit".
2) Disconnect hose (2) on the cylinder head

end and block the hose end with a plate.

3) Start the engine and apply the relief pres-
sure to the bottom end of the cylinder with
5) After the measurement, make sure that the
PC200/220(LC)-7 20-135
(11)
TESTING AND ADJUSTING MEASUREMENT OF OIL LEAKAGE AMOUNT
4. Measurement of oil leakage amount from 3) Disconnect drain hose (6) of the travel
swing motor motor and fit a blind plug in the hose end.
1) Disconnect drain hoses (4) and (5) and fit a 4) Start the engine and apply the travel relief
blind plug in the hoses. pressure with the engine running at high
2) Turn the swing lock switch to the ON posi- idle, then measure an oil leakage amount
kIn this measurement, an erroneous oper-

tion. under such conditions.
3) Start the engine. Apply the swing relief pres-
sure with the engine running at high idle and ation of the control lever will likely lead to
measure an oil leakage amount under such a serious accident. Make sure that all the
conditions. signals and confirmations are followed
a After keeping the conditions in 3) above without fail.
for 30 seconds, measure the oil leakage a After keeping the conditions in 4) above
amount for one minute. for 30 seconds, measure the oil leakage
a After the first measurement, turn the up- amount for one minute.
per structure by 180 degrees and take a Repeat the measurement several times,
measurement again in the same way. slightly rotating the motor, i.e. shifting
the position of valve plate and cylinder,
and the position of cylinder and piston,
and take measurement several times.
4) After the measurement, make sure that the

5. Measurement of oil leakage amount from 5) After the measurement, make sure that the
travel motor machine is back to normal condition.
1) Take off the travel motor cover.
2) Start the engine and lock the travel.
k Put pin [1] in between the sprocket and the
track frame to block the travel.
20-136 PC200/220(LC)-7
(11)
TESTING AND ADJUSTING AIR BLEEDING OF VARIOUS PARTS
AIR BLEEDING OF VARIOUS PARTS

Steps for air bleeding
Air bleeding item
1 2 3 4 5 6
Hydraulic Cylinder Swing Travel
Engine Operation
pump air air motor air motor air
Contents of Work start start
bleeding bleeding bleeding bleeding
Change of hydraulic oil
{ { { { { {
Cleaning of strainer (Note) (Note)
Replacement of return filter element { {
Repair or replacement of
hydraulic pump { { { {
Removing suction pipe
Repair or replacement of control valve { { {
Replacement of cylinder
{ { {
Removing cylinder piping
Replacement of swing motor
{ { {
Removing swing motor piping
Replacement of travel motor swivel
{ { {
Removing travel motor swivel piping
Note: Bleed air from the swing motor and travel motor only when oil in the casing is drained.
1. Air bleeding from hydraulic pump 2. Air bleeding from hydraulic cylinder
1) Loosen air bleeding plug (1) and confirm 1) Start the engine and kept it running at low
that oil seeps out from the plug. idle for 5 minutes.
2) If the oil seepage is confirmed, tighten air 2) Raise and lower the boom 4 to 5 times with
bleeding plug (1). the engine running at low idle.
3 Air bleeding plug: a Be careful not to apply the relief pres-
7.89.8 Nm{0.81.0 kgm} sure, stopping the piston rod approx.
a Precautions for starting engine 100 mm before its stroke end.
When starting the engine after the air bleed- 3) Repeat the steps in Item 2) above, but this
ing work explained above, run the engine at time with the engine running at high idle.
low idle for 10 minutes. 4) Apply the relief pressure by extending the
If the engine coolant temperature is low and piston rod to its stroke end and with the
an automatic engine warming-up function is engine running at low idle.
relied on, use the fuel dial, when it becomes 5) For bleeding air from the arm cylinder and
necessary to cancel it. bucket cylinder, follow the same steps
explained in Item 2) through 4) above.
a In case a cylinder is replaced with new one,
it is advised to bleed air from the new one be-
fore mounting the work equipment. It is es-
pecially so with the boom cylinder, because
its rod does not extend to the stroke end of
LOWER side, after the work equipment is
mounted.
PC200/220(LC)-7 20-137
(11)
TESTING AND ADJUSTING AIR BLEEDING OF VARIOUS PARTS
3. Air bleeding from swing motor

1) Start the engine and run it at low idle.
2) Bleed air from the motor by swinging the
upper structure slowly.
4. Air bleeding from travel motor

1) Start the engine and run it at low idle.
2) Loosen air bleeding plug (2) and confirm
that oil seeps out from the plug.
3) If the oil seepage is confirmed, tighten air
bleeding plug (2).
3 Air bleeding plug:
27.535.3 Nm{2.83.6 kgm}
20-138 PC200/220(LC)-7
(11)
TESTING AND ADJUSTING INSPECTION PROCEDURES FOR DIODE
INSPECTION PROCEDURES FOR DIODE

a Check an assembled-type diode (8 pins) and sin- 3) Determine if a specific diode is good or no
gle diode (2 pins) in the following manner. good with the indicated value.
a The continuity direction of an assembled-type di- No change in the indicated value: No
ode is as shown in the diagram below. continuity (defective).
a The continuity direction of a single diode is Change in the indicated value: Continui-
shown on the diode surface. ty established (normal) (Note)
Note: A silicon diode shows a value between
400 and 600.
2. When using analog type circuit tester

1) Switch the testing mode to resistance range.
2) Check the needle swing in case of the fol-
lowing connections.
i) Put the red probe (+) of the test lead to
the anode (P) and the black probe () to
the cathode (N) of diode.
ii) Put the red probe (+) of the test lead to
the cathode (N) and the black probe ()
to the anode (P) of diode.
3) Determine if a specific diode is good or no
good by the way the needle swings.
1. When using digital type circuit tester If the needle swings in Case i), but does
1) Switch the testing mode to diode range and not swing in Case ii): Normal (but the
confirm the indicated value. breadth of swing (i.e. resistance value)
a Voltage of the battery inside is displayed will differ depending on a circuit tester
with conventional circuit testers. type or a selected measurement range)
2) Put the red probe (+) of the test lead to the If the needle swings in either case of i)
anode (P) and the black probe () to the and ii): Defective (short-circuited inter-
cathode (N) of diode, and confirm the dis- nally)
played value. If the needle does not swing in any case
of i) and ii): Defective (short-circuited in-
ternally)
PC200/220(LC)-7 20-139
(12)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
[1] Figure input switch 1 [6] Figure input switch 6 [ ] Return switch
[2] Figure input switch 2 [7] Figure input switch 7 [ ] Upward move switch
[3] Figure input switch 3 [8] Figure input switch 8 [ ] Downward move switch
[4] Figure input switch 4 [9] Figure input switch 9 [ ] Input confirmation switch
[5] Figure input switch 5 [0] Figure input switch 0
20-140 PC200/220(LC)-7
Monitor panel functions - conventional and special

The monitor panel is provided with conventional and special functions, and various kind of information are
shown in the multi-display. Display items consists of automatic display items that are preset in the monitor panel
and others that are shown by switch operations.
1. Conventional function: Operator's Menu

This is a function by which an operator can set or show displays by switch operations. The display contents
are those which are normally shown.
2. Special function: Service Menu

This is a function by which a service mechanic can set or show displays by special switch operations. The
display contents are those which are not normally shown. It is mainly used for inspection, adjustment, trou-
ble-shooting or special setting of machines.
Operator's Menu Service Menu

1 Function for inputting and setting password 16 Function for monitoring [01]
2 Function for showing Komatsu's logo Function for fail- Electrical system
17
Function for machine inspection before start- ure history [02] Mechanical system
3
ing day's work
18 Function for maintenance history [03]
4 Function for showing machine maintenance
19 Function for maintenance mode change [04]
5 Function for showing precaution items
20 Function for recording phone No. [05]
Function for confirming working mode and
6 Mode with key on
travel speed
Function for ini- Language
7 Function for display of ordinary items tial value set-
21 Unit
Function for adjusting display luminance and ting and default
8 [06] Attachment installed/No
contrast
attachment installed
Function for adjusting breaker and attachment
9 Adjustment of governor
flow rate
lever stroke
Function for confirming maintenance informa-
10 Fuel pump absorbin torque
tion Function for
22
11 Function for showing service meter reading adjustment [07] RPM at low idle
12 Function for checking display LCD Adjustment of oil flow to
attachment
Function for showing occurrence of caution
13
item
14 Function for showing users' code No.
Function for showing service code No. and
15
failure code No.
PC200/220(LC)-7 20-141
(11)
Operation of Operator's Menu and Display (Outline)
a This section introduces only the outline of the op-

erator's menu. For details on the contents and
operation steps of each menu, refer to the oper-
ation and maintenance manual or the chapter of
"STRUCTURE AND FUNCTION" in this shop
manual.
1. Function for inputting and setting password

When the engine starting switch is turned ON,
the password inputting display is shown.
a This display is shown only when a password
is registered.
2. Function for showing KOMATSU logo

When a password is inputted, or when the
engine starting switch is turned ON, KOMATSU
logo is shown for two seconds.
3. Function for machine inspection before

starting day's work
Following the KOMATSU logo, the display of
machine inspection before starting day's work is
shown for 2 seconds.
4. Function for machine maintenance

Following the display of machine inspection
before starting day's work, the maintenance
mark appears for 30 seconds, if there is an oil fil-
ter whose maintenance time is approaching or
has just passed.
a This display appears only when the mainte-
nance function is set.
20-142 PC200/220(LC)-7
(1)
5. Function for showing precaution items

If there is any item of machine inspection before
starting day's work that indicates some abnor-
mality, a corresponding symbol mark is shown
after the display of machine inspection before
starting day's work.
6. Function for confirming working mode and

travel speed
After the display of machine inspection before
day's work, amplified symbol marks for working
mode and travel speed are shown for two sec-
onds to urge an operator to confirm the setting.
7. Function for display of ordinary items

The display of confirming working mode and
travel speed is switched to this display of ordi-
nary items.
If the working mode setting or travel speed
setting is changed, or auto-deceleration or
windshield wiper setting is activated while
this is in display, an amplified corresponding
symbol mark is shown for two seconds.
In this display, a symbol mark for preheat
monitor is shown only when preheating is
carried out.
8. Function for adjusting display luminance

and contrast
Luminance as well as contrast of the display can
be adjusted by operating the display adjusting
switch.
PC200/220(LC)-7 20-143
9. Function for adjusting breaker and attach-

ment flow rate (For machines equipped with
breaker attachment)
When a breaker or other attachments are used,
hydraulic pump flow rate can be adjusted by
operating the select switch.
Note that the symbol mark and contents of
display partially differ between the breaker
and the other attachments.
10. Function for confirming maintenance infor-

mation
Detailed information on maintenance items (set
time and elapse of time) can be confirmed and
resetting after the confirmation is feasible by
operating the maintenance switch.
Use service Menu for setting or releasing
maintenance items and setting maintenance
time.
11. Function for showing service meter reading

Only the service meter reading can be shown by
the following switching operation, when the
engine starting switch is turned OFF.
Switching operation: [ ] + [ ] (synchro-
nized switching operation)
12. Function for checking display LCD

Display of the Display LCD can be confirmed by
the following switching operation in the display
of inputting and setting password as well as in
the display of ordinary items
Switching operation: [ ] + [A] (synchro-
nized switching operation)
All the LCD light up, turning the entire screen
white. If there is no showing in black, the dis-
play is normal.
This display returns to the immediately pre-
ceding one, if making any other switching
operation.
20-144 PC200/220(LC)-7
13. Function for showing occurrence of caution

item
If any of the caution items occurs, the magnified
corresponding symbol mark is shown for two
seconds and thereafter stays on the display as a
small symbol mark until it is dissolved.
14. Function for showing users' code No.

When a trouble occurs on the machine, the
user's code is automatically displayed depend-
ing on the magnitude of the trouble to call atten-
tion of the operator for a proper action.
a This display turns to the display of service
code and failure code, if operating the switch
(Refer to Item No. 15)
a Relation between User Code and Action Directed to Operator
User
Failed System Action Directed to Operator
Code
Ordinary work may be resumed by turning the emergency pump drive switch ON,
E02 PC-EPC Valve
but call for the inspection service immediately.
Release the brake after turning emergency swing and parking brake switch ON.
When applying the swing brake, operate the swing lock switch manually. The
E03 Swing Brake
swing brake may not be released depending on the nature of the trouble. In either
case, call for the inspection service immediately.
The governor control has become inoperable. Operate the governor control lever
E05 Governor manually. For fixing the lever at full throttle position, use a fixing bolt provided at
the bracket. In this case, call for the inspection service immediately.
PC200/220(LC)-7 20-145
(1)
15. Function for showing service code No. and

failure code No.
If the following switching operation is made
while the users' code No. is shown, a phone
symbol (if registered), phone numbers (if regis-
tered), service code No. and failure code No.
are shown in turn.
Switching operation: [ ] (keep the switch
depressed)
a The following items are repeatedly displayed
in order according to the operation of the
switch.
Telephone symbol mark

Telephone No.

Service code No. and failure code No.
a The telephone symbol mark and telephone
No. are shown only when they are registered
in the monitor panel.
For registration, correction and deletion of
telephone No., use Service Menu.
a For details on the displayed service code No.
and failure code No., refer to the Table for
Service and Failure Code Nos.
20-146 PC200/220(LC)-7
(10)
Table for Service and Failure Code Nos.
Classification
Service Code Failure Code
User Code
Failure
No.
Code
Content Code No. Location Phenomenon
No.
Abnormality
E101 Abnormal data in error history DAF0KT Failure history
in data
Short circuit in wiper motor drive, normal rota-
Windshield wiper motor (nor-
E112 DY2DKB Short circuit
tion system mal rotation)
Short circuit in wiper motor drive, reverse rota-
Windshield wiper motor
E113 DY2EKB Short circuit
tion system (reverse rotation)
E114 Short circuit in windshield washer drive
DY2CKB Windshield washer motor Short circuit
E115 Abnormality of windshield wiper in motion
DY20KA Windshield wiper motor Disconnection
E116 Abnormality of windshield wiper in retraction
DY20MA Windshield wiper motor Malfunctioning
Travel interlocking solenoid
E201 Short circuit in travel interconnection solenoid DW91KB Short circuit
valve
E03 E203 Short circuit in swing holding brake solenoid DW45KB Swing holding solenoid valve Short circuit
E204 Short circuit in merge/divide solenoid DWJ0KB Merge solenoid valve Short circuit
E205 Short circuit in 2-stage relief solenoid DWK0KB 2-stage relief solenoid valve Short circuit
Travel Hi-Lo shifting solenoid
E206 Short circuit in travel speed shifting solenoid DW43KB Short circuit
valve
Travel interlocking solenoid
E211 Disconnection in travel interlocking solenoid DW91KA Disconnection
valve
E03 E213 Disconnection in swing holding brake solenoid DW45KA Swing holding solenoid valve Disconnection
E214 Disconnection in merge/divide solenoid DWJ0KA Merge solenoid valve Disconnection
E215 Disconnection in 2-stage relief solenoid DWK0KA 2-stage relief solenoid valve Disconnection
Travel Hi-Lo shifting solenoid
E216 Disconnection in travel speed shifting solenoid DW43KA Disconnection
Electrical system
valve
Nonconfor-
E217 Abnormality in model code input DA2SKQ S_NET mance in model
selecting signal
E218 Disconnection in S_NET signal DA2SKA S_NET Disconnection
E222 Short circuit in LS-EPC solenoid DXE0KB LS-EPC solenoid valve Short circuit
E223 Disconnection in LS-EPC solenoid DXE0KA LS-EPC solenoid valve Disconnection
E224 Abnormality in F pump pressure sensor DHPAMA F pump pressure sensor Malfunctioning
E225 Abnormality in R pump pressure sensor DHPBMA R pump pressure sensor Malfunctioning
Lowering in out-
E226 Abnormality in pressure sensor power source DA25KP Governor pump controller
put voltage
E227 Abnormality in engine revolution sensor DLE2MA Engine revolution sensor Malfunctioning
E228 Short circuit in ATT return switching relay D196KB ATT switching relay Short circuit
E02 E232 Short circuit in PC-EPC solenoid DXA0KB TVC solenoid valve Short circuit
E02 E233 Disconnection in PC-EPC solenoid DXA0KA TVC solenoid valve Disconnection
E238 Disconnection in ATT return switching relay D196KA ATT switching relay Disconnection
ATT flow rate throttling EPC
E245 Short circuit in ATT flow rate adjusting EPC DXE4KB Short circuit
valve
ATT flow rate throttling EPC
E246 Disconnection in ATT flow rate adjusting EPC DXE4KA Disconnection
valve
Abnormality in
E256 Incorrect nonvolatile memory data DA20KT Nonvolatile memory
data
Governor motor feedback
E306 Abnormality in governor potentiometer DK54KZ Malfunctioning
potentiometer
E05 E308 Abnormality in fuel dial DK10KZ Throttle potentiometer Malfunctioning
E315 Short circuit in battery relay output D110KB Battery relay Short circuit
E316 Abnormality in governor motor step-out DY10K4 Governor motor Out of control
PC200/220(LC)-7 20-147
(1)
Classification
Service Code Failure Code
User Code
Failure
No.
Code
Content Code No. Location Phenomenon
No.
E05 E317 Disconnection in both governor motors A and B DY10KA Governor motor Disconnection
E05 E318 Short circuit in both governor motors A and B DY10KB Governor motor Short circuit
Electrical system
Error in operation
E50 E501 No setting in model selection DA2AKM Governor pump controller
or setting
Abnormality in
E50 E502 Malfunction in model selecting signal DA20KT Governor pump controller
data
Abnormality in boom angle sensor (short circuit
E50 E511 DKA0KB Boom angle sensor Short circuit
in power source)
None Engine high idle out of rate A000N1 Engine Overrunning
Low idle out of
None Engine low idle out of rate A000N2 Engine
rate
None Air cleaner clogged AA10NX Air cleaner element Clogging
Insufficient
Mechanical system
None Charging voltage abnormally low AB00KE Alternator
charging
Oil pressure low-
None Engine oil pressure abnormally low B@BAZG Engine oil
ered
None Engine oil level abnormally low B@BAZK Engine oil Oil level lowered
None Engine cooling water overheated B@BCNS Engine cooling water Overheating
Cooling water
None Radiator water level abnormally low B@BCZK Engine cooling water
level lowered
None Hydraulic oil overheated B@HANS Hydraulic oil Overheating
Auto-lubrication system con-
None Auto-lubrication system abnormal DA80MA Malfunction
troller
a This table is arranged in the sequence of Service Code No.

a In case there is no number assigned in the column of User Code No., or in case "none" is described in the
column of Code No. of Service Code, the corresponding service code or failure code is not shown in the dis-
play of ordinary items, even if some abnormality occurs. It is recorded only in the failure history (either in elec-
trical system or mechanical system) of Service Menu.
a History Classification indicates that a specific failure is classified as belonging to either electrical system or
mechanical system, when it is recorded in Service Menu.
a "E" at the head of Code No. of Service Code means the following status of a specific failure.
With "E": The failure is yet to be dissolved and continues.
Without "E": The failure has already been dissolved.
20-148 PC200/220(LC)-7
(11)
Operation and Display of Service Menu
Way of switching to Service Menu

When using Service Menu, change the display to
Service Menu display through the following spe-
cial operation.
1) Confirmation of display
Confirm that the display of ordinary items is
shown.
Changing to Service Menu cannot be made
from displays other than this.
2) Switch operation
Operate the switch as instructed below.
Switch operation: [ ] + [1] [2] [3]
(Enter a figure, depressing [ ])
3) Showing Service Menu display

The display is changed to the initial display of
Service Menu program. Select an appropriate
item from among the menu.
No. Service Menu

00 Return (Termination of Service Menu)
01 Monitoring
02 Abnormality Record
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
06 / Default
07 Adjustment
08
4) Termination of Service Menu function

When terminating the initial display or any sub-
sequent display of Service Menu, do that
through any one of the following methods.
Depress [ ] switch. (This method may be
used for terminating any display)
If "Return" switch is shown, depress it.
If "Return" menu is shown, call that menu
and depress [ ] switch.
PC200/220(LC)-7 20-149
16. Function of monitoring [01]

The monitor panel monitors signals from an
assortment of switches, sensors and actuators
installed in various parts of the machine. Moni-
tored information can be put in display or con-
firmed on a real time basis through the following
operations.
1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.
2) Setting of monitoring item

Select or register an item to be monitored
through the following switch operation.
[ ] switch: Selection
[ ] switch: Selection
[ ] switch: Registration
A monitoring item can be set in any number
between the min. one to the max. four. (De-
pending upon the selected item, the max.
number is less than four)
In case of monitoring 1 to 3 items, move to
the monitored information display through
any of the following switch operations, after
the registration work has been completed.
Keep [ ] switch depressed. (For about
3 seconds)
Select Menu 999 and depress [ ]
switch.
The display automatically moves to the dis-
play of monitored information, when all of the
registrable items have been duly registered.
Monitored information are transmitted via
communication circuits. Thus the number of
selected items can impact the communica-
tion speed. If truly real time monitoring is re-
quired, reduce the selected items to the
minimum.
For details on the monitoring items, display
unit, etc., refer to the Table for Monitoring
Items.
20-150 PC200/220(LC)-7
3) Monitoring operation
Call the monitoring information display and
confirm the monitored information, while
operating the machine.
4) Monitored information holding function

If [ ] switch is depressed while monitoring,
all the monitored information are put on
hold. If [ ] switch is depressed in this con-
dition, information holding is released.
5) Machine setting mode switching function

If it becomes necessary to change settings
of working mode, select mode, travel speed
and auto-decel while monitoring, depress
the corresponding switch, then the mode
confirmation display is shown.
An illustration at right shows the display in A
mode and E mode. Symbol marks are par-
tially different in B mode.
When a specific setting is confirmed, de-
press [ ] switch, then the display returns to
that of monitoring.
In case a specific setting has been changed
while monitoring, the new setting is still
maintained when returning from Service
Menu to Operator's Menu after the monitor-
ing is finished.
PC200/220(LC)-7 20-151
Table for Monitoring Items

Code Unit (Default: ISO)
Item to be monitored Remark
No. ISO Meter Inch
000 Return (Not displayed) Termination menu
Execute
999 To Display Screen (Not displayed)
Command menu
002 Controller Model Select Figure
003 Controller Model Select Figure
010 Engine Speed r/min rpm rpm
011 F Pump Pressure MPa kg/cm 2
psi
012 R Pump Pressure MPa kg/cm2 psi
013 PC-EPC Sol. Curr. mA mA mA
015 LS-EPC Sol. Curr. mA mA mA
016 2nd Eng. Speed Command r/min rpm rpm
017 Service Sol. Curr. mA mA mA
Swing ON/OFF
Travel ON/OFF
Pressure Boom Lower ON/OFF
019
Switch 1 Boom Raise ON/OFF
Arm Curl ON/OFF
Arm Dump ON/OFF
Bucket Curl ON/OFF
Bucket Dump ON/OFF
Pressure
021 Offset ON/OFF (Not used)
Switch 2
Service ON/OFF
Travel Steering ON/OFF
Lever Sw. ON/OFF
022 Switch Input 1 Swing Release Sw. ON/OFF
Swing Brake Sw. ON/OFF
Travel Junction ON/OFF
Swing Brake ON/OFF
023 Solenoid valve 1 Merge-divider ON/OFF
2-stage Relief ON/OFF
Travel Speed ON/OFF
024 Solenoid valve 2 Service Return ON/OFF
Model Select 1 ON/OFF
027 Switch Input 2 Model Select 3 ON/OFF
030 Fuel Dial Vol. V V V
031 Gov. Motor Potentio Vol. V V V
032 Battery Voltage V V V
033 Gov. Motor Phase A Curr. mA mA mA
034 Gov. Motor Phase B Curr. mA mA mA
035 Battery Relay O/P Vol. V V V
036 Switch Input 3 Key Switch ON/OFF
037 Controller Output Batt. Relay Dr. ON/OFF
041 Engine Water Temperature C C F
042 Fuel Lever Sensor Vol. V V V
20-152 PC200/220(LC)-7
Code Unit (Default: ISO)

Item to be monitored Remark
No. ISO Meter Inch
043 Battery Charge Vol. V V V
044 Hydr. Oil Temperature C C F
Key Switch ON/OFF
Start ON/OFF
045 Monitor Input 1 Preheat ON/OFF
Light ON/OFF
Rad. level ON/OFF
Aircleaner ON/OFF
Eng. Oil Press. ON/OFF
046 Monitor Input 2 Eng. Oil Level. ON/OFF
Spare ON/OFF
Battery Charge ABNNOR
Swing Brake Sw. ON/OFF
Buzzer cancel Sw. ON/OFF
049 Monitor Input 3 Window Limit Sw. ON/OFF
W Limit Sw. ON/OFF
P Limit Sw. ON/OFF
200 Monitor Prog. Version Figure
201 Controller Prog. Version Figure
Select the most favorite display unit from among the prepared three kinds, i.e. ISO, meter and inch. When
changing one display unit for another, refer to "Unit" in the initial value setting of Service Menu.
Abbreviations, ABN and NOR, stand for the following conditions.
ABN: Abnormal, NOR: Normal
PC200/220(LC)-7 20-153
17. Function for Abnormality Record [02]

The monitor panel records failures that occurred
on the machines in the past after classifying
them into failures in the electric system and
those in the mechanical system. Information on
them can be displayed through the following
operation.
Select 02 Abnormality Record in the initial
display of Service Menu and depress [ ]
switch.
2) Selection of Submenu
Select an appropriate item from Submenu in
the Abnormality Record display and depress
[ ] switch.
No. Abnormality Record Submenu
Return
00
(termination of Abnormality Record)
01 Electrical System
02 Mechanical Systems
3) Information shown in display of Abnormality

Record in the electrical system
: The numerator expresses sequence of
failure occurrence, counting from the
latest one. The denominator expresses
the total number of a specific failure
recorded.
: Service Code
: Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
: Time elapsed since the occurrence of
the first failure
: Contents of failure
Refer to "Table for Service Code and Ab-
normality Code" in Operator's Menu.
4) Information shown in display of Failure His-

tory in the mechanical systems
: Record No.
: Contents of Abnormality
: Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
: Total number of occurrence
: Service meter reading at the initial
occurrence
Refer to "Table for Service Code and Ab-
normality Code" in Operator's Menu.
20-154 PC200/220(LC)-7
5) Resetting Electrical Systems

a Resetting Electrical Systems (deletion)
is possible only with the electrical sys-
tem. The failure history in the mechani-
cal system cannot be reset.
a For resetting any specific or all informa-
tion in the Electrical Systems, follow the
operation explained below.
i) Through the following switch operation,
call the resetting display in the display of
Electrical Systems.
Switch operation: [ ] +[1] [2] [3]
aThis is the same switch operation in
changing the display to Service Menu.
ii) Operate the switch, following the instruc-
tions shown in the resetting display.
aWhen resetting specific information
only, call the display of that specific
information and reset it with either
[ ] switch or [ ] switch.
aWhen resetting all the information, a
display of any information will do.
PC200/220(LC)-7 20-155
(12)
18. Function for Maintenance Record [03]

The monitor panel records information on the
maintenance of filters and oils. The stored infor-
mation can be displayed through the following
switch operation.
Select 03 Maintenance Record in Service
Menu and depress [ ] switch.
2) Information to be displayed
: Name of oils and filters
: Times of replacement to date
: Service meter reading at the latest
replacement
20-156 PC200/220(LC)-7
19. Function for Maintenance Mode Change [04]

Conditions set for controlling maintenance dis-
play function can be changed in the following
manner.
Turn the function effectual or ineffectual.
Change the set interval for replacement.
Select 04 Maintenance Mode Change in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of item to be changed

Select an item to be changed in the display
of Maintenance Mode Change Selecting
Menu.
No. Maintenance mode change item
00 Return
01 Maintenance Mode On/Off
02 Engine Oil Exch. Int.
03 Engine Oil Filter Exch. Int.
04 Fuel Filter Exch. Int.
05 Hydr. Oil Filter Exch. Int.
06 H/Tank Breather Exch. Int.
07 Corro. Resis. Exch. Int.
08 PTO Oil Service Int.
09 Final Drive Oil Exch. Int.
10 S/Machinery Oil Exch. Int.
11 Hydraulic Oil Exch. Int.
12 Use Default Values
01 and 12 menus are provided for setting the

whole maintenance mode, while those from
02 through 11 are for setting individual items.
3) Contents of Maintenance Mode On/Off

Use: The maintenance display function
of all oil and filter-related items are
turned effectual. (Irrespective of whether
"On" or "Off" set for individual items, this
setting prevails)
Do not use: The maintenance display
function of all oil and filter-related items
are turned ineffectual. (Irrespective of
whether "On" or "Off" set for individual
items, this setting prevails)
PC200/220(LC)-7 20-157
4) Set contents of individual items

: Default: The maintenance time set in
the monitor (recommended by the man-
ufacturer and cannot be changed).
: Set: Maintenance time that can be
freely set. The maintenance mode pro-
gram functions based on this mainte-
nance time. (The maintenance time can
be increased or decreased by 50 hours
with [ ] or [ ] switch)
: On: Maintenance display function with
this instruction becomes effectual.
: Off: Maintenance display with this
instruction becomes ineffectual.
The lowest maintenance time is 50 h.
5) Set contents of "Use Default Values"

When selecting this menu and depressing
the switch [ ], all individual time settings
are reduced to the initial settings.
20-158 PC200/220(LC)-7
20. Function for Phone Number Entry [05]

In the display of User Code, a telephone number
and Service Code are shown alternately. Phone
number can be inputted or modified in the fol-
lowing manner.
If there is no Phone number registered, the
display for Phone numbers does not appear.
Select 05 Phone Number Entry menu in the
display of Service Menu, and depress [ ]
switch.
2) Changing the display

Select Entry next to change the display to
the Phone Number Entry display.
Even if a Phone number is already input-
ted, it is deleted, upon switching to the
Phone Number Entry display.
3) Entry and setting Phone number

Following the method explained below,
Entry a Phone number in the Phone
Number Entry display. (Entry automatically
begins with a cursor at the left end)
i) Enter a number into a cursor at the left
end with a ten-key.
ii) Depress [ ] switch when all the num-
bers have been entered.
Numbers can be entered up to the max.
12 digits, but omit unnecessary digits.
When entering a wrong number, de-
press [B] switch, then the cursor goes
back by one digit.
When input is finished, the display
changes to Entry display shown above.
If the inputted Phone number is shown in
this display, the input is normal.
PC200/220(LC)-7 20-159
21. Function for /Default

[06]
It is possible to change the following settings for
the monitor panel as well as the machine. Make
a change as is required.
Working mode when the engine starting
switch is in the ON position.
Display language in Service Menu
Display unit in the monitoring function
With/Without Service Cir.
Select 06 "/Default menu" in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of submenu
Select an item to change from the submenu,
No. /Default submenu
00 Return (termination of /Default)
01 Key-on Mode
02 /Language
03 Unit
04 With/Without Service Cir.
3) Function for Key-on Mode

When the engine starting switch is turned
ON, a working mode can be set that is
shown in the monitor panel.
A, E, L and B Modes: If any of them is
set, the machine always ramps up with
that working mode, when turning the en-
gine starting switch ON.
Mode at Previous Key-off: If this mode is
set, the machine ramps up with the
working mode that was last used in the
previous machine operation.
Default Value: If this mode is set, the
machine ramps up with the default mode
(A mode) that was originally set at the
time of delivery from the factory.
Irrespective of this setting mode, a ma-
chine "With attachment" always ramps
up with B mode, when the engine start-
ing switch is turned ON at the subse-
quent operation, if that was the working
mode used in the last machine work.
20-160 PC200/220(LC)-7
4) Function for /Language

In Service Menu, the language in use can
be changed between Japanese and Eng-
lish.
a English is used as the language for de-
fault setting in the monitor panel.
a If the monitor panel for spare parts is to
be used in a Japanese-speaking region
or organization, change the language
from English to Japanese, using this
function.
5) Function for unit selection

As the unit to be used in the monitoring
function display of Service Menu, three
kinds of unit are provided.
a Unit used for default setting in the moni-
tor panel is SI, i.e. International System
of Units.
6) Function for selecting distinction of With/

Without Service Cir.
It is possible in this function to set a distinc-
tion between with or without attachment.
With Service Circuit: When an attach-
ment is installed.
Without Service Circuit: When no attach-
ment is installed.
a If "With Service Circuit" setting is not
made in this display, while it is actually
installed on a specific machine, SELECT
function in Operator's Mode (attachment
oil flow rate adjustment) cannot be uti-
lized.
PC200/220(LC)-7 20-161
(1)
22. Function for Adjustment [07]

The monitor panel has a function of making vari-
ous adjustments of the machine.
Select 07 adjustment in the initial display of
Service Menu, and depress [ ] switch.
2) Selection of submenu
Select an item to change from the submenu
No. Adjustment submenu
00 Return (termination of adjustment)
01 Governor Motor Adjustment
02 Pump Absorption Torque
03 Low Idle Speed
04 Service Current Adjust.
3) Function for Governor Stroke Adjustment

a If the governor actuator, fuel injection
pump, or governor spring is removed
and installed or the high idle speed is low
or the engine speed is unstable, adjust
the governor lever stroke according to
the following procedure.
i) Call the display of governor lever stroke
adjustment and set the fuel dial at MAX.
a Under this condition, the governor
actuator lever moves to the FULL
position. Keep this display until ad-
justment is finished.
a The engine speed is indicated in 10
rpm at the center of the display.
a The turning direction of the governor
spring when the fuel injection pump
is seen from the governor actuator is
indicated.
20-162 PC200/220(LC)-7
(11)
ii) Loosen locknuts (2) and (3) of rod (1).

a Locknut (3) has left-hand threads.
iii) Turn rod (1) counterclockwise to
increase installed length (a) of governor
spring (4) and return governor lever (5)
of the fuel injection pump to a position at
which it will not touch the full stop.
a Take care that the outer cylinder of
governor spring (4) will not be
dragged and the water drain hole will
not be moved from the bottom.
iv) Turn rod (1) clockwise to decrease
installed length (a) of governor spring
(4). If governor lever (5) touches the full
stop, stop turning the rod.
Standard installed length (a): 456.7
mm (Reference)
v) Turn rod (1) 2 more turns to compress
the spring in governor spring (4).
a Since the internal spring is com-
pressed, only the outside cylinder of
governor spring (4) moves about 5.0
mm toward the governor actuator
(The installed length does not
change).
vi) Fixing rod (1), tighten locknuts (2) and
(3).
a Before tightening the locknuts,
check that the water drain hole of the
3 Nut:
governor spring is directed down.
11.8 19.6 Nm {1.2 2.0 kgm}

vii) Return the fuel control dial to the MIN
position, and then turn it toward the
MAX side gradually. At this time, check
that governor spring (4) is lengthened
about 5.0 mm after governor lever (5)
touches the full stop.
PC200/220(LC)-7 20-163
(11)
1) Function for Pump Absorption Torque

adjustment
The pump absorption torque can be
adjusted within the range shown in the table
below.
Adjustment value Torque adjustment value
220 +4.0 kgm
221 +3.0 kgm
222 +2.0 kgm
223 +1.0 kgm
224 0.0 kgm
225 1.0 kgm
226 2.0 kgm
227 3.0 kgm
228 4.0 kgm
2) Function for Low Idle Speed adjustment

The engine rotation at low idle can be
adjusted within the range shown in the table
below.
Adjustment value Low idle rotation
320 1,000 rpm
321 1,100 rpm
322 1,200 rpm
323 1,300 rpm
3) Function for Service Current Adjust.

When a machine is used for a compound
operation, distribution of hydraulic pump oil
flow can be adjusted within the range shown
in the table below.
Distribution of oil flow
Adjustment value
to attachment
320 0.5 Time
321 0.7 Time
322 1.0 Time
323 0.4 Time
20-163-1 PC200/220(LC)-7
(11)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Section to display Section to operate special Section to operate special function 2

special functions function 1 (Basic operation) (Selecting operation and special operation)
1. Display section 3. Caution buzzer stop switch 7. Working mode selector (UP) switch
2. Service meter 4. Auto-decelerator switch 8. Working mode selector (DOWN) switch
section 5. Setting switch (Black switch)
6. Travel speed shifting switch
20-164 PC200/220(LC)-7
(10)
Ordinary functions and special functions of monitor panel

The monitor panel has the ordinary functions and special functions and displays various pieces of information
on display section (1) and service meter section (2).
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed by operating switches.
1. Ordinary functions: Operator menu

The items in this menu are displayed normally or displayed automatically when a trouble occurs.
2. Special functions: Service menu

The items in this menu are not displayed normally. Each serviceman can display them by operating special
switches. These functions are used for special setting, testing, adjusting, or troubleshooting.
Flow of each function
Ordinary functions (Operator menu) Special functions (Service menu)

<Operation of switch> O
1 Function of displaying service meter 3 Function of displaying service code [01]
O <Automatic> 4 Monitoring function [02]
2 Function of displaying user code 5 Function of adjusting governor [03]
6 Function of selecting maintenance period [04]
7 Function of selecting default working mode [05]
8 Function of setting installation of attachment [16]
Special function of monitoring replacement

9
of engine oil
a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.
PC200/220(LC)-7 20-165
(10)
Display of operator menu
a Only outline of the operator menu is described in

this section. For details of each menu, see OP-
ERATION MANUAL or the volume of STRUC-
TURE AND FUNCTION.
1. Function of displaying service meter

While the machine is used normally, the monitor
panel displays the following information.
Display section (1): Nothing is displayed
Service meter section (2): Service meter
2. Function of displaying user code

If the machine has any trouble, the correspond-
ing user code is displayed automatically in dis-
play section (1) and the caution buzzer is turned
ON to urge the operator to take a proper rem-
edy, depending on the degree of the trouble.
a Service meter section (2) continues display-
ing the service meter.
a For displayed user codes and the remedies
shown to the operator, see "User codes and
remedies shown to operator".
a Each user code simply shows occurrence of
a trouble to the operator. To find out the
cause of the trouble, a serviceman must
check the service code with the "Function of
displaying service code [01]" in the service
menu.
<Reference>
A user code is displayed only when a serious
trouble occurs.
Even if a user code is not displayed, a trouble
may have occurred. If you feel any abnormality,
be sure to check for a service code with the
"Function of displaying service code [01]" in the
service menu.
a User codes and remedies shown to operator
User Caution
Error mode Remedy (shown to operator)
code buzzer
If the emergency pump drive switch is set in the upper position, the
Error in pump
E02 machine can operate normally. Have the machine inspected immediately, q
control system
however.
Set the swing holding brake release switch in the upper position to release
Error in swing the brake. When applying the swing brake, operate the swing lock switch
E03 q
brake system manually. The brake may not be released, depending on the cause of the
failure. In this case, have the machine inspected immediately.
Error in governor
E05 Have the machine inspected immediately. q
system
20-166 PC200/220(LC)-7
(10)
Operation and display of service menu
How to select service menu

a When using the general functions in the service
menu, perform the following switch operation to
change the screen of the monitor panel.
3. Function of displaying service code [01]
4. Monitoring function [02]
5. Function of adjusting governor [03]
6. Function of selecting maintenance period
[04]
7. Function of selecting default working
mode [05]
8. Function of setting installation of attach-
ment [16]
1) Operating switches
While holding caution buzzer stop switch (3),
hold auto decelerator switch (4) for 2.5 seconds.
2) Displaying display section and service meter

section
If the switches are operated as shown above,
the first menu No. [01] (Monitoring function) is
displayed in service meter section (2).
a Nothing is displayed in display section (1).
3) Selecting menu
operate working mode selector switches (7) and
(8) to select a menu you will use.
UP switch (7): Increase Menu No.
DOWN switch (8): Decrease Menu No.
Menu Service menu

No. (Excluding special functions)
01 Function of displaying error code
02 Monitoring function
03 Function of adjusting governor
04 Function of selecting maintenance period
05 Function of selecting default working mode
16 Function of setting installation of attachment
4) Executing menu
Select a menu you will use and press set switch
(5), and the menu is executed.
5) Finishing service menu

hold auto decelerator switch (4) for 2.5 seconds
(similarly to the selecting operation).
a The service menu is finished and the ordi-
nary screen appears.
a The service menu can be also finished by
turning the starting switch OFF while the
service menu is selected. (In this case, the
ordinary screen appears when the starting
switch is turned ON again.)
PC200/220(LC)-7 20-167
(10)
a To use the following special function, you must

operate the switches differently from the above.
See details of this function "9. Special function
of monitoring replacement of engine oil".
3. Function of displaying service code [01]

With this function, you can check the service
code of a trouble which is occurring at present
or has occurred in the past.
1) Selecting and executing function

i) Select menu No. [01] in the menu selec-
tion mode.
ii) Press set switch (5) to execute this
function.
2) Information displayed in display section and

service meter section 1 (When service code
is recorded)
If a service code is recorded, the following
information is displayed in display section
(1) and service meter section (2).
(a): Service code
(b): Service meter reading increased after
trouble occurred
(c): Mark [E] to indicate that trouble is occur-
ring at present
a Mark [E] to indicate that a trouble is oc-
curring at present indicates that the serv-
ice code is being detected now. It is not
displayed if the trouble has been re-
paired or the service code is not detect-
ed.
a For the service codes which the monitor
panel and engine throttle and pump con-
troller can detect, see the "Service
codes table".

service meter section 2 (When service code
is not recorded)
If a service code is not recorded, display
section (1) and service meter section (2)
display as shown in the figure.
4) Number of recorded service codes and dis-

play order of them
This function can record up to 20 service
codes, which are displayed in order from the
latest one.
a If a new trouble occurs while 20 service
codes are recorded, the oldest service
code is deleted and the service code of
the new trouble is recorded.
20-168 PC200/220(LC)-7
(10)
5) Change of displayed service codes

While holding caution buzzer stop switch
(3), operate working mode selector switches
(7) and (8) to change the displayed service
codes.
UP switch (7):
Next service code appears.
DOWN switch (8):
Previous service code appears.
6) How to delete service code

i) While holding caution buzzer stop
switch (3), turn the starting switch OFF
and keep holding caution buzzer stop
switch (3).
ii) Under the above condition, turn the
starting switch ON again and hold cau-
tion buzzer stop switch (3) for 5 sec-
onds.
a A service code having the mark [E] is not
deleted.
PC200/220(LC)-7 20-169
(10)
Service codes table

User code Service code Trouble
E101 Abnormality in error history data
E104 Clogging of air cleaner (Equivalent to error code [AA10NX])
E108 Overheating of engine coolant (Equivalent to error code [B@BCNS])
E112 Short circuit in wiper motor drive forward system
E113 Short circuit in wiper motor drive reverse system
E114 Short circuit in windshield washer drive system
E115 Trouble in operation of windshield wiper
E116 Trouble in storage of windshield wiper
E201 Short circuit in travel junction solenoid
E03 E203 Short circuit in swing holding brake solenoid
E204 Short circuit in merge-divider solenoid
E205 Short circuit in 2-stage relief solenoid
E206 Short circuit in travel speed shifting solenoid
E211 Disconnection in travel junction solenoid
E03 E213 Disconnection in swing holding brake solenoid
E214 Disconnection in merge-divider solenoid
E215 Disconnection in 2-stage relief solenoid
E216 Disconnection in travel speed shifting solenoid
E217 Abnormality in input model code
E218 Disconnection in S-NET signal line
E222 Short circuit in LS-EPC solenoid
E223 Disconnection in LS-EPC solenoid
E224 Abnormality in F pump pressure sensor
E225 Abnormality in R pump pressure sensor
E226 Abnormality in pressure sensor power supply
E227 Abnormality in engine speed sensor
E228 Short circuit in ATT return selector relay
E02 E232 Short circuit in PC-EPC solenoid
E02 E233 Disconnection in PC-EPC solenoid
E238 Disconnection in ATT return selector relay
E256 Illegal non-volatile memory data
E306 Abnormality in governor potentiometer
E05 E308 Abnormality in fuel control dials
E313 Abnormality in auto grease system (Equivalent to error code [DA80MA])
E315 Short circuit in battery relay output line
E316 Abnormality in step-out of governor motor
E05 E317 Disconnection in phases A and B of governor motor
E05 E318 Short circuit in phases A and B of governor motor
a For troubleshooting for a service code having the description of (Equivalent to error code [******]), see the
section of the corresponding "Error code of mechanical system".
a "E" at the head of each service code indicates the following condition.
With E: The trouble has not been repaired.
Without E: The trouble has been repaired.
20-170 PC200/220(LC)-7
(10)
4. Monitoring function [02]

With this function, you can monitor the revolu-
tion speed, oil pressure, current, voltage, input
condition, output condition, etc. in real time by
the signals from the sensors, switches, and
solenoids installed to various parts of the
machine.

tion mode.
function.
2) Selecting and executing monitoring code

While holding caution buzzer stop switch
(3), operate working mode selector switches
(7) and (8) to select a monitoring code dis-
played in service meter section (1).
UP switch (7): Increase code No.
DOWN switch (8): Decrease code No.
a This function displays monitoring code
[001] and its information first.
a For the items and code Nos. which you
can monitor, see the "Monitoring codes
table".

service meter section 1 (When numeral
code is displayed)
If a numeral monitoring code is selected, the
following information is displayed in display
section (1) and service meter section (2).
(a): Monitoring code
(b): Monitoring information (Value is dis-
played)

service meter section 2 (When 6-bit code is
displayed)
If a 6-bit monitoring code is selected, the fol-
lowing information is displayed in display
section (1) and service meter section (2).
(a): Monitoring code
(b): Monitoring information (6 pieces of
information are displayed in bits)
a In the 6-bit display mode, only the top
and bottom of the 7-segments mark are
used to display. "Solid black" indicates
the ON state, and "white on black back-
ground" indicates the OFF state.
a For the No. of each bit, see the "Monitor-
ing codes table" and the drawing at-
tached to it.
PC200/220(LC)-7 20-171
(10)
Monitoring codes table

Code Monitoring item Unit Remarks
002 Engine throttle and pump controller model code Numeral
003 Engine throttle and pump controller model code Numeral
010 Engine speed 10 rpm
011 F pump discharge pressure kg/cm2
012 R pump discharge pressure kg/cm2
013 PC-EPC solenoid output current 10 mA
015 LS-EPC solenoid output current 10 mA
016 2nd throttle speed 10 rpm
017 (Unused)
a Swing oil pressure switch (ON) (6 bit)
b Travel oil pressure switch (ON) (6 bit)
c Boom LOWER oil pressure switch (ON) (6 bit)
019 Input condition 1 of switch
d Boom RAISE oil pressure switch (ON) (6 bit)
e Arm IN oil pressure switch (ON) (6 bit)
f Arm OUT oil pressure switch (ON) (6 bit)
a Bucket CURL oil pressure switch (ON) (6 bit)
b Bucket DUMP oil pressure switch (ON) (6 bit)
c (Unused) (6 bit)
d Service oil pressure switch (ON) (6 bit)
e Travel differential pressure switch (6 bit)
f (Unused) (6 bit)
a (Unused) (6 bit)
b (Unused) (6 bit)
c One-touch power maximizing switch (ON) (6 bit)
d Swing holding brake release switch (RELEASE) (6 bit)
e Swing lock switch (LOCK) (6 bit)
f (Unused) (6 bit)
a (Unused) (6 bit)
b Travel junction solenoid (ON) (6 bit)
Drive condition of solenoid c Swing holding brake solenoid (ON) (6 bit)
023
valve 1 d Merge-divider solenoid (ON) (6 bit)
e 2-stage relief solenoid (ON) (6 bit)
f Travel speed shifting solenoid (ON) (6 bit)
a (Unused) (6 bit)
b (Unused) (6 bit)
Drive condition of solenoid c (Unused) (6 bit)
024
valve 2 d ATT return selector relay (ON) (6 bit)
e (Unused) (6 bit)
f (Unused) (6 bit)
20-172 PC200/220(LC)-7
(10)

a Model selection 1 (Connected to ground) (6 bit)
b Model selection 2 (Connected to ground) (6 bit)
Input condition of model c Model selection 3 (Connected to ground) (6 bit)
027
selection signal d Model selection 4 (Connected to ground) (6 bit)
e Model selection 5 (Connected to ground) (6 bit)
f Kerosene mode (Connected to ground) (6 bit)
030 Fuel control dial input voltage 10 mV
031 Governor potentiometer input voltage 10 mV
032 Controller power source voltage 100 mV
033 Governor motor phase A output current 10 mA
034 Governor motor phase B output current 10 mA
035 Battery relay BR output voltage 100 mV
a (Unused) (6 bit)
b (Unused) (6 bit)
c (Unused) (6 bit)
036 Input condition of signal
d (Unused) (6 bit)
e Starting switch signal C (START) (6 bit)
f (Unused) (6 bit)
a Battery relay (DRIVEN) (6 bit)
b (Unused) (6 bit)
c (Unused) (6 bit)
037 Output condition of signal
d (Unused) (6 bit)
e (Unused) (6 bit)
f (Unused) (6 bit)
041 Engine coolant sensor input voltage 10 mV
042 Fuel level sensor input voltage 10 mV
043 Alternator input voltage 100 mV
044 Hydraulic oil temperature sensor input voltage 10 mV
a Starting switch signal ACC (ON) (6 bit)
b Starting switch signal C (START) (6 bit)
c Starting switch signal R1 (HEAT) (6 bit)
045 Input condition of switch 4
d Lamp switch (ON) (6 bit)
e Radiator coolant level switch (OPEN) (6 bit)
f (Unused) (6 bit)
a Air cleaner clogging switch (OPEN) (6 bit)
b (Unused) (6 bit)
c Engine oil pressure switch (OPEN) (6 bit)
046 Input condition of sensor
d Engine oil level switch (OPEN) (6 bit)
e (Unused) (6 bit)
f Alternator (Normal generation) (6 bit)
PC200/220(LC)-7 20-173
(10)

a Swing lock switch (LOCK) (6 bit)
b Caution buzzer stop switch (ON) (6 bit)
c Windows limit switch (ON) (6 bit)
049 Input condition of switch 5
d Wiper contact W (ON) (6 bit)
e Wiper contact P (ON) (6 bit)
f (Unused) (6 bit)
200 Monitor panel program version Numeral
201 Engine throttle and pump controller program version Numeral
a When the wiper is stopped, (d) and (f) of code No. [048] light up. When the wiper is operated, (c) and (f) or
(d) and (e) light up.
Display of numeral code Display of 6-bit code
20-174 PC200/220(LC)-7
(10)
5. Function of adjusting governor [03]

This function is used to adjust the governor lever
stroke after the governor actuator, fuel injection
pump, or governor spring is removed and
installed or replaced, or when the high idle
speed is low or engine speed is not stabilized.

tion mode.
function.
2) Condition of governor motor

If this function is executed, all the governor
control functions are cancelled, and then the
operating angle of the governor actuator fol-
lows up only the operation signal of the fuel
control dial.
a While this function is executed, [GOV] is
displayed in display section (1) and
[gSET] is displayed in service meter sec-
tion (2).
3) Adjusting governor lever stroke

a The turning direction of the governor
spring described below is the direction
when the fuel injection pump is seen
from the governor actuator side.
i) Keep the fuel control dial in the MAX
position.
ii) Loosen locknuts (2) and (3) of rod (1).
a Locknut (3) is left-handed.
iii) Turn rod (1) counterclockwise to
increase installed length (a) of governor
spring (4) and return governor lever (5)
of the fuel injection pump to a position
where it does not touch the full stopper.
a Take care that the outer cylinder of
governor spring (4) will not be
dragged to change the position of
the water drain hole from the bottom.
iv) Turn rod (1) clockwise to decrease
installed length (a) of governor spring
(4) and stop it when governor lever (5)
touches the full stopper.
Standard installed length (a):
456.7 mm (Reference)
PC200/220(LC)-7 20-175
(11)
v) Turn rod (1) clockwise further by 2 turns

to compress the spring in governor
spring (4).
a Since the inside spring is com-
pressed, only the outer cylinder of
governor spring (4) moves toward
the governor actuator by about 5.0
mm (the installed length does not
change).
vi) While fixing rod (1), tighten locknuts (2)
and (3).
a Before tightening the locknuts,
check that the water drain hole of the
3 Locknut:
governor spring is directed down.
11.8 19.6 Nm {1.2 2.0 kgm}

vii) Return the fuel control dial to the MIN
position, and then turn it again slowly
toward the MAX position. At this time,
check that governor spring (4) expands
by about 4.0 mm after governor lever (5)
reaches the full stopper.
20-176 PC200/220(LC)-7
(10)
6. Function of selecting maintenance period [04]

With this function, you can adjust the mainte-
nance period of the engine oil for the function of
the engine oil replacement monitor.

tion mode.
function.
2) Selecting maintenance period

The current display mode or maintenance
period is displayed in service meter section
(2). Press set switch (5) to select a mainte-
nance period.
a Nothing is displayed in display section
(1).
a Each time the set switch is pressed, the
display mode or maintenance period
changes in the following order.
Display mode/
Display
Maintenance period
0 Maintenance function is reset.
125 125-hour interval
d Demonstration mode
3) Settling maintenance period

The display or maintenance period
becomes effective when it is selected.
Accordingly, perform the ordinary finishing
operation.
<Special functions of engine oil replacement

monitor>
a For the method of displaying the engine oil
replacement monitor, method of checking
the elapsed time after replacement of engine
oil, method of clearing the elapsed time, and
method of displaying demonstration mode,
see "9. Special functions of engine oil re-
placement monitor".
PC200/220(LC)-7 20-176-1
(10)
7. Function of selecting default working mode [05]

With this function, you can freely select the
working mode which is set automatically when
the starting switch is turned ON (When the
machine is delivered, mode A is set).

tion mode.
function.
2) Selecting default working mode

The currently set working mode is displayed
in service meter section (2). Press working
mode selector switches (7) and (8) to select
a working mode.
UP switch (7): Next mode is displayed.
DOWN switch (8): Previous mode is dis-
played.
a Nothing is displayed in display section
(1).
a The working mode changes in the fol-
lowing order: A o E o B
3) Settling default working mode

Press set switch (5) to settle the selected
working mode.
20-176-2 PC200/220(LC)-7
(10)
8. Function of setting installation of attachment [16]

With this function, you can set installation of
attachment.
a When an attachment is installed, if IN-
STALLED is not set with this function, the B-
mode function (automatic single/double op-
eration selecting function) cannot be used.

tion mode.
function.
a While this function is executed, [16SET]
is displayed in the service meter section
(2) and [0] or [1] is displayed in display
section (1).
2) Selecting installation of attachment

i) The current setting is displayed in serv-
ice meter section (1). Check the actual
installation of attachment and setting.
[0]: Attachment is not installed.
[1]: Attachment is installed.
ii) While holding caution buzzer stop
switch (3), operate working mode selec-
tor switches (7) and (8) to select [0] or
[1].
UP switch (7): [1] is selected.
DOWN switch (8): [0] is selected.
3) Settling installation of attachment

Press set switch (5) to settle the selected
setting of installation of attachment.
PC200/220(LC)-7 20-176-3
(10)
9. Special functions of engine oil replacement monitor

1) Ordinary display of engine oil replacement
monitor
If the rest of time before the set engine oil
replacement time is 10 hours or shorter,
engine oil replacement monitor (10) lights
up and display the elapsed time in service
meter section (2) for 20 seconds each time
the starting switch is turned ON.
2) Checking elapsed time

To check the elapsed time while engine oil
replacement monitor (10) is OFF, turn the
starting switch OFF and press set switch (5)
and then turn the starting switch ON and
keep holding set switch (5).
3) Clearing elapsed time

To clear the elapsed time after replacing the
engine oil, hold set switch (5) for 3 seconds
while the elapsed time is displayed in serv-
ice meter section (2).
a If the above operation is performed, the
elapsed time in the monitor panel is set
to 0 hours.
4) Function of demonstration mode

If the demonstration mode is selected, you
can perform demonstration of the oil mainte-
nance function when teaching the operation
to a customer.
The functions and display of the demonstra-
tion mode are as follows.
i) The internally set interval is recognized
as 250 hours and the elapsed time is
recognized as 240 hours.
ii) When the starting switch is turned ON
after the demonstration mode is set, the
ordinary display is repeated up to 3
times (number of the times of turning
the starting switch ON).
iii) After the demonstration is finished,
resetting of maintenance setting [0] is
recognized.
a When the demonstration is repeated 3
times, resetting of maintenance setting
is recognized. If setting is necessary at
this time, see "Function of selecting
maintenance period".
20-176-4 PC200/220(LC)-7
(10)
TESTING AND ADJUSTING PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL

SYSTEM
PC200, 200LC-7 Serial No. 200001 250000 2. Governor pump controller
PC220, 220LC-7 Serial No. 60001 65000 a The governor pump controller is installed un-
der a cover behind the operator's seat.
a When diagnosing electric circuits related to the 1) Remove three caps (1) and then three
monitor panel and governor pump controller, first securing bolts.
open up the connector portions in the following a When removing the caps, use of a thin
manner. flat-head screw driver is recommended.
2) Take off cover (2).
1. Monitor panel
a The cover is fixed with two upper and
lower clips. Pull it up for the removal.
a If a sunlight sensor is equipped for an air
conditioner, detach P15 connector at the
cover rear side.
3) Insert or connect a T-adapter for diagnosis

with C01, C02 and C03 connectors of gov-
ernor pump controller (3).
a The connectors are fixed with screws.
Loosen the screws and detach the con-
nectors.
a When putting the connectors back into
2) Remove three securing screws and take position, tighten them to the specified
3 Screw: 2.82 Nm {0.288 kgm}

monitor panel (2) off the mount. torque.
a Be careful not to let fall the securing
screws inside the console.
3) Insert or connect a T-adaptor for diagnosis
with P01, P02 and P70 (multi-monitor only)
connectors.
PC200/220(LC)-7 20-177
(7)
TESTING AND ADJUSTING PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
PC200, 200LC-7 Serial No. 250001 and up 2. Governor pump controller

PC220, 220LC-7 Serial No. 65001 and up a The governor pump controller is installed un-
der a cover behind the operator's seat.
a When diagnosing electric circuits related to the 1) Remove three bolts and then cover (5).
monitor panel and governor pump controller, first
open up the connector portions in the following
manner.
1. Monitor panel
a The cover is fixed with two upper and
lower clips. Pull it up for the removal.
a If a sunlight sensor is equipped for an air
conditioner, detach P15 connector at the
cover rear side.
2) Insert or connect a T-adapter for diagnosis

with C01, C02 and C03 connectors of gov-
ernor pump controller (6).
a The connectors are fixed with screws.
Loosen the screws and detach the con-
nectors.
a When putting the connectors back into
position, tighten them to the specified
3 Screw: 2.82 Nm {0.288 kgm}

torque.
2) Remove three securing screws and take

monitor panel (2) off the mount.
a Be careful not to let fall the securing
screws inside the console.
3) Insert or connect a T-adaptor for diagnosis
with P01, P02 and P70 (multi-monitor only)
connectors.
20-177-1 PC200/220(LC)-7
(5)
20-178 PC200/220(LC)-7
Engine (PC200, 200LC) Hydraulic system (PC200, 200LC)
PC200/220(LC)-7
20-179
Model Serial No. Service meter reading Client user's name Implemented on: Inspected by:
20-180
1. Engine (PC200, 200LC-7)
Condition setting Standard value
No. Working Auto One-touch po- Measurement item Unit Measured value Judgement
Fuel dial mode decelerator wer max. switch Work equipment operation New machine Failure judgement
1 Operating travel control lever Engine rotation rpm 2,080 2,220 Good / No good
Full (Do not travel machine)
2 Engine oil pressure MPa{kg/cm2} 0.39 0.64{4.0 6.5} 0.25{2.6} Good / No good
OFF
3 Engine rotation rpm 980 1,080 Good / No good
Low OFF All control levers in NEUTRAL
4 A Engine oil pressure MPa{kg/cm2} Min. 0.15{Min. 1.5} 0.09{2.9} Good / No good
5 Engine rotation rpm 1,800 2,000 Good / No good
ON Arm (extended) relief
6 Full Blow-by pressure kPa{mmH2O} Max. 1.2{Max. 123} 5.1{520} Good / No good
7 ON OFF All control levers in NEUTRAL Engine rotation rpm 1,300 1,500 Good / No good
2. Work equipment speed (PC200, 200LC-7)

o
Hydraulic oil temperature (45 55 C)
No. Unit PC200-7 PC200LC-7 Measured value Judgement
Fuel dial Working Work equipment posture Measurement item
mode New model Failure judgement New model Failure judgement
1 No load, fully extended Boom RAISE 2.9 3.7 Max. 4.7 2.9 3.7 Max. 4.7 Good / No good
2 A Arm DUMPING 2.4 3.0 Max. 3.5 2.4 3.0 Max. 3.5 Good / No good
3 3.2 3.8 Max. 4.5 3.2 3.8 Max. 4.5 Good / No good
Boom held level
4 E Arm DIGGING 3.3 3.9 Max. 4.6 3.3 3.9 Max. 4.6 Good / No good
5 ( L) 5.8 7.0 Max. 7.4 5.8 7.0 Max. 7.4 Good / No good
6 Boom and arm held level Bucket DIGGING 2.3 2.9 Max. 3.3 2.3 2.9 Max. 3.3 Good / No good
Right Good / No good
7 Full Fully extended Swing (5 turns) Sec. 21.7 26.7 Max. 30 21.7 26.7 Max. 30
Left Good / No good
Lo 46.2 56.4 46.2 60.4 50.3 61.5 50.3 65.5
A Left Good / No good
Track shoe raised Travel Right Good / No good
8 at one side ( Mi) 33.7 41.3 33.7 45.3 36.7 44.9 36.7 48.9
(5 turns) Left Good / No good
Hi 26.6 29.4 26.6 31.4 29.0 32.0 29.0 34.0
Left Good / No good
: The "Mi" and "L" modes are on the multi-monitor specification machine only.
3. Work equipment hydraulic drift amount (PC200, 200LC-7)

Hydraulic oil temperature (45 55oC)
No. Working Measurement item Unit PC200-7 PC200LC-7 Measured value Judgement
Fuel dial mode Work equipment posture New model Failure judgement New model Failure judgement
Boom and arm held Hydraulic drift amount at 600 Max. 900 600 Max. 900 Good / No good
1 Engine stop level, Bucket loaded bucket tooth tip (15 min.) mm
PC200/220(LC)-7
4. Inspection of hydraulic circuit (PC200, 200LC-7)
Condition setting 600 kg/cm2 600 kg/cm2 600 kg/cm2 600 kg/cm2 60 kg/cm2
No. Part to be checked Remarks
Working Auto-dece- One-touch po- F main pump R main pump F pump LS R pump LS Control circuit
Fuel dial Work equipment operation pressure
mode lerator wer max. switch
1 Self-decompression valve Circuit pressure 3.2 MPa {33 kg/cm2}
OFF Arm dumping relief
2 Main relief valve
PC200/220(LC)-7
34.8 37.3 MPa
3 (When power increased) ON {355 380 kg/cm2}
Neutral MainLS=3.9 MPa{40 kg/cm2}
LS valve (LS differential pressure = Unload pressure)
4 (LS differential Travel without load, Right
pressure valve) Full A OFF engine at Hi idle and MainLS=2.2 MPa{22.0 kg/cm2} (LS pressure)
control lever at half stroke Left
Swing lock Right

i relief
5 Swing safety valve OFF switch ON 30.9 MPa {315 kg/cm2}
Left relief
Right forward
Main relief valve, Right reverse
6 Travel safety valve, Track shoe 38.2 MPa {390 kg/cm2}
Travel interlocking valve locked Left forward
Left reverse
Connection to be changed to hoses and

No. Part to be checked Working Auto- One-touch po- circuit Remarks
Fuel dial mode decelerator wer max. switch Work equipment operation F main pump R main pump F pump servo R pump servo Control
pressure
Servo Full Arm dumping relief Main servo pressure balance

7 A OFF OFF / = / = 3/5
Connection to be changed to hoses and , and gauge to be replaced with
one with 60 K capacity.

No. Part to be checked Working Auto- One-touch po- PC LS Control circuit Remarks <Reference value: kg/cm2>
Fuel dial mode decelerator wer max. switch Work equipment operation F main pump R main pump
EPC EPC pressure
Low <34>
A
< 3>
8 PC-EPC valve E OFF OFF Arm dumping relief <14>
Full
( L) <21>
B <16>
Neutral At neutral: 2.9MPa {30kg/cm2}
A
9 LS-EPC valve Full OFF OFF When 2 pumps relieved: 0MPa {0kg/cm2}
Arm dumping relief
( L) When one pump relieved: 1.5MPa {15kg/cm2}
: The "L" mode is on the multi-monitor specification machine only
(11)
20-181
20-182 PC200/220(LC)-7
(1)
Engine (PC220, 220LC) Hydraulic system (PC220, 220LC)
PC200/220(LC)-7
20-183
Model Serial No. Service meter reading Client user's name Implemented on: Inspected by:
20-184
1. Engine (PC220, 220LC-7)
No. Working Auto One-touch po- Measurement item Unit Measured value Judgement
Fuel dial mode decelerator wer max. switch Work equipment operation New machine Failure judgement
1 Operating travel control lever Engine rotation rpm 2,130 2,270 Good / No good
Full (Do not travel machine)
2 Engine oil pressure MPa{kg/cm2} 0.39 0.64{4.0 6.5} 0.25{2.6} Good / No good
OFF
3 Engine rotation rpm 980 1,080 Good / No good
Low OFF All control levers in NEUTRAL
4 A Engine oil pressure MPa{kg/cm2} Min. 0.15{Min. 1.5} 0.09{2.9} Good / No good
5 Engine rotation rpm 1,850 2,050 Good / No good
ON Arm (extended) relief
6 Full Blow-by pressure kPa{mmH2O} Max. 1.2{Max. 123} 5.1{520} Good / No good
7 ON OFF All control levers in NEUTRAL Engine rotation rpm 1,300 1,500 Good / No good
2. Work equipment speed (PC220, 220LC-7)

o
Hydraulic oil temperature (45 55 C)
No. Unit PC220-7 PC220LC-7 Measured value Judgement
Fuel dial Working Work equipment posture Measurement item
mode New model Failure judgement New model Failure judgement
1 No load, fully extended Boom RAISE 3.1 3.9 Max. 4.9 3.1 3.9 Max. 4.9 Good / No good
2 A Arm DUMPING 2.7 3.3 Max. 3.5 2.7 3.3 Max. 3.5 Good / No good
3 3.4 4.2 Max. 4.5 3.4 4.2 Max. 4.5 Good / No good
Boom held level
4 E Arm DIGGING Good / No good
5 ( L) Good / No good
6 Boom and arm held level Bucket DIGGING 2.6 3.2 Max. 3.3 2.6 3.2 Max. 3.3 Good / No good
7 Full Fully extended Swing (5 turns) Sec. 23.3 28.5 Max. 31 23.3 28.5 Max. 31
Left Good / No good
Lo 48.7 59.6 48.7 63.6 52.8 64.6 52.8 68.6
A Left Good / No good
Track shoe raised Travel Right Good / No good
8 at one side ( Mi) 35.6 43.6 35.6 47.6 38.6 47.2 38.6 51.2
(5 turns) Left Good / No good
Hi 26.7 29.5 26.7 31.5 28.9 31.9 28.9 33.9
Left Good / No good
: The "Mi" and "L" modes are on the multi-monitor specification machine only.
3. Work equipment hydraulic drift amount (PC220, 220LC-7)

Hydraulic oil temperature (45 55oC)
No. Working Measurement item Unit PC220-7 PC220LC-7 Measured value Judgement
Fuel dial mode Work equipment posture New model Failure judgement New model Failure judgement
Boom and arm held Hydraulic drift amount at 600 Max. 900 600 Max. 900 Good / No good
1 Engine stop level, Bucket loaded bucket tooth tip (15 min.) mm
PC200/220(LC)-7
4. Inspection of hydraulic circuit (PC220, 220LC-7)
No. Part to be checked Remarks
Working Auto-dece- One-touch po- F main pump R main pump F pump LS R pump LS Control circuit
Fuel dial Work equipment operation pressure
mode lerator wer max. switch
1 Self-decompression valve Circuit pressure 3.2 MPa {33 kg/cm2}
OFF Arm dumping relief
2 Main relief valve
PC200/220(LC)-7
34.8 37.3 MPa
3 (When power increased) ON {355 380 kg/cm2}
Neutral MainLS=3.9 MPa{40 kg/cm2}
LS valve (LS differential pressure = Unload pressure)
4 (LS differential Travel without load, Right
pressure valve) Full A OFF engine at Hi idle and MainLS=2.2 MPa{22.0 kg/cm2} (LS pressure)
control lever at half stroke Left
Swing lock Right

i relief
5 Swing safety valve OFF switch ON 30.9 MPa {315 kg/cm2}
Left relief
Right forward
Main relief valve, Right reverse
6 Travel safety valve, Track shoe 38.7 MPa {395 kg/cm2}
Travel interlocking valve locked Left forward
Left reverse
Connection to be changed to hoses and

No. Part to be checked Working Auto- One-touch po- circuit Remarks
Fuel dial mode decelerator wer max. switch Work equipment operation F main pump R main pump F pump servo R pump servo Control
pressure
Servo Full Arm dumping relief Main servo pressure balance

7 A OFF OFF / = / = 3/5
Connection to be changed to hoses and , and gauge to be replaced with
one with 60 K capacity.

No. Part to be checked Working Auto- One-touch po- PC LS Control circuit Remarks <Reference value: kg/cm2>
Fuel dial mode decelerator wer max. switch Work equipment operation F main pump R main pump
EPC EPC pressure
Low <34>
A
< 3>
8 PC-EPC valve E OFF OFF Arm dumping relief <14>
Full
( L) <21>
B <16>
Neutral At neutral: 2.9MPa {30kg/cm2}
A
9 LS-EPC valve Full OFF OFF When 2 pumps relieved: 0MPa {0kg/cm2}
Arm dumping relief
( L) When one pump relieved: 1.5MPa {15kg/cm2}
: The "L" mode is on the multi-monitor specification machine only.
(11)
20-185
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202

SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...................... 20-218
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-236
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE

"MECHANICAL SYSTEM" ARE INDICATED ...................................................................................... 20-301
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................. 20-501
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) ................................. 20-601
PC200/220(LC)-7 20-201
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. Use the results of the investigation and in-
spection in Items 2 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1)Start from the simple points.
problems with the machine condition before 2)Start from the most likely points.
this? 3)Investigate other related parts or infor-
4) Under what conditions did the failure occur? mation.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 PC200/220(LC)-7
TESTING AND ADJUSTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC200/220(LC)-7 20-203
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-204 PC200/220(LC)-7
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water
should get into the connector, the pins will
be short-circuited by the water, so if any
water gets in, immediately dry the connector
or take other appropriate action before
passing electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.
PC200/220(LC)-7 20-205
2) Removing, installing, and drying connectors

and wiring harnesses
Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
Never pull with one hand.
2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
If the connector is twisted up and down
or to the left or right, the housing may
break.
3) Action to take after removing connectors

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 PC200/220(LC)-7
Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
If there is any damage or breakage, re-
place the connector.
2) Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3) Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
4) If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
Connecting connectors (DT type connector)

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

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 PC200/220(LC)-7
3) Handling control box

1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.
3) Do not place objects on top of the control

box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
If there is any change, there is probably
defective contact in that circuit.
PC200/220(LC)-7 20-209
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
necessary to be particularly careful.
1) Be careful of the operating environment.

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

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210 PC200/220(LC)-7
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
5) Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
PC200/220(LC)-7 20-211
(1)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
value
1. Check fuel level, type of fuel Add fuel
2. Check for impurities in fuel Clean, drain
3. Check hydraulic oil level Add oil
Lubricating oil,
4. Check hydraulic oil strainer Clean, drain

coolant
5. Check swing machinery oil level Add oil

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

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

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

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

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

Classification of troubleshooting
Mode Content
Troubleshooting when Service Code (electrical system) and Failure Code (mechanical
Code display
system) are displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine assembly
Steps for troubleshooting

If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting
No. and proceed to the explanations for diagnosis.
1. Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [ ] switch to display Service Code. Following displayed Ser-
vice Code for the electrical system, carry out the troubleshooting along the corresponding code display.
2. Troubleshooting steps when the electrical system Service Code or mechanical system Failure Code
is recorded in the failure history:
If not calling User Code in the monitor panel, check the electrical system Service Code or mechanical sys-
tem Failure Code, using the failure history function of the monitor panel.
a If Service Code in the electrical system is recorded, delete the all codes once and revive the code in the
display again to check if the same abnormality still persists.
a Failure Code in the mechanical system cannot be deleted.
3. Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that
the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechan-
ical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from
among "Failure like Phenomena and Troubleshooting No." and carry out E mode or H mode troubleshooting
related to the phenomenon in question.
PC200/220(LC)-7 20-213
(5)
Failure-looking Phenomenon and Troubleshooting No.
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Action to be taken concerning Service Code, User Code and Failure Code
1 Display User Code in monitor panel Accord-
Display Service Code in electrical system after checking failure ing to
2
history dis-
Display Failure Code in mechanical system after checking failure played
3 code
history
Engine-related failure
Engine does not start up easily. (It always takes some time to start
4 S-1
up the engine)
5 Engine does not rotate E-1 S-2 (1)
6 Engine rotates, but there is no exhaust gas S-2 (2)
Engine does not start
There is exhaust gas, but engine does not
7 S-2 (3)
start
8 Engine pickup is poor. (Engine does not follow acceleration) S-3
9 Engine stops while in operation E-2 H-2 S-4
10 Engine rotation is irregular. (There is hunting) E-3 S-5
11 Engine is short of output, or lacks power H-1 S-6
12 Color of exhaust gas is too dark. (Incomplete combustion) S-7
13 Excessive engine oil consumption, or color of exhaust gas is blue S-8
14 Premature engine oil contamination S-9
15 Excessive fuel consumption S-10
16 Engine coolant is mixed with engine oil, spurts out or decreases S-11
17 Engine oil amount increases. (Water or fuel gets in) S-13
18 Abnormal noises are heard S-15
19 Excessive vibrations are caused S-16
20 Engine does not stop E-4
21 Auto-decelerator does not work E-5 H-5
22 Engine auto warming-up device does not work E-6
23 Engine preheater does not work E-7
Failure related to work equipment, swing and travel
Speeds of all work equipment, travel and swing are slow, or they
24 H-1 S-6
lack power
25 Engine rotation drops sharply or stalls H-2 S-4
26 All work equipment, travel and swing do not move E-8 H-3
27 There are abnormal noises from around hydraulic pump H-4
28 Fine control mode function works poorly, or shows slow response H-6
20-214 PC200/220(LC)-7
(11)
Troubleshooting
display
Work equipment-related failure
29 Boom moves slowly or lacks power E-21, 22 H-7
30 Arm moves slowly or lacks power E-23, 24 H-8
31 Bucket moves slowly or lacks power E-25, 26 H-9
32 Work equipment does not move when individual operation H-10
33 Natural drift of work equipment is too fast H-11
34 Work equipment time lag is too big H-12
Other work equipment moves, when specific work equipment is
35 H-13
relieved
36 One-touch power max. switch does not work E-9, 2126 H-14
Compound operation-related failure
In compound operation, work equipment receiving larger load
37 H-15
moves slowly.
38 In swing + boom RAISE operation, boom moves slowly H-16
39 In swing + travel operation, travel speed drops sharply H-17
Travel-related failure
40 Machine tends to swerve while in travel H-18
41 Travel speed is slow E-28 H-19
42 Machine is difficult to steer, or lacks power E-28, 29 H-20
43 Travel speed cannot be shifted or is slow or fast E-28 H-21
44 Track shoe does not move (only on one side) H-22
Swing-related failure
45 Machine does not swing E-27 H-23
46 Swing acceleration is poor, or swing speed is slow H-24
47 Upper structure overruns excessively, when stopping swing H-25
48 There is a big shock caused when stopping swing H-26
49 There is abnormal noise generated when stopping swing H-27
50 Hydraulic drift of swing is large. H-28
Monitor panel-related failure (Operator's Menu: ordinary display)
51 No display appears in monitor panel at all E-10
52 Part of display is missing in monitor panel E-11
53 Descriptions on monitor panel do not apply to the machine model E-12
In startup inspection, radiator coolant level monitor lamp lights up
54 B@BCZK
red ( )
55 In startup inspection, engine oil level monitor lamp lights up red B@BAZK
: The multi-monitor specification machine only.
PC200/220(LC)-7 20-215
(11)
Troubleshooting
display
Refer to Operation and Maintenance
56 In startup inspection, maintenance hour monitor lamp lights up red
Manual
While engine is running, battery charging level monitor lamp lights
57 AB00KE
up red
58 While engine is running, fuel level monitor lamp lights up red E-13
While engine is running, air cleaner clogging monitor lamp lights up
59 AA10NX
red
While engine is running, engine coolant temperature monitor lamp
60 B@BCNS
lights up red
While engine is running, hydraulic oil temperature monitor lamp
61 B@HANS
lights up red ( )
62 Engine coolant temperature gauge does not display correctly E-14
63 Hydraulic oil temperature gauge does not display correctly ( ) E-15
64 Fuel gauge does not display correctly E-16
65 Swing lock monitor does not display correctly E-17
66 When operating monitor switch, no display appears E-18
67 Windshield wiper does not work E-19
68 Warning buzzer cannot be stopped E-20
Monitor panel-related failure (Service Menu: Special Function Display)
In monitoring function, "Boom RAISE" cannot be displayed cor-
69 E-21
rectly
In monitoring function, "Boom LOWER" cannot be displayed cor-
70 E-22
rectly
In monitoring function, "Arm DIGGING" cannot be displayed cor-
71 E-23
rectly
In monitoring function, "Arm DUMPING" cannot be displayed cor-
72 E-24
rectly
In monitoring function, "Bucket DIGGING" cannot be displayed
73 E-25
correctly
In monitoring function, "Bucket DUMPING" cannot be displayed
74 E-26
correctly
75 In monitoring function, "Swing" cannot be displayed correctly E-27
76 In monitoring function, "Travel" cannot be displayed correctly E-28
In monitoring function, "Travel Differential Pressure" cannot be dis-
77 E-29
played correctly
78 In monitoring function, "Service" cannot be displayed correctly E-30
Other failure
79 Air conditioner does not work E-31
80 Travel alarm does not sound E-32
20-216 PC200/220(LC)-7
(11)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT

DIAGRAM BY SYSTEM
Connector table
PC200, 200LC-7 Serial No. 200001 250000
PC220, 220LC-7 Serial No. 60001 65000
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
A01 X 4 Intermediate connector T-1 H-6 I-5 I-8
A02 X 4 Intermediate connector T-1 H-6 I-4
A03 D 12 Intermediate connector N-1 H-6 I-2 I-8
A04 SWP 12 Intermediate connector O-1 I-7
A05 SWP 14 Intermediate connector T-1 H-5 I-6
A06 SWP 14 Intermediate connector N-1 H-5 I-5
A07 SWP 16 Intermediate connector S-1 H-3 I-1 I-4
A08 SWP 12 Intermediate connector N-2
A09 SWP 8 Intermediate connector N-2 I-3
A10 Terminal 1 Revolving frame grounding H-1 H-1 J-5 J-4
A11 Terminal 1 Revolving frame grounding H-1 I-1
A13 Terminal 1 Revolving frame grounding I-2 I-1 J-4 J-8
A14 Terminal 1 Revolving frame grounding K-2 I-1
A15 Terminal 1 Revolving frame grounding I-2 I-1 J-4
A20 Terminal 1 Battery relay (E terminal) J-1 I-2 J-4
A21 Terminal 1 Battery relay (BR terminal) J-1 I-1 J-4
A22 Terminal 1 Battery relay (M terminal) J-1 J-2 K-4
A23 Terminal 1 Battery relay (B terminal) J-2 J-1 K-4
A25 Terminal 1 Heater relay (coil) L-3 K-6
A26 Terminal 1 Heater relay (contact) L-3 K-2
A27 X 2 Starter safety relay (S and R terminals) K-2 J-2
A29 Terminal 1 Starter safety relay (C terminal) L-3
A30 YAZAKI 2 Air conditioner outside air temperature sensor L-4
A31 D 2 Air cleaner clogging sensor L-4 K-4
A33 X 2 Radiator coolant level sensor L-4 K-5
A34 L 2 Fusible link (65A) A-4 K-6 K-5
A35 M 2 Fusible link (30A) A-5 K-6 K-4
A40 AMP 1 Alarm horn (low tone) H-1
A41 AMP 1 Alarm horn (high tone) H-1
A42 X 1 Intermediate connector I-9 J-7
A43 X 2 Travel alarm I-2 K-4
A44 M 1 Front right lamp A-6 K-7
20-218 PC200/220(LC)-7
(11)
Address
Connector No. of
No. pin
A50 KES0 2 Window washer monitor (tank) K-3 K-5
A51 D 3 F pump hydraulic oil pressure sensor K-3 K-5
A52 D 3 R pump hydraulic oil pressure sensor J-9 K-5
A60 X 1 Fuel level sensor D-9 K-4
A61 D 2 Hydraulic oil temperature sensor H-9 K-5
C01 DRC 24 Governor pump controller V-9 A-3 A-8 A-8
C02 DRC 40 Governor pump controller W-9 A-3 A-7 A-7
C09 S 8 Model selection connector W-6 C-9
D01 SWP 8 Assembled type diode W-7 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-7 A-8 D-1
D03 SWP 8 Assembled type diode P-1 H-1
D04 SWP 8 Assembled type diode Q-1 A-8 F-1 I-1
Suction type air heater
E01 Terminal 1 J-9 L-2 L-6
(electrical intake air heater)
E02 Terminal 1 Engine hydraulic switch L-8 K-6
E03 D 2 Engine oil level switch L-6 K-5
E04 D 2 Engine rotation sensor K-9 K-8
E05 D 2 Engine coolant temperature sensor J-9 K-4
E06 M 3 Fuel dial K-8
Air conditioner compressor electromagnetic
E06 X 1 O-8
switch
E08 X 1 Intermediate connector L-7 J-3 J-5
E10 D 3 Governor potentiometer J-9 K-3
E11 D 4 Governor motor K-9 K-2
E12 X 2 Alternator L-7 K-3 K-5
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 Fuse box W-5 I-9 C-4 F-9
G01 V-2
G02 V-3
G03 V-3
G04 V-2
G05 V-3
H08 M 8 Intermediate connector W-4 K-8
H09 S 8 Intermediate connector W-4 J-8
H10 S 16 Intermediate connector T-9 D-6 I-8
H11 S 16 Intermediate connector S-9 D-5 I-8 B-9
H12 S 12 Intermediate connector S-9 D-5 I-7
H15 S090 20 Intermediate connector N-7 C-2 E-2 C-2
PC200/220(LC)-7 20-219
(11)
Address
Connector No. of
No. pin
J01 J 20 Junction connector (black) W-8 C-9 D-9 C-9
J02 J 20 Junction connector (black) W-8 D-9 D-9 D-9
J03 J 20 Junction connector (green) W-8 D-9 D-9
J04 J 20 Junction connector (green) W-7 E-9 E-9 E-9
J05 J 20 Junction connector (pink) W-6 E-9 E-9 E-9
J06 J 20 Junction connector (orange) W-6 F-9 H-9
J07 J 20 Junction connector (orange) U-9 F-9 F-9 H-9
J08 J 20 Junction connector (pink) U-9 I-9
K19 M 2 Pump resistor (for driving emergency pump) U-2 E-3
K30 D 3 CAN terminating resistor T-9 A-2 C-1
K31 D 3 CAN terminating resistor N-4 A-4 K-7
M07 M 3 Lamp switch P-8 C-2
M09 M 1 Working lamp (front right) E-9 K-7
M13 KES0 2 Speaker (right) AC-8
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio U-2
M22 Y090 2 Horn switch N-7
M23 Y090 2 Knob switch T-1
M26 S 12 Air conditioner unit W-5
M27 SWP 16 Air conditioner unit W-5
M29 040 20 Air control panel W-3
M30 040 16 Air control panel W-3
M31 M 2 Option power source (2) U-2
M32 M 2 Option power source (1) S-9
M33 M 2 Option power source (3)
M33 SWP 8 Air conditioner unit S-9
M34 YAZAKI 2 Air conditioner inside air sensor W-8
M40 YAZAKI 2 Working lamp Z-8 K-8
M41 YAZAKI 2 Working lamp (additional) Y-7 K-8
M42 M 1 Intermediate connector K-3 J-7
M43 M 1 Working lamp (rear) K-7
M45 D 12 Intermediate connector U-2
M46 S090 4 RS232C relaying connector U-9 B-9
M71 M 2 Room lamp Z-8
M72 M 4 DC/AC converter U-2
M73 KES0 2 Speaker (left) AD-8
M79 YAZAKI 2 12V electrical equipment socket V-9
20-220 PC200/220(LC)-7
(11)
Address
Connector No. of
No. pin
P01 070 12 Monitor panel N-6 A-7 K-8
P02 040 20 Monitor panel N-5 A-6 K-8 A-9
P03 M 2 Buzzer canceling switch P-9 D-1
P05 M 2 Revolving warning lamp switch W-3
P15 Y050 2 Air conditioner sun light sensor N-6
R10 R 5 Lamp relay O-8 E-1
R11 R 5 Engine starting motor cutting relay (PPC lock) P-8 E-1
Engine starting motor cutting relay (personal
R13 R 5 Q-9 F-1
code)
R20 R 5 Attachment circuit switching relay W-6 C-9
R21 W-7
S01 X 2 Bucket digging oil pressure switch S-8 K-2
S02 X 2 Boom lowering oil pressure switch L-7 K-3
S03 X 2 Swing oil pressure switch, left L-7 K-2
S04 X 2 Arm digging oil pressure switch L-6 K-3
S05 X 2 Bucket dumping oil pressure switch L-5 K-2
S06 X 2 Boom raise oil pressure switch L-5 K-3
S07 X 2 Swing oil pressure switch, right L-5 K-2
S08 X 2 Arm dumping oil pressure switch L-4 K-3
Service oil pressure switch (intermediate con-
S09 X 2 K-3 K-1
nector)
S10 X 2 Service oil pressure switch, front K-1
S11 X 2 Service oil pressure switch, rear K-1
S14 M 3 Lever lock switch S-1 K-9 F-8
S21 Terminal 6 Pump emergency driving switch R-9 E-2
Swing and parking brake emergency releasing
S22 Terminal 6 R-9 F-2
switch
S25 S090 16 Intermediate connector Q-9 E-3
S30 X 2 Travel hydraulic switch O-1 A-1
S31 X 2 Travel steering hydraulic switch P-1 A-1
SC Terminal 1 Engine starting motor (C terminal) K-8
SSW Terminal 5 Engine starting switch N-7
T05 Terminal 1 Floor frame grounding W-3 J-8
T06 Terminal 1 Radio body grounding
T06A M 1 Intermediate connector T-2
T11 Terminal 1 Operator's cab grounding AD-3
T13 D 1 Engine starting motor (C terminal) L-6 J-3
PC200/220(LC)-7 20-221
(11)
Address
Connector No. of
No. pin
V01 D 2 PPC hydraulic lock solenoid valve J-2 K-6
V02 D 2 Travel interlocking solenoid valve J-2 K-6
V03 D 2 Merge/divide valve solenoid valve J-2 K-6
V04 D 2 Travel speed solenoid valve J-3 K-5
V05 D 2 Swing and parking brake solenoid valve J-3 K-5
V06 D 2 2-stage relief solenoid valve K-3 K-6
V12 D 2 Attachment return switching solenoid valve I-9 K-4
V21 D 2 PC-EPC solenoid valve I-9 K-7
V22 D 2 LS-EPC solenoid valve I-9 K-7
Attachment oil flow rate adjusting EPC solenoid
V30 X 2 P-1 A-1
valve
W03 X 2 Rear limit switch (window) AB-9 L-8
W04 M 6 Windshield wiper motor Y-4 B-9
X05 M 4 Swing lock switch Q-9 D-2 C-2
Y08 G-9
Y09 G-1
Y10 G-9
Y11 A-6
Y12 G-9
Y13 G-1
Y16 G-9
20-222 PC200/220(LC)-7
(1)
Connector No. Detailed information

D or DT Japanese and German makes DT type connector (08192-XXXXX)
L Product of Yazaki Corporation L type connector (08056-2XXXX)
J Product of Sumitomo Wiring Systems 090 type splice
M Product of Yazaki M type connector (08056-0XXXX)
R Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S Product of Yazaki S type connector (08056-1XXXX)
X Product of Yazaki X type connector (08055-0XXXX)
PA Product of Yazaki PA type connector
SWP Product of Yazaki SWP type connector (08055-1XXXX)
DRC Japanese and German makes DRC type connector
040 Product of Japan AMP 040 type connector
Y050 Product of Yazaki 050 type connector
S090 Product of Sumitomo 090 type connector
YAZAKI Yazaki-made connector
KES0 KES0 type connector (08027-0XXXX)
Terminal Round pin type single terminal connector
Terminal Round terminal
*An affiliated company of Mitsubishi Cable Industries, Ltd.
PC200/220(LC)-7 20-223
(5)
Connector table
PC200, 200LC-7 Serial No. 250001 and up
Address
Connector No. of
No. pin
A01 X 4 Intermediate connector M-8 H-6 I-5 I-8
A02 X 4 Intermediate connector M-9 H-6 I-4
A03 D 12 Intermediate connector M-9 H-6 I-2 I-8
A05 SWP 14 Intermediate connector M-8 H-5 I-7
A06 SWP 14 Intermediate connector O-9 H-5 I-5
A07 SWP 16 Intermediate connector M-8 H-4 I-5 I-4
A08 SWP 12 Intermediate connector O-9
A14 Terminal 1 Revolving frame grounding K-2 I-1 J-4
A29 Terminal 1 Starter safety relay (C terminal) L-3 K-2
A42 X 1 Intermediate connector I-9
20-223-1 PC200/220(LC)-7
(11)
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
No. pin
P05 M 2 Revolving warning lamp switch W-3
Engine starting motor cutting relay (personal
R13 R 5 Q-9 F-1
code)
R20 R 5 Attachment circuit switching relay W-6 C-9
R21 W-7
S01 X 2 Bucket digging oil pressure switch S-8 K-2
Service oil pressure switch (intermediate con-
S09 X 2 K-3 K-1
nector)
S14 M 3 Safety lever lock switch S-1 K-9 F-8
switch
SC Terminal 1 Engine starting motor (C terminal) K-8
T05 Terminal 1 Floor frame grounding W-3 J-8
T06 Terminal 1 Radio body grounding
PC200/220(LC)-7 20-221
Address
Connector No. of
No. pin
V01 D 2 PPC hydraulic lock solenoid valve J-2 K-6
V30 X 2 P-1 A-1
valve
Y08 G-9
Y09 G-1
Y10 G-9
Y11 A-6
Y12 G-9
Y13 G-1
Y16 G-9
20-222 PC200/220(LC)-7

PC200/220(LC)-7 20-223
(5)
Connector table
Address
Connector No. of
No. pin
A01 X 4 Intermediate connector M-8 H-6 I-5 I-8
A02 X 4 Intermediate connector M-9 H-6 I-4
A03 D 12 Intermediate connector M-9 H-6 I-2 I-8
A05 SWP 14 Intermediate connector M-8 H-5 I-7
A06 SWP 14 Intermediate connector O-9 H-5 I-5
A07 SWP 16 Intermediate connector M-8 H-4 I-5 I-4
A08 SWP 12 Intermediate connector O-9
A14 Terminal 1 Revolving frame grounding K-2 I-1 J-4
A29 Terminal 1 Starter safety relay (C terminal) L-3 K-2
A42 X 1 Intermediate connector I-9
20-223-1 PC200/220(LC)-7
(11)
Address
Connector No. of
No. pin
Boom cylinder bottom pressure sensor for over-
A70 D 3 G-1 K-4
load alarm
C01 DRC 24 Governor pump controller U-9 A-3 A-8 A-8
C02 DRC 40 Governor pump controller V-9 A-3 A-7 A-7
C09 S 8 Model selection connector U-9 C-9
D01 SWP 8 Assembled type diode W-9 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-7 A-8 D-1
Suction type air heater
E01 Terminal 1 J-9 L-2 L-6
(electrical intake air heater)
E02 Terminal 1 Engine hydraulic switch L-8 K-6
E03 D 2 Engine oil level switch L-6 K-6
E04 D 2 Engine rotation sensor K-9 K-8
E05 D 2 Engine coolant temperature sensor J-9 K-4
E06 M 3 Fuel dial O-8 F-1
Air conditioner compressor electromagnetic
E06 X 1 K-8
switch
E08 X 1 Intermediate connector L-8 J-3 J-5
E10 D 3 Governor potentiometer J-9 K-3
E11 D 4 Governor motor K-9 K-2
E12 X 2 Alternator L-7 K-3 K-5
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 Fuse box U-2 I-9 C-4 F-9
G01
G02
G03
G04
G05
H08 M 8 Intermediate connector W-6 K-8
H09 S 8 Intermediate connector W-6 J-8
H11 S 16 Intermediate connector S-9 D-5 I-8 B-9
H15 S090 20 Intermediate connector N-7 C-2 E-2 C-2
J01 J 20 Junction connector (black) T-9 C-9 D-9 C-9
J02 J 20 Junction connector (black) V-2 D-9 D-9 D-9
J03 J 20 Junction connector (green) V-2 D-9 D-9
J04 J 20 Junction connector (green) V-3 E-9 E-9 E-9
J05 J 20 Junction connector (pink) V-3 E-9 E-9 E-9
J06 J 20 Junction connector (orange) V-3 F-9
J07 J 20 Junction connector (orange) W-3 F-9 F-9 H-9
K19 M 2 Pump resistor (for driving emergency pump) W-3 E-3
PC200/220(LC)-7 20-223-2
(11)
Address
Connector No. of
No. pin
K30 D 3 CAN terminating resistor T-9 A-2 C-1
K31 D 3 CAN terminating resistor N-4 A-4 K-7
M07 M 3 Lamp switch P-8 C-1
M09 M 1 Working lamp (front right) E-9 K-7
M13 KES0 2 Speaker (right) AC-8
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio T-1
M22 Y090 2 Horn switch N-7
M23 Y090 2 One-touch power max. switch S-1
M26 S 12 Intermediate connector W-3
M29 040 20 Air control panel T-2
M30 040 16 Air control panel U-2
M31 M 2 Option power source (2) W-6
SUMIT-
M33 4 Air conditioner unit W-5
OMO
M40 YAZAKI 2 Working lamp Z-8 K-8
M41 YAZAKI 2 Working lamp (additional) Y-7 K-8
M42 M 1 Intermediate connector K-3 K-7
M43 M 1 Working lamp (rear) K-7
M45 D 12 Intermediate connector W-7
M46 S090 4 RS232C relaying connector V-9 B-9
M71 M 2 Room lamp Z-8
M72 M 4 DC/AC converter W-7
M73 KES0 2 Speaker (left) AD-8
M79 YAZAKI 2 12V electrical equipment socket W-8
P05 M 2 Revolving warning lamp switch U-2
P17 S09 2 Air conditioner high/low pressure switch
Engine starting motor cutting relay
R13 R 5 Q-9 F-1
(personal code)
R20 R 5 Attachment circuit switching relay U-9 C-9
R21
20-223-3 PC200/220(LC)-7
(5)
Address
Connector No. of
No. pin
R30 R 5 Air conditioner blower relay W-4
R31 R 4 Air conditioner compressor relay W-4
S01 X 2 Bucket digging oil pressure switch L-8 K-3
Service oil pressure switch
S09 X 2 K-3 K-2
(intermediate connector)
S14 M 3 Lever lock switch S-1 K-9 F-8
switch
SC Terminal 1 Engine starting motor (C terminal) K-8 K-3
T05 Terminal 1 Floor frame grounding U-2
T06 Terminal 1 Radio body grounding T-1
V01 D 2 PPC hydraulic lock solenoid valve I-2 K-6
V30 X 2 P-1 A-1
valve
PC200/220(LC)-7 20-223-4
(11)
Address
Connector No. of
No. pin
Y08
Y09
Y10
Y11
Y12
Y13
Y16
Y27
20-223-5 PC200/220(LC)-7
(5)

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

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

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

PC200, 200LC-7 Serial No. 200001 250000
PC220, 220LC-7 Serial No. 60001 65000
20-230 PC200/220(LC)-7
(7)
a This circuit diagram has been compiled by extracting the monitor panel system and engine starting system
from the overall electrical circuit diagram.
PC200/220(LC)-7 20-231
(5)
Monitor Panel System Circuit Diagram (M Circuit)

20-231-1 PC200/220(LC)-7
(7)
a This circuit diagram has been compiled by extracting the monitor panel system and engine starting system
from the overall electrical circuit diagram.
PC200/220(LC)-7 20-231-2
(5)
Governor Control System Circuit Diagram (G Circuit) of GovernorPump Controller

PC200, 200LC-7 Serial No. 200001 250000
20-232 PC200/220(LC)-7
(5)
a This circuit diagram has been compiled by extracting the governorpump controller system (power source,
governor control, model selection and communication) from the overall electrical circuit diagram.
PC200/220(LC)-7 20-233
(5)
Governor Control System Circuit Diagram (G Circuit) of GovernorPump Controller

20-233-1 PC200/220(LC)-7
(7)
a This circuit diagram has been compiled by extracting the governorpump controller system (power source,
governor control, model selection and communication) from the overall electrical circuit diagram.
PC200/220(LC)-7 20-233-2
(5)
Pump Control System Circuit Diagram (P Circuit) of GovernorPump Controller

PC200, 200LC-7 Serial No. 200001 250000
PC220, 220LC-7 Serial No. 60001 65000
20-234 PC200/220(LC)-7
(7)
a This circuit diagram has been compiled by extracting the governorpump controller system (pump control),
PPC lock system and backup alarm system from the overall electrical circuit diagram.
PC200/220(LC)-7 20-235
(5)
Pump Control System Circuit Diagram (P Circuit) of GovernorPump Controller

20-235-1 PC200/220(LC)-7
(9)
a This circuit diagram has been compiled by extracting the governorpump controller system (pump control),
PPC lock system and backup alarm system from the overall electrical circuit diagram.
PC200/220(LC)-7 20-235-2
(9)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
Electric wire size: 0.85 Electric wire size: 0.85

Grommet: Black Grommet: Black
Qty: 20 Qty : 20

Grommet: Red Grommet: Red
Qty: 20 Qty: 20
20-236 PC200/220(LC)-7
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
PC200/220(LC)-7 20-237
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:

Grommet: Black Grommet: Black
Qty: 20 Qty: 20
Terminal part No.: Terminal part No.:

Grommet: Red Grommet: Red
Qty: 20 Qty: 20
20-238 PC200/220(LC)-7
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
PC200/220(LC)-7 20-239
(5)
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
20-240 PC200/220(LC)-7
(1)
S type connector
No.of
pins T-adapter
Part No.
10

(Blue)
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
PC200/220(LC)-7 20-241
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Qty: 5) Body part No.: 79A-222-2630 (Qty: 5)
11 Body part No.: 79A-222-2680 (Qty: 5) Body part No.: 79A-222-2670 (Qty: 5)
5 799-601-2710
Body part No.: 79A-222-2620 (Qty: 5) Body part No.: 79A-222-2610 (Qty: 5)
9 799-601-2950
13 799-601-2720
20-242 PC200/220(LC)-7
MIC type connector

No.of
pins T-adapter Part
No.
17 799-601-2730
21 799-601-2740

(Qty: 50) (Qty: 50)
PC200/220(LC)-7 20-243
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
Housing part No.: 79A-222-3430 (Qty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-244 PC200/220(LC)-7
AMP070 type connector

No.of
pins T-adapter Part
No.
10 799-601-7510
Part No.: 7821-92-7330
12 799-601-7520
Part No.: 7821-92-7340
14 799-601-7530
Part No.: 7821-92-7350
18 799-601-7540
Part No.: 7821-92-7360
20 799-601-7550
Part No.: 7821-92-7370
PC200/220(LC)-7 20-245
(12)
L type connector
No.of
pins T-adapter Part
No.
Connector for PA
No.of
pins T-adapter Part
No.
Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460
20-246 PC200/220(LC)-7
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
Part No.:08027-10310 Part No.:08027-10360
08027-10420 (Black) 08027-10470 (Black)
08027-10620 (Black) 08027-10670 (Black)
PC200/220(LC)-7 20-247
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No.of
pins T-adapter Part
No.
5 799-601-7360
6 799-601-7370
20-248 PC200/220(LC)-7
F type connector
No.of
pins T-adapter
Part No.
PC200/220(LC)-7 20-249
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-250 PC200/220(LC)-7

(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
PC200/220(LC)-7 20-251

(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
20-252 PC200/220(LC)-7

(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
PC200/220(LC)-7 20-253
(5)

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
20-254 PC200/220(LC)-7
(1)
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
PC200/220(LC)-7 20-255
(1)
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
20-256 PC200/220(LC)-7
(5)
DTM Series connector

No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter Part
No.
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC200/220(LC)-7 20-257
DT Series connector
No.of
pins T-adapter
Part No.
24 799-601-9360
Part No.:7821-93-3110
40
799-601-9350
(A)
Part No.:7821-93-3120
40
799-601-9350
(B)
Part No.:7821-93-3130
20-258 PC200/220(LC)-7
(7)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Connector type or
Part No. No. of pins

part name
799-601-2600 Measurement box Econo-21P Q Q Q Q Q Q

799-601-3100 Measurement box MS-37P Q
799-601-3200 Measurement box MS-37P Q
799-601-3300 Measurement box Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P Q Q
799-601-3420 BENDIX (MS) 24P Q Q
799-601-3430 BENDIX (MS) 17P Q Q
799-601-3440 BENDIX (MS) 17P Q Q
799-601-3450 BENDIX (MS) 5P Q Q
799-601-3460 BENDIX (MS) 10P Q Q
799-601-3510 BENDIX (MS) 5P Q Q
799-601-3520 BENDIX (MS) 14P Q Q
799-601-3530 BENDIX (MS) 19P Q Q
799-601-2910 BENDIX (MS) 14P Q Q
799-601-3470 Case Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Additional cable Q Q Q
799-601-2850 Case Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
799-601-7320 SWP 16P Q
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
PC200/220(LC)-7 20-259
(5)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Connector type or
Part No. No. of pins

part name
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Case Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Brown Q Q
799-601-9110 DT 12P-Gray Q Q
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Brown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
799-601-9230 HD30 18-20 Q Q
799-601-9240 HD30 18-21 Q Q
799-601-9250 HD24 24-9 Q Q
799-601-9260 HD30 24-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 Measurement box For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
For fuel, boost
799-601-9420 3P Q
press.
799-601-9430 PVC socket 2P Q
20-260 PC200/220(LC)-7
(5)
TROUBLESHOOTING BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE

Error codes, failure codes, and possible causes
20-262 PC200/220(LC)-7
(5)
PC200/220(LC)-7 20-263
(5)
20-264 PC200/220(LC)-7
(5)
PC200/220(LC)-7 20-265
(5)
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power directly
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting for an electric system, you should check its fuse box and fusible link to
see if the power is supplied normally.
Type of power
Fuse No. Fuse capacity Destination of power
supply
Engine throttle and pump controller (Controller power supply)
1 10A Emergency pump drive resistor
Swing holding brake release switch
Switch power Engine throttle and pump controller (Solenoid power supply)
supply 2 20A
Attachment return switching relay (Coil side and contact side)
(Fusible link:
A34) 3 10A Lock switch
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn switch
6 10A (Spare)
Rotary lamp switch
7 10A
Switch power Additional relay (Coil side and contact side)
supply
8 10A Light relay (Contact side)
(Fusible link:
A34) One-touch power maximizing switch
9 10A
Radio
10 10A (Spare)
11 20A Air conditioner unit
Starting motor cut-out (Personal code) relay (Coil side)
12 20A
Switch power Monitor panel
supply
13 20A Light switch
(Fusible link:
A34) 14 10A Service power supply (M32 connector)
Travel alarm
15 10A
DC/DC converter
Radio
16 10A
Air conditioner unit
Constant power
supply 17 20A Monitor panel
(Fusible link: 18 10A Starting switch
A35)
19 10A Room lamp
20 10A (Spare)
20-266 PC200/220(LC)-7
(11)
Problems which occur when controller power supply of engine throttle and pump controller is defective
a The controller power supply (FB1-1) of the engine throttle and pump controller drives the controller system.
a Accordingly, if the controller power supply is turned off, the controller cannot control the governor motor and
battery relay and the following problems occur.
1) The engine can be started but cannot be stopped.
2) The engine speed cannot be controlled with the fuel control dial.
a If the above problems occur, check the related fuse (FB1-1) and "green LED" of the engine throttle and pump
controller to see if the power is supplied normally.
Lighting: The controller power is supplied (There is not an error and the power supply is normal).
Flashing: The controller power is supplied (There is an error).
Put out: The controller power is not supplied.
Green LED of engine throttle and pump controller (GREEN)
PC200/220(LC)-7 20-267
(5)
Problems which occur when solenoid power supply of engine throttle and pump controller is defective
a The solenoid power supply (FB1-2) of the engine throttle and pump controller is used by the controller to drive
the solenoids and relays.
a Accordingly, if the solenoid power supply is turned off, when the controller outputs the power to the solenoids
or relays, the power is not supplied to any of the solenoids and relays and all or some of the following error
codes are displayed simultaneously.
[E212]: Disconnection in travel junction solenoid
[E213]: Disconnection in swing holding brake solenoid
[E214]: Disconnection in pump merge-divider solenoid
[E215]: Disconnection in 2-stage relief solenoid
[E216]: Disconnection in travel speed shifting solenoid
[E223]: Disconnection in LS-EPC solenoid
[E233]: Disconnection in PC-EPC solenoid
[E248]: Disconnection in attachment flow rate adjustment EPC solenoid (when attachment is installed)
a If the above problems occur, check the related fuse (FB1-2) and inlet voltage of the engine throttle and pump
controller.
1) Disconnect connector C03 of the controller and connect a T-adapter to the wiring harness side.
2) Turn the starting switch ON.
3) Measure the voltage between each of pins (2) and (12) and each of pins (31), (32), and (33).
Pins (2) and (3) are the power supply pins and pins (31), (32), and (33) are the ground pins.
If the voltage is 20 30 V, it is normal.
Power supply connector (C03) of engine throttle and pump controller
20-268 PC200/220(LC)-7
(5)
TROUBLESHOOTING WHEN SERVICE CODE
"ELECTRICAL SYSTEM" AND FAILURE CODE
"MECHANICAL SYSTEM" ARE INDICATED
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-304

Service Code in Electrical System E101 (Abnormal data in error history) ................................................. 20-306
Service Code in Electrical System E112 (Short-circuiting in normal rotation system of
windshield wiper motor drive) ............................................................................................................... 20-308
Service Code in Electrical System E113 (Short-circuiting in reverse rotation system of
windshield wiper motor drive) ............................................................................................................... 20-310
Service Code in Electrical System E114 (Short-circuiting in window washer drive system) ...................... 20-312
Service Code in Electrical System E115 (Abnormal windshield wiper motion) .......................................... 20-314
Service Code in Electrical System E116 (Abnormality in retracting windshield wiper) .............................. 20-316
Service Code in Electrical System E201 (Short-circuiting in travel interlocking solenoid) ......................... 20-318
Service Code in Electrical System E203 (Short-circuiting in swing and parking brake solenoid................ 20-320
Service Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)................................. 20-322
Service Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)................................. 20-324
Service Code in Electrical System E206 (Short-circuiting in travel speed shifting solenoid) ..................... 20-326
Service Code in Electrical System E211 (Disconnection in travel interlocking solenoid)........................... 20-328
Service Code in Electrical System E213 (Disconnection in swing holding brake solenoid) ....................... 20-330
Service Code in Electrical System E214 (Disconnection of merge/divide solenoid) .................................. 20-332
Service Code in Electrical System E215 (Disconnection in 2-stage relief solenoid) .................................. 20-334
Service Code in Electrical System E216 (Disconnection in travel speed shifting solenoid) ....................... 20-336
Service Code in Electrical System E217 (Abnormality in inputting model code)........................................ 20-338
Service Code in Electrical System E218 Disconnection of S-NET signal) ................................................. 20-342
Service Code in Electrical System E222 (Short-circuiting in LS-EPC solenoid) ........................................ 20-344
Service Code in Electrical System E223 (Disconnection in LS-EPC solenoid system) ............................. 20-345
Service Code in Electrical System E224 (Abnormality in F pump pressure sensor).................................. 20-346
Service Code in Electrical System E225 (Abnormality in R pump pressure sensor) ................................. 20-348
Service Code in Electrical System E226 (Abnormality in pressure sensor power source) ........................ 20-350
Service Code in Electrical System E227 (Abnormality in engine rotation sensor) ..................................... 20-352
Service Code in Electrical System E228 (Short-circuiting in attachment return switching relay) ............... 20-353
Service Code in Electrical System E232 (Short-circuiting in PC-EPC solenoid ......................................... 20-354
Service Code in Electrical System E233 (Disconnection in PC-EPC solenoid system)............................. 20-356
Service Code in Electrical System E238 (Disconnection in attachment return switching relay) ................ 20-358
Service Code in Electrical Equipment E245 (Short-circuiting in attachment oil flow rate adjusting EPC) .. 20-360
Service Code in Electrical System E246 (Disconnection in attachment oil flow rate adjusting EPC)
(Multi-monitor only)............................................................................................................................... 20-361
Service Code in Electrical System E256 (Incorrect nonvolatile memory data) .......................................... 20-362
Service Code in Electrical System E306 (Abnormality in governor potentiometer).................................... 20-364
Service Code in Electrical System E308 (Abnormality in fuel dial) ............................................................ 20-366
Service Code in Electrical System E315 (Short-circuiting in battery relay) ................................................ 20-368
Service Code in Electrical System E316 (Step-out in governor motor) ...................................................... 20-370
PC200/220(LC)-7 20-301
(5)
TROUBLESHOOTING
Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B) .................... 20-372
Service Code in Electrical System E318 (Short-circuiting in governor motor Phase A and Phase B) ....... 20-374
Service Code in Electrical System E501 ("Model Selection" function not provided yet) ............................ 20-376
Service Mode in Electrical System E502 (Model selecting signal fault) ..................................................... 20-377
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idle) ............................. 20-378
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idle) .............................. 20-378
Failure Code in Mechanical System AA10NX (Air cleaner clogging) ......................................................... 20-379
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage).............................. 20-380
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure) ........................ 20-382
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)............................... 20-383
Failure Code in Mechanical System B@BCNS (Engine coolant overheating) ........................................... 20-384
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator coolant level) ..................... 20-385
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)................................................ 20-386
20-302 PC200/220(LC)-7
(11)
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

The troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-
tents fully before proceeding to actual troubleshooting work.
User Code Service Code Failure Code

Failure
Display in Display in Display in Title of failure phenomenon shown in failure history
phenomenon
monitor panel monitor panel monitor panel
Failure content Failure status as detected by monitor panel or controller
Response from
Action taken by the monitor panel or controller to protect an affected system or equipment, when they
monitor panel
detect some failure.
or controller
Phenomenon
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or
occurring on
controller
machine
Relative
Information on the failure occurred as well as the troubleshooting
information
Cause Standard value in normalcy and references for troubleshooting

<Content Included>
Standard value in normalcy by which to pass "Good" or "No good" judgement over the
presumed cause
1
Reference for passing the above "Good" or "No Good" judgement
<Phenomenon of Wiring Harness Failure>

Presumed cause and standard value in normalcy
Disconnection
There is a faulty contact at the connector or disconnection of wiring harness occurred.
Defective grounding
2 A wiring harness that is not connected with a grounding circuit has a contact with the
grounding circuit.
Short-circuiting
Cause that presumably A wiring harness that is not connected with a 24 V electric circuit has a contact with the
triggered failure in ques- electric circuit.
tion
3 (The assigned No. is for <Precaution for Troubleshooting>
filing purpose only. It 1) Connector No. display method and handling of T-adapter
does not stand for any Insert or connect T-adapters in the following manner before starting troubleshooting
priority) unless otherwise instructed.
If there is no indication of "male" or "female" in a specific connector No., disconnect
the connector and insert the T-adapter into both male and female sides.
4 If there is an indication of "male" or "female" in a specific connector No., disconnect
the connector and connect the T-adepter with only one side of either "male" or "fe-
male".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative () lead OFF a circuit tester in the fol-
lowing manner unless otherwise instructed.
Connect the positive (+) lead with the pin No. indicated at the front or the wiring har-
5
ness.
Connect the negative () lead with the pin No. indicated at the front or the wiring har-
ness.
20-304 PC200/220(LC)-7
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
Connector No.: Indicates (Type - numbers of a pin) (color)

Arrow: Roughly indicates the location in the machine where it is installed.
PC200/220(LC)-7 20-305
(1)
TROUBLESHOOTING E101
Service Code in Electrical System E101 (Abnormal data in Error History)
User Code Service Code Failure Code Failure Abnormal data in the error history
E101 DAF0KT phenomenon (in Monitor Panel system)
The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or
Failure content
exceeded 36 V.
Response from
None in particular
Monitor Panel
Phenomenon
occurring on A display for information on the failure history (in the electrical system) cannot be called.
machine

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

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

(Short-circuiting in normal rotation system of windshield wiper motor drive)
User Code Service Code Failure Code Failure Short-circuiting in normal rotation system of wind-
E112 DY2DKB phenomenon shield wiper motor drive (in monitor panel system)
Failure content Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.
Response from
Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Monitor Panel
Phenomenon
occurring on The windshield wiper stops moving.
machine

Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between and Continued
Between and grounding Above 1 M
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness for the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) and Resistance
circuit) Above 1 M
W04 (male) and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Below 3 V
Between and grounding Below 3 V20 30 V
ON
(at constant cycle)
20-308 PC200/220(LC)-7
Electric Circuit Diagram for Monitor Panel Windshield Wiper Motor
PC200/220(LC)-7 20-309

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

Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
or grounding fault) Between and Continued
Between and grounding Above 1 M
harness for the troubleshooting.
2
circuit) Above 1 M
W04 (male) and grounding value
P01 Windshield wiper switch Voltage
OFF Below 3 V
Between and grounding Below 3 V20 30 V
ON
(at constant cycle)
20-310 PC200/220(LC)-7
Electric Circuit Diagram for Monitor Panel Windshield Wiper Motor
PC200/220(LC)-7 20-311
(1)

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

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

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

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

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


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

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

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

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

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

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

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

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

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

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

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

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


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

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

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

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

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

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

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

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

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


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

PC200, 200LC-7 Serial No. 200001 250000
PC220, 220LC-7 Serial No. 60001 65000
User Code Service Code Failure Code Failure Disconnection in travel interlocking solenoid
E211 DW91KA phenomenon (in governor pump controller system)
Failure content No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from None in particular (The solenoid does not function as there is current flowing to it)
controller When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
It is difficult to steer the machine while traveling.
occurring on
machine
Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E201].)

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

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

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

(Disconnection in swing holding brake solenoid)
PC200, 200LC-7 Serial No. 200001 250000
PC220, 220LC-7 Serial No. 60001 65000
User Code Service Code Failure Code Failure Disconnection in swing holding brake solenoid
E03 E213 DW45KA phenomenon (in governor pump controller system)
Failure content No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Response from None in particular (The solenoid does not function as there is no current flowing to it)
Phenomenon
occurring on The machine's upper structure does not swing. (The swing holding brake is not released)
machine
If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing
by moving the emergency swing brake release switch to the FREE position. (In this case, however, the
Relative
parking brake does not work, when stopping the machine)
information
a While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in
the OFF position.
a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
Swing holding brake a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
solenoid defective during the troubleshooting.
1
(Internal disconnec- V05 (male) Resistance value
tion) Between (1) and (2) 20 60 z
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
(Internal disconnec-
tion) OFF Below 1 z
Between (3) and (4)

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

User Code Service Code Failure Code Failure Disconnection in swing holding brake solenoid
E03 E213 DW45KA phenomenon (in governor pump controller system)
Failure content No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Phenomenon
occurring on The machine's upper structure does not swing. (The swing holding brake is not released)
machine
If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing
by moving the emergency swing brake release switch to the FREE position. (In this case, however, the
Relative
parking brake does not work, when stopping the machine)
information
a While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in
the OFF position.
a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
Swing holding brake a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
solenoid defective during the troubleshooting.
1
(Internal disconnec- V05 (male) Resistance value
tion) Between (1) and (2) 20 60 z
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
tion) OFF Below 1 z
Between (3) and (4)
LOCK Above 1 Mz
diode D01 defective during the troubleshooting.
3
Resistance
Disconnection of Wiring harness between C03 (female) (37) and D01 (female) (7) Below 1 z
value
wiring harness
Resistance
4 (Disconnection or Wiring harness from D01 (female) (3) to J02 to X05 (male) (3) Below 1 z
value
defective contact
Wiring harness from X05 (male) (4) to V05 (female) (1) Below 1 z
value
Wiring harness between C03 (female) (3) (13) (23) and V05 Resistance
Below 1 z
(female) (2) value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Wiring harness ing the troubleshooting.
5
(Contact with 24V Between wiring harness between C03 (female) (37) and D01
Governor pump
6 C03 (female) Resistance value
controller defective Disconnect D01 and connect pins
Between (37) and (3) (13) (3) and (7) of the female side. 20 60 z
(23)
20-331-1 PC200/220(LC)-7
(7)
Electrical Circuit Diagram for Swing Holding Brake Solenoid in Governor Pump Controller
PC200/220(LC)-7 20-331-2
(5)
Service Code in Electrical System E214 (Disconnection of merge/divide solenoid)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Below 1
(female) value
2
circuit) Above 1 M
C02 (female) and grounding value
Short-circuiting of wiring Turn the engine starting switch OFF for the preparations, and hold it in the ON position
3
(Contact with 24 V cir- Between wiring harness between P02 (female) and
cuit) Voltage Below 1 V
C02 (female) and grounding
4 Monitor panel defective P02 (male) Voltage
Between and 69V
Governor pump
5 C02 (male) Voltage
Between and 69V
20-342 PC200/220(LC)-7
Electrical Circuit Diagram for S-NET Communication between Monitor Panel and Governor Pump
Controller
PC200/220(LC)-7 20-343
(1)
Service Code in Electrical System E222 (Short-circuiting in LS-EPC solenoid)
User Code Service Code Failure Code Failure Disconnection in LS-EPC solenoid
E222 DXE0KB phenomenon (in governor pump controller system)
Failure content Abnormal current flew to the LS-EPC solenoid circuit.
The controller reduces the output to the LS-EPC solenoid circuit to 0.
Response from
Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too
occurring on
fast. (The LS valve set pressure cannot be controlled)
machine
Relative Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No. 015: LS-EPC solenoid current)

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

LS-EPC solenoid defec- tion during the troubleshooting.
1 tive
harness
Max. 1 z
3
(Contact with 24 V cir- Between wiring harness between C03 (female) (6) and
V22 (female) (1) and grounding
4
Between (6) and (3) (13) (23) 7 14 z
Electrical Circuit Diagram for LS-EPC Solenoid in Governor Pump Controller
PC200/220(LC)-7 20-345
(5)
Service Code in Electrical System E224 (Abnormality in F pump pressure sensor)
User Code Service Code Failure Code Failure Abnormality in F pump pressure sensor
E224 DHPAMA phenomenon (in governor pump controller system)
Failure content Signal voltage from the F pump pressure sensor dropped below 0.3 V or exceeded 4.72 V.
Response from The controller controls the F pump pressure at 0 MPa{0 kg/cm2}.
controller If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on The travel speed does not shift automatically.
machine
Relative Input from the F pump pressure sensor (pressure) can be confirmed in the monitor function.
information (Code No. 011: F pump pressure)

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

Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to A51 Resistance
harness Max. 1 z
(female) (B) value
tive contact with connec- Wiring harness between C01 (female) (10) and A51 Resistance
Max. 1 z
tor) (female) (A) value
Wiring harness between C01 (female) (8) and A51 Resistance
Max. 1 z
(female) (C) value
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
4
circuit) Min. 1 Mz
A51 (female) (C) and grounding value
harness Between wiring harness between C01 (female) (22), J07
5 Voltage Max. 1 V
(Contact with 24 V cir- and A51 (female) (B) and grounding
cuit) Between wiring harness between C01 (female) (8) and
Voltage Max. 1 V
A51 (female) (C) ang grounding
6
Between (22) and (10) Power supply 4.5 5.5 V
Between (8) and (10) Signal 0.5 4.5 V
20-346 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for F Pump Pressure Sensor in Governor Pump Controller
PC200/220(LC)-7 20-347
(1)
Service Code in Electrical System E225 (Abnormality in R pump pressure sensor)
User Code Service Code Failure Code Failure Abnormality in R pump pressure sensor
E225 DHPBMA phenomenon (in governor pump controller system)
Failure content Signal voltage from the R pump pressure sensor dropped below 0.3 V or exceeded 4.42 V.
Response from The controller controls the R pump pressure as 0 MPa {0 kg/cm2}.
controller If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on The travel speed does not shift automatically.
machine
Relative Input from the R pump pressure sensor (pressure) can be confirmed in the monitor function.
information (Code No. 012: R pump pressure)

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

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

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

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

(Abnormality in engine rotation sensor)
User Code Service Code Failure Code Failure Abnormality in engine rotation sensor
E227 DLE2MA phenomenon (in governor pump controller system)
Failure content A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.
Response from The controller exercises a control equivalent to E mode.
controller If the failure cause disappears of itself, the signal input returns to normalcy.
Phenomenon
occurring on The machine lacks power a bit.
machine
Relative Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine RPM)

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

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

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

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

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

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

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

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

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

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

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

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

1
(Internal short-circuiting V30 (male) Resistance value
harness
V30 (male) (1) and grounding value
tor) Between wiring harness between C03 (female) (3) (13) Resistance
Max. 1 z
(23) and V30 (male) (2) and grounding value
3
4
Between (26) and (3) (13) (23) 7 14 z
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor Pump
Controller
PC200/220(LC)-7 20-361
(5)
Service Code in Electrical System E256 (Incorrect nonvolatile memory data)
User Code Service Code Failure Code Failure Incorrect nonvolatile memory data
E256 DA20KT phenomenon (in governor pump controller)
Failure content The data in the nonvolatile memory in the controller cannot be updated.
None in particular
Response from
Even if the failure cause disappears, the nonvolatile memory does not return to normalcy, unless the
controller
Phenomenon
In some cases control parameters of the machines change, resulting in increase or decrease of the ma-
occurring on
chine's power.
machine
Relative
Recorded in the nonvolatile memory are part of the machine control parameters
information
Presumed Cause Standard value in normalcy and references for troubleshooting

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

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

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

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

Presumed cause and standard
1 Fuel dial defective If Service Code [E308] is displayed, troubleshoot that failure first.
2 Governor potentiometer defective If Service Code [E306] is displayed, troubleshoot that failure first.
value in normalcy
3 Governor motor defective (disconnection) If Service Code [E317] is displayed, troubleshoot that failure first.
4 Governor motor defective (short-circuiting) If Service Code [E318] is displayed, troubleshoot that failure first.
Refer to the section of "Inspection and Adjustment - Special Func-
5 Governor lever adjustment improper
tion of Monitor Panel" in this manual.
6 Engine fuel control system defective Refer to Engine Shop Manual.
As this is an internal failure, no troubleshooting can be carried out.
7 Governor pump controller defective (If there is none of the failures listed above, the controller is judged
as defective)
20-370 PC200/220(LC)-7
Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B)
User Code Service Code Failure Code Failure Disconnection in governor motor Phase A and B
E05 E317 DY10KA phenomenon (in governor pump controller)
Failure content No current flew to the governor motor, when power was supplied to the motor.
Response from None in particular.
controller If the failure cause disappears, the governor returns to normalcy.
The engine rotation drops to low idle.
Phenomenon
There is hunting in the rotation
occurring on
machine
The governor motor steps out.
Relative Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)

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

Between and 2.5 7.5 z
Wiring harness between C03 (female) and E11 Resistance
Max. 1 z
Disconnection of wiring (female) value
harness Wiring harness between C03 (female) and E11 Resistance
(female) value
tor) Wiring harness between C03 (female) and E11 Resistance
Max. 1 z
(female) value
Wiring harness between C03 (female) and E11 Resistance
Max. 1 z
(female) value
3
20-372 PC200/220(LC)-7
(11)
PC200/220(LC)-7 20-373
(1)

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

Governor motor defec- E11 (male) Resistance value
tive Between and 2.5 7.5 z
1
or grounding fault) Between and 2.5 7.5 z
Between and grounding Min. 1 Mz

Between wiring harness between C03 (female) and Resistance
Min. 1 Mz
Disconnection of wiring E11 (female) and grounding value
harness Between wiring harness between C03 (female) and Resistance
2 (Disconnection or defec- Min. 1 Mz
E11 (female) and grounding value
tor) Between wiring harness between C03 (female) and Resistance
Min. 1 Mz
Between wiring harness between C03 (female) and Resistance
Min. 1 Mz
C03 (female) Resistance value
Governor pump Between and 2.5 7.5 z
3
20-374 PC200/220(LC)-7
(11)
PC200/220(LC)-7 20-375
TESTING AND ADJUSTING E501 / E502
Service Code in Electrical System E501 ("Model Selection" function not provided yet)
User Code Service Code Failure Code Failure "Model Selection" function not provided yet
E501 DA2AKM phenomenon (in governor pump controller system)
Failure content Model Code is not inputted yet.
Model data and rated load cannot be set.
Response from
Even when the failure cause disappears, Service Code does not return to normalcy, unless the engine
controller
starting switch is once turned OFF.
Phenomenon
occurring on The excess load alarm does not work normally.
machine
Relative Model names that the controller recognizes (figure) can be confirmed in the monitor function.
information (Code No. 150: Model Code)

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

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

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

Check if there has been an internal or external factor that would cause
Presumed Failure in engine mechan-
1 the engine to overrun at high idle, and troubleshoot the mechanical sys-
cause and ical system
tem of the engine.
standard value
in normalcy As this is an internal failure, troubleshooting cannot be conducted.
Governor pump
2 (Unless there is any visible trouble found in the machine, use of the con-
troller may be continued as it is)
20-378 PC200/220(LC)-7
(11)
TROUBLESHOOTING AA10NX
Failure Code in Mechanical System AA10NX (Air cleaner clogging)
User Code Service Code Failure Code Failure Air cleaner clogged
AA10NX phenomenon (in mechanical system)
While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e. dis-
Failure content
connected from grounding circuit).
Response from
None in particular
monitor panel
Phenomenon
occurring on There is a possibility that the engine is damaged, if it is used continuously without corrective action.
machine
This Failure Code is recorded, when the air cleaner clogging caution symbol is displayed in the monitor
Relative panel while the engine is running.
information Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the monitor panel.
(Code No. 046: Monitor input 2)

Air cleaner clogged
1 (when the system is in a Check the air cleaner for clogging. If it is clogged, clean or replace it with new one.
normal condition)
Air cleaner clogging
2 switch defective A31 (male) Air cleaner Resistance value
(Internal disconnection) When in normal condition Max. 1 z
Between (1) and (2)
When clogged Min. 1 Mz
Disconnection of wiring troubleshooting.
harness
Wiring harness between P02 (female) (5) and A31 Resistance
(female) (1) value
tor) Resistance
Between wiring harness A31 (female) (2) and grounding Max. 1 z
value
4 Monitor panel defective P02 Air cleaner Voltage
When in normal condition Max. 1 V
When clogged 20 30 V
Electrical Circuit for Air Cleaner Clogging Switch in Monitor Panel
PC200/220(LC)-7 20-379
(5)
TROUBLESHOOTING AB00KE
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage)
User Code Service Code Failure Code Failure Charging voltage abnormally lowered
AB00KE phenomenon (in mechanical system)
Failure content Generation signal from the alternator is not inputted, while the engine is running.
Response from
None in particular
monitor panel
Phenomenon
There is a possibility that the battery may not be charged, if charging is continued without corrective
occurring on
action.
machine
This Failure Code is recorded, if the charging caution symbol is displayed in the monitor panel, while the
Relative engine is running.
information Input from the alternator (voltage) can be confirmed in the monitor function.
(Code No. 043: Charging voltage)

Alternator defective troubleshooting.

1
(short generating output) E12 (male) Engine rotation Voltage
Between (1) and grounding Above medium speed 27.5 29.5 V
Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tive contact with connec- Wiring harness from P02 (female) (11) to J02 to E12 Resistance
Max. 1 z
tor) (female) (1) value
harness
3 Wiring harness from P02 (female) (11) to J02 to E12
circuit) (female) (1), or between P02 (female) (11) and D01 (female) Min. 1 Mz
value
(6), or between P02 (female) (11) and A27 (female) (2)
P02 Engine rotation Voltage
Between (11) and grounding Above medium speed 27.5 29.5 V
20-380 PC200/220(LC)-7
(5)
Electrical Circuit Diagram for Engine Start, Stop and Charging in Monitor Panel
PC200, 200LC-7 Serial No. 200001 250000
PC220, 220LC-7 Serial No. 60001 65000
PC200/220(LC)-7 20-381
(5)
Electrical Circuit Diagram for Engine Start, Stop and Charging in Monitor Panel
20-381-1 PC200/220(LC)-7
(8)
TROUBLESHOOTING B@BAZG
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure)
User Code Service Code Failure Code Failure Engine oil pressure abnormally lowered
B@BAZG phenomenon (in mechanical system)
The signal circuit in the engine oil pressure switch was closed (i.e. connected with grounding), while the
Failure content
engine was running.
Response from
None in particular
monitor panel
Phenomenon
occurring on There is a possibility that the engine may seize, if the engine is kept running without corrective action.
machine
This Failure Code is recorded, if the engine oil pressure caution symbol is displayed in the monitor panel,
Relative while the engine is running.
information Input from the engine oil pressure switch (ON or OFF) can be confirmed in the monitor function.

Engine oil pressure low-
1 ered (the system in nor- a Check the failure cause and damage to the engine, and then make repairs.
mal condition)
Engine oil pressure
2 switch defective E02 (on switch side) Engine oil pressure Resistance value
(Internal short-circuiting) Between terminal and When in normal condition Min. 1 Mz
grounding When lowered Max. 1 z
3
(Contact with grounding Between wiring harness between P02 (female) (7) and E02 Resistance
circuit) Min. 1 Mz
(terminal) and grounding value
4 Monitor panel defective P02 Engine oil pressure Voltage
When in normal condition 20 30 V
When lowered Max. 1 V
Electrical Circuit Diagram for Engine Oil Pressure Switch in Monitor Panel
20-382 PC200/220(LC)-7
(5)
TROUBLESHOOTING B@BAZK
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)
User Code Service Code Failure Code Failure Engine oil level abnormally lowered
B@BAZK phenomenon (in mechanical system)
The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding), when the
Failure content
engine is stopped (with the starting switch in the ON position).
Response from
None in particular
monitor panel
Phenomenon
occurring on There is a possibility that the engine seizes if it is kept running without a corrective action.
machine
This Failure Code is recorded if the engine oil level caution symbol is displayed, when the engine is
Relative stopped (with the starting key in the ON position).
information Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code No.
046: Monitor input 2)

Engine oil level lowered
a Check the engine oil level, and refill oil.
1 (System in normal condi-
(If the phenomenon occurs frequently, check the cause)

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

Engine Overheating
1 (system in normal condi- a Check the engine for the cause and damage, and repair it.
tion)
Engine coolant tempera- Engine coolant
2 ture sensor defective E05 (male) Resistance value
temperature
Between (1) and (2) 90 3.5 kz
10 100 C
3
(Contact with grounding Between wiring harness between P02 (female) (1) and Resistance
circuit) Min. 1 Mz
E05 (female) (2) and grounding value
Engine coolant
4 Monitor panel defective P02 (female) Resistance value
temperature
10 100 C
Electrical Circuit Diagram for Engine Coolant Temperature Sensor in Monitor Panel
20-384 PC200/220(LC)-7
(11)
TROUBLESHOOTING B@BCZK
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator coolant level)
(Multi-monitor only)
User Code Service Code Failure Code Failure Radiator coolant level abnormally lowered
B@BCZK phenomenon (in mechanical system)
Failure content The signal circuit in the radiator coolant level switch was opened (i.e. disconnected from grounding).
Response from
None in particular
monitor panel
Phenomenon
machine
This Failure Code is recorded, if the radiator coolant level caution symbol is displayed in the monitor
Relative panel, when the engine is running.
information Input from the radiator coolant level switch (ON or OFF) can be confirmed in the monitor function.

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

User Code Service Code Failure Code Failure Hydraulic oil overheated
B@HANS phenomenon (in mechanical system)
Failure content The hydraulic oil temperature sensor inputted a signal of 102C, while the engine was running.
Response from
None in particular
monitor panel
Phenomenon
machine
This Failure Code is recorded, if the hydraulic oil temperature gauge is displayed in the red range, when
Relative the engine is running.
information Input from the hydraulic oil temperature sensor (temperature) can be confirmed in the monitor function.
(Code No. 044: Hydraulic oil temperature)

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

BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE ........................................................... 20-502-1
E-1 Engine does not start (Engine does not rotate) ................................................................................ 20-503
E-2 Engine stops while in operation ........................................................................................................ 20-507
E-3 Engine speed is irregular, or there is hunting ................................................................................... 20-508
E-4 Engine does not stop ........................................................................................................................ 20-510
E-5 Auto-decelerator does not work ........................................................................................................ 20-512
E-6 Auto engine warm-up device does not work ..................................................................................... 20-513
E-7 Preheater does not work................................................................................................................... 20-514
E-8 All work equipment, swing and travel do not move........................................................................... 20-516
E-9 One-touch power maximizing function does not work ...................................................................... 20-518
E-10 No display in monitor panel at all ...................................................................................................... 20-519
E-11 Part of display on monitor panel is missing....................................................................................... 20-520
E-12 Monitor panel displays contents irrelevant to the model ................................................................... 20-520
E-13 Fuel level monitor red lamp lights up while engine is running........................................................... 20-521
E-14 Engine coolant temperature gauge does not indicate correctly ........................................................ 20-522
E-15 Hydraulic oil temperature gauge does not display correctly ............................................................. 20-523
E-16 Fuel gauge does not display correctly .............................................................................................. 20-524
E-17 Swing lock monitor does not display correctly .................................................................................. 20-526
E-18 When the monitor switch is operated, no display appears ............................................................... 20-528
E-19 Windshield wiper does not work ....................................................................................................... 20-530
E-20 Alarming buzzer cannot be cancelled ............................................................................................... 20-532
E-21 "Boom RAISE" is not correctly displayed in monitor function ........................................................... 20-533
E-22 "Boom LOWER" is not correctly displayed in monitor function ......................................................... 20-534
E-23 "Arm DIGGING" is not correctly displayed in monitor function ......................................................... 20-535
E-24 "Arm DUMPING" is not correctly displayed in monitor function ........................................................ 20-536
E-25 "Bucket DIGGING" is not correctly displayed in monitor function ..................................................... 20-537
E-26 "Bucket DUMPING" is not correctly displayed in monitor function.................................................... 20-538
E-27 "SWING" is not correctly displayed in monitor function .................................................................... 20-540
E-28 "TRAVEL" is not correctly displayed in monitor function................................................................... 20-542
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function ..................................... 20-544
E-30 "Service" is not correctly displayed in monitor function..................................................................... 20-546
E-31 Troubleshooting for air conditioner system ....................................................................................... 20-548
E-32 Travel alarm does not sound ............................................................................................................ 20-560
PC200/220(LC)-7 20-501
(11)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

a The following information are edited and contained in the "Information Contained in Troubleshooting Table".
You are required to proceed with troubleshooting after fully grasping the contents.
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
The standard values in normalcy by which to judge "good" or "no good" about pre-
1 sumed causes.
References for making judgement of "good" or "no good"
<Phenomena of wiring harness fault>

Failure due to disconnection
Defective contact with connector or disconnection of wiring harness has occurred.
2
Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in contact
with it.
Cause for presumed Failure due to short-circuiting
failure A wiring harness that is not originally connected with a power source circuit (24 V) is
(The attached No. for in contact with it.
3
filing and reference
purpose only. It does not <Points to remember in troubleshooting>
stand for any priority) 1) Connector denotation method and handling of T-adapters
Insert or connect T-adapters in the following manner, unless specifically otherwise
instructed.
If there is no indication of (male) or (female) in the connector No., pull off a connec-
4
tor and insert a T-adapter into both sides of male and female.
If there is an indication of (male9 and (female) in the connection No., pull off a con-
nector and insert a T-adapter into only one side of (male) or (female).
2) Description sequence of pin No. and handling of circuit tester leads
Connect the positive lead (+) and negative lead () for troubleshooting in the follow-
5 ing manner unless specifically otherwise instructed.
Connect the positive lead (+) to a pin No. marked at the front or wiring harness.
Connect the negative lead () to a pin No. marked at the rear or wiring harness.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
Connector No.: Indicates (Type - numbers of a pin) (color)

Arrow: Roughly indicates the location in the machine where it is installed.
20-502 PC200/220(LC)-7
(1)
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE
BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE
Connection table of fuse box

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

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

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

Between (1) and (3)
LOCK Max. 1 z
Engine starting during the troubleshooting.
motor cut relay, R11
and R13 defective R11 (female) & R13 (male) Resistance value
5
(Internal Between (1) and (2) 100 500 z
disconnection or Between (3) and (5) Min. 1 Mz
short-circuiting)
Between (3) and (6) Max. 1 z
during the troubleshooting. (If all of the power source, grounding (GND), generation signal
and engine start input are normal and yet the engine start output is not normal, the engine
starting motor relay is defective)
Engine start-
Engine starting Safety relay Voltage
ing switch
motor fault
6 (Internal Power source: Between B terminal and grounding 20 30 V
disconnection or GND (grounding): Between E terminal and grounding Connected
short-circuiting) Generation signal: Between R terminal (A27 (2)) and
Max. 1 V
grounding Start
Engine start input: Between S terminal (A27 (1)) and
20 30 V
grounding
Engine start output: Between C terminal and grounding 20 30 V
during the troubleshooting. (If all of the power source, grounding (GND), generation signal
and engine start input are normal and yet the engine start output is not normal, the engine
Engine starting
starting motor relay is defective)
motor fault
7 Engine start-
(Internal disconnec- Engine starting motor Voltage
tion or damage) ing switch
Power source: B terminal and grounding 20 30 V
Start
Engine start input: C terminal and grounding 20 30 V
PC200/220(LC)-7 20-503
(11)
TROUBLESHOOTING E-1

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

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

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

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

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

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

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

Arm DUMPING Lever operation: ON
4 019 Arm DUMPING
signal fault Lever NEUTRAL: OFF
Bucket DIGGING Lever operation: ON
5 021 Bucket DIGGING
Bucket DUMPING Lever operation: ON
6 021 Bucket DUMPING
Lever operation: ON
7 Swing signal fault 019 Swing
Lever NEUTRAL: OFF
Lever operation: ON
8 Travel signal fault 019 Travel
Lever NEUTRAL: OFF
Attachment signal Lever operation: ON
9 021 Service
Governor pump As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the
10
controller defective causes listed in Item 1 through 9, the controller is judged as defective.
20-512 PC200/220(LC)-7
(5)
TROUBLESHOOTING E-6
E-6 Auto engine warm-up device does not work
Failure
The auto engine warm-up device does not work.
information
The auto engine warm-up device is activated, when the engine coolant temperature is below 30C, and
Relative raise the engine rotation up to 1,200 rpm.
information The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.

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

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

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

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

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

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

information

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

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

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

information

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

information

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

information

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

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

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

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

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

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

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

information

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

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

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

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

information

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

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

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

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

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

information

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

information

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

information

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

information

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

information

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

information

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

information

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

information

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

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

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

information

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

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

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

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

Troubleshooting procedure for air conditioner system

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

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

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

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

a Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective recirculated
standard value in normal state
starting switch ON.

1 air sensor
THI (male) Resistance
Possible causes and
Between (1) and (2) 300 z 430 kz
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, Air conditioner.
Self-diagnosis
notice Trouble Short circuit in recirculated air sensor
E12
Contents of
Short circuit in the recirculated air sensor system is detected.
trouble
Fixes the recirculated air temperature for control.
Related
information

Defective recirculated air
starting switch ON.

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

Defective coolant tem-
starting switch ON.

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

Defective coolant tem-
starting switch ON.

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

Defective daylight sen-

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

information

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

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

H-1 All work equipment lack power, or travel and swing speeds are slow .............................................. 20-605
H-2 Engine speed sharply drops or engine stalls .................................................................................... 20-606
H-3 No work equipment, travel or swing move ........................................................................................ 20-607
H-4 Abnormal noise is heard from around hydraulic pump ..................................................................... 20-607
H-5 Auto-decelerator does not work ........................................................................................................ 20-608
H-6 Fine control mode does not function................................................................................................. 20-608
H-7 Boom moves slowly or lacks power .................................................................................................. 20-609
H-8 Arm moves slowly or lacks power..................................................................................................... 20-610
H-9 Bucket moves slowly or lacks power ................................................................................................ 20- 611
H-10 Work equipment does not move in its single operation .................................................................... 20-611
H-11 Work equipment has a bit too fast hydraulic drift .............................................................................. 20-612
H-12 Work equipment has big time lag...................................................................................................... 20-613
H-13 Other work equipment moves when relieving single circuit .............................................................. 20-613
H-14 One-touch power maximizing function does not operate.................................................................. 20-613
H-15 In compound operation, work equipment with larger load moves slowly .......................................... 20-614
H-16 In swing + boom RAISE operation, boom moves slowly .................................................................. 20-614
H-17 In swing + travel, travel speed drops sharply.................................................................................... 20-614
H-18 Machine swerves in travel ................................................................................................................ 20-615
H-19 Machine travels slowly ...................................................................................................................... 20-616
H-20 Machine cannot be easily steered or lacks power ............................................................................ 20-617
H-21 Travel speed does not shift, or it is too slow or fast. ......................................................................... 20-618
H-22 Track shoe does not turn (on one side only)..................................................................................... 20-619
H-23 Machine does not swing ................................................................................................................... 20-620
H-24 Swing acceleration is poor, or swing speed is slow .......................................................................... 20-621
H-25 Excessive overrun when stopping swing .......................................................................................... 20-622
H-26 There is big shock when stopping swing .......................................................................................... 20-623
H-27 There is big abnormal noise caused when stopping swing .............................................................. 20-623
H-28 Swing natural drift is too big.............................................................................................................. 20-624
PC200/220(LC)-7 20-601
(11)
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
20-602 PC200/220(LC)-7
(11)
TESTING AND ADJUSTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a
reference material when troubleshooting the hydraulic and mechanical systems.
PC200/220(LC)-7 20-603
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

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

Relative information Information on occurred failures and troubleshooting

2
Cause for presumed
failure <Contents>
(The attached No. for The standard values in normalcy by which to judge "good" or "no good" about
3
filing and reference presumed causes.
purpose only. It does not stand References for making judgement of "good" or "no good"
for any priority)
4
20-604 PC200/220(LC)-7
TROUBLESHOOTING H-1
H-1 All work equipment lack power, or travel and swing speeds are slow
Failure information All the work equipment lack power, or their travel and swing speeds are slow.
Relative information Set the working mode at A mode for troubleshooting.

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

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

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

Control lever Main relief pressure

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

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


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

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

This troubleshooting mode is applied when the auto-decelerator does not work, while operating
the travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch
only in the travel circuit -actually located inside PPC valve)
Set the working mode at A mode for the troubleshooting.

Presumed cause and stan-
dard value in normalcy

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

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

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


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


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


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

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


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


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

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

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

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

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


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

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


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

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

Combination of compound operation Work equipment with larger load
Malfunctioning of pressure Boom RAISE + arm DIGGING Boom RAISE
1 compensation valve for work
Boom RAISE + arm DUMPING Arm DUMPING
equipment with larger load
Boom RAISE + bucket DIGGING Boom RAISE
Arm DUMPING + bucket DIGGING Arm DUMPING
Boom LOWER + arm DUMPING Arm DUMPING
H-16 In swing + boom RAISE operation, boom moves slowly
Failure information In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Relative information If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.

Malfunctioning of LS select The LS select valve is presumed to malfunction, or the seal is suspected to
1
valve or seal defective be defective. Check the valve and seal themselves.
H-17 In swing + travel, travel speed drops sharply
Failure information In a compound operation of swing + travel, the travel speed drops sharply.
Relative information If the travel speed is slow in the single operation of travel, carry out the H-19 check first.

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


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

Oil Pressure ratio
Oil pressure to be Travel without load
Improper adjustment or mal- measured All control levers in
3 (control lever held at half
functioning of LS valve NEUTRAL
stroke)
Pump delivery pressure 1
Malfunctioning of travel inter-
4 Operating one side only 0 {0}
locking solenoid valve
2.84 3.43 MPa
Operating both sides
{29 35 kg/cm2}
5 The travel interlocking valve is presumed to malfunction. Check the valve itself.
locking valve
Malfunctioning of travel control The spool in the travel interlocking valve is presumed to malfunction. Check the
6
valve (spool) spool itself.
7 Malfunction of travel motor Travel control lever Amount of oil leakage from travel motor
Travel relief 27.2 /min
The final drive is suspected of an internal failure. Check the inside of the final
drive directly.
8 Final drive defective a An internal failure in the final drive may well be determined by an abnormal
noise from within, abnormal heat or metal chip or dust contained in the drained
oil.
PC200/220(LC)-7 20-615
(11)
H-19 Machine travels slowly
Failure information The machine's travel speed is slow.


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

{29 35kg/cm2}
LS-EPC valve output
Malfunctioning of LS-EPC pressure
3
valve Approx. 2.9 MPa
Lo NEUTRAL
{approx. 30 kg/cm2}
Hi Travel control lever 0 {0}
Malfunction of travel control The spool in the travel control valve is presumed to malfunction. Check the spool
4
Malfunctioning of travel control
The pressure compensation valve in the travel control valve is presumed to mal-
valve)
Malfunctioning of travel control The suction valve in the travel control valve is presumed to malfunction. Check
6
valve (suction valve) the valve itself.
Malfunctioning of LS shuttle The LS shuttle valve in the bucket control valve is presumed to malfunction.
7
valve (bucket) Check the valve itself.
7 Malfunction of travel motor Travel control lever Amount of oil leakage from travel motor
drive directly.
8 Final drive defective a An internal failure in the final drive may well be determined by an abnormal
noise from within, abnormal heat or metal chip or dust contained in the drained
oil.
20-616 PC200/220(LC)-7
(11)
H-20 Machine cannot be easily steered or lacks power
Failure information The machine cannot be easily steered.


Travel control lever PPC valve output pressure (steering)
Malfunctioning of travel PPC
1 NEUTRAL on both sides 0 {0}
valve (steering spool)
Above 2.7 MPa
Operating one side only
{Above 28 kg/cm2}
Travel control lever Solenoid valve output pressure
2 Operating both sides 0 {0}
locking solenoid valve
2.84 3.43 MPa
{29 35 kg/cm2}
3 The travel interlocking valve is presumed to malfunction. Check the valve itself.
locking valve
Travel control lever Solenoid valve output pressure
4 Operating both sides 0 {0}
solenoid valve
2.84 3.43 MPa
{29 35 kg/cm2}
5 The merge/divide valve is presumed to malfunction. Check the valve itself.
valve
Malfunction of travel control The spool in the travel control valve is presumed to malfunction. Check the spool
6
Malfunctioning of travel control
The pressure compensation valve in the travel control valve is presumed to mal-
valve)
Malfunctioning of travel control The suction valve in the travel control valve is presumed to malfunction. Check
8
valve (suction valve) the valve itself.
Malfunctioning of LS shuttle The LS shuttle valve in the bucket control valve is presumed to malfunction.
9
valve (bucket) Check the valve itself.
Check valve seal defective at The seal in the check valve of LS oil pressure pickup port is suspected to be
10
LS oil pressure pickup port defective. Check the seal itself.
The seal in the check valve of the travel motor is suspected to be defective.
Malfunctioning of travel motor Check the seal itself.
11
(safety valve) a Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.
The seal in the check valve of the travel motor is suspected of defect. Check the
Malfunctioning of travel motor seal itself.
12
(check valve) a Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.
PC200/220(LC)-7 20-617
(11)
H-21 Travel speed does not shift, or it is too slow or fast.
Failure information Travel speed does not shift, or it is either too fast or slow.

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

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

Travel control valve (suction The suction valve seat in the travel control valve is suspected of defect. Check
1
valve) seat defective the seat itself.
Travel motor (safety valve) The safety valve seat in the travel motor is suspected of defect. Check the seat
2
seat defective itself.
Travel motor (check valve) The check valve seat in the travel motor is suspected of defect. Check the seat
3
seat defective itself.
4 Travel Motor speed reduced Travel control lever Amount of oil leakage from travel motor
drive directly.
5 Final drive defective a A failure inside the final drive may well be determined by an abnormal noise
from within, abnormal heat generated or metal dust or chips contained in the
drained oil.
PC200/220(LC)-7 20-619
(11)
H-23 Machine does not swing
Failure information (1) The machine swings neither to the right nor to the left.

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

Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction.
2
(parking brake) Check it directly.
Swing lock switch Swing control lever Swing relief pressure
3 functioning of swing motor ON Swing relief
{295 335 kg/cm2}
(safety valve)
If the oil pressure does not return to normalcy even after the adjustment, the
safety valve is presumed to malfunction, or suspected of an internal failure.
4 Swing motor defective Swing control lever Amount of oil leakage from swing motor
Swing relief Below 10 /min
The swing machinery is suspected of an internal failure. Check the inside of the
swing machinery directly.
5 Swing machinery defective a A failure inside the swing machinery may well be determined by an abnormal
noise from within, abnormal heat generated or metal dust or chips contained in
the drained oil.
Failure information (2) The machine does not swing in one direction.


Left control lever PPC valve output pressure
1 Malfunctioning of PPC valve
NEUTRAL 0 {0}
Swing operation Above 2.7 MPa {Above 28 kg/cm2}
Malfunctioning of swing control The spool in the swing control valve is presumed to malfunction. Check the spool
2
The seal in the suction valve of the swing motor is suspected of defect. Check the
Swing motor (suction valve) seal itself.
3
seal defective a Whether the seal is defective or not may well be determined by swapping the
right and left suction valves and watching if there is any change.
The seal in the check valve of the swing motor is suspected of defect. Check the
Swing motor (check valve) seal itself.
4
right and left check valves and watching the result.
20-620 PC200/220(LC)-7
(11)
H-24 Swing acceleration is poor, or swing speed is slow
Failure information (1) Swing acceleration is poor, or swing speed is slow.


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

Swing control lever PPC valve output pressure

NEUTRAL 0 {0}
Left or right Above 2.7 MPa {Above 28 kg/cm2}
Malfunctioning of swing control The spool in the swing control valve is presumed to malfunction. Check the valve
2
Malfunctioning of swing motor
The pressure compensation valve in the swing motor is presumed to malfunction.
3 (pressure compensation
valve)
The seal in the suction valve of the swing motor is suspected of defect. Check the
Swing motor (suction valve) seal itself.
4
right and left suction valves and watching the result.
The seal in the check valve of the swing motor is suspected of defect. Check the
Swing motor (check valve) seal itself.
5
right and left check valves and watching the result.
PC200/220(LC)-7 20-621
(11)
H-25 Excessive overrun when stopping swing
Failure information (1) The work equipment overruns excessively when stopping swing.



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

Swing control lever PPC valve output pressure
NEUTRAL 0 {0}
The PPC slow return valve is suspected of clogging. Check the valve itself.
Swing PPC slow return valve
2 a Whether the valve is clogged or not may well be determined by swapping
clogged
the right and left valves and watching the result.
Malfunctioning of swing control The spool in the swing control valve is resumed to malfunction. Check the
3
valve (spool) valve itself.
The seal in the suction valve of the swing motor is suspected of defect.
Swing motor (suction valve) Check the seal itself.
4
seal defective a Whether the seal is defective or not may well be determined by swapping
the right and left suction valves and watching the result.
The seal in the check valve of the swing motor is suspected of defect.
Swing motor (check valve) Check the seal itself.
5
seal defective a Whether the seal is defective or not may well be determined by swapping
the right and left check valves and watching the result.
20-622 PC200/220(LC)-7
(11)
H-26 There is big shock when stopping swing
Failure information There is a big shock caused when stopping a swing motion.


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

Malfunctioning of backpres-
1 The backpressure valve is presumed to malfunction. Check the valve itself.
sure valve
Malfunction of swing motor The safety valve in the swing motor is presumed to malfunction. Check the
2
(safety valve) valve itself.
The seal in suction valve of the swing motor is suspected of defect. Check
Malfunction of swing motor the seal itself.
3
(suction valve) a Whether the seal is defective or not may well be determined by swapping
the right and left valves and watching the result.
The swing machinery is suspected of an internal failure. Check the inside of
the machinery itself.
4 Swing machinery defective a A failure inside the swing machinery may well be determined by monitoring
abnormal noise, abnormal heat generated or metal dust or chips con-
tained in the drained oil.
PC200/220(LC)-7 20-623
(11)
H-28 Swing natural drift is too big
Failure information (1) Natural drift of the swing is too big (when the parking brake is activated).
When the emergency swing release switch is in the OFF position (this is a normal condition), the
swing and parking brake is activated and the swing is fixed with a disc brake.


Swing and parking brake sole- Swing control lever Solenoid valve output pressure
1
noid valve malfunctioned NEUTRAL 0 {0}
Left or right 2.84 3.43 MPa {29 35 kg/cm2}
Swing motor (parking brake The parking portion of the swing motor is suspected of malfunctioning and
2
portion) malfunctioned interior failure. Check that portion directly.
Failure information (2) Natural drift of the swing is too big (when the parking brake is released).
When the emergency swing release switch is in the ON condition (this is an emergent condition),
the swing and parking brake is released and the swing is retained only hydraulically.

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

Swing control valve (pressure

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

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

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

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and
mark the Cause column with E to use Causes
as reference for locating the cause of
tion)
the failure. However, do not use this
injec
when making calculations to narrow
down the causes.
fuel
2. Use the E in the Cause column as ref-
sive
erence for [Degree of use (Operated for
zzle
xces
nce
long period)] in the [Questions] section
n no
p (e
fere
g
as reference. As a rule, do not use it
jectio
men
timin
pum
inter
r
nde
when calculating the points for locating
le
uel in
tion
ction
er e
ger,
, cyli
the cause, but it can be included if nec-
injec
lean
ed f
l inje
char
ring
essary to determine the order for trou-
, seiz
fuel
air c
r fue
bleshooting. urbo
ton
ctive
n pis
ged
ged
rope
ed t
Defe
Clog
Clog
Seiz
Wor
Imp
Confirm recent repair history
Degree of use Operatred for long period
PC200/220(LC)-7 20-703
(5)
Example of troubleshooting when exhaust gas is black

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

General causes why exhaust gas is black
Insufficient intake of air
Improper condition of fuel injection
Excessive injection of fuel
Causes
d
hea
tion)
)
ized
der
injec
r se
cylin
fuel
nge
e, va rger and
sive
k, plu
eat
zle
xces
lve s
(rac
ction tion noz
leme nce
a
boch
p (e
re
ump
g
nt
terfe
timin
pum
r
n tu
jec
der
ance
on p
uffle
valv
er, in
el in
tion
twee
n
er e
, cyli
jecti
lear
dm
ct of
injec
d fu
harg
lean
ir be
l inje
lve c
el in
ring
gge
conta
eize
Legend
rboc
fuel
air c
of a
r fue
, clo
e fu
n
r va
: Possible causes (judging from Questions and check items)
to
s
ed tu
ctive
ctive
,
n pis
ectiv
kage
hed
ged
ged
rope
rope
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period) Defe
Crus
Defe
Clog
Clog
Seiz
Wor
Deff
Imp
Imp
Lea
: Items to confirm the cause.
Degree of use Operated for long period
Suddenly became black
Questions
Color of exhaust gas Gradually became black

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

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

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

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

charging rate of 70% in the above table.
In cold areas the specific gravity must exceed the value
for the charging rate of 75% in the above table.
20-706 PC200/220(LC)-7
(5)
Replace Defe
ctive
Replace Defe regu
lator
ctive
Replace Defe alter
nato
ctive r
Replace Defe or de
terio
ctive rated
Adjust Defe injec
tion batte
tive nozz ry
Replace injec
tion le
PC200/220(LC)-7
Defe
tive timin
Correct injec g
Leak tion
age, pum
Clean c lo p
TROUBLESHOOTING
Clog ggin (rack

ged g, air , plu
nger
Replace Defe
air b
reath
in fu
el pip stuc
ctive er ho ing k)
Replace Defe feed
p
le in
f
Causes
ctive ump uel t

boos ank
t com
pens
ator
canc
el
(5)
20-707
S-1
TROUBLESHOOTING S-2
S-2 Engine does not start
(1) Engine does not turn
General causes why engine does not turn Causes
Internal parts of engine seized

a If internal parts of the engine are seized, car-
ry out troubleshooting for "Engine stops dur-
ing operations".
n
ectio
it
Failure in hydraulic pump system
ttery
circu
conn
Defective electrical system
d ba
ting
inal
ch
otor
e
star
lay
t
term
swit
iora
lay
ng m
ry re
ty re
g of
eter
ting
ery
ear
atte
tarti
wirin
safe
or d
star
batt
ing g
b
s
ctive
ctive
ctive
ctive
ctive
ctive
ctive
en r
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Brok
Questions
Degree of use of machine Operated for long period

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

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

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

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

smoke comes out
Supply of fuel impossible

Supply of fuel is extremely small
Improper selection of fuel (particularly in winter) Causes
a Standards for use of fuel
)
ized
r se
nge
y
nk
t, ke
el ta
k, plu
n
shaf
pisto
in fu
c
p (ra
er
g
drive
pipin
r
mp
rain
hole
n e
pum
u
i
stra
tank
ump
t
p
fuel
her
eed
d
pum
tion
ilter,
on p
l use
reat
el in
king
en f
injec
uel f
air b
jecti
feed
nt fu
r fue
, lea
brok
f
ctive
en in
fficie
ged
ged
ged
rope
ged
ed,
Defe
Clog
Clog
Clog
Clog
Brok
Seiz
Insu
Imp
Questions

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

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

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

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

engine does not start
.)
r, etc
Lack of rotating force due to defective electrical
k)
stuc
r leve
system
cap
y
spra
r
rocke
nge
tank
em
tive
, plu
syst
alve,
ery
fuel
Improper selection of fuel
efec
k
liner
m (v
batt
c
fuel
t
p (ra
le in
n
aine
le, d
ter
leme
e r
syste
der
ted
r in
rain
r ho
hea
pum
p str
nozz
n
iora
i
er e
g, a
i
t
l
alve
s
y
e
e air
d
c
h
pum
tion
eter
l use
lean
filter
tion
reat
ggin
,
ken v
ring
intak
injec
or d
injec
feed
air b
air c
, clo
r fue
fuel
, bro
ton
ctive
ctive
ctive
n pis
kage
ged
ged
ged
ged
ged
rope
ctive
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Lea
Imp
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from

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

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

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

smoothly

ap
y
seat
spra
Improper condition of fuel injction
nk c
alve
Improper fuel used
tive
el ta
nce
nd v
efec
ger
in fu
r
fere
r line
nt
g
iner
ve a
plun
le, d
pipin
leme
inter
aine
ance
hole
nde
stra
f val
nozz
mp
er e
, str
fuel
ger,
i
lear
her
, cyl
mp
act o
n pu
lean
filter
tion
char
reat
king
lve c
u
ring
p
jectio
cont
injec
feed
air c
air b
, lea
urbo
l
r va
e
ton
fu
ed in
ctive
n pis
ged
ged
rope
ged
ged
ged
ed t
ged
Clog
Defe
Clog
Clog
Clog
Clog
Seiz
Seiz
Clog
Wor
Imp
Questions
Operation Manual
Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

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

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

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

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

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

smoothly
p
zzle
pum
Air in fuel system
d no
feed
Defective governor mechanism
p an
and
Defective governor motor mechanism
pum
nk
a If hunting stops when governor spring is dis-
tank
el ta
k
r
l rac
feed
erno
connected, carry out troubleshooting for E
rnor
fuel
in fu
ntro
n
v
mode.
gove
een
aine
f go
twee
ner
hole
o low
of co
betw
i
p str
nt o
stra
it be
tank
n of
her
is t o
tion
stme
cuit
pum
circu
lter,
ratio
el in
reat
ir
pera
c
i
adju
uel f
spee
ope
feed
air b
air in
nt fu
air in
o
f
ctive
ctive
ctive
fficie
ged
ged
ged
ged,
ged,
idle
Clog
Defe
Clog
Clog
Defe
Defe
Clog
Insu
Clog
Low
Occurs at a certain speed range
Questions
Occurs at low idle

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

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

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

t
men
y
eat
ragm
spra
Improper fuel used
t
lve s
djus
nk
iaph
(if non-specified fuel is used, output drops)
tive
el ta
nce
ve a
d va
Lack of output due to overtaking
efec
or d
in fu
er
fere
i
e an
t
g
nt
a If there is overheating and lack of output,
efec
iping
r
nsat
e, d
aine
plun
er
leme
inter
hole
e
der
valv
train
c
carry out troubleshooting for overheating.
g, d
ozzl
uel p
mpe
n
p str
mp
cylin
a
er e
ger,
her
lear
prin
t of
s
on n
n pu
st co
pum
f
,
filter
reat
lean
char
king
,
ntac
lve c
ring
or s
jecti
boo
air b
feed
jecti
air c
, lea
urbo
fuel
o
vern
r va
ton
c
i n
ctive
ctive
ed in
n pis
ged
ged
ged
ged
rope
ged
ged
ed t
t go
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Clog
Seiz
Seiz
Ben
Wor
Imp
Suddenly
Power was lost
Gradually
Questions

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

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

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

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When fuel dial is placed at FULL position, lever does not contact stopper
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Remedy
Clean
Clean
Clean
Clean
20-714 PC200/220(LC)-7
(11)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (Incomplete combustion)
General causes why exhaust smoke is black Causes
ifold
man
d)
on)
eize
take
jecti
seat
er s
y
nd in
spra
ve in
lung
alve
ger a
timin efective
essi
nce
ck, p
nd v
char
fere
(exc
nt
p (ra
ve a
turbo
le, d
leme
inter
ance
r
r
p
inde
uffle
f val
pum
pum
nozz
een
er e
ger,
lear
, cyl
dm
act o
tion
tion
betw
ction
lean
tion
char
ve c
gge
ring
injec
injec
cont
injec
of air
air c
r inje
, clo
l
urbo
r va
ton
ctive
ctive
ctive
n pis
hed
ged
rope
ged
rope
age
ed t
Defe
Defe
Defe
Crus
Clog
Leak
Clog
Seiz
Wor
Imp
Imp
Suddenly became black
Color of exhaust gas Gradually became black
Questions

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

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

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

minutes continuously. (Both low and high idle)
rger
ocha
General causes why oil consumption is excessive
Turb
Abnormal combustion of oil
seal
ad
e
External leakage of oil
r he
c
stem
hose
a
oler
ken
r f
Wear of lubrication system
al su
inde
il co
, bro
e sy
her
plug
r cyl
l, se
or o
reat
r
intak
ide)
nde
d
nd
n
ing
an o
a
rain
ine e
er e
or b
lter
, gu
e
, cyli
l pip
ar s
om
oil d
oil p
oil fi
blow
ring
stem
ther
turb
in fr
oler
ring
n re
o i
from
from
from
from
iston
brea
il co
al at
lve (
al at
ked
roke
ton
en o
n pis
t suc
en p
kage
kage
kage
n se
kage
n va
n se
ged
n, b
Brok
Clog
Brok
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Lea
Lea
Lea
Oil consumption suddenly increased
Questions
Engine oil becomes contaminated quickly

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

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

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

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

quickly
Entry of exhaust gas due to internal wear

Clogging of lubrication passage
Improper fuel
Improper oil used
Operation under excessive load
PC200/220(LC)-7 20-717
(5)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes
Leakage of fuel
n)
jectio
n)
er
pisto
el filt
g
sprin
ive in
mp (
g, fu
r
rnor
cess
cove
er
d pu
pipin
lung
ay
gove
p (ex
timin
head
e fee
r spr
fuel
p
nt of
pum
pum
olde
ction
id
side
from
s
al in
stme
h
tion
el in
l inje
io
age
le
t
oil se
nozz
injec
injec
adju
of fu
e
leak
fu
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Leak
Defe
Defe
Defe
Defe
Defe
Defe
Exte
Operated for long period
Questions
Degree of use of machine

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

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

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

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

Internal leakage in cooling system
t
aske
k
bloc
ring
ad g
r
oole
, O-
der
, he
ting
cylin
core
oil c
ead
y pit
er h
ks in
oler
aulic
b
used
ylind
il co
crac
y d r
en o
en h
en c
s ca
rnal
Brok
Brok
Hole
Brok
Inte
Questions
Suddenly increased
Oil level
Gradually increased
Hard water is being used as coolant
Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, spurts back

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

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

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

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

shooting for "Oil is in coolant".
General causes why oil level rises
r
cove
al
ead
Coolant in oil (milky white)
nt se
ide h
mp
Fuel in oil (diluted, and smells of diesel fuel)
et
ipme
ace
gask
n pu
Entry of oil from other component
g ins
eve
surf
ring
equ
ectio
k
d
le
bloc
hea
pipin
, O-
seal
s
iary
lder
n j
ad,
der
core
ting
i
l
om
rear
t
side
i
osta
x
le ho
p au
r he
cylin
y pit
el fr
oler
n
ged
erm
art i
nozz
nde
pum
de b
of fu
side
il co
ama
h
p
l i
t
y
s ma
ctive
ctive
ctive
ks in
ctive
en o
en c
kage
n, d
Defe
Defe
Defe
Hole
Brok
Defe
Crac
Brok
Wor
Lea
Questions

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

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

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

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

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

Drop in heat dissipation efficiency
Defective cooling circulation system
re
)
ratu
pen
Rise in oil temperature in hydraulic pump system
t
aske
aug
mpe
ot o
a Carry out troubleshooting for H mode.
pulle
g
ins
ad g
es n
oil te
ure
tor f
fan
ler
, he
erat
e
t (do
o
valv
radia
ump
worn
o
core
ting
ead
oil c
p
osta
tem
p
ure
lic p
pum
y pit
shed
er h
ing,
ator
ken
herm
ress
r
t
wate
olan
drau
b
ylind
ater
slipp
, bro
radi
, cr u
e
p
d
t
of co
in hy
en w
s ma
ctive
ctive
ctive
en c
ged
ged
ged
belt
Lack
Defe
Brok
Brok
Defe
Clog
Hole
Defe
Clog
Rise
Clog
Fan
Suddenly overheated
Questions
Condition of overheating
Always tends to overheat
Coolant temperature Rises quickly
gauge Does not go down from red range
Radiator water level monitor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on coolant
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
There is play when fan pulley is rotated

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

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

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

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

nal noise.
ifold
e)
.)
man
, etc
engin
d)
General causes why abnormal noise is made
n)
n )
eize
ositio
lever
ta ke
o
less
t i
injec
er s
nd in
ance
t of p
cker
Abnormality due to defective parts
liner
lung
e, ro
Abnormal combustion
d ou
ger a
lear
ce
v
der (
essi
nce
ck, p
eren
le
(valv
Air sucked in from intake system
boar
ve c
ch a r
cylin
nozz
fere
(exc
ash
f
p (ra
nter
f val
ystem
iding
turbo
ing,
inter
ackl
tion
mp
g
i
pum
nt o
ton r
r (div
l t
n pu
lve s
een
c
ushi
ain b
n be
ger,
tme
of pis
j
ed in
tion
b e tw
uffle
ic va
ectio
ed b
char
n, fa
ar tr
djus
injec
ide m
wear
seiz
ynam
of air
seiz
urbo
d fa
j
r ge
n
a
i
ctive
ctive
ctive
ct ins
,
ssive
rme
rope
ged
en d
ed t
ing,
age
Defe
Defe
Defo
Defe
Leak
Clog
Miss
Defe
Seiz
Exce
Brok
Imp
Questions
Condition of abnormal Gradually occurred

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

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

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

tion, carry out troubleshooting also for "Abnormal
k)
. stuc
noise is made".
tion)
d
gne
r, etc
ion
injec
isali
General causes why vibration is excessive
cush
r leve
fuel
pm
ocke
ken
sive
pum
Defective parts (abnormal wear, breakage)
ring
lve, r
, bro
xces
Improper alignment
bea
ulic
m (va
bolts
ash
Abnormal combustion
ydra
p (e
main
r
mpe
ackl
syste
ting
pum
h
rod,
e da
ain b
and
alve
oun
g
tion
shin
cting
nsid
mic v
gine
ar tr
em
injec
u
art i
dyna
f en
ngin
nne
r ge
mb
ctive
en p
ter o
n co
n ca
rope
se e
ctive
Defe
Brok
Wor
Wor
Cen
Defe
Loo
Imp
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idle
Vibration occurs at mid-range speed
Check items
Vibration follows engine speed

Exhaust smoke is black

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

When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-724 PC200/220(LC)-7
(11)
12
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL ........................ 30-3 SWING MOTOR AND SWING
Removal and Installation of Assemblies ....... 30-3 MACHINERY ASSEMBLY .......................... 30-41
Disassembly and Assembly of Assemblies... 30-4 Removal ..................................................... 30-41
PRECAUTIONS WHEN PERFORMING Installation .................................................. 30-41
OPERATION ................................................. 30-5 Special Tools............................................... 30-42
SPECIAL TOOL LIST......................................30-6-1 Disassembly ............................................... 30-44
SKETCHES OF SPECIAL TOOLS .................30-6-5 Assembly .................................................... 30-46
STARTING MOTOR ASSEMBLY....................... 30-7 CARRIER ROLLER ASSEMBLY ..................... 30-49
Removal........................................................ 30-7 Special Tools............................................... 30-49
Installation..................................................... 30-7 Assembly .................................................... 30-49
FUEL INJECTION PUMP ASSEMBLY .............. 30-8 TRACK ROLLER ASSEMBLY ......................... 30-50
Special Tools ................................................. 30-8 Special Tools............................................... 30-50
Removal........................................................ 30-8 Assembly .................................................... 30-50
Installation................................................... 30-10 IDLER ASSEMBLY ......................................... 30-51
ENGINE FRONT SEAL.................................... 30-12 Special Tools............................................... 30-51
Special Tools ............................................... 30-12 Disassembly ............................................... 30-51
Removal...................................................... 30-12 Assembly .................................................... 30-52
Installation................................................... 30-12 RECOIL SPRING ASSEMBLY ........................ 30-54
ENGINE REAR SEAL ...................................... 30-14 Special Tools............................................... 30-54
Removal...................................................... 30-14 Disassembly ............................................... 30-54
Installation................................................... 30-15 Assembly .................................................... 30-55
CYLINDER HEAD ASSEMBLY........................ 30-16 SPROCKET .................................................... 30-56
Special Tools ............................................... 30-16 Removal ..................................................... 30-56
Removal...................................................... 30-16 Installation .................................................. 30-56
Installation................................................... 30-19 TRACK SHOE ASSEMBLY ............................. 30-57
RADIATOR ASSEMBLY................................... 30-22 Special Tools............................................... 30-57
Removal...................................................... 30-22 Removal and Expansion (Iron) ................... 30-57
Installation................................................... 30-23 Installation .................................................. 30-58
HYDRAULIC OIL COOLER ASSEMBLY ......... 30-24 Removal and Expansion of Road Liners .... 30-59
Removal...................................................... 30-24 Installation .................................................. 30-60
Installation................................................... 30-25 SWING CIRCLE ASSEMBLY .......................... 30-61
ENGINE AND HYDRAULIC PUMP Removal ..................................................... 30-61
ASSEMBLIES ............................................. 30-26 Installation .................................................. 30-61
Special Tools ............................................... 30-26 REVOLVING FRAME ASSEMBLY .................. 30-62
Removal...................................................... 30-26 Removal ..................................................... 30-62
FINAL DRIVE ASSEMBLY............................... 30-32 CENTER SWIVEL JOINT ASSEMBLY............ 30-64
Removal...................................................... 30-32 Removal ..................................................... 30-64
Special Tools ............................................... 30-33 Special Tools............................................... 30-66
Disassembly................................................ 30-33 Disassembly ............................................... 30-66
Assembly .................................................... 30-35 Assembly .................................................... 30-66
PC200/220(LC)-7 30-1
(12)
HYDRAULIC TANK ASSEMBLY ......................30-67 AIR CONDITIONER UNIT ASSEMBLY ........ 30-92-1
Removal ......................................................30-67 Special Tools............................................ 30-92-1
Installation ...................................................30-68 Removal................................................... 30-92-1
CONTROL VALVE ASSEMBLY .......................30-69 Installation................................................ 30-92-2
Removal ......................................................30-69 COUNTERWEIGHT ASSEMBLY..................... 30-93
Installation ...................................................30-71 Removal...................................................... 30-93
Disassembly................................................30-72 Installation................................................... 30-93
Special Tools ...............................................30-72 OPERATORS CAB ASSEMBLY ..................... 30-94
Assembly.....................................................30-73 Removal...................................................... 30-94
HYDRAULIC PUMP ASSEMBLY .....................30-75 Installation................................................... 30-95
Special Tools ...............................................30-75 OPERATORS CAB GLASS
Removal ......................................................30-75 (STUCK GLASS) ........................................ 30-99
Installation ...................................................30-77 Special Tools............................................. 30-100
OIL SEAL IN HYDRAULIC PUMP Removal.................................................... 30-100
INPUT SHAFT.............................................30-78 Installation................................................. 30-101
Special Tools ...............................................30-78 FRONT WINDOW ASSEMBLY...................... 30-109
Removal ......................................................30-78 Removal.................................................... 30-109
Installation ...................................................30-78 Installation..................................................30-111
WORK EQUIPMENT PPC VALVE MONITOR ASSEMBLY.................................. 30-114
ASSEMBLY .................................................30-79 Removal.................................................... 30-114
Assembly.....................................................30-79 Installation................................................. 30-115
WORK EQUIPMENT PPC VALVE GONERNOR, PUMP CONTROLLER
ASSEMBLY ..............................................30-79-1 ASSEMBLY............................................... 30-115
Assembly..................................................30-79-1 Removal.................................................... 30-115
TRAVEL PPC VALVE ASSEMBLY ................30-79-2 Installation................................................. 30-115
Assembly..................................................30-79-2
HYDRAULIC CYLINDER ASSEMBLY .............30-81
Special Tools ...............................................30-81
Disassembly................................................30-81
Assembly.....................................................30-83
WORK EQUIPMENT ASSEMBLY ...................30-87
Special Tools ...............................................30-87
Removal ......................................................30-87
Installation ...................................................30-88
AIR CONDITIONER UNIT ASSEMBLY............30-90
Special Tools ...............................................30-90
Removal ......................................................30-90
Installation ...................................................30-92
30-2 PC200/220(LC)-7
(12)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
HOW TO READ THIS MANUAL
REMOVAL AND INSTALLATION OF ASSEMBLIES

SPECIAL TOOLS INSTALLATION OF PARTS
Special tools that are deemed necessary for Except where otherwise instructed, install
removal or installation of parts are listed. parts is the reverse order of removal.
List of the special tools contains the following Instructions and precautions for installing
kind of information. parts are shown with mark in the
1) Necessity INSTALLATION Section, identifying which
: Special tools which cannot be substi- step the instructions are intended for.
tuted, should always be used. Marks shown in the INSTALLATION Section
: Special tools which are very useful if stand for the following.
available, can be substituted with
commercially available tools. This mark indicates safety-related pre-
cautions which must be followed when
2) Distinction of new and existing special doing the work.
tools This mark gives guidance or precau-
N: Tools with new part numbers, newly tions when doing the procedure.
developed for this model.
R: Tools with upgraded part numbers, This mark stands for a specific coating
remodeled from already available agent to be used.
tools for other models. This mark indicates the specified
Blank: Tools already available for other mod- torque.
els, used without any modification.
This mark indicates an amount of oil or
3) Circle mark (!) in sketch column: water to be added.
A circle mark means that a sketch of the
special tool is presented in the section of
Sketches for Special Tools. SKETCHES OF SPECIAL TOOLS
Part No. of special tools starting with 79*T
Various special tools are illustrated for the
means that they are locally made parts and as
convenience of local manufacture.
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL OF PARTS
The REMOVAL Section contains procedures,

precautions and the amount of oil or water to
be drained.
Various symbols used in the REMOVAL Sec-
tion are explained and listed below.
This mark indicates safety-related pre-

cautions which must be followed
when doing the work.
This mark gives guidance or precau-
tions when doing the procedure.
This mark shows that there are instruc-
tions or precautions for installing
parts.
This mark shows oil or water to be

drained.
PC200/220(LC)-7 30-3
c
DISASSEMBLY AND ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES

SPECIAL TOOLS ASSEMBLY
Special tools which are deemed necessary for Section titled ASSEMBLY contain proce-
disassembly and assembly are listed in this dures, precautions and the know-how for the
section. work, as well as the amount of oil or water to
List of the special tools contains the following be added.
kind of information. Various symbols used in the ASSEMBLY Sec-
1) Necessity tion are explained and listed below.
: Special tools which cannot be substi-
tuted, should always be used.
: Special tools which are very useful if doing the work.
available, can be substituted with This mark gives guidance or precautions
commercially available tools. when doing the procedure.
2) Distinction of new and existing special
tools This mark stands for a specific coating
N: Tools with new part numbers, newly agent to be used.
developed for this model. This mark indicates the specified torque.
R: Tools with upgraded part numbers,
remodeled from already available This mark indicates an amount of oil or
tools for other models. water to be added.
Blank: Tools already available for other mod-
els, used without any modification. SKETCHES OF SPECIAL TOOLS
3) Circle mark (!) in sketch column: 1) Various special tools are illustrated for the
A circle mark means that a sketch of the convenience of local manufacture.
special tool is presented in the section of
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T
means that they are locally made parts
and as such not interchangeable with
those made by Komatsu in Japan e.g.
79*T--- xxx --- xxxx.
DISASSEMBLY
The DISASSEMBLY Section contains proce-

dures, precautions and the amount of oil or
water to be drained.
Various symbols used in the DISASSEMBLY
Section are explained and listed below.

doing the work.
This mark gives guidance or precautions
when doing the procedure.
This mark shows that there are instruc-
tions or precautions for installing parts.
This mark shows oil or water to be

drained.
30-4 PC200/220(LC)-7
c
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
12
PRECAUTIONS WHEN PERFORMING OPERATION
Be sure to follow the general precautions given below when performing removal or installation (disassem-
bly or assembly) of units.
1. Precautions when performing removal work
If the engine coolant water contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from
entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force
to the wiring, hold onto the connectors when disconnecting them.
Fasten tags to wires and hoses to identify and show their installation position and help prevent any
mistakes when re-installing.
Count and check the number and thickness of the shims, and keep them in a safe place.
When raising or lifting components, be sure to use proper lifting equipment of ample strength and
safety.
When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt
from entering after removal.
Precautions when handling piping during disassembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
A. Face seal type hoses and tubes

Nominal number Plug (nut end) Nut (elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
B. Split flange type hoses and tubes

Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
C. If the part is not under hydraulic pressure, the following corks can be used:
Nominal Dimensions
Part Number
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
PC200/220(LC)-7 30-5
3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
12
2. Precautions when carrying out installation work
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with two or three drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press-fitting parts, coat the surface with anti-friction compound (LM-P).
After installing snap rings, check that the snap ring is installed securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then con-
nect securely.
When using eye bolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydrau-
lic equipment removed for repair, bleed the air as follows:
1. Start the engine and run it at low idle.
2. Operate the work equipment control lever to operate the hydraulic cylinders, 4 - 5 times, stopping
the cylinders 100 mm from the end of their stroke.
3. Next operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this run the engine at normal speed.
When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operations

If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the
specified level. Run the engine to circulate the coolant water through the system. Then check the
coolant water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment, have been removed for repair, Bleed the air from the system
after reassembling the parts.
For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
related parts.
30-6 PC200/220(LC)-7
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79 T- - cannot be supplied (they are items to be locally manufac-
tured).
a Necessity: t ........... Cannot be substituted, must always be installed (used)
q ........... Extremely useful if available or can be substituted with commercially available part
a New/Remodel:N ........... Tools with new part numbers, newly developed for this model
R ........... Tools with upgraded part numbers, remodeled from items already available for other
models
Blank: ... Tools already available for other models, can be used without any modification
a Tools marked in the Sketch column are tools introduced in the sketches of the special tools (See SKETCH-
ES OF SPECIAL TOOLS).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
Removal of fuel injection

A 795-799-1390 Puller t 1
pump
1 795-799-2610 Installer t 1 Installation of engine front
B
Engine 2 795-799-2620 Installer t 1 seal
assembly Removal and installation of
1 795-799-1170 Installer t 1
nozzle holder assembly
C
Retightening of cylinder
2 790-331-1110 Wrench t 1
head bolt
Engine,
hydraulic pump D 796-460-1210 Oil stopper t 1 Oil stopper
assembly
790-101-2501 Push-puller q 1
790-101-2510 Block 1
790-101-2520 Screw 1
791-112-1180 Nut 1
Center swivel Disassembly and assembly
E 790-101-2540 Washer 1
joint assembly of center swivel joint
790-101-2630 Leg 2
790-101-2570 Plate 4
790-101-2560 Nut 2
790-101-2650 Adapter 2
Removed and installation of
1 796-427-1200 Wrench t 1
nut
796T-427-1220 Push tool t 1 Q
790-101-2510 Block t 1
792-104-3940 Bolt t 2
01580-11613 Nut t 2
Final drive 2 Installation of bearing
F 01643-31645 Washer t 2
assembly
01643-32060 Washer t 2
790-105-2100 Jack t 1
790-101-1102 Pump t 1
Tightening of cover mount-
3 790-331-1110 Wrench t 1
ing bolt
4 791-545-1510 Installer t 1 Installation of floating seal
PC200/220(LC)-7 30-6-1
(12)
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Press-fitting of main bear-

796T-426-1410 Push tool t 1 N Q
ing (For PC200-7)
1
Press-fitting of main bear-
Swing motor, 790-201-2860 Push tool t 1
ing (For PC220-7)
swing machin- G
2 796-426-1120 Push tool t 1 Press-fitting of sub bearing
ery assembly
796T-426-1130 Plate t 1 Q
3 790-101-5241 Grip t 1 Press-fitting of oil seal
01010-61240 Bolt t 1
790-101-5201 Push tool kit q 1
790-101-5221 Grip
01010-51225 Bolt Disassembly and assembly
Idler assembly H
790-101-5271 Plate of idler assembly
790-434-1630 Installer t 1
790-101-1000 Oil pump t 1
791-600-2001 Compressor (A) t 1
or
791-685-8006 Compressor (B) t 1
790-201-2780 Spacer t 1 Disassembly and assembly
1
790-635-3160 Extension t 1 of recoil spring assembly
790-101-1600 Cylinder (686 kN {70 t}) t 1
Recoil spring
J 790-101-1102 Pump t 1
assembly
791-640-2180 Guide bolt t 1 N
790-201-1620 Plate 1
2 Installation of dust seal
790-101-5021 Grip 1
01010-50816 Bolt
790-101-5001 Push tool kit q
790-101-5081 Plate
Carrier roller 790-101-5021 Grip Disassembly and assembly
K
assembly 01010-50816 Bolt of carrier roller assembly
790-434-1660 Installer t 1
790-101-1000 Oil pump t 1
790-101-5221 Grip
01010-51225 Bolt
Track roller Disassembly and assembly
L 790-101-5261 Plate
assembly of track roller assembly
790-434-1640 Installer t 1
790-101-1000 Oil pump t 1
790-331-1110 Wrench t 1
30-6-2 PC200/220(LC)-7
(12)
New/Remodel
Necessity
Symbol
Sketch
Q'ty
791-630-3000 Remover & installer t 1

Track shoe Cylinder Separation and installation
M 790-101-1300 t 1
assembly (980 kN {100 t}) of track shoe assembly
790-101-1102 Pump t 1
Hydraulic 791-463-1141 Push tool t 1
Press-fitting of input shaft
pump assem- N
790-201-2740 Spacer t 1 seal
bly
796-946-1310 Guide
t 1
(For 723-46-40100)
796-946-1610 Guide
t 1
(For 723-46-41100)
796-946-1810 Guide
1 t 1
(For 723-46-43100, 723-46-43400)
796-946-2210 Guide
t 1
(For 723-46-45100)
796-946-1910 Guide
t 1
(For 723-46-46101, 723-46-46300)
796-946-1320 Guide
t 1
(For 723-46-40100)
796-946-1620 Guide
t 1
(For 723-46-41100)
796-946-1520 Guide
t 1
(For 723-46-42700)
2
Control valve 796-946-1820 Guide Replacement of pressure
P t 1
assembly (For 723-46-43100, 723-46-43400) compensation valve seal
796-946-2220 Guide
t 1
(For 723-46-45100)
796-946-1920 Guide
t 1
(For 723-46-46101, 723-46-46300)
796-946-1330 Sleeve
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)
3
796-946-1830 Sleeve
t 1
(For 723-46-43100, 723-46-43400)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1930 Sleeve
t 1
(For 723-46-46101, 723-46-46300)
PC200/220(LC)-7 30-6-3
(8)
New/Remodel
Necessity
Symbol
Sketch
Q'ty
790-502-1003 Cylinder repair stand q 1 Disassembly and assembly

1
790-101-1102 Pump q 1 of hydraulic cylinder
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
(boom, arm)
Installation of piston ring
4 07281-01279 Clamp q 1
796-720-1660 Rubber band (bucket) q 1
07281-01159 Clamp q 1
790-201-1702 Push tool kit t 1
790-201-1831 Push tool (bucket) 1
Hydraulic cylin-
Q 790-201-1930 Push tool (arm) 1
der assembly 5 Press-fitting of bushing
790-201-1940 Push tool (boom) 1
790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1500 Push tool kit (bucket) q 1
790-201-1640 Push tool 1
790-101-5021 Grip 1
6 01010-50816 Bolt 1 Press-fitting of dust seal

790-201-1980 Plate (boom) q 1
790-201-1990 Plate (arm) q 1
790-101-5021 Grip q 1
01010-50816 Bolt q 1
796-900-1200 Remover t 1
Work equip- Puller
R 790-101-4000 t 1 Removal of foot pin
ment assembly (490kN {50t} long)
790-101-1102 Pump (294kN {30t} ) t 1
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump (100V) t 1
Air conditioner Charging of air conditioner
S 799-703-1111 Vacuum pump (220V) t 1
assembly gas
799-703-1121 Vacuum pump (240V) t 1
799-703-1401 Gas leak detector t 1
Operators cab 1 793-498-1210 Lifter (Suction cup) t 2 Removal and installation of
Y
glass 2 20Y-54-13180 Adapter t 2 operators cab glass
30-6-4 PC200/220(LC)-7
(12)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
F2 Push tool
G1 Push tool (PC200-7)
PC200/220(LC)-7 30-6-5
(12)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
G3 Plate
30-6-6 PC200/220(LC)-7
(12)
DISASSEMBLY AND ASSEMBLY STARTING MOTOR ASSEMBLY
12
REMOVAL AND INSTALLATION OF STARTING MOTOR
ASSEMBLY ASSEMBLY
REMOVAL
Disconnect the cable from the negative (-)
terminal of the battery.
1. Open up the engine hood.
2. Disconnect the two wires from the engine

starting motor at:
Wire (1) and (2) from terminal B.
Wire (3) from the T13 side of terminal C.
3. Remove two mounting bolts (4) to detach

engine starting motor assembly (5).
INSTALLATION
Install in reverse order of removal.
Engine starting motor Terminal B

Securing nut:
17.7 to 24.5 Nm (1.8 to 2.5 kgm)
Both faces of engine starting motor

gasket: Gasket sealant (LG-1)
Engine starting motor Terminal B

Securing nut:
43 6 Nm (4.38 0.61 kgm)
PC200/220(LC)-7 30-7
c
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
12
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP

ASSEMBLY ASSEMBLY
SPECIAL TOOLS 5. Disconnect fuel inlet hose (5) and fuel outlet
hose (6).
Part
Mark Part No.
Name
Necessity Qty Distinction* Sketch When disconnecting the hoses, oil will
A 795-799-1390 Puller 1
flow out. Stop the flow by inserting a
wooden plug into the hoses.
*Distinction between new and existing part.
REMOVAL
Leave the negative (-) terminal of the

battery disconnected.
2. Remove plate (1) and cover (2).
6. Disconnect tubes (7) and (8) between the fuel

filter and the fuel injection pump, then
remove fuel filter bracket (9).
3. Take off radiator fan guard (3).
4. Disconnect air intake hose (4).
7. Disconnect lubrication tube (10).
8. Disconnect six delivery tubes (11).
9. Detach E11 governor motor connector and

then detach governor spring (12) on the fuel
injection pump side.
30-8 PC200/220(LC)-7
c
12
12. Remove nut (15) and washer (16) from the

fuel injection pump.
Be careful not to drop the nut or washer

inside the case.
10. Adjust the timing gear to the injection timing,

using timing pin (13) on the timing gear side.
Refer to the Inspection and Adjustment of
Fuel Injection Timing Section.
13. Separate the fuel injection pump shaft and

drive gear, using tool A.
11. Unscrew cap (14) to remove it.

Use a filter wrench to unscrew the cap.
14. Remove two bracket mounting bolts (17) on

the lower part of the fuel injection pump.
PC200/220(LC)-7 30-9
c
12
15. Remove sound absorbing material (18).
16. Remove four nuts (19) to remove fuel injec- Install the fuel injection pump assembly in the
tion pump assembly (20). following manner.
1) Check that the timing pin is properly
adjusted to the fuel injection timing.
Refer to Step 10 in the previous proce-
dure, REMOVAL.
2) Remove plug (21), then reverse timing pin
(22) of the fuel injection pump and assem-
ble the plug to the pump again.
Check that the cutout portion on the
timing pin is engaged with protrusion
a inside the pump.
Refer to the Inspection and Adjust-
ment of Fuel Injection Timing section
of the TESTING AND ADJUSTING,
chapter in this manual.
INSTALLATION
Air intake hose clamp:

5.4 - 6.4 Nm (0.55 - 0.65 kgm)
Hose clamp:
2.84 - 3.82 Nm (0.29 - 0.39 kgm)
3) Mount fuel injection pump assembly (20)

Joint bolt:
and secure it with four nuts (19).
19.6 - 29.4 Nm (2.0 - 3.0 kgm)
Nut: 9.8 2 Nm (1.0 0.2 kgm)
Sleeve nut:
24 4 Nm (2.45 0.41 kgm)
Adjust the governor lever stroke, refer to

the Special Function of Monitor Panel sec-
tion in the INSPECTION AND ADJUST-
MENT chapter, of this manual.
Nut: 95 10 Nm (9.7 1.0 kgm)
30-10 PC200/220(LC)-7
c
12
4) Install washer (16) and tighten it with nut
(15) temporarily.
When installing the nut and washer,
be careful not to let them fall into the
case.
Tighten the nut temporarily to the

following specified torque. Take care
not to damage the timing pin.
3 Nut temporary tightening torque:

12.5 2.5 Nm {1.27 0.25 kgm}
5) Disengage the timing pin on the timing

gear side from protrusion "a", and return
the position of the timing pin of the fuel
injection pump to the original point.
6) Tighten fuel injection pump mounting nut
(15) to the specified torque.
3 Nut: 95 10 Nm {9.7 1.01 kgm}
Air bleeding
Bleed air from the fuel injection system.
30-11
(12)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
12
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL

SPECIAL TOOLS 5. Holding cover (6) securely and using a screw-
driver, push out oil seal (7) from the backside
Part to the front side of the cover.
Mark Part No. Necessity Qty Distinction Sketch
Name
1 795-799-2610 Installer t 1
B
2 795-799-2620 Installer t 1
REMOVAL
1. Remove the radiator assembly, refer to the

Removal and Installation of Radiator Assem-
bly section in this manual.
2. Take off engine fan belt (1) and pulley (2),

using lever [1].
INSTALLATION
Check both index lines on damper hub B

and on inertial material C (marked as A),
when installing the pulsation damper. If
the two index lines are misaligned by
more than 1.59 mm, replace the pulsation
damper. Replace rubber material D, if it is
3. Remove four mounting bolts (3), and then defective.
take off the crankshaft pulley and pulsation
damper (4).
4. Remove 20 mounting bolts (5) to take off

cover (6).
Tighten the crankshaft pulley and pulsa-

tion damper mounting bolt temporarily,
then install engine fan belts and tighten
the bolt to the specified torque.
3 Crankshaft pulley and pulsation
damper mounting bolt:
125 5 Nm {12.75 0.51 kgm}
30-12
(12)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
12 4) Remove plastic part [2] (front oil seal

guide) on the inside of the front cover.
1. Front oil seal

1) Set front oil seal (7) to tool B1.
Since plastic part [2] on the inside of
the front oil seal is used to guide the
front cover to the crankshaft, do not
remove it from the front oil seal.
2) Press fit front oil seal (7) to front cover (6).
Press fit the front oil seal until the
shoulder of tool B1 touches the inside
end of the front cover.
2. Front cover 3. Dust seal

1) Apply ThreeBond 1207D or equivalent in Even if a dust seal has not been installed,
the form of a continuous string 1 2 mm install the dust seal contained in the front seal
thick to the gasket fitting face of front kit.
cover (6). 1) Using tool B2, press fit dust seal (8) to the
2) Install the gasket to front cover (6), and end of the crankshaft.
then install them to the engine. Press fit the dust seal until the inside
3) Tighten the 20 mounting bolts in the end of tool B2 touches the end of the
order shown at right. crankshaft.
3 Front cover mounting bolt:

24 4 Nm {2.45 0.4 kgm}
30-13
(12)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
12
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
REMOVAL Drill a hole of approx. 3 mm in diameter

on the seal carrier with a drilling machine.
1. Remove the hydraulic pump assembly, refer
to the "Hydraulic pump assembly removal"
section in this manual.
2. Remove damper assembly (1).
3. Remove the mounting bolts from flywheel

assembly (2) and set guide bolts [1]. Then lift
it off to remove it.
Attach a dent puller to a slide hammer

and insert the hammer into the drilled
hole. Then pull out seal (3) by sliding the
hammer.
4. Remove seal (3).

A suggested method for removing the
seal is to drill a hole approx. 3 mm in
diameter on the seal carrier, then insert a
slide hammer with a dent puller attached
into the hole and pull the seal out.
The seal may be removed by destroying
the seal carrier with a hammer. When
using this method, take care so that the
flywheel seal and crankshaft wear ring are
not damaged.
30-14
(12)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
12
INSTALLATION
Install in reverse order of removal. 2) Push the oil seal into the flywheel by
inserting pilot (2) with oil seal (4) into the
crankshaft.
Flywheel mounting bolt:
3) Pull out pilot (2). Push the oil seal into the
137 7 Nm (13.97 0.71 kgm) front cover from the inside to the outside.
Tighten the mounting bolts in the 4) Install the oil seal on the flywheel housing
sequence illustrated below. to the proper depth. Use an alignment
tool.
Tap the head, bottom, right and left
sides of the alignment tool to make
sure that the seal carrier is not
twisted, when it is being pushed in.
Install the oil seal in the following man-

ner.
1) Attach pilot (2) to new oil seal (4).
Before installing the oil seal, clean the
crankshaft sealing face and the seal
lip face. Remove all oil and dry thor-
oughly to prevent oil leakage.
PC200/220(LC)-7 30-15
c
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
12
REMOVAL AND INSTALLATION OF CYLINDER HEAD

ASSEMBLY ASSEMBLY
SPECIAL TOOLS
Part
Mark Part No. Necessity Qty Distinction* Sketch
Name
1 795-799-1170 Installer 1
C
2 790-331-1110 Wrench 1
REMOVAL
.Disconnect the cable from the negative

terminal (- ) of battery.
10. Remove heat cover (8) from the turbocharger
1. Drain engine coolant. assembly.
11. Remove exhaust muffler connector cover (9).

Hydraulic oil: 22.8 l
2. Close the fuel stop valve.
4. Remove clamp (1) from the engine oil level

gauge guide.
Put the clamp aside near the counter-
weight after removing it.
6. Disconnect tubes (3) and (4) between the fuel 12. Disconnect air cleaner suction hose (10).
filter and the fuel injection pump.
13. Disconnect air intake hose (11) between the

7. Remove bracket (5) in one piece with the fuel turbocharger and the after-cooler.
filter assembly.
14. Remove V clamp (12) from the exhaust muf-

8. Remove ribbon heater harness CN-E01 (6). fler.
9. Disconnect six delivery tubes (7). 15. Disconnect lubricant inlet tube (13) and lubri-
cant outlet tube (14).
16. Remove turbocharger assembly (15).
30-16 PC200/220(LC)-7
c
12
17. Detach exhaust manifold (16). 24. Remove the four mounting bolts to detach the
fan and fan pulley (25).
Put the fan pulley aside near the radiator.
25. Disconnect radiator inlet hose (26) and heater

hose (27).
18. Detach air compressor wiring connector CN-

E06 (17).
19. Loosen tension on the air compressor belt,

then loosen adjusting bolt (18) to remove belt
(19).
26. Disconnect connector E12 (29) at terminal B
(28) from the alternator.
20. Remove air compressor assembly (20).
Remove the mounting bracket in one 27. Remove three alternator bracket mounting
piece with the air compressor assembly bolts (30) and the two alternator plate mount-
and put them aside near the counter ing bolts, and remove alternator assembly
weight. (31) in one piece with the bracket.
21. Detach radiator fan guards (21) and (22).
28. Disconnect connector E05 (32) from the

engine coolant temperature sensor, and
22. Loosen air compressor belt (23), using remove the wiring clamp.
wrench b and remove it.
Be careful not to get a finger caught in
the belt, when removing it.
23. Remove tension pulley (24).
30-17
(11)
12
32. Remove head cover (37).
29. Remove the clamps (two places) and discon-

nect the spill tube (33).
33. Detach rocker arm assembly (38).
30. Remove six nozzle holders (34).
Loosen the lock nut, and unscrew the
If it is difficult to remove the nozzle holder adjusting screw 2 to 3 turns.
assemblies, use tool C1.
Be careful not to allow dust or foreign
matter to stick where the nozzle holder
assembly is installed.
34. Remove push rod (39).
31. Disconnect ribbon heater wiring (35) and

remove air intake connector (36).
35. Remove 26 mounting bolts from cylinder

head assembly (40) and lift it off for disassem-
bly.
Cylinder head assembly: 52 kg
30-18 PC200/220(LC)-7
c
36. Remove cylinder head gasket (41).
Tighten the exhaust manifold mounting

bolts in the sequence illustrated below.
Exhaust manifold mounting bolt:
1st step: Tighten to 24 4 Nm (2.45 0.41 kgm)

in the sequence of (1) through (12).
2nd step: Tighten to 43 6 Nm (4.38 0.61 kgm)
3rd step: Tighten to 43 6 Nm (4.38 0.61 kgm)
INSTALLATION
Coat the threads of the clamp bolt (used

for securing the engine oil level gauge
guide) with gasket sealant.
Air intake hose clamp bolt:

5.4 - 6.4 Nm (0.55 - 0.65 kgm)
Air Compressor Belt Tension section in
the TESTING AND ADJUSTING chapter in
Joint bolt: this manual.
19.6 - 29.4 Nm (2.0 - 3.0 kgm)
Radiator fan and fan pulley

Coat the threads of only one bolt on the mounting bolt:
head cover side of the fuel filter bracket 33 5 Nm (3.37 0.51 kgm)
with gasket sealant.
Radiator inlet hose clamp bolt:

Sleeve nut: 8.3 - 9.3 Nm (0.85 - 0.95 kgm)
24 4 Nm (2.45 0.41 kgm)
Heater hose clamp bolt:
8.83 - 14.7 Nm (0.9 - 1.5 kgm)
Air cleaner suction hose clamp bolt:

5.4 - 6.4 Nm (0.55 - 0.65 kgm) Spill tube bolt:
30 5 Nm (3.06 0.51 kgm)
Intake air hose clamp bolt:

5.4 - 6.4 Nm (0.55 - 0.65 kgm) Nozzle holder assembly:
60 9 Nm (6.12 0.92 kgm)
PC200/220(LC)-7 30-19
c
4) Install rocker arm assembly (38) and

tighten the bolts by hand.
Check that the adjusting screw ball is
Head cover mounting bolt: well seated in the push rod socket.
24 4 Nm (2.45 0.41 kgm)
Coat the threads and seat surface of
mounting bolts (8 mm and 12 mm)
Mount the rocker arm assembly and the cylin- with engine oil (15W-40).
der head assembly in the following manner.
Check that there is no dust or foreign mat-
ter stuck to the cylinder head installing
face or inside the cylinders.
1) Place cylinder head gasket (41) on the cyl-
inder block.
Check that the gasket is properly
matched with the cylinder block holes.
2) Lift cylinder head assembly (40) and place
it on the cylinder block.
5) Tighten the cylinder head mounting bolts

in the sequence as illustrated below.
Coat the threads and seat surface of
the mounting bolts with engine oil
(15W-40).
Cylinder head mounting bolt:

1st step: Tighten to 90 5 Nm
(9.18 0.51 kgm) in the
sequence of (1) through (26).
3) Assemble push rod (39). 2nd step: Tighten to 120 5 Nm
(12.24 0.51 kgm) in the
Coat the push rod surface with engine
sequence of (3), (6), (11), (14),
oil (15W-40).
(19) and (22).
30-20 PC200/220(LC)-7
c
3rd step:
i) If Tool C2 is used:
Using an angle tightening wrench
(Tool C2), tighten the bolts by turning
them 90 5 in the sequence of (1)
through (26).
7) Adjust the valve clearance.

Refer to the Adjusting of Valve Clear-
ance section in the TESTING AND
ADJUSTING chapter of this manual.
Refilling coolant
Refill engine coolant up to the specified level.
ii) If Tool C2 is not used: Let the coolant circulate to release any air
Put counter mark on the bolts and cyl- pockets by starting the engine. Check the
inder head with a felt-tip pen, and coolant level again.
then tighten the bolts by turning them
to 90 5.
6) Tighten the rocker arm assembly mount-

ing bolts (8 mm).
Rocker arm assembly mounting
bolt: 24 3 Nm (2.45 0.31 kgm)
30-21
(11)
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
12
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY

REMOVAL 7. Remove bell mouth shroud (8).
1. Drain the engine coolant. 8. Remove the mounting clamp for heater hose
(9).
Engine coolant: Approx. 22.8 l After removing the clamp, keep the heater
hose away from the radiator cover.
3. Remove covers (1), (2) and (3).
9. Sling the radiator assembly with two lifting

hooks (1).
4. Disconnect reservoir tank hose (4).

Disconnect the hose at the radiator side.
5. Disconnect two radiator hoses (5) on the

upper and lower sides.
6. Remove radiator fan guards (6) and (7).
10. Remove the four radiator mounting bolts and

lift out the radiator assembly (10) .
Radiator assembly: 45 kg
30-22
(11)
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
INSTALLATION
Radiator hose clamp bolt:

8.3 - 9.3 Nm (0.85 - 0.95 kgm)
To maintain the heat balance, make sure

that sponge sheets are assembled in the
original position.
Adjust clearance a between the radiator
circumference and the bell mouth shroud,
using oblong hole b for mounting the bell
mouth shroud, so that the clearance may
be even all around the circumference.
Check that clearance a shows the follow-
ing value, measured at four points on the
right, left, top and bottom sides.
Standard clearance a (on all the cir-
cumference): Min. 13 mm
Fan diameter c: 620mm
Shroud inner diameter d: 650mm
Refilling engine coolant

Refill engine coolant through the coolant filler
port up to the specified level. Let the coolant
circulate to release any air pockets by starting
the engine. Check the coolant level again.
Engine coolant: Approx. 22.8 l
30-23
(11)
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER ASSEMBLY
12
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER

ASSEMBLY ASSEMBLY
REMOVAL 5. Detach control valve drain hose (4) and tank

return hose (5).
1. Open up the engine hood. Plug the hoses to prevent oil from flowing
out.
2. Remove cover (1).
3. Remove hydraulic oil cooler drain plug (2)

and drain the hydraulic oil.
Before draining oil, unscrew the hydraulic
tank cap to release the pressure inside the
tank, and drain oil through the cooler
hose.
If a plug on top of the hydraulic oil cooler
is loosened, draining oil becomes easier.
Hydraulic oil cooler: Approx. 5.0 l
6. Remove the mounting clamp and put aside

reservoir tank hose (6).
When lifting out the hydraulic oil cooler,
keep it where it will not interfere with
other parts.
7. Remove the mounting clamp and disconnect

A30 air conditioner ambient temperature sen-
sor (7) from the condenser bracket.
8. Disconnect hydraulic oil cooler drain hose (8).
30-24 PC200/220(LC)-7
c
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER ASSEMBLY
12
9. Remove four mounting bolts from hydraulic

oil cooler assembly (9) and lift it out.
If bolts for the after-cooler and condenser
mounting bracket are removed before-
hand, removing the hydraulic oil cooler
assembly becomes easier.
INSTALLATION

Refilling hydraulic oil (hydraulic tank)
Refill hydraulic oil through oil filler port up to
the specified level and circulate oil in the
hydraulic system by starting the engine. Then
check the oil level again.
Hydraulic oil cooler: Approx. 5.0 l
PC200/220(LC)-7 30-25
c
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES
12
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC

PUMP ASSEMBLIES PUMP ASSEMBLIES
SPECIAL TOOLS
Part 3. Lift up engine hood (1).

Name
Oil
D 796-460-1210 1 Support the engine hood with an appropri-
Stopper
ate strap and lifting device.
REMOVAL
Lower the work equipment to the ground

for safety and stop the engine. Disconnect
the cable from the negative terminal (- ) of
the battery.
To release the internal pressure, gradually
loosen the oil filler cap on the hydraulic
tank.
Attach an identification tag to each pipe. This

will avoid a possible mistake when reinstall-
ing. 4. Remove pin (2) and mounting bolt (3). Lift off
the hood and set it aside.
1. Remove the hydraulic tank strainer and stop
the flow of oil, using Tool D.
When not using tool D, remove the drain
plug to drain oil from the hydraulic tank
and piping.
Hydraulic tank: Approx. 240 l
5. Remove covers (4) and (5).
6. Remove radiator fan guards (6) and (7).
2. Drain engine coolant.
30-26
(11)
7. Loosen air compressor belt tension adjusting 12. Disconnect fuel return hose (16).
bolt (8) and remove belt (9).
8. Disconnect E06 air conditioner wiring connec-

tor (10) and E01 ribbon heater wiring connec-
tor (11).
9. Displace air compressor assembly (12).
Remove air compressor assembly (12) in

one piece with the bracket, and set them
aside near the counter weight.
13. Disconnect engine wiring connectors at the

following five points.
(17): E02 (Engine oil temperature switch)
(18): E05 (Engine coolant temperature
sensor)
(19): E04 (Engine revolution sensor)
(20): E10 (Governor and potentiometer)
E11 (Governor and motor)
11. Disconnect fuel inlet hose (14) and fuel outlet

hose (15).
30-27
(11)
12
14. Remove bell mouth shroud (21). 18. Remove cover (28) and plate (29).
15. Disconnect two radiator hoses (22) on the

upper and lower sides.
19. Remove covers (30) and (31).
20. Disconnect eight hoses.

16. Disconnect engine starting motor wiring (23) (32): Front pump discharging port hose
and connectors (24), (25) and (26). (33): Rear pump discharging port hose
(23): Engine starting motor terminal B (34): Pump pressure input port hose
(red)
(35): Drain port hose
(24): E08 (Intermediate connector)
(36): EPC source pressure port hose
(25): T13 (color band, yellow)
(Engine starting motor terminal C )
(37): Load pressure input port hose
(26): E03 (Engine oil level sensor) (color band, red)
(39): Suction port hose
17. Disconnect engine ground (27).
30-28 PC200/220(LC)-7
c
12
21. Remove clamp (40). 25. Remove cover (47).
22. Disconnect the pump wiring connectors at 26. Remove water separator wiring clamp (48).
the following three points.
(41): A61 (Hydraulic oil temperature sensor) 27. Remove four engine mounting bolts (49) at
Color band, white the front and rear.
(42): V21 (PC-EPC solenoid valve)
Color band, white
(43): V22 (LS-EPC solenoid valve)
Color band, red
23. Disconnect exhaust muffler drain tube (44).
Check that there is no wiring or piping still

connected.
28. Lift out engine and hydraulic pump assembly

(50).
Engine and hydraulic pump assembly:

24. Disconnect engine oil filter outlet hose (45) 770 kg
and engine oil filter inlet hose (46).
PC200/220(LC)-7 30-29
c
INSTALLATION Install the hose clamp and tighten the

clamp screw as shown in the diagram
Install in reverse order of removal. below.

Air Compressor Belt Tension section in
the TESTING AND ADJUSTING chapter of
this manual.
Air intake hose clamp screw:

5.4 - 6.4 Nm (0.55 - 0.65 kgm)
Fuel inlet hose clamp screw:

29.4 4.9 Nm (3.0 0.5 kgm)
The engine mounting rubber pads differ
in shape at the front and rear. Place them
as illustrated below, and install the engine
Radiator hose clamp screw: and hydraulic pump assembly.
8.3 - 9.3 Nm (0.85 - 0.95 kgm)
Engine mounting bolt:
245 - 308.7 Nm (25 - 31.5 kgm)
After tightening the suction hose clamp
screw, check that the screw is in the posi-
tion as illustrated below.
Suction hose clamp screw:

8.8 0.5 Nm (90 5 kgm)
30-30 PC200/220(LC)-7
c
12
Refilling engine coolant

Refill engine coolant through the water filler
port up to the specified level.
Refilling hydraulic oil (hydraulic tank)

Refill hydraulic oil through oil filler port up to
the specified level.
Let the coolant circulate to release any air

pockets by starting the engine. Check the
coolant level again.
Circulate oil in the hydraulic system by start-
ing the engine. Then check the oil level again.
Air bleeding
Refer to the Air Bleeding of Various Part sec-
tion in the TESTING AND ADJUSTING chapter
of this manual.
30-31
(11)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
12
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY

REMOVAL 4. Remove the 18 mounting bolts from final
drive assembly (3) and lift if off to remove.
1. Remove the sprocket, refer to the Removing
Sprocket section in this manual.
Be careful. Do not damage the face of the
Lower the work equipment to the ground fitting seal at the base of the hose.
for safety. Stop the engine and loosen the
When lifting off the final drive assembly,
oil filler cap on the hydraulic tank to release
do not use a tapped hole for lifting the
pressure inside.
cover.
2. Remove cover (1). Final drive assembly: 330 kg
3. Disconnect four travel motor hoses (2).
INSTALLATION
Final drive assembly mounting bolt:

245 - 309 Nm (25 - 31 kgm)
Refilling hydraulic oil

Refill hydraulic oil through the oil filler port to
the specified level, and let the oil circulate in
the hydraulic system by starting the engine.
Then check the oil level again.
Air bleeding
Refer to the Air Bleeding of Variuos Part sec-
of this manual.
30-32 PC200/220(LC)-7
c
12
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

SPECIAL TOOLS 3. Spacer
Remove spacer (2).
Part
Name
1 796-427-1200 Wrench 1
796T-427-1220 Push tool 1 !
790-101-2510 Block 1
792-104-3940 Bolt 2
01580-11613 Nut 2
2
F 01643-31645 Washer 2
01643-32060 Washer 2
790-105-2100 Jack 1
790-101-1102 Pump 1
3 790-331-1110 Wrench 1
4 791-545-1510 Installer 1
4. No. 1 carrier assembly
DISASSEMBLY 1) Remove No. 1 carrier assembly (3).
1. Draining Oil
Remove drain plug and drain oil from final
drive case.
Final drive case: Approx. 4.7 l
2. Cover
Remove mounting bolts, then remove cover
(1) using eyebolts b.
When raising ring gear (12) and cover (1)
as one unit, tap the ring gear with a 2) Disassemble No. 1 carrier assembly as
wooden hammer to remove the ring gear. follows.
i) Push in pin (4) and pull out shaft (5)
from carrier (6).
After removing the shaft, remove
pin (4).
ii) Remove thrust washer (7), gear (8),
bearing (9), and thrust washer (10).
PC200/220(LC)-7 30-33
c
5. No.1 sun gear shaft

Remove No. 1 sun gear shaft (11).
2) Disassemble No. 2 carrier assembly as

follows.
i) Push in pin (17) and pull out shaft (18)
6. Ring gear from carrier (19).
Remove ring gear (12).
After removing the shaft, remove
pin (17).
7. Thrust washer
Remove thrust washer (13). ii) Remove thrust washer (20), gear (21),
8. No. 2 sun gear
Remove No. 2 sun gear (14).
11. Nut
1) Remove lock plate (24).
9. Thrust washer 2) Use tool F1 and remove nut (25).
Remove thrust washer (15).

1) Remove No. 2 carrier assembly (16)
30-34 PC200/220(LC)-7
c
12
12. Hub assembly ASSEMBLY

1) Using eyebolts c, remove hub assembly
Clean all parts and check for dirt or damage.
(26) from travel motor.
Coat the sliding surfaces of all parts with
engine oil before installing.
1. Hub assembly
1) Using push tool, press fit bearings (28)
and (29) to hub (30).
2) Disassemble hub assembly as follows.

i) Remove floating seal (27).
ii) Remove bearing (28) and (29) from
hub (30).
When removing bearing (28), do not
hit the resin retainer of the bearing.
2) Using tool F4, install floating seal (26).
Remove all oil and grease from the O-
ring and O-ring contact surface. Dry
the parts before installing the floating
seal.
After installing the floating seal, check
that the angle of the floating seal is
within 1 mm.
After installing the floating seal, coat
the sliding surface thinly with engine
oil.
3) Remove floating seal (31) from travel

motor (32).
PC200/220(LC)-7 30-35
c
12
3) Using tool F4, install floating seal (31)

onto travel motor (32).
The procedure for installation is the
same as in Step 2. above.
4) Using eyebolts c, set hub assembly (26)

onto the travel motor. Use the push tool
and tap to press fit the bearing.
vi) Using push-pull scale d, measure

tangential force in the direction of
rotation of the hub in relation to the
motor case.
Tangential force: Max. 294 N
{30 kg}
The tangential force is the maxi-
mum force when starting rotation.
2. Nut
1) Install nut as follows.
i) Using tool F2, push bearing inner
race.
Do not heat the bearing with a
burner, or directly push or hit the
resin retainer.
Pushing force:
8.8 - 12.7 kN (0.9 - 1.3 tons)
Rotate the hub 2 - 3 times before
applying the pushing force to the
bearing inner race.
ii) Measure dimension a in the condition
in Step 1) above.
iii) Measure thickness b of the nut itself.
iv) Calculate a - b = c.
v) Using tool F1, tighten nut (25) to a
point where dimension d is c 0 .
-0.1
30-36 PC200/220(LC)-7
c
12Do not coat the tap portion of the nut with thread tightener
vii) Install lock plate (24).
Install the lock plate as shown in the dia- ii) Align the position of pin holes on the
gram. shaft and carrier, then tap with a plas-
tic hammer to install shaft (18).
Thread of mounting bolt:
When installing the shaft, rotate
Thread tightener (LT-2)
the planetary gear. Be careful not
Do no coat the tap portion of the nut to damage the thrust washer.
with thread tightener (LT-2). iii) Insert pin (17).
After inserting the pin, caulk the
pin portion of the carrier.
After assembling the carrier assembly,
check that gear (21) rotates smoothly.

1) Assemble No. 2 carrier assembly as fol-
lows.
Replace thrust washers (20), (23) and
pin (17) with new ones.
There are remains of caulking when
the pin is inserted at the end face of
hole h at the side of the carrier.
Remove the caulked metal from the
inside diameter of the hole before
starting to assemble.
i) Assemble bearing (22) to gear (21), fit
top and bottom thrust washers (20)
and (23), and set gear assembly in
carrier (19).
PC200/220(LC)-7 30-37
c
12
2) Install No. 2 carrier assembly (16). i) Assemble bearing (9) to gear (8), fit
top and bottom thrust washers (7) and
Align the position so that the three
(10), and set gear assembly in carrier
tips of the gear shafts of the carrier
(6).
assembly (16) enter the three hollows
in the end face of the motor case, then
install.
ii) Align the position of pin holes on the

shaft and carrier, then tap with a plas-
tic hammer to install shaft (5).
4. Thrust washer When installing the shaft, rotate
Install thrust washer (15). the planetary gear. Be careful not
to damage the thrust washer.
5. No. 2 sun gear iii) Insert pin (4).
Install No. 2 sun gear (14). After inserting the pin, caulk the
pin portion of the carrier.
6. Thrust washer After assembling the carrier assembly,
Install thrust washer (13). check that gear (8) rotates smoothly.
7. No. 1 sun gear shaft
Install No. 1 sun gear shaft (11).

1) No. 1 carrier assembly as follows.
Replace thrust washers (7), (10) and
pin (4) with new ones.
There are remains of caulking when
the pin is inserted at the end face of
hole h at the side of the carrier.
Remove the caulked metal from the
inside diameter of the hole before
starting to assemble.
30-38 PC200/220(LC)-7
c
12
2) Install No. 1 carrier assembly (3).
9. Spacer
Install spacer (2).
10. Ring gear

Fit O-ring to hub end. Then using eyebolts [4],
align the position of the bolt holes on hub and
ring gear (12), and install.
Remove all grease and oil from the mat-
ing surface of the ring gear and hub.
Do not put any gasket sealant on the mat-
ing surface of the ring gear and hub under
any circumstances. 12. Refilling with oil
Tighten drain plug and add engine oil
through the oil filler.
5 Final drive case: Approx. 4.7 l
Do a final check of the oil level at the

determined position after installing the
final drive assembly to the chassis.
11. Cover
Using eyebolts [1], fit cover (1), then tighten
mounting bolts with angle tightening wrench
F3.
2 Mounting surface of cover:
3 Mounting bolt:
1st pass: 98 Nm {10 kgm}
2nd pass: Turn 80 - 90
30-39
(12)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY ASSEMBLY
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING

MACHINERY ASSEMBLY
PREPARATION WORK
a If the bearing-shaft-case assembly of the swing machinery on PC200(LC)-7, serial No. 200001 203890 is
repaired (See Disassembly and assembly of swing motor and swing machinery assembly), the swing motor
is heightened by 51 mm. Accordingly, prepare the following hoses in advance to replace the existing hoses.
Hose (2): 20Y-62-41252 (30 mm longer than existing one)

Hose (6): 02763-00508 (100 mm longer than existing one)
PC200/220(LC)-7 30-41
(12)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING

MACHINERY ASSEMBLY
REMOVAL 4. Lift off swing motor and swing machinery assem-
k Release the residual pressure in the hydraulic bly (9) to remove.
circuit. Refer to the Release of Remaining Pres- a When lifting off the swing motor and swing
sure in Hydraulic Circuit section in the TESTING machinery assembly for removal, do slowly
AND ADJUSTING chapter of this manual. so that the hoses and other parts may not be
k Lower the work equipment to the ground for
damaged.
safety. After stopping the engine, loosen the oil 4 Swing motor and swing machinery
filler cap on the fuel tank to release the residual assembly: 230 kg
pressure inside the tank and move the lock lever
to the LOCK position.
1. Remove the mounting bracket for hose clamp

(1).
a Keep the removed mounting bracket away
from the swing motor and swing machinery
assembly.
2. Disconnect six swing motor hoses (2) through

(7).
(2): Between the swing motor and control
valve (MA port)
(3): Between the swing motor and control
valve (MB port)
(4): Suction hose (S port) INSTALLATION
(5): Pilot hose for relieving swing brake Install in reverse order of removal.
(B port)
(6): Between the drain hose and swing a When repairing, replace hoses (2), (3), (6),
motor, and swivel joint (T port) and (10). For hose (10), see the explanation
(7): Between drain hose and swing motor, of repair.
and hydraulic tank (T port)
3. Remove 12 mounting bolts (8). 3 Swing motor and swing machinery

assembly mounting bolt:
490 608 Nm (50 62 kgm)
Refilling hydraulic oil

Refill hydraulic oil through the oil filler port to the
specified level. Let the oil circulate in the hydrau-
lic system by starting the engine. Then check the
oil level again.
Air bleeding
Refer to the Air Bleeding of Various Parts section
in the TESTING AND ADJUSTING chapter of
this manual.
30-41-1 PC200/220(LC)-7
(12)
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND

SWING MACHINERY ASSEMBLY
PC200-7 Serial No.: 200001 203890 Parts to be prepared
PC220-7 Serial No.: 60001 60353 PC220(LC)-7, Serial No.: 60001 60353
1. Bearing (31): 206-26-73150

SPECIAL TOOLS 2. Bearing (27): 206-26-73160
3. Cover (30): 206-26-73120
New/Remodel
4. Oil seal (29): 20Y-26-22420
Necessity
Sketch
5. Washer (57): 01643-31032 (12)
Qty
6. Bolt (56): 01010-81040 (12)
7. O-ring (34): 07000-15100
8. Spacer (33): 206-26-73140
796T-426-1410 9. Shaft (28): 206-26-73130
Push tool t 1 N Q
(PC200-7) 10. Case (32): 206-26-73110
1
790-201-2860
Push tool t 1 a Reuse the O-rings, except (34).
(PC220-7)
G 2 796-426-1120 Push tool t 1
796T-426-1130 Plate t 1 Q
3 790-101-5241 Grip t 1
01010-61240 Bolt t 1
PREPARATION WORK
a Do not disassemble bearing-shaft-case assem-
bly (51) [bearings (52) and (53), case (54), and
shaft (55)] but discard it. Prepare the following
parts for repair. As a result, the grease-lubricat-
ed structure will be changed to the oil-lubricated
structure.
a Do not reuse the bearings since their durability
cannot be assured once they are removed. (The
size of bearing (52) is not changed, but discard
it.)
30-42 PC200/220(LC)-7
(12)
PC200(LC)-7, Serial No.: 200001 203890
1. Gauge (41): 20Y-26-31431

2. Filler (42): 20Y-26-31421
3. Tube (43): 20Y-26-31411
4. Bearing (44): 20Y-26-22330
5. Bearing (45): 20Y-26-22340
6. Cover (46): 20Y-26-22191
7. Oil seal (47): 20Y-26-22420
8. Bolt (48): 01024-81045
9. Shaft (49): 20Y-26-21142
10. Case (50): 20Y-26-31110
a Since the swing motor is heightened by 51 mm

after the repair, replace gauge (41), filler (42),
and tube (43). Reuse the cap, however.
PC200/220(LC)-7 30-43
(12)
DISASSEMBLY 4. No. 1 carrier assembly

1) Remove No. 1 carrier assembly (3).
1. Draining oil
Loosen the drain plug and drain the oil from the
swing machinery case.
6 Swing machinery case:

Approx. 6.6 l (PC200-7)
Approx. 7.5 l (PC220-7)
2. Swing motor assembly

1) Set the swing motor and swing machinery
assembly on block [1].
2) Remove the 6 mounting bolts and lift off
swing motor assembly (1).
4 Swing motor assembly: 70 kg
a When repairing PC200-7, remove oil filler 2) Disassemble No. 1 carrier assembly accord-
(42) and oil supply tube (43). (Reuse the ing to the following procedure.
cap, however.) i) Remove snap ring (4), and then remove
thrust washer (8), gear (6), bearing (7),
and plate (9).
ii) Using the press, remove shaft (5).
a Press fitting force for installing shaft
(Reference value):
11.2 25.8 kN {1,140 2,630 kg}
a PC200-7
3. No. 1 sun gear

a PC220-7
30-44 PC200/220(LC)-7
(12)
5. Ring gear 3) Disassemble the No. 2 carrier assembly

Remove the mounting bolts and ring gear (10). according to the following procedure.
i) Push in pin (14) and drive shaft (15) out
of carrier (16).
a After removing the shaft, remove pin
(14).
iii) Remove plate (21).
a PC200-7
6. No. 2 sun gear

a PC220-7
7. Bolt
Remove holder mounting bolts (12).

2) Remove drain part (35) from the case.
a When repairing, reuse the drain part.
9. Bearing-shaft-case assembly
If the bearing-shaft-case assembly needs to be
disassembled, do not disassemble it for repair
but discard it. (Described before)
PC200/220(LC)-7 30-45
(12)
ASSEMBLY
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with engine
oil before installing.
a Steps 1 4 are procedures for assembling the
repaired section. Use the prepared parts for
those steps (described before).
1. Bearing
Using push tool [5], press fit bearing (27) to case
(32).
2. Cover assembly
1) Set oil seal (29) on cover (30) horizontally.
2) Using push tool G3, press fit oil seal (29) to 3) Install cover assembly (26) to case (32) and
cover (30). tighten mounting bolts (23).
2 Periphery of oil seal: a Match the drain ports.
Gasket sealant (LG-6) 2 Cover fitting face:
a Take care that the gasket sealant (LG-6) Gasket sealant (LG-6)
will not stick to the oil seal lip. a When applying the gasket sealant, take
a When not using push tool G3, use anoth- care not to project it into the drain port.
3 Mounting bolt:
er push tool to push part A around the oil
seal evenly.
a Take care that oil seal (29) will not slant 66.2 7.4 Nm {6.75 0.75 kgm}
while press fitting it. 2 Oil seal lip: Grease (G2-LI)
30-46 PC200/220(LC)-7
(12)
3. Shaft and case assembly 5) Set the assembly on the press.

a Perform steps 1) and 2) for only PC220-7. 6) Using push tools G1, [8] and [10], press fit
1) Install O-ring (34) to spacer (33). the bearing inner race.
2) Using push tool [4], press fit spacer (33) to a Press fitting force: Several ton
shaft (28). a Set push tool [10] so that case assembly (25)
a Take care that O-ring (34) will not be will not slant largely.
caught. a Hit the flange of case assembly (25) lightly
and frequently to correct its slant.
a Set case assembly (25) horizontally so that
oil seal lip contact face B of shaft (28) will be
at the center of oil seal (29).
3) Set case assembly (25) to shaft (28).

a Take care not to damage the oil seal.
4) Using push tools G1 and [8], hit the shaft so

that it will not fall down.
a Loosen sling [9].
PC200/220(LC)-7 30-47
(12)
4. Bearing a PC220-7
Using tool G2, press fit bearing (31).
a Press the bearing inner race and outer race
simultaneously. Do not press only the inner
race.
a Press fitting force:
Inner race side: 9.4 26.6 kN {960 2,710 kg}
Outer race side: 0 8.9 kN {0 910 kg}
a After press fitting the bearing, check that the
case rotates smoothly.
iii) Aligning the pin holes of shaft (15) and

carrier, lightly hit the shaft with a plastic
hammer to install.
a When installing the shaft, revolve the
planetary gear and take care not to dam-
age the thrust washers.
iv) Insert pin (14).
a When inserting the pin, do not set the 3
claws (parts "a") on the periphery to the
5. No. 2 carrier assembly thin part of the carrier (part "b").
1) Assemble the No. 2 carrier assembly The thin part may be on the opposite
according to the following procedure. side, however. Check the thin part and
a There is caulking mark (h) made when avoid setting the claws to it.
the pin was inserted around the side v) After inserting the pin, caulk 2 parts (h)
hole of carrier (16) (See v) ) and the in- around the pin hole of the carrier.
side wall of the hole is swelled at that a Check that all the gears turn smoothly.
mark. Flatten the swelled part in ad-
vance.
i) Install plate (21) to carrier (16).
ii) Install bearing (19) to gear (18) and fit
(20), and then set the gear assembly to
carrier (16).
a PC200-7
30-48 PC200/220(LC)-7
(12)
7. No. 2 sun gear

1) Install No. 2 sun gear (11).
2) Install the O-ring to case (32).
6. Bolt
2 Threads of mounting bolt:

Tighten bolt (12). 8. Ring gear
Using eyebolts (M10 x 1.5), install ring gear (10)
3 Mounting bolt:
Adhesive (LT-2) as explained below.
a Degrease the mating surfaces of ring gear
157 196 Nm {16 20 kgm} (10) and case (32).
a If repair was made, install drain part (35). a Do not stick gasket sealant to the mating sur-
faces of ring gear (10) and case (32).
3 Mounting bolt:
a Install the washer.
157 196 Nm {16 20 kgm}
PC200/220(LC)-7 30-48-1
(12)
a For PC200-7 9. No. 1 carrier assembly

When installing the ring gear, set its counter 1) Assemble the No. 1 carrier assembly
mark (part "d") and the projection (part "c") of according to the following procedure.
the case flange as shown below. i) Press fit shaft (5) to the carrier in the
direction of the arrow until the snap ring
groove is seen.
a Press fitting force (Reference value):
11.2 25.8 kN {1,140 2,630 kg}
ii) Install snap ring (4), and then push it
back until it is fitted to face P of the car-
rier. Take care not to push it back too
much.
iii) Install plate (9), and then install thrust

washers (8), bearing (7), and gear (6).
iv) Install snap rings (4) to shaft (5).
a PC200-7
a For PC220-7
When installing the ring gear (10), match
counter mark (part "d") on its top to the projec-
tion (part "c") on the periphery of case (32).
30-48-2 PC200/220(LC)-7
(12)
a PC220-7 a PC220-7
2) Install No. 1 carrier assembly (3). a PC220-7

a "p": Press fitting plate
10. No. 1 sun gear assembly

Install No. 1 sun gear (2).
a Take care not to install the No. 1 sun gear

upside down.
a Install the No. 1 sun gear with the tooth side
(part "e") down.
PC200/220(LC)-7 30-48-3
(12)
11. Swing motor assembly a PC220-7

1) Fit the O-ring to ring gear (10) and install
swing motor assembly (1).
a Degrease the mating surfaces of swing mo-
tor assembly (1) and ring gear (10).
a Do not stick gasket sealant to the mating sur-
faces of swing motor assembly (1) and ring
gear (10).

a Set motor port (part "f") and projection (part
"c") of the case as shown in the figure.
3 Mounting bolt:
a "c" and "d": See 8. Ring gear.
59 74 Nm {6 7 kgm}
a PC200-7
2) Install oil filler (42) and oil level gauge (41)
(which are newly prepared).
3) Install oil supply tube (43) (which is newly
prepared).
a Use the cap again.
12. Refilling with oil

Tighten the drain plug and add engine oil
through the oil filler to the specified level.
5 Swing machinery case (after repair):

Approx. 7.1 l (PC200-7)
Approx. 8.2 l (PC220-7)
a PC200-7
30-48-4 PC200/220(LC)-7
(12)
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND

SWING MACHINERY ASSEMBLY
PC200-7 Serial No.: 203891 and up DISASSEMBLY
PC220-7 Serial No.: 60354 and up
1. Draining oil
SPECIAL TOOLS Loosen the drain plug and drain the oil from the
swing machinery case.
New/Remodel
5
Necessity
Sketch
Swing machinery case:
Qty
Approx. 7.1 l (PC200-7)
Approx. 8.2 l (PC220-7)
796T-426-1410 2. Swing motor assembly

Push tool t 1 N Q
(PC200-7) 1) Set the swing motor and swing machinery
1
790-201-2860 assembly on block [1].
Push tool t 1 2) Remove the 6 mounting bolts and lift off
(PC220-7)
G 2 796-426-1120 Push tool swing motor assembly (1).
t 1
796T-426-1130 Plate t 1 Q 4 Swing motor assembly: 70 kg
3 790-101-5241 Grip t 1
01010-61240 Bolt t 1
a If shaft (28) is removed from case assembly (25),

the durability of the bearings cannot be assured.
Accordingly, do not reuse bearings (27) and (31)
and oil seal (29). Prepare new ones.
PC200-7
Bearing (27) .......20Y-26-22340
Bearing (31) .......20Y-26-22330
Oil seal (29)........20Y-26-22420
PC220-7
Bearing (27) .......206-26-73160
Bearing (31) .......206-26-73150
Oil seal (29)........20Y-26-22420 3. No. 1 sun gear
PC200/220(LC)-7 30-48-5
(12)
4. No. 1 carrier assembly 5. Ring gear

1) Remove No. 1 carrier assembly (3). Remove the mounting bolts and ring gear (10).
2) Disassemble No. 1 carrier assembly accord- 6. No. 2 sun gear

ing to the following procedure. Remove No. 2 sun gear (11).
i) Remove snap rings (4), and then
remove thrust washers (8), gear (6),
bearing (7), and plate (9).
ii) Using the press, remove shaft (5).
a Press fitting force for installing shaft
(Reference value):
11.2 25.8 kN {1,140 2,630 kg}
a PC200-7
7. Bolts
Remove holder mounting bolts (12).

a PC220-7
30-48-6 PC200/220(LC)-7
(12)
2) Disassemble the No. 2 carrier assembly 9. Shaft and case assembly

according to the following procedure. 1) Remove mounting bolts (23).
i) Push in pin (14) and drive shaft (15) out 2) Set the shaft and case assembly on the
of carrier (16). press. Using push tool [2], remove shaft
a After removing the shaft, remove pin assembly (24) from case assembly (25).
(14).
iii) Remove plate (21).
a PC200-7
3) Disassemble the shaft assembly according

to the following procedure.
i) Using push tool [3], remove cover
assembly (26) and bearing (27) from
shaft (28).
ii) Remove oil seal (29) from cover (30).
a PC220-7
PC200/220(LC)-7 30-48-7
(12)
4) Remove spacer (33) and O-ring (34) from ASSEMBLY

shaft (28).
a Clean the all parts and check them for dirt or
a Perform this step for only PC220-7. damage. Coat their sliding surfaces with engine
oil before installing.
a Do not reuse the removed bearings and oil seals.
1. Bearing
Using push tool [5], press fit bearing (27) to case
(32).
a Use new bearing (27).
10. Bearing
Using the push tool, remove bearing (31) from
case (32).
2. Cover assembly
1) Set oil seal (29) on cover (30) horizontally.
2) Using push tool G3, press fit oil seal (29) to
cover (30).
2 Periphery of oil seal:

a Use new oil seal (29).
a Take care that the gasket sealant (LG-6)

will not stick to the oil seal lip.
a When not using push tool G3, use anoth-
er push tool to push part A around the oil
seal evenly.
a Take care that oil seal (29) will not slant.
30-48-8 PC200/220(LC)-7
(12)
3. Shaft and case assembly

a Perform steps 1) and 2) for only PC220-7.
1) Install O-ring (34) to spacer (33).
2) Using push tool [4], press fit spacer (33) to
shaft (28).
a Take care that O-ring (34) will not be caught.
3) Set case assembly (25) to shaft (28).

a Take care not to damage the oil seal.
3) Install cover assembly (26) to case (32) and

tighten mounting bolts (23).
2 Cover fitting face:

a Match the drain ports.

a When applying the gasket sealant, take
care not to project it into the drain port.
3 Mounting bolt: 4) Using push tools G1 and [8], hit the shaft so
2 Oil seal lip: Grease (G2-LI)

66.2 7.4 Nm {6.75 0.75 kgm} that it will not fall down.
a Loosen sling [9].
PC200/220(LC)-7 30-48-9
(12)
5) Set the assembly on the press. 4. Bearing

6) Using push tools G1, [8] and [10], press fit Using tool G2, press fit bearing (31).
the bearing inner race. a Use new bearing (31).
a Press fitting force: Several ton a Press the bearing inner race and outer race
a Set push tool [10] so that case assembly (25) simultaneously. Do not press only the inner
will not slant largely. race.
a Hit the flange of case assembly (25) lightly a Press fitting force:
and frequently to correct its slant. Inner race side:
a Set case assembly (25) horizontally so that 9.4 26.6 kN {960 2,710 kg}
oil seal lip contact face B of shaft (28) will be Outer race side: 0 8.9 kN {0 910 kg}
at the center of oil seal (29). a After press fitting the bearing, check that the
case rotates smoothly.

1) Assemble the No. 2 carrier assembly
according to the following procedure.
a There is caulking mark (h) made when
the pin was inserted around the side
hole of carrier (16) (See v) ) and the in-
side wall of the hole is swelled at that
mark. Flatten the swelled part in ad-
vance.
i) Install plate (21) to carrier (16).
ii) Install bearing (19) to gear (18) and fit
(20), and then set the gear assembly to
carrier (16).
30-48-10 PC200/220(LC)-7
(12)
a PC200-7
a PC220-7
a Check that all the gears turn smoothly.

iii) Aligning the pin holes of shaft (15) and 6. Bolt
2 Threads of mounting bolt:

carrier, lightly hit the shaft with a plastic Tighten bolt (12).
hammer to install.
3 Mounting bolt:
a When installing the shaft, revolve the Adhesive (LT-2)
planetary gear and take care not to dam-
age the thrust washers. 157 196 Nm {16 20 kgm}
iv) Insert pin (14).
a When inserting the pin, do not set the 3
claws (parts "a") on the periphery to the
thin part of the carrier (part "b").
The thin part may be on the opposite
side, however. Check the thin part and
avoid setting the claws to it.
v) After inserting the pin, caulk 2 parts (h)
around the pin hole of the carrier.
PC200/220(LC)-7 30-48-11
(12)
7. No. 2 sun gear a For PC200-7

1) Install No. 2 sun gear (11). When installing the ring gear, set its counter
2) Install the O-ring to case (32). mark (part "d") and the projection (part "c") of
the case flange as shown below.
8. Ring gear
Using eyebolts (M10 x 1.5), install ring gear (10)
as explained below.
a Degrease the mating surfaces of ring gear
(10) and case (32).
faces of ring gear (10) and case (32).
3 Mounting bolt:
a Install the washer.
157 196 Nm {16 20 kgm}
a For PC220-7
When installing the ring gear (10), match
counter mark (part "d") on its top to the projec-
tion (part "c") on the periphery of case (32).
30-48-12 PC200/220(LC)-7
(12)
9. No. 1 carrier assembly a PC220-7

1) Assemble the No. 1 carrier assembly
according to the following procedure.
i) Press fit shaft (5) to the carrier in the
direction of the arrow until the snap ring
groove is seen.
a Press fitting force (Reference value):
11.2 25.8 kN {1,140 2,630 kg}
ii) Install snap ring (4), and then push it
back until it is fitted to face P of the car-
rier. Take care not to push it back too
much.
iii) Install plate (9), and then install thrust

washers (8), bearing (7), and gear (6).
iv) Install snap rings (4) to shaft (5).
a PC200-7 10. No. 1 sun gear assembly

Install No. 1 sun gear (2).
a Take care not to install the No. 1 sun gear

upside down.
PC200/220(LC)-7 30-48-13
(12)
a Install the No. 1 sun gear with the tooth side

(part "e") down.
a PC200-7
a PC200-7
a PC220-7
a "p": Press fitting plate
a PC220-7
11. Swing motor assembly

Fit the O-ring to ring gear (10) and install swing
motor assembly (1).
a Degrease the mating surfaces of swing mo-
tor assembly (1) and ring gear (10).
faces of swing motor assembly (1) and ring
gear (10).

a Set motor ports (part "f") and projection (part
"c") of the case as shown in the figure.
a "c" and "d": See 8. Ring gear. 12. Refilling with oil
3 Mounting bolt:
Tighten the drain plug and add engine oil
through the oil filler to the specified level.
59 74 Nm {6 7 kgm}
5 Swing machinery case (after repair):
Approx. 7.1 l (PC200-7)
Approx. 8.2 l (PC220-7)
30-48-14 PC200/220(LC)-7
(12)
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER

ASSEMBLY ASSEMBLY
This section deals with only precautions to be Carrier roller cover mounting bolt
followed when reassembling the carrier roller
assembly. Carrier roller cover mounting bolt:
SPECIAL TOOLS 44.12 - 53.93 Nm (4.5 - 5.5 kgm)
Part
Carrier roller
Name Check the amount of air leakage from the
Push tool seal with tool K by applying the standard
790-101-5001 1
kit pressure to the oil filler port.
790-101-5081 Plate Check that the gauge needle does not go
K 790-101-5021 Grip down, when the below standard pressure
01010-50816 Bolt is applied for 10 seconds.
790-434-1660 Installer 1 Standard pressure: 0.1 Mpa (1 kg/cm)
790-101-1000 Oil pump 1
ASSEMBLY
Floating seal
Before installing a floating seal, com-
pletely degrease both contact surfaces of
the O-ring and the floating seal (hatched
area in the illustration). Furthermore, take
care so that no dust will stick to the con-
tact surface of the floating seal.
After inserting the floating seal, check that
inclination of the seal is less than 1 mm Fill the carrier roller assembly with oil,
and that protrusion a of the seal remains using tool K, and screw in the plug.
within the range of 9 - 11 mm.
Carrier roller: 75 - 85 cc (E030-CD)
Carrier roller plug:

30.89 - 37.75 Nm
(3.15 - 3.85 kgm)
PC200/220(LC)-7 30-49
c
DISASSEMBLY AND ASSEMBLY TRACK ROLLER ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER

ASSEMBLY ASSEMBLY
This chapter deals with only precautions to be
followed when reassembling the TRACK
Roller Assembly.
SPECIAL TOOLS
Part
Name
Push tool
790-101-5201
kit
1
790-101-5221 Grip
01010-51225 Bolt
L
790-101-5261 Plate
790-434-1640 Installer 1
790-101-1000 Oil pump 1
790-331-1110 Wrench 1
ASSEMBLY
Floating seal
Before installing a floating seal, com-
the O-ring and the floating seal (hatched
After inserting the floating seal, check that
inclination of the seal is less than 1 mm
and that protrusion a of the seal remains
Plug
Track roller oil: 190 - 200 cc (EO30-CD)
Plug: 10 - 20 Nm (1 - 2 kgm)
30-50 PC200/220(LC)-7
c
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY

SPECIAL TOOLS 3. Detach idler (4) from shaft (5) and support
assembly (7).
Mark Part No.
Part
Necessity Qty Distinction* Sketch The idler contains 80 cc of oil. Drain the
Name
oil at this stage of disassembly. Take care
Push tool and spread a cloth on the floor to prevent
790-101-5201
kit
1
smearing the floor with flushing oil.
790-101-5221 Grip
H 01010-51225 Bolt 4. Remove floating seal (6) on the opposite side
790-101-5271 Plate from idler (4), shaft (5) and support assembly
790-434-1630 Installer 1 (7).
790-101-1000 Oil pump 1
DISASSEMBLY
5. Remove dowel pin (8) to detach support (7)

from shaft (5).
6. Remove bushings (9) and (10) from idler (4).
1. Remove dowel pin (1) and then support (2).
2. Remove floating seal (3) from support (2) and

idler (4).
PC200/220(LC)-7 30-51
c
12
ASSEMBLY After inserting the floating seal, check that

inclination of the seal is Max. 1 mm and
1. Press fit bushing (9) and (10) to idler (4). that protrusion a of the seal remains
2. Fit O-ring and install support (7) to shaft (5)

with dowel pin (8).
4. Assemble shaft (5) and support (7) assembly

to idler (4).
3. Using tool H, install floating seal (6) to idler
(4), shaft (5) and support (7) assembly.
Floating seal
Before installing the floating seal, com-
an O-ring and the floating seal (hatched
30-52
(11)
12
5. Using tool H, install floating seal (3) to idler 6. Install O-ring, then install support (2) with
(4) and support (2). dowel pin (1).
7. Add oil and tighten plug.
Oil: Approx. 80 cc (SAE30)
Plug: 205.8 49 Nm {21 5 kgm}
Coat the sliding surface of the floating seal

with oil, and be careful not to let any dirt or
dust get stuck to it.
Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
PC200/220(LC)-7 30-53
c
DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING

ASSEMBLY ASSEMBLY
SPECIAL TOOLS 1. Remove piston assembly (2) from recoil
spring assembly (1).
Mark Part No. Part Name Necessity Qty Distinction* Sketch
790-600-2001 Compressor (A) 1 2. Disassembly of recoil spring assembly
or
1) Set recoil spring assembly (1) to tool J1.
791-685-8006 Compressor (B) 1
790-201-2780 Spacer 1
The recoil spring is under large
1 791-635-3160 Extension 1
installed load, so be very sure to set
Cylinder
the tool properly.
790-101-1600 1
J (686 kN - 70 T) Failure to do this is dangerous.
790-101-1102 Pump 1
Installed load of spring: 108.8 kN
791-640-2180 Guide bolt 1 N
{11,100 kg}
790-201-1500 Push tool kit 1
790-201-1620 Plate 1
2
790-101-5021 Grip 1
01010-50816 Bolt 1
DISASSEMBLY
2) Apply hydraulic pressure slowly to com-

press spring and remove lock plate (3).
Then remove nut (4).
Compress the spring to a point where
the nut becomes loose.
Release the hydraulic pressure slowly
and release the tension of the spring.
Free length of spring: 558 mm
3) Remove yoke (6), cylinder (7), and dust
seal (8) from spring (5).
3. Dissassembly of piston assembly

1) Remove lock plate (10) from piston (9),
then remove valve (11).
2) Remove snap ring (12), then remove U-
packing (13) and ring (14).
30-54 PC200/220(LC)-7
c
DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY
12
ASSEMBLY 2. Assembly of recoil spring assembly

1) Using tool J2, install dust seal (8) to cylin-
der (7).
2) Assemble cylinder (7) and yoke (6) to

spring (5), and set in tool J1.
Sliding portion of cylinder:
Grease (G2-L1)
1. Assembly of piston assembly

1) Assemble ring (14) and U-packing (13) to
piston (9) and secure with snap ring (12).
2) Tighten valve (11) temporarily, and secure
with lock plate (10).
PC200/220(LC)-7 30-55
c
DISASSEMBLY AND ASSEMBLY SPROCKET
12
REMOVAL AND
INSTALLATION OF
SPROCKET
3) Apply hydraulic pressure slowly to com- REMOVAL
press the spring and tighten nut (4) so
that the installed length of the spring is 1. Remove track shoe assembly. For details, see
dimension "a", then secure it with lock TRACK SHOE ASSEMBLY, REMOVAL.
plate (3).
Installed length "a" of spring: 2. Swing work equipment 90, push up chassis
437 mm with work equipment and place block b
between track frame and track shoe.
3. Lift off sprocket (1).
Sprocket: 40 kg
4) Remove recoil spring assembly (1) from

tool J1.
3. Assemble piston assembly (2) to recoil spring

assembly (1).
Sliding portion of wear ring:
Grease (G2-L1)
Install the piston assembly so the valve
installing position is on the outside. INSTALLATION
Fill the inside of the cylinder with 300 cc
of grease (G2-L1), then bleed the air and
check that grease comes out of the grease
hole.
Thread of sprocket mounting bolt:
Sprocket mounting bolt:

441 - 490 Nm {45 - 50 kgm}
30-56 PC200/220(LC)-7
c
DISASSEMBLY AND ASSEMBLY TRACK SHOE ASSEMBLY
12
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY

SPECIAL TOOLS 3. Using tool M, pull out master pin (2).

Remover
791-630-3000 & 1
Installer
M Cylinder
790-101-1300 1
(980 kN - 100 T)
790-101-1102 Pump 1
REMOVAL AND EXPANSION OF

TRACK SHOE ASSEMBLY
(IRON)
4. Remove tool M and move the machine for-
1. Stop the machine at a point where the master
ward so the position of temporary pin c is at
pin is midway between the idler and carrier
roller, and where there is space to lay out the the front of the idler. Place block b in posi-
track assembly on the ground. tion.
2. Lower work equipment, then loosen lubrica- 5. Remove temporary pin c, and remove the
tor (1), and relieve track tension. dust seal. Drive the machine in reverse to lay
out the track (3).
The adjustment cylinder is under extremely
high pressure. Never loosen the lubricator
more than one turn. If the grease does not
come out, move the machine backwards
and forwards.
PC200/220(LC)-7 30-57
c
12
INSTALLATION

Track Shoe Tension section in the TEST-
ING AND ADJUSTING chapter of this
manual.
Installation procedures for shoe bolts and
nuts
1) Turn the R side of shoe nut (1) to the
link seat surface, and assemble the
shoes in a way that both seat surfaces
are in close contact with each other.
If the shoe bolts are installed in
reverse, nut corners will interfere with
the link seat surface and raise the nut,
which can cause the bolt to loosen.
2) Tighten the shoe bolts to the follow-
ing torques.
1st step (initial torque):
490 50 Nm (50 5 kgm)
2nd step (finishing torque):
490 - 610 Nm (50 - 62 kgm)
(For swamp shoes)
Retightening angle for 2nd step:
120 10
Retighten the shoe bolts after
checking that the mating surfaces
are in close contact.
30-58 PC200/220(LC)-7
c
12
Press-fit the master pin, using tool M, in

such a way that the master pin protrusion
amount is the following dimension a.
Master pin protrusion amount a:
2.5 1 mm
3. Remove road liners (2).
4. Place block B against the shoe assembly.
5. Using tool M and dumb pin C, pull out mas-

ter pin (3).
Before installing a dust seal, coat its con-

tact surface with the bushing with grease
(G2-LI).
If you have road liners (rubber pad type shoe
plates), replace the shoe plates with new ones
immediately when it is discovered that the
rubber is worn out or broken. Otherwise, the
shoe bolt heads will be damaged. Once the
bolt heads are crushed, it becomes extremely
difficult to remove them.
REMOVAL AND EXPANSION OF 6. Take tool M away, move the machine forward
ROAD LINERS and pull out with dumb pin (2).
1. Stop the machine so the master pin is right 7. Remove the dust seal and expand track shoe
above the idler and the track shoe assembly assembly (4), while moving the machine for-
can be expanded to the front and to the rear. ward.
2. Lower the work equipment to the ground, and

unscrew lubricator (1) to loosen track shoe
tension.
The pressure inside the adjusting cylin-

der is kept quite high. Do not attempt to
unscrew lubricator (1) by more than one
turn. If grease inside oozes out poorly,
move the machine back and forth.
PC200/220(LC)-7 30-59
c
12
INSTALLATION OF ROAD LINERS

Road liner mounting bolt:
490 - 608 Nm (50.0 - 62 kgm)
Track Shoe Tension section in the TEST-
ING AND ADJUSTING chapter of this
manual. Press-fit the master pin, using tool M, so
Installation procedures for shoe bolts and the master pin protrusion amount is the
nuts following dimension a.
1) Turn the R side of shoe nut (1) to the Master pin protrusion amount a:
link seat surface, and assemble the 2.5 1 mm
shoes so that both seat surfaces are in
close contact with each other.
If the shoe bolts are installed in
reverse, nut corners will interfere
with the link seat surface and
raise the nut, which can cause the
bolt to loosen.
2) Tighten the shoe bolts to the follow-
ing torques.
1st step (initial torque):
490 50 Nm (50 5 kgm)
Retightening angle for 2nd step:
120 10
Retighten the shoe bolts after
checking that the mating surfaces
are in close contact.
Before installing a dust seal, coat its con-

tact surface with the bushing with grease
(G2-LI).
30-60 PC200/220(LC)-7
c
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
12
REMOVAL AND INSTALLATION OF SWING CIRCLE

ASSEMBLY ASSEMBLY
REMOVAL
1. Remove revolving frame assembly. For Swing circle mounting bolt:

details, see REMOVAL OF REVOLVING FRAME 1st pass:
ASSEMBLY. Tighten to 191.2 19.6 Nm
{19.5 2 kgm}
2. Remove 36 mounting bolts (1) to remove the 2nd pass:
swing circle assembly (2).
1) Using the angle of the bolt head as the
base, make start marks on the swing
3. Lift off swing circle assembly (2). circle and socket.
2) Make an end mark at a point (on swing
circle) 48 5 from the start mark.
Swing circle assembly: 270 kg 3) Tighten so that the start mark on the
socket is aligned with the end mark on
the swing circle at the 48 5 position.
Set the soft zone S mark on the inside ring

of the inner race facing the right side as
shown in the diagram. Then install to the
track frame.
Swing circle:
Grease (G2-L1) 14.6 l
INSTALLATION
Thread of swing circle mounting bolt:

30-61
(12)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME ASSEMBLY
REMOVAL AND INSTALLATION OF REVOLVING FRAME

ASSEMBLY ASSEMBLY
REMOVAL
Extend the arm and bucket fully, then lower

the work equipment to the ground and move
the safety lock lever to the LOCK position.
1. Disassemble the work equipment assembly,

refer to the Disassembling Work Equipment
Assembly section in this manual.
2. Remove the counter weight assembly, refer to

the Removal of Counterweight Assembly sec-
tion in this manual.
6. Remove plate (5), air intake hose (6) and fan
3. Disconnect four boom cylinder hoses (1). guard (7).
Plug the hose to stop oil flow-out.
Remove other parts which may interfere
with a sling, when removing the revolving
frame.
4. Sling boom cylinder assembly (2).
7. Disconnect the six hoses above the swivel

joint assembly at the swivel joint side.
(8): Center swivel joint (D port) -
Swing motor (T port)
(9): Center swivel joint (E port) -
Solenoid valve
(10): Center swivel joint (B port) -
Travel control valve, left (A2 port)
Travel control valve, right (B5 port)
(12): Center swivel joint (A port) -
Travel control valve, left (B2 port)
(13): Center swivel joint (C port) -
5. Remove plate (3) and pin (4) and lift off boom Travel control valve, right (A5 port)
cylinder assembly (2) to remove it.
Remove the boom cylinder assembly on
the opposite side in the same manner.
4 Boom cylinder assembly: 180 kg
30-62
(12)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME ASSEMBLY
12
8. Pull out pin (14) to detach jam plate (15) from INSTALLATION
the swivel joint.
Air intake hose clamp screw:

5.4 - 6.4 Nm (0.55 - 0.65 kgm)
Swivel circle mating surface:

Threads of revolving frame mounting
bolt: Adhesive compound (LT-2)
Revolving frame mounting bolt

9. Remove the 32 revolving frame mounting
1st step: 294.2 29.4 Nm (30 3 kgm)
bolts and remove revolving frame assembly
2nd step: Retightening by 60 or
(16) by lifting it off.
588 - 677 Nm (60 - 69 kgm)
Attain fore and aft balance and right and
left balance of the revolving frame assem- Refilling hydraulic oil
bly without two mounting bolts at the Refill hydraulic oil through the oil filler port to
front and rear being removed and using a the specified level, and let the oil circulate in
lever block. Only when the right balance the hydraulic system by starting the engine.
is obtained, remove the remaining two Then check the level again.
bolts. Air bleeding
Bleed air from the travel motor, refer to the
When removing the revolving frame Air Bleeding of Various Parts section in the
assembly, take care so that it does not TESTING AND ADJUSTING chapter of this
hit the swivel joint assembly. manual.
Revolving frame assembly
Revolving frame only

Assembly
(Reference value)
PC200-7 5,050 kg 1,729 kg
PC200/220(LC)-7 30-63
c
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT ASSEMBLY
12
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT

ASSEMBLY ASSEMBLY
REMOVAL (10): Center swivel joint (E port) -
Solenoid valve
Release the remaining pressure in the (11): Center swivel joint (B port) -
hydraulic circuit. For details, see TESTING Travel control valve, left (A2 port)
AND ADJUSTING, release of remaining (12): Center swivel joint (D port) -
pressure in hydraulic circuit. Travel control valve, right (B5 port)
Mark all the piping with tags to prevent mis-
Travel control valve, left (B2 port)
takes in the mounting position when install-
ing. (14): Center swivel joint (C port) -
Travel control valve, right (A5 port)
1. Disconnect six hoses (1) through (6) from the
travel motor center swivel joint. 3. Pull out pin (15) on the side of center swivel
joint and remove the jam plate from the cen-
(1): Center swivel joint (T port) -
ter swivel joint.
Travel motor, left (T port)
(2): Center swivel joint (T port) -
Travel motor, right (T port)
(3): Center swivel joint (B port) -
Travel motor, left (PA port)
Travel motor, right (PB port)
Travel motor, left (PB port)
(6): Center swivel joint (C port) -
Travel motor, right (PA port)
4. Remove four mounting bolts (16).
2. Disconnect eight hoses (7) through (14).

Travel motor, left (P port)
Travel motor, right (P port)
Swing motor (T port)
30-64 PC200/220(LC)-7
c
12
5. Remove center swivel joint assembly (17).
Center swivel joint assembly: 40 kg
INSTALLATION
Install the center swivel joint facing in the

direction shown in the diagram.
(The diagram shows the machine as seen
from above)
Refilling with oil (hydraulic tank)

Add oil through the oil filter to the speci-
fied level. Run the engine to circulate the
oil through the system. Then check the oil
level again.
Bleeding air
Bleed the air from the travel motor. For
details see TESTING AND ADJUSTING,
Air Bleeding of Various Parts.
PC200/220(LC)-7 30-65
c
12
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT

ASSEMBLY ASSEMBLY
SPECIAL TOOLS 3. Using tool E. pull out swivel rotor (4) and ring
(3) from swivel shaft (5).
790-101-2501 Push puller

1
4. Remove seal (6) from swivel shaft (5).
790-101-2510 Block 1 5. Remove O-ring (7) and slipper seal (8) from
790-101-2520 Screw 1 swivel rotor (4).
791-112-1180 Nut 1
E
790-101-2540 Washer 1
790-101-2630 Leg 2
790-101-2570 Plate 4
790-101-2560 Nut 2
790-101-2650 Adapter 2
DISASSEMBLY
ASSEMBLY
1. Assemble slipper seal (8) and O-ring (7) to

swivel rotor (4).
2. Assemble seal (6) in swivel shaft (5).
3. Set swivel shaft (5) to block, then using push

tool, tap swivel rotor (4) with a plastic ham-
mer to install.
Contact surface of rotor, shaft:
Grease (G2-L1)
When installing the rotor, be extremely
careful not to damage the slipper seal and
the O-ring.
4. Install ring (3) and secure with snap ring (2).
5. Fit O-ring and install cover (1).
Mounting bolt: 31.4 2.9 Nm

{3.2 0.3 kgm)
2. Remove snap ring (2).
30-66 PC200/220(LC)-7
c
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
12
REMOVAL AND INSTALLATION OF HYDRAULIC TANK

ASSEMBLY ASSEMBLY
REMOVAL 6. Remove hydraulic tank side cover (8).
Remove two cover (8) mounting bolts at
1. Drain oil from hydraulic tank the front after removing cover (9) and (10).
Hydraulic oil: 240 l
3. Remove engine hood (1), hydraulic pump

upper cover (2) and control valve cover (3).
4. Remove cover mounting frame (4) and engine

partition plate (5).
7. Disconnect the seven hoses.

(11): Hydraulic oil return hose
(12): Swing motor drain hose
(13): Pump drain hose
(14): PPC drain hose
(15): Solenoid valve drain hose
(16): Main valve drain hose
(17): Pump suction hose
Disconnect suction hose (17) after discon-
necting the sump suction tube.
5. Remove engine partition plate (6) and parti- Attach a tag to the hoses for identification.
tion bracket mounting bolts (7) on the hydrau-
Protect the fitting and the tapered seal
lic tank side.
portion of the elbow with a sleeve nut so
that they may not be damaged.
8. Remove hose clamp (18).
PC200/220(LC)-7 30-67
c
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
12
9. Sling the hydraulic tank assembly and

remove six mounting bolts (19).
Install the hose clamp and tighten the

below.
10. Lift off hydraulic tank assembly (20) to
remove it.
Hydraulic tank assembly: 130 kg
Hose clamp screw:

245.2 308.9 Nm
{25 31.5 kgm}
INSTALLATION Refilling with oil (hydraulic tank)

Add oil through the oil filler to the speci-
Install in reverse order of removal. fied level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
Hydraulic tank drain plug:
58.8 78.5 Nm Hydraulic tank: Approx. 240 l
{6.0 8.0 kgm}
Bleeding air
Bleed the air.
After tightening the suction hose clamp For details, see TESTING AND ADJUST-
screw, check that the screw is located ING. Air Bleeding of Various Parts.
within the range shown in the diagram.
Hose clamp screw:

8.8 0.5 Nm {0.9 0.05 kgm}
30-68
(12)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY
12
REMOVAL AND INSTALLATION OF CONTROL VALVE

ASSEMBLY ASSEMBLY
REMOVAL (9): Swing LS separator valve hose
(10): Left swing hose (Hose band, red)
Lower the work equipment to the ground for
(11): Travel right front and reverse hose
safety and stop the engine. Unscrew the oil
(Hose band, blue)
filler cap on the hydraulic tank slowly to
release pressure inside the tank. Then move (12): Arm dump hose (Hose band, yellow)
the lock lever to the LOCK position.
Attach an identification tag to each piping to

avoid a mistake in the position of installation
later.
1. Open up engine hood (1).
2. Remove control valve upper cover (2).
5. Disconnect the seven PPC hoses at right.

(13): PPC hoses from the top to bottom
Bucket digging (Hose band, white)
Travel left front and reverse
(Hose band, red)
Boom lower (Hose band, brown)
Right swing
Travel right front (Hose band, green)
Arm digging (Hose band, blue)
3. Remove engine partition cover (3) and control (14): Divide/merge valve hose (Hose band,
valve partition cover (4). yellow blue)
4. Disconnect the eight PPC hoses at left.

(5): Relief valve hose
(6): Bucket dump hose (Hose band, black)
(7): Travel left front and reverse hose
(8): Boom raise hose (Hose band, green)
30-69
(11)
12
6. Disconnect four boom hoses (15). (21): From top to bottom

B1 port hose (Bucket bottom side)
7. Remove boom tube mounting clamps (16) B2 port hose (Swivel joint A port)
and (17). B3 port tube (Boom head side)
B4 port hose (Swing motor MB port)
B5 port hose (Swivel joint B port)
B6 port hose (Arm bottom side)
(22): Drain hose (TS port)
9. Disconnect hose (23) between the control

valve and the swing motor as well as hose
(24) between the control valve and the sole-
noid.
8. Disconnect the 13 control valve hoses and

two tubes.
(18): PLS1 Hose
(19): PLS2 hose (hose band, red)
(20): From top to bottom
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)
30-70 PC200/220(LC)-7
c
12
10. Disconnect the seven hoses.

(25): PP1 port hose (Rear pump) (Hose
band, yellow)
(26): PP2 port hose (Front pump)
(27): PEPC port hose (Pump)
(28): P1 port hose (Solenoid)
(29): PPS2 port hose (Front pump)
(30): PST port hose (Solenoid) (Hose
band, brown)
(31): T port hose (Oil cooler)
12. Remove the three mounting bolts for control

valve assembly (34) and lift it off for removal.
Control Valve Assembly: 220 kg
11. Disconnect the control valve wiring connec-

tors at two points.
(32): CAN-A51 (Front pump pressure sen-
sor)
INSTALLATION

Add oil through the oil filler to the speci-
fied level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
Bleeding air
(33): CN-A52 (Rear pump pressure sensor) Bleed the air from the circuit between the
valve and the hydraulic cylinder.
For details, see TESTING AND ADJUST-
ING, Air Bleeding of Various Parts.
PC200/220(LC)-7 30-71
c
12
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE

ASSEMBLY ASSEMBLY
This chapter deals with only precautions to be Procedures for replacing pressure compen-
followed when disassembling and reassem- sation valve seal
bling the control valve assembly.
1. Remove the seal from pressure compensation
SPECIAL TOOLS valve.
Clean the pressure compensation valve
Distinc- thoroughly, and then assemble the seal,
Mark Part No. Part Name Necessity Qty Sketch
tion*
using a tool, as indicated in the diagram.
796-946-1310 Guide
1
(For 723-46-40100)
2. Fit an O-ring to piston (1).
796-946-1610 Guide
1
(For 723-46-41100)
3. Set tool P1 to piston (1) and push it in slowly
796-946-1810 Guide
1 1 by hand so that seal (2) may spread out
(For 723-46-43100 & 723-46-43400)
evenly.
796-946-2210 Guide
1 The seal may be also fitted by pushing it
(For 723-46-45100)
down to the flat surface of the tool and
796-946-1910 Guide
1 then pushing it in with the tool fitted to
(For 723-46-46101 & 723-46-46300)
the piston.
796-946-1320 Guide
1
(For 723-46-40100)
796-946-1620 Guide
1
(For 723-46-41100)
796-946-1520 Guide
1
(For 723-46-42700)
2
796-946-1820 Guide
P 1
(For 723-46-43100 & 723-46-43400)
796-946-2220 Guide
1
(For 723-46-45100)
796-946-1920 Guide
1
(For 723-46-46101 & 723-46-46300)
796-946-1330 Sleeve
1
(For 723-46-40100)
796-946-1630 Sleeve
1
(For 723-46-41100) 4. Likewise, set tool P2 to piston (1) in the same
796-946-1430 Sleeve direction and push it slowly by hand so that
1
(For 723-46-42700) another seal (3) may be spread out evenly.
3
796-946-1830 Sleeve The seal may be also fitted by pushing it
1
(For 723-46-43100 & 723-46-43400) down to the flat surface of the tool and
796-946-2230 Sleeve then pushing it in with the tool fitted to
1
(For 723-46-45100) the piston.
796-946-1930 Sleeve
1
(For 723-46-46101 & 723-46-46300)
30-72 PC200/220(LC)-7
c
12
5. Keep compensation tool P3 fitted to piston (1) ASSEMBLY

for about one minute so that seal (2) and (3) Coat the sliding surface with engine oil and
will become well adapted. then reassemble the control valve assembly.
Check that there is no protrusion or cut on Upper and lower control valve covers
the seal.
Mating surfaces of upper and lower
control covers:
Sealant 242 or equivalent
Tighten the mounting bolts for the upper and
lower control covers in the sequence illus-
trated at right.
Mounting bolt for upper and lower

control covers:
156.9 - 176.5 Nm (16 - 18 kgm)
6. Assemble the piston in the sleeve.

If its found difficult to install the sleeve, do
not attempt to push it in forcibly, but try it
again after repeating the same process in
the Item 5. above and confirming the
seals are well adapted.
After the installation, push the piston by
hand and check that the piston reacts only
with spring force.
Merge-divider valve
Mating surfaces of merge-divider
valve: Sealant 242 or equivalent
Tighten the mounting bolts for the merge-
divider valve in the same sequence as that for
the control valve cover mounting bolts.
Merge-divider valve mounting bolt:

156.9 - 176.5 Nm (16 - 18 kgm)
A filter for the valve assembly is to be assem-

bled in the direction shown in the illustration
at right.
PC200/220(LC)-7 30-73
c
12
Tighten the boom lock valve mounting bolts

and the back pressure valve mounting bolts in
the same sequence as that for the control
valve cover mounting bolts.
Mounting bolts for boom lock valve

and back pressure valve:
58.8 - 73.6 Nm (6 - 7 kgm)
Pressure compensation valve

Install each pressure compensation valve,
paying attention to the counter mark that
was put when removing it.
Main relief valve assembly
After assembling the main relief valve assem-
bly in the control valve, refer to the section of
Inspection and Adjustment of Hydraulic Oil
Pressure in Hydraulic Circuit for Work Equip-
ment, Swing and Travel in the chapter, TEST-
ING AND ADJUSTING, in this manual.
30-74 PC200/220(LC)-7
c
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY
12
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP

ASSEMBLY ASSEMBLY
SPECIAL TOOLS 3. Sling engine hood (1).

D 796-460-1210 Oil stopper 1
REMOVAL
Disconnect the negative terminal (-) of the

battery before starting with the work.
Lower the work equipment to the ground
and stop the engine. Then loosen the oil
filler cap on the hydraulic tank slowly to
release pressure inside the tank.
Attach identification tags to all piping to avoid 4. Remove pin (2) and mounting bolt (3). Then
mistakes when installing. lift off the engine hood to remove it.
1. Remove hydraulic tank strainer and stop oil

flow-out using tool D.
If tool D is not used, remove the drain
plug and drain oil from the hydraulic tank
and piping.
5. Remove cover (3) and plate (4).
2. Drain oil from the damper case.
PC200/220(LC)-7 30-75
c
12
6. Remove covers (5) and (6). 9. Disconnect the following connectors at three
points.
7. Disconnect the following eight hoses. (16): A61 (Hydraulic oil temperature sen-
sor) (Color band, white)
(7): Front pump discharging port hose
(17): V21 (PC-EPC solenoid valve)
(8): Rear pump discharging port hose
(Color band, white)
(9): Pump pressure input port hose
(18): V22 (LS-EPC solenoid valve)
(10): Drain port hose (Color band, red)
(11): EPC source pressure port hose
(Color band, yellow) 10. Disconnect exhaust muffler drain tube (19).
(Color band, red)
(14): Suction port hose
11. Lift off hydraulic pump assembly (20) to

remove it.
Hydraulic pump assembly: 170 kg

8. Remove clamp (15).
30-76 PC200/220(LC)-7
c
12
INSTALLATION
Install in reverse order of removal. Refilling hydraulic oil (Damper case)

the specified level.
After tightening the hose clamp screw,
check that the screw is in the position
Damper hydraulic oil : Approx. 0.75 l
shown in the diagram at right.
Suction hose clamp screw: Refilling hydraulic oil (hydraulic tank)

8.8 0.5 Nm {0.9 0.05 kgm}
the specified level, and let the oil circulate in
the hydraulic system by starting the engine.
Then check the oil level again.
Hydraulic tank : Approx. 240 l
Air bleeding
Refer to the Air Bleeding of Various Parts sec-
in this manual.
Install the hose clamp and tighten the

below.
Hydraulic pump involute spline:

Anti-friction compound (LM-G)
Hydraulic pump case mating surface:
30-77
(12)
DISASSEMBLY AND ASSEMBLY OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
12
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC

PUMP INPUT SHAFT PUMP INPUT SHAFT
SPECIAL TOOLS INSTALLATION
Mark Part No. Part Name Necessity Qty Distinction* Sketch Install in reverse order of removal.
791-463-1141 Push tool 1
N
790-201-2740 Spacer 1
*Distinction between new and existing part. Oil seal lip portion: Grease (G2-LI)
REMOVAL Oil seal outer circumference:

Grease (G2-LI)
1. Remove the hydraulic pump assembly, refer-
Coat the oil seal outer circumference
ring to the section of Removing Hydraulic
thinly with grease.
Pump Assembly.
Press-fit oil seal (3), using tool N.
2. Remove snap ring (1) and then remove spacer
(2).
3. Pry off oil seal (3) with a screwdriver.
When attempting to pry off the seal, do

not damage the shaft.
30-78
2
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC

VALVE ASSEMBLY
PC200, 200LC-7 Serial No. 200001 202418 a When assembling piston (8), coat the piston
PC220, 220LC-7 Serial No. 60001 60239 outer periphery and body hole inner periph-
3 Plate (5) mounting bolt:

ery with grease.
a This section deals with only precautions to be fol-
2 Joint (4) sliding surface:

lowed when reassembling the PPC valve assem- 11.8 14.7 Nm {1.2 1.5 kgm}
bly for work equipment.
2 Body female screw portion:

Grease 2 4 cc (G2-LI)
Adhesive compound (LT-2)

a Coat the female screw body with Loctite at
two spots as shown in the diagram below.
Each spot is to be coated with a drop (ap-
3 Joint (4): 39 49 Nm {4 5 kgm}

prox. 0.02 g).
a Strictly follow the specified torque for the

joint.
2 Contact surfaces of piston (8) and

disc (2):
3 Nut (1):
Grease 0.3 0.8 cc (G2-LI)
98 127 Nm {10 13 kgm}

ASSEMBLY a After assembling the disc, refer to the "Ad-
Reassembling work equipment PPC valve reas- justment of work equipment and swing PPC
sembly valve" section of the TESTING AND AD-
a Install spring (11) so that the end surface of JUSTING chapter of this manual.
smaller end coil diameter (inner diameter)
will face the shim (12) side.
a Springs (10) in use differ in the number of
turns according to hydraulic ports as classi-
fied in the table below. Hence take care
when installing one.
Port location Spring free length
P1, P2 44.4 mm
P3, P4 42.4 mm
a The location of each port is stamped in the
2 Piston (8): Grease (G2-LI)

lower part of the valve body.
PC200/220(LC)-7 30-79
(12)
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC

VALVE ASSEMBLY
PC200, 200LC-7 Serial No. 202419 and up a When assembling piston (8), coat the piston
PC220, 220LC-7 Serial No. 60240 and up outer periphery and body hole inner periph-
3 Plates (5), (15) mounting bolt:

ery with grease.
a This section deals with only precautions to be fol-
2 Joint (4) sliding surface:

lowed when reassembling the PPC valve assem- 11.8 14.7 Nm {1.2 1.5 kgm}
bly for work equipment.
2 Body female screw portion:

Grease 2 4 cc (G2-LI)
Adhesive compound (LT-2)

a Coat the female screw body with Loctite at
two spots as shown in the diagram below.
Each spot is to be coated with a drop (ap-
3 Joint (4): 39 49 Nm {4 5 kgm}

prox. 0.02 g).
a Strictly follow the specified torque for the

joint.
2 Contact surfaces of piston (8) and

disc (2):
3 Nut (1): 69 88 Nm {7 9 kgm}

Grease 0.3 0.8 cc (G2-LI)
a After assembling the disc, refer to the "Ad-

ASSEMBLY justment of work equipment and swing PPC
Reassembling work equipment PPC valve reas- valve" section of the TESTING AND AD-
sembly JUSTING chapter of this manual.
a Install spring (11) so that the end surface of
smaller end coil diameter (inner diameter)
will face the shim (12) side.
a Springs (10) in use differ in the number of
turns according to hydraulic ports as classi-
fied in the table below. Hence take care
when installing one.
Port location Spring free length
P1, P2 44.4 mm
P3, P4 42.4 mm
a The location of each port is stamped in the
2 Piston (8): Grease (G2-LI)

lower part of the valve body.
30-79-1 PC200/220(LC)-7
(12)
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE

ASSEMBLY
7. Tighten each part to the following torque.
Plug (11): 6 11 Nm {0.6 1.1 kgm}
PC200, 200LC-7 Serial No. 200001 252873 Bolt (12): 3.9 4.9 Nm {0.4 0.5 kgm}
PC220, 220LC-7 Serial No. 60001 56436 (Apply LOCTITE #262.)
Screw (13): 7.8 9.8 Nm {0.8 1.0 kgm}
a This chapter deals only with precautions to be Plug (14): 4 9 Nm {0.4 0.9 kgm}
followed when reassembling. Bolt (15): 25 31 Nm {2.5 3.2 kgm}
a When assembling, clean and inspect the parts Bolt (16): 27 34 Nm {2.8 3.5 kgm}
closely and take care fully so that dirt, rush, flaw,
etc. will not cause a trouble.
1. When installing piston (1), apply grease (G2-LI)

to its outside and the inside of the body hole.
2. Install spring (2) with its small diameter side on

the shim (3) side.
Diameter of spring (Inside diameter)
Small diameter side: 4.9 mm
Large diameter side: 5.55 mm
3. Do not drive in bushing (4) by hitting it directly

with a hammer.
4. Do not drive in pin (5) by hitting it directly with a

hammer.
5. Apply grease (G2-LI) to the rocking part of shaft

(6) and the contact surfaces of lever (7) and pis-
ton (1) and the contrast surfaces of plate (8) and
2 Quantity of grease (G2-LI)

pin of lever (9).
Rocking part of shaft (6):

4 8 cc/periphery
Connecting part of lever (7) and pis-
ton (1): 0.3 0.8 cc/part
Connecting part of plate (8) and le-
ver (9): 0.3 0.8 cc/part
6. Install washer (10) 1.6 mm thick first. If the differ-

ence between both sides at the stroke and of the
lever exceeds 0.7, change the washer thickness
to reduce the difference to below 0.7. (If the
washer thickness is reduced by 0.3 mm, the
stroke end angle is increased by 0.39.)
Thickness of washers: 1.0, 1.3, 1.6 mm
PC200/220(LC)-7 30-79-2
(12)
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE

ASSEMBLY
PC200, 200LC-7 Serial No. 252874 and up 7. Tighten each part to the following torque.
PC220, 220LC-7 Serial No. 65437 and up Plug (11): 34 44 Nm {3.5 4.5 kgm}
Plug (12): 9.8 14.7 Nm {1 1.5 kgm}
a Only precautions for assembling the travel PPC Plug (13): 24.5 34.3 Nm {2.5 3.5 kgm}
valve assembly are explained below. Bolt (14): 19.6 27.4 Nm {2.0 2.8 kgm}
a Clean and check the parts carefully to prevent a Screw (15): 0.44 0.588 Nm {0.045 0.06 kgm}
trouble caused by dirt, rust, flaw, etc., and as- Bolt (16): 25 31 Nm {2.5 3.2 kgm}
semble them with extreme care. Bolt (17): 27 34 Nm {2.8 3.5 kgm}
Plug (18): 6 11 Nm {0.6 1.1 kgm}
1. When assembling piston (1), apply grease (G2- Plug (19): 4 9 Nm {0.4 0.9 kgm}
LI) to the outside of the piston and inside of the
hole of the body.
2. Install spring (2) with the small diameter end on

the shim (3) side.
Diameter of (Inside diameter) of spring
Small diameter side: 4.9 mm
Large diameter side: 5.55 mm
3. Do not insert bushing (4) by hitting it with a ham-

mer directly.
4. Do not insert pin (5) by hitting it with a hammer

directly.
5. Apply grease (G2-LI) to the sliding parts of shaft

(6), contact parts of lever (7) and piston (1), and
contact parts of the lever of damper (9) and pin
2 Quantity of grease (G2-LI) applied

(8).
Sliding parts of shaft (6):

4 8 cc/periphery
Contact parts of lever (7) and piston
(1): 0.3 0.8 cc/part
Contact parts of lever of damper (9)
and pin (8): 0.3 0.8 cc/part
6. Install washer (10) 1.6 mm thick first. If the differ-

ence of the lever stroke angle between the right
and left exceeds 0.7, replace the washer with
one of different thickness to reduce the differ-
ence below 0.7. (If the washer thickness is re-
duced by 0.3 mm, the stroke angle is increased
by 0.39.)
Thicknesses of washers: 1.0, 1.3, 1.6 mm
30-80 PC200/220(LC)-7
(12)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER

ASSEMBLY ASSEMBLY
SPECIAL TOOLS 3) Pull out piston rod assembly (2).
Place a container under the cylinder to
Distinc- catch the oil.
tion
Cylinder repair
790-502-1003
stand
1
1
790-101-1102 Pump
790-102-4300 Wrench Assembly 1
2
790-102-4310 Pin 2
3 790-720-1000 Expander 1
Rubber Band
796-720-1670
(for boom and arm)
1
07281-01279 Clamp 1
4
Rubber band
796-720-1660
(for bucket)
1
07281-01159 Clamp 1
790-201-1702 Push tool kit 1

Push tool
790-201-1830 1
(for bucket) 4) Disassemble piston rod assembly as fol-
Q Push tool
790-201-1930 11 lows.
5 (for arm)
i) Set piston rod assembly (2) in tool Q1.
Push tool
790-201-1940 1
(for boom)
790-101-5021 Grip 1
01010-50816 Bolt 1
Push tool kit
790-201-1500
(for bucket)
1
790-201-1640 Push tool 1
790-101-5021 Grip 1
01010-50816 bolt 1
6
790-201-1980 Plate (for boom) 1
790-201-1990 Plate (for arm) 1
790-101-5021 Grip 1
01010-50816 Bolt 1
DISASSEMBLY ii) Remove stopper screw (3) of piston

assembly.
1. Piston rod assembly
Common screw size for boom,
1) Remove piping from cylinder assembly. arm, and bucket cylinder: M12 x Pitch
2) Remove mounting bolts and disconnect 1.75.
head assembly (1).
30-81
(12)
12
If the caulking of screw (3) is too

strong and it cannot be removed,
tighten the screw fully, then fit a tap to
the thread and remove the screw.
vii) Remove cap (8), and pull 12 balls (9),

then remove plunger (10).
Arm cylinder only
iii) Using tool Q2, remove piston assem-

bly (4).
When not using tool Q2, use the
drill holes (DH) ( 10, 4 places) and
loosen the piston assembly.
2. Disassembly of piston assembly

1) Remove rings (11).
2) Remove wear rings (12).
3) Remove piston ring (13).
4) Remove O-ring and backup ring (14).
iv) Remove plunger (5).
Boom and arm cylinder only
v) Remove collar (6).
vi) Remove head assembly (7).
30-82
(12)
12
3. Disassembly of cylinder head assembly 4) Using tool Q6, install dust seal (17), and
1) Remove O-ring and backup ring (15). secure with snap ring (16).
2) Remove snap ring (16), then remove dust 5) Install backup ring and O-ring (15).
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove busing (20).
ASSEMBLY
Be careful not to damage the packing, dust

seals, and O-rings.
Clean each part, then cover the piping ports
and pin-inserting hole to prevent dust from
entering them.
Do not try to force the backup ring into posi-
tion. 2. Assembly of piston assembly
Warm it in warm water (50 - 60C) before 1) Using tool Q3, expand piston ring (13).
installing it. Set the piston ring on tool Q3, and
turn the handle 8 - 10 times to expand
1. Assembly of head assembly the ring.
1) Using tool Q5, press fit bushing (20). 2) Set tool Q4 in position, and compress pis-
2) Assemble buffer ring (19). ton ring (13).
3) Assemble rod packing (18).
30-83
(12)
12
3) Install backup ring and O-ring (14). 2) Assemble head assembly (7).
4) Assemble wear rings (12). 3) Fit O-ring and backup ring to collar (6),
5) Assemble rings (11). then assemble.
Be careful not to open the end gap of Boom and arm cylinder only
the ring too wide. 4) Assemble plunger (5).
Ring grove: Grease (G2-LI)
5) Set cushion plunger (10) to piston rod,

then assemble 12 balls (9) and secure
3. Piston rod assembly
with cap (8).
1) Set piston rod assembly (2) to tool Q1. Check that there is a small amount of
play at the tip of the plunger.
Arm cylinder only
30-84
(12)
12
6) Assemble piston assembly (4) as follows.
When using piston rod assembly (2) When using a new part for either or both of
and piston assembly (4) again: piston rod assembly (2) and piston assembly
(4)
Wash thoroughly and remove all
metal particles and dirt. For the rod with bottom cushion, mark the
cap position on the end of the rod. (See
i) Screw in piston assembly (4), then
step 5).)
use tool Q2 to tighten piston
assembly (4) so the position of the Arm cylinder only
screw thread hole (H) matches i) Screw in until piston assembly (4) con-
Remove all burrs and flashes tacts end face of rod, then use tool to
with a file. tighten.
3 Piston assembly: 294 29.4 Nm

{30 3.0 kgm)
After tightening the piston, check that

there is play in plunger (5).
Boom, arm cylinder only
ii) Tighten screw (3).

2 Screw thread: Loctite No. 262
3 Screw: 58.9 73.6 Nm

{6 7.5 kgm}
iii) Caulk thread at 2 places with ii) Machine one of the holes used to install
punch [1]. screw (3).
Align a drill horizontal with the V-
groove of the thread of piston rod
assembly (2) and piston assembly (4),
then carry out machining.
For the cylinder with bottom cushion
(arm cylinder), avoid the cap (8)
machining holes position when
machining. (See step 5).)
Screw machining dimension (mm)
Drill Bottom
Tap used Tap depth
diameter hole depth
10.3 27 12 x 1.75 20
30-85
(12)
12
iii) After machining, wash thoroughly to 7) Assemble piston rod assembly (2).
remove all metal particles and dust. Set the end gap of the ring horizontally (at
the side position), align axial center of cyl-
inder tube, then insert.
After inserting, check that the ring is not
broken and has not come out, then push
in fully.
iv) Tighten screw (3).
Screw: 58.9 - 73.6 Nm {6 - 7 kgm}
v) Caulk thread at 4 places with punch.
8) Tighten head assembly (1) with mounting

bolts.
Mounting bolt:
Cylinder Tightening torque

Bucket 270 39 Nm {27.5 4.0 kgm}
Arm 373 54 Nm {38.0 5.5 kgm}
Boom 270 39 Nm {27.5 4.0 kgm}
9) Install piping.
30-86 PC200/220(LC)-7
c
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT ASSEMBLY
12
REMOVAL AND INSTALLATION OF WORK EQUIPMENT

ASSEMBLY ASSEMBLY
SPECIAL TOOLS Remove the boom cylinder on the other
side in the same manner.
Distinc-
tion* 5. Disconnect bucket cylinder hoses (6) and arm
796-900-1200 Remover 1 cylinder hoses (7), two for each.
790-101-4000
Puller
1 Plug the hoses to prevent oil flow-out,
R (490 kN 50-T-long)
and fasten them on the valve side.
Pump
790-101-1102
(294 kN 30 T)
1
*Distinction between new and existing part. 6. Disconnect intermediate connector CN-A42
(8) for a working lamp.
REMOVAL
Extend the arm and bucket fully. Lower the
work equipment to the ground and set the
lock lever to the lock position.
Release the residual pressure in the hydrau-
lic circuit. Refer to the Release of Remaining
Pressure in Hydraulic Circuit section in the
TESTING AND ADJUSTING chapter of this
manual.
1. Disconnect grease hose (1).
2. Sling boom cylinder assembly (2), and

remove lock bolt (3). 7. Lift off the work equipment and remove plate
(9) and then pin (10) at the foot.
3. Remove plate (4), then remove head pin (5).
There are shims installed, so check the

number and thickness, and keep them in a
safe place.
When removing them, first remove plate

(9) and then remove pin (10) at the foot,
using Tool R.
Shims are installed, so do not forget to
check their number and each location of
installation.
4. Start the engine and retract the piston rod.
Fasten the piston rod with wire so that it
will not slip out and lower the cylinder
onto a stand, or place a support under the
bottom of the cylinder to support it. In the
latter case, remove the grease fitting on
the bottom side first.
30-87
(11)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT ASSEMBLY
12
INSTALLATION
When tightening the locknut, tighten so

that clearance a between the plate and
nut is 0.5 - 1.5 mm.
8. Lift off work equipment assembly (11) and dis-

assemble it.
Work equipment assembly:

3,300 kg
Inside surface of bushing when

assembling pin:
Anti-friction compound (LM-P)
Grease after assembling pin:
Grease (LM-G)
When aligning the position of the pin

hole, never insert your fingers into the
pin hole.
Adjust the shim thickness so that clear-

ance a between cylinder rod (12) and
plate (4) is Max. 1.5 mm.
Standard shim thickness: 1.0 mm and
2.0 mm.
30-88
(11)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
2 Inside surface of bushing when assem-

bling pin:
2 Grease after assembling pin:

Anti-friction compound (LM-P)
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers into the pin hole.
a Adjusut clearance "a" between boom (14)
and frame (15) with shim (13) (Thickness:
2.0 mm) so that it will be Max. 1 mm.
Thickness of standard shims:
2.0, 2.5, 3.0 and 3.5 mm
Bleeding air
a Bleed the air from the cylinder. For details,
see TESTING AND ADJUSTING, Air Bleed-
ing of Various Parts.

a Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then check the oil level
again.
PC200/220(LC)-7 30-89
(12)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT

ASSEMBLY
PC200, 200LC-7 Serial No. 200001 250000 3. Pull down outside air filter cover opening-closing
PC220, 220LC-7 Serial No. 60001 and up lever (2).
SPECIAL TOOLS
Distinction
Necessity
Sketch
Qty

Vacuum Pump
799-703-1100 t 1
(100 V)
Vacuum Pump
799-703-1111 t 1
S (220 V)
Vacuum Pump
799-703-1121 t 1
(240 V)
Gas leak 4. Remove outside air filter (3).
799-703-1401 t 1
detector
REMOVAL
k First, disconnect the cable from the negative ter-
minal () of the battery.
k Collect the air conditioner refrigerant.
1. Drain coolant.
6 Coolant: Approx. 22.8 l
2. Remove floor mat (1).
5. Remove monitor panel lower covers (4) and (5).

a When removing cover (4), first remove the
M19 wiring for cigarette lighter.
30-90 PC200/220(LC)-7
(12)
6. Remove duct (6) on the right side. 11. Remove cover (15).
7. Remove rear covers (7), (8) and (9). 12. Disconnect cab intermediate connectors (18) at
the following two points.
H09: Upper side
H08: Lower side
a Do not use wires (16) and (17) for this ma-
chine.
13. Disconnect radio antenna (19).
14. Remove plate (20) and then remove cover (21).
8. Remove rear duct (10).
9. Remove plate (11) and then remove duct (12).
10. Remove plate (13) and right duct (14).
15. Remove duct (22).
16. Disconnect connectors at the following seven

points.
(23): D01
(Assembled-type diode connector)
(24): D02
(Assembled-type diode connector)
(25): C09 (Model selection switch connec-
tor)
(26): Air conditioner unit connector
From top to bottom, M26, M27, M28
and M33 option power source connec-
tor
PC200/220(LC)-7 30-91
(12)
17. Remove the mounting clamp and disconnect air INSTALLATION

conditioner wiring connector (27). Install in reverse order of removal.
a Install hoses in the air conditioner circuit with
18. Remove the 4 mounting bolts and remove gov- care so that dirt, dust, water, etc. may not enter
ernor pump control assembly (28). them.
a Put the governor pump control assembly a Install air conditioner hoses only after checking
aside. that an O-ring is in place at the connecting part.
a Check that there is no damage on O-rings, or
19. Remove cover (29). that they have not deteriorated.
a When connecting the refrigerant piping, coat

the O-ring with compressor oil for R134a
(DENSO: ND-OIL 8, ZEXEL: ZXL 100 PG
(PAG 46 or equivalent)) and tighten the nuts
3 Hose clamp screw:

with 2 spanners.
3 Hose screw M16 x 1.5:

8.83 14.7 Nm {0.9 1.5 kgm}
3 Hose screw M24 x 1.5:

11.8 14.7 Nm {1.2 1.5 kgm}
29.4 34.3 Nm {3.0 3.5 kgm}
Filling air conditioner gas

20. Disconnect air conditioner hoses (30) and (31) Fill the air conditioner circuit with air conditioner
as well as air conditioner tubes (32) and (33). gas (R134a), using tool S.
21. Remove the 8 mounting bolts and remove air

conditioner unit assembly (34).
a When removing the air conditioner unit as-
sembly, do not forget to disconnect the 2 air
conditioner hoses connected to the bottom.
30-92 PC200/220(LC)-7
(12)
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT

ASSEMBLY
PC200, 200LC-7 Serial No. 250001 and up 4. Remove duct (5), cover (6), and plate (7).
SPECIAL TOOLS 5. Remove plate (8) and duct (9).

a Remove the duct lock clip.
New/Remodel
Necessity
Sketch
6. Remove ducts (10) and (11).
Qty

Vacuum pump
799-703-1100 t 1
(100V)
Vacuum pump
799-703-1111 t 1
S (220V)
Vacuum pump
799-703-1121 t 1
(240V)
Gas leak
799-703-1401 t 1
detector
REMOVAL 7. Disconnect connectors D01 (12), D02 (13), C09

k Disconnect the cable from the negative () ter-
(14), R22 (15), R20 (16), and K19 (17).
minal of the battery.
k Collect the air conditioner refrigerant.
8. Remove and sling controller (18).
9. Remove plate (19).

1. Swing the upper structure by 90.
10. Disconnect air conditioner unit connectors M27
2. Open the engine hood. (20) and M33 (21).
3. Remove rear covers (1), (2), (3), and (4).
PC200/220(LC)-7 30-92-1
(12)
11. Remove the air conditioner unit undercover. INSTALLATION

a Part A Carry out installation in the reverse order to
removal.
a When installing the air conditioner circuit
hoses, take care that dirt, water, etc. will not
enter them.
a When connecting each air conditioner hose,
check that the O-ring is fitted to the joint.
a Check that each O-ring is free from flaw and
deterioration.
[*1]
a When connecting the refrigerant piping, coat
the O-ring with compressor oil for R134a
(DENSO: ND-OIL 8, ZEXEL: ZXL 100 PG
(PAG 46 or equivalent)) and tighten the nuts
12. Remove mounting bolt (24) and connector (25). with 2 spanners.
3 Hose clamp (M6 bolt):

[*1]
13. Disconnect heater hoses (22) and (23) and air 7.84 11.8 Nm {0.8 1.2 kgm}
3 Hose screw of M16 x 1.5:

conditioner tube (26). [*1]
a Put tags to the disconnected hoses and
tubes to prevent a mistake in re-connecting 11.8 14.7 Nm {1.2 1.5 kgm}

them.
19.6 24.5 Nm {2.0 2.5 kgm}

29.3 34.3 Nm {3.0 3.5 kgm}
Charging air conditioner with refrigerant gas

Using tool S, charge the air conditioner circuit
with refrigerant (R134a) from the compressor.
a Quantity of refrigerant: 950 50 g
14. Remove the 7 mounting bolts and air conditioner

unit assembly (27).
30-92-2 PC200/220(LC)-7
(12)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL AND INSTALLATION OF COUNTERWEIGHT

ASSEMBLY
REMOVAL INSTALLATION
1. Attach eyebolts b to counterweight assembly
2 Thread of counterweight mounting bolt:
(1), and sling.
3 Counterweight mounting bolt:

2. Remove 4 mounting bolts (2)
1,180 1,470 Nm {120 150 kgm}
3. Lift off counterweight (1) horizontally with wire or
chain block.
a Be careful not to it the engine, radiator or a Installing and adjusting counterweight
cooler. 1) Sling counterweight with crane and place in
4
position on the frame.
Counterweight assembly: 3,750 kg
2) Push counterweight, install mounting bolts,
and adjust to the following dimensions.
Clearance from revolving frame:
10 5 mm (left and right)
Clearance from bodywork door:
10 5 mm (left and right)
Stepped difference b from revolving
frame in left-to right direction:
Max. 5 mm
Stepped difference a from bodywork
door in left-to right direction: 10 4
Stepped difference c from bodywork top
cover in up-down right direction:
Max. 5 mm
PC200/220(LC)-7 30-93
(2)
DISASSEMBLY AND ASSEMBLY OPERATORS CAB
REMOVAL AND INSTALLATION OF OPERATORS CAB

ASSEMBLY
PC200, 200LC-7 Serial No. 200001 250000 4. Disconnect cab wiring intermediate connectors
PC220, 220LC-7 Serial No. 60001 and up H10 (7), H11 (8) and H12 (9).
REMOVAL 5. Remove duct (10) on the right side and rear duct
k First, disconnect the cable from the negative ter- (11).
minal () of the battery.
6. Remove left plates (12) and (13).
1. Remove floor mat (1).
7. Pull down outside air filter cover opening-closing

2. Remove covers (2) and (3) under the monitor lever (14).
panel.
a When removing cover (2), first disconnect
the CN-M19 wiring for cigarette lighter.
8. Remove outside air filter (15).
3. Remove rear covers (4), (5) and (6).
30-94 PC200/220(LC)-7
(5)
9. Remove duct (16). 15. Remove step plate (24).
10. Remove cover (17). 16. Remove five mounting bolts (25) and four
mounting nuts (26).
a Check the bolt length beforehand.
11. Disconnect cab wiring intermediate connectors

(20) at the following two points.
H09: Upper side 17. Lift off operator's cab assembly (27) to remove
H08: Lower side it.
4 Operator's cab assembly: 290 kg
13. Remove duct (22) on the right side. INSTALLATION

14. Remove window washer hose (23).
PC200/220(LC)-7 30-95
(5)
REMOVAL AND INSTALLATION OF OPERATORS CAB

ASSEMBLY
PC200, 200LC-7 Serial No. 250001 and up 5. Remove air conditioner connector plate (14).
REMOVAL
k Disconnect the cable from the negative () ter-
minal of the battery.
1. Remove rear covers (1), (2), (3), and (4).
6. Disconnect connectors M71 (15), H10 (16), H11

(17), and H12 (18).
7. Disconnect upper and lower duct joints (19) and

(20).
2. Remove duct (5), cover (6), and plate (7). 8. Remove controller sub-plate (21) and incline it
against the air conditioner.
3. Remove plate (8), duct (9) and the element.
a Remove the duct lock clip.
9. Remove cover (22) and floor mat (23).
4. Remove clip (10) and disconnect cab wiring

connectors M45 (11), H08 (12), and H09 (13).
30-96 PC200/220(LC)-7
(5)
10. Move right console (24) into the cab. 17. Take grommet (35) out of the right front of the
cab.
11. Remove monitor panel undercover (25).
18. Disconnect the windshield washer hose from
(36).
19. Remove 4 mounting bolts (37) and 5 mounting

bolts (38).
a Check the types of the bolts.
a In the initial period, 7 mounting bolts (38) are
used.
12. Disconnect cab wiring connector W04 (26)

(Wiper motor).
13. Remove ducts (27) and (28).

a Both (27) and (28) are 2 in number.
a Cut the tie-wrap on the monitor wiring har-
ness.
14. Remove cover (29) and monitor assembly (30). 20. Using lever block [1], lift off operator's cab
assembly (39).
4 Operator's cab assembly: 300 kg
16. Remove clip (32) and take wiring harness (33)

out of grommet (34).
PC200/220(LC)-7 30-97
(5)
21. When starting the engine while the operator's INSTALLATION

cab is removed (for transportation, etc.), use the Carry out installation in the reverse order to
following brackets. removal.
1) Bracket (41) for controller (40)
Part No.: 208-53-13920
2) Bracket (42) for monitor panel assembly

(30)
Part No.: 208-53-13910
30-98 PC200/220(LC)-7
(5)
DISASSEMBLY AND ASSEMBLY OPERATORS CAB GLASS (STUCK GLASS)
REMOVAL AND INSTALLATION OF OPERATORS CAB GLASS

(STUCK GLASS)
a Among the panes of window glass on the 4 sides (1) : Right side window glass
of the operator's cab, 4 panes (1) (4) are stuck. (2) : Left side rear window glass
In this section, the procedure for replacing the (3) : Door lower window glass
stuck glass is explained. (4) : Front window glass
When replacing front window glass (4), remove (5) : Front window assembly
front window assembly (5). (It is impossible to (Front window glass + Front frame)
replace only the front window glass while the (6) : Both-sided adhesive tape
front window assembly is installed to the opera- (16): Center trim seal
tor's cab.)
For the procedure for replacing the front window
assembly, see REMOVAL AND INSTALLATION
OF FRONT WINDOW ASSEMBLY.
PC200/220(LC)-7 30-99
(5)
SPECIAL TOOLS (The figure shows the operator's cab of a

wheel loader.)
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
Lifter
1 793-498-1210 t 2
Y (Suction cup)
2 20Y-54-13180 Adapter t 2
REMOVAL
a Remove the window glass to be replaced ac-
cording to the following procedure.
1. Using seal cutter [1], cut the adhesive between a If the window glass is broken finely, it may be
broken window glass (7) and operator's cab removed with knife [4] and a screwdriver.
(metal sheet) (8). a Widening the cut with a screwdriver, cut the
adhesive and both-sided adhesive tape 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 both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
both ends of the wire with priors [3], etc. (or
hold them by winding them onto something) 2. Remove the window glass.
and move the wire to the right and left to cut
the adhesive and both-sided adhesive tape.
Since the wire may be broken by the friction-
al heat, apply lubricant to it.
30-100 PC200/220(LC)-7
(5)
INSTALLATION 3. Apply primer (10).

1. Using a knife and scraper [5], remove the a The using limit of primer (10) is 4 months af-
remaining adhesive and both-sided adhesive ter the date of manufacture. Do not use prim-
tape from the metal sheets (glass sticking sur- er (10) after this limit.
faces) of the operator's cab. a Use the primer within 2 hours after unpack-
a Remove the adhesive and both-sided adhe- ing it.
sive tape to a degree that they will not affect a Even if the primer is packed again just after
adhesion of the new adhesive. Take care it is unpacked, use it within 24 hours after it
not to scratch the painted surfaces. (If the is unpacked for the first time. (Discard the
painted surfaces are scratched, adhesion primer 24 hours after it is packed.)
will be lowered.) 1) Stir the primers for paint and glass suffi-
ciently before using them.
(The figure shows the operator's cab of a a If the primer has been stored in a refrig-
wheel loader.) erator, leave it at the room temperature
for at least half a day before stirring it. (If
the primer is unpacked just after taken
out of the refrigerator, water will be con-
densed. Accordingly, leave the 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 glass primer.
2. Remove oil, dust, dirt, etc. from the sticking sur-

faces 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
them for at least 5 minutes to dry.
(The figure shows the operator's cab of a

wheel loader.)
PC200/220(LC)-7 30-101
(5)
3) Evenly apply paint primer to the surfaces to

stick both-sided adhesive tapes and the sur-
faces out of those surfaces on operator's
cab (8) which will be coated with the adhe-
2 Paint primer:
sive.
SUNSTAR PAINT PRIMER

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 Parts to be coated with primer: Apply the

primer all over dimension a.
a Never apply wrong primer. If the glass
Dimension to apply primer a: 25 mm
primer is applied by mistake, wipe it off
with white gasoline.
4) Evenly apply glass primer to the sticking
2 Glass primer:
surfaces of window glass (9).
SUNSTAR GLASS PRIMER

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, apply the

primer to right side window glass (1) and
door lower window glass (3).
Range to apply primer additionally for
right side window glass (1): b
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.
30-102 PC200/220(LC)-7
(5)
a Parts to be coated with primer: Apply the a When sticking both-sided adhesive tape (6)
primer to the sticking surfaces of window around a frame, do not lap its finishing end
glass (9) and all over dimension d which over the starting end but make clearance e of
will be on both-sided adhesive tape (6) about 5 mm between them.
and operator's cab (8). 1) Stick both-sided adhesive tape (6) for right
a Do not apply the primer to the boarder side window glass (1) as shown in the fig-
about 5 mm wide between the black part ure.
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 wrong primer. If the glass
primer is applied by mistake, wipe it off
with white gasoline.
a Stick both-sided adhesive tape (6a) addition-

ally for right side window glass (1).
Positions to stick additional both-sided adhe-
sive tape for right side window glass:
f : 50 mm
g : 90 mm
4. Stick both-sided adhesive tape (6) along the h : 250 mm
inside edge of the glass sticking section.
a Do not remove the release tape of the both-
sided adhesive tape on the glass sticking
side before sticking the glass.
a When sticking the both-sided adhesive tape,
do not touch the cleaned surface as long as
possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window frame.
2) Stick both-sided adhesive tape (6) for left

side rear window glass (2) as shown in the
figure.
PC200/220(LC)-7 30-103
(5)
3) Stick both-sided adhesive tape (6) for door a Stick both-sided adhesive tape (6c) of
lower window glass (3) as shown in the fig- the lower side of the front window glass
ure. along the outside edge of the lower line,
differently from other both-sided adhe-
sive tapes (6). (If it is stuck along the in-
side, it will be seen through the
transparent part of the glass.)
a Stick both-sided adhesive tape (6b) ad-

ditionally for door lower window glass
(3).
a Positions to stick additional both-sided
adhesive tape for door lower window 5. Position the new window glass.
glass: 1) Check the clearance between the window
j : 110 mm glass and the operator's cab on the right,
k : 90 mm left, upper, and lower sides, and then adjust
m : 200 mm it evenly.
2) Stick tapes [6] between window glass (9)
and operator's cab (8) and draw positioning
line n.
a Stick tapes [6] to the right, left, and lower
parts of the right side window glass, left
side rear window glass, and door lower
window glass for accurate positioning.
3) Cut the tape between window glass (9) and
operator's cab (8) with a knife, and then
remove the window glass.
a Do not remove the tapes left on the win-
dow glass and operator's cab before in-
stalling the window glass.
4) Stick both-sided adhesive tape (6) for front

window glass (4) as shown in the figure.
30-104 PC200/220(LC)-7
(5)
1) Break aluminum seal (13) of the outlet of

adhesive cartridge (12) and install the noz-
zle.
a When positioning front window glass (4),

set its horizontal position to the frame
width and set its vertical position so that
height difference p between it and the
frame top will be 3 mm. 2) Cut the tip of the adhesive nozzle (14) so
that dimensions q and r will be as follows.
Dimension q : 10 mm
Dimension r : 15 mm
6. Apply adhesive.
2 Adhesive (Summer):
a Use either of the 2 types of the adhesive.
SUNSTAR PENGUINE 3) Set adhesive cartridge (12) to caulking gun

[7].
2 Adhesive (Winter):
SEAL 580 SUPER "S"
a An electric caulking gun is more efficient.
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
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 from the nozzle tip.
PC200/220(LC)-7 30-105
(5)
4) Remove the release tape of the both-sided

adhesive tape on the glass side.
5) Apply adhesive (15) to the outside of both-
sided adhesive tape (6) of the operator's
cab.
a Apply adhesive (15) to dimensions s and

t of both-sided adhesive tape (6) of oper-
ator's cab (8).
Dimension s : 10 mm
Dimension t : 15 mm
a Apply adhesive (15) higher than both-
sided adhesive tape (6).
a Apply the adhesive evenly.
7. Install the window glass.
1) Install window glass (9), matching it to the
lines of the positioning tapes drawn in step
5.
a Since the window glass cannot be re-
moved and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after ap-
plying the adhesive.
2) After sticking window glass (9), press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
a Apply adhesive (15) additionally for ad-

ditional both-sided adhesive tape (6a) of
the right side window glass and addition-
al both-sided adhesive tape (6b) of door
lower window glass.
30-106 PC200/220(LC)-7
(5)
a You can perform this work efficiently by

pulling window glass (9) from inside of
the operator's cab with suction cup Y1.
a After installing front window glass (4), fill

the clearances between it and center
trim seal (16) with caulking material in
range s to dimensions (t) and u.
After applying the primer to glass (4) of
section A A, apply adhesive as caulk-
ing material.
Caulking dimension t : 2 mm
Caulking dimension u : 5 mm 8. Fix the window glass.
a When caulking, mask the glass side and 1) After installing right window glass (1) to the
form the adhesive with a rubber spatula operator's cab, insert stopper rubbers Y2 to
as shown in the figure. 2 places v at the bottom of the glass to fix
2 Glass primer:
a Wipe off projected adhesive. the glass.
SUNSTAR GLASS
2 Adhesive:
PRIMER 580 SUPER
SUNSTAR PENGUINE
SEAL 580 SUPER "S" or "W"
PC200/220(LC)-7 30-107
(5)
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and both-
sided adhesive tape to fit them completely.
9. After installing the window glass, remove the

primer and adhesive from the operator's cab
and window glass.
a Using white gasoline, wipe off the adhesive
before it is dried up.
a When cleaning the glass, do not give an im-
pact to 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, styrene
foam blocks, and rubber bands, wait at least
14 hours, at least 24 hours in total, before
operating the machine actually.
30-108 PC200/220(LC)-7
(5)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY

k Lower the work equipment to the ground and 7. Remove rollers (8) and (9) under the both sides
stop the engine. of the front window.
a To replace the front window glass, the front win-
dow assembly must be removed from the opera-
tor'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 blocks (1) and (2) and right

corner block (3). [*1]
3. Remove left striker bolt (4), right striker bolt (5),

left corner block bracket (6), and right corner
block bracket (7). [*2]
4. Install left striker bolt (4) to the operator's cab

again and tighten it lightly.
a This bolt will be used to hang the pull-up as-
sist cable in step 8.
8. Remove left lower pin (10). [*3]

a If left lower pin (10) is removed, plate (12) at
the end of pull-up assist cable (11) comes
off.
a Hang plate (12) on the left striker bolt.
k The return load of 58.8 N {6 kg} is applied to
the rear of the operator's cab. Accordingly,
take care when removing left lower pin (10)
to disconnect pull-up assist cable (11).
5. Release the rear locks.
6. Lower the front window assembly carefully a lit-

tle. Put out rollers (8) and (9) under the both
sides of the front window through the portion
from which the corner blocks were removed in
step 3 (the portion where the rail is open) and
hold them.
PC200/220(LC)-7 30-109
(12)
11. Twist front window assembly (13) to the right

and left to remove both upper rollers (14) and
(15) from the rails, and then remove front win-
dow assembly (13).
9. Put out the bottom of front window assembly

(13) through the rail opening portion and lower it
gradually.
10. Lower front window assembly (13) completely.

a Do not let the front window assembly touch
the monitor.
30-110 PC200/220(LC)-7
(5)
INSTALLATION 4. Install right corner block (3) and fix right corner
Carry out installation in the reverse order to block bracket (7) with right striker bolt (5).
removal. a Tighten the striker bolt securely after adjust-
ing it in step 6.
[*1] [*2] a Install the right corner block so that there will
Adjust opening and closing of the front window be no level difference at part "a".
assembly according to the following procedure. a Install the right corner block so that level dif-
ference "b" between the rail and right corner
1. Open and close the front window to check that it block (3) will be 0 1.0 mm. Check that the
does not interfere with the rails and the rollers right corner block is not projected from the
are not hitch. rail at the rolling surface of the roller.
a Secure roller clearance "c" at part P.
2. If there is any problem in opening or closing of
the front window, loosen the mounting bolts of
roller adjustment brackets (16) and (17) and
adjust the condition of the front window, and
3 Mounting bolt: 9.8 Nm {1.0 kgm}

then tighten the mounting bolts again.
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 opera-
tor's cab are applied securely.
PC200/220(LC)-7 30-111
(12)
5. Install left corner blocks (1) and (2) and secure 6. Adjust the striker bolts according to the following
left corner bracket (6) with left striker bolt (4). procedure (Adjust the "CLOSE" positions of the
a Tighten the striker bolt securely after adjust- front window assembly locks).
ing it in step 6. 1) Tighten left striker bolt (4) and right striker
a Install the left corner blocks so that there will bolt (5) at roughly right positions so that
be no level difference at 2 part "d". front window glass (18) will be fitted to cab-
a Secure roller clearance "e". side trim seal (19).
30-112 PC200/220(LC)-7
(12)
2) Open and close the front window assembly

and check the working condition of both
locks (20) and (21).
i) If both locks do not work normally, move
the striker bolts toward the rear of the
cab and tighten them again.
ii) After moving the striker bolts, check the
fitness of the front window glass and
cab-side trim seal which was checked in
step 1).
iii) Repeat the work in i) and ii) until the fit-
ness of the front window and the work-
ing condition of both locks (20) and (21)
are acceptable, and then tighten the
striker bolts.
9. Adjust the front window stoppers.

1) After adjusting "opening" lock of the front
window assembly in step 8, check the con-
7. After adjusting the striker bolts, splash water tact of both front window stoppers (23).
heavily over the front window glass and check 2) If both stoppers (23) do not contact nor-
that the water does not leak into the cab. mally, adjust and fix them at places where
they contact normally.
8. Adjust the "opening" lock of the front window
assembly.
1) After adjusting the "closing" lock of the front
window in steps 6 and 7, raise the front win-
dow assembly to the ceiling.
2) Set the right and left front window assembly
locks at the rear of the operator's cab to the
"OPEN" positions, and then check the fol-
lowing items.
heck that right and left locks (20) and
(21) are closed normally.
Check that right and left locks (20) and
(21) are inserted in parallel in right and
left striker plates (22).
Check that right and left rubber stoppers
(24) are in contact with the front window
assembly and their deflection allowance
is 1.5 3.0 mm.
3) After checking the above items, if neces-
sary, adjust them by moving right and left
striker plates (22) at the rear of the opera-
tor's cab.
PC200/220(LC)-7 30-113
(12)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW, MONITOR
REMOVAL AND INSTALLA-

TION OF MONITOR ASSEM-
BLY
10. Check the latching effort of the front window REMOVAL
assembly. k First, disconnect the cable from the negative ter-
1) After finishing steps 6 9, check that latch- minal () of the battery.
ing efforts of both locks (20) and (21) are
even. 1. Remove cover (1) and then disconnect the wir-
a Check the latching efforts on both "closing connector P15 for air conditioner sunlight
ing" side (in the front of the operator's sensor (2).
cab) and "opening" side (in the rear of a Lift the cover up to remove it.
the operator's cab). 2. Remove the three mounting screws and remove
monitor assembly (3).
a Disconnect monitor panel wiring connectors
P01, P02 and P03 at the three points, and
then remove the monitor assembly.
3 Left lower pin:

[*3]
27 34 Nm {2.75 3.47 kgm}

2 Mounting bolt: Adhesive (LT-2)
INSTALLATION
30-114 PC200/220(LC)-7
(8)
DISASSEMBLY AND ASSEMBLY ENGINE THROTTLE AND PUMP CONTROLLER
REMOVAL AND INSTALLATION OF GOVERNOR,

PUMP CONTROLLER ASSEMBLY
PC200, 200LC-7 Serial No. 200001 250000 PC200, 200LC-7 Serial No. 250001 and up
REMOVAL REMOVAL
k First, disconnect the cable from the negative ter- k First, disconnect the cable from the negative ter-
minal () of the battery. minal () of the battery.
1. Remove cover (1). 1. Remove covers (1), (2) and (3).
2. Disconnect governor, pump controller wiring 2. Disconnect governor, pump controller wiring
connectors C01 (2), C02 (3) and C03 (4). connectors C01 (4), C02 (5) and C03 (6).
3. Remove the four mounting bolts and remove 3. Remove the four mounting bolts and remove
governor, pump controller assembly (5). governor, pump controller assembly (7).
INSTALLATION INSTALLATION
Install in reverse order of removal. Install in reverse order of removal.
PC200/220(LC)-7 30-115
(5)
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM

PC200-7, PC200LC-7 .......................................................................................................................... 90- 3
PC220-7, PC220LC-7 .......................................................................................................................... 90- 5
ELECTRICAL CIRCUIT DIAGRAM
PC200-7, PC200LC-7: Serial No. 200001 250000
PC220-7, PC220LC-7: Serial No. 60001 65000
FOR MULTI MONITOR.................................................................................................................. 90- 7
FOR 7-SEGMENT MONITOR ....................................................................................................... 90- 15
PC200-7, PC200LC-7: Serial No. 250001 and up,
PC220-7, PC220LC-7: Serial No. 65001 and up................................................................................ 90-17-6
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER................................................................... 90- 19
PC200/220(LC)-7 90-1
(9)
OTHERS HYDRAULIC CIRCUIT DIAGRAM

PC200-7, PC200LC-7
PC200-7 90-3
OTHERS HYDRAULIC CIRCUIT DIAGRAM

PC220-7, PC220LC-7
PC200-7 90-5
ELECTRICAL CIRCUIT DIAGRAM (1/4)
FOR MULTI MONITOR
PC200-7, PC200LC-7 (Serial No. 200001 250000)
PC220-7, PC220LC-7 (Serial No. 60001 65000)
PC200/220(LC)-7 90-7
(6)
FOR MULTI MONITOR
PC200-7, PC200LC-7 (Serial No. 200001 250000)
PC220-7, PC220LC-7 (Serial No. 60001 65000)
PC200/220(LC)-7 90-9
(6)
FOR MULTI MONITOR
PC200-7, PC200LC-7 (Serial No. 200001 250000)
PC220-7, PC220LC-7 (Serial No. 60001 65000)
PC200/220(LC)-7 90-11
(6)
FOR MULTI MONITOR
PC200-7, PC200LC-7 (Serial No. 200001 250000)
PC220-7, PC220LC-7 (Serial No. 60001 65000)
PC200/220(LC)-7 90-13
(6)
FOR 7-SEGMENT MONITOR
PC200-7, PC200LC-7 (Serial No. 200001 250000)
PC220-7, PC220LC-7 (Serial No. 60001 65000)
PC200/220(LC)-7 90-15
(9)
PC200-7, PC200LC-7 (Serial No. 200001 250000)
PC220-7, PC220LC-7 (Serial No. 60001 65000)
PC200/220(LC)-7 90-17
(9)
PC200-7, PC200LC-7 (Serial No. 200001 250000)
PC220-7, PC220LC-7 (Serial No. 60001 65000)
PC200/220(LC)-7 90-17-2
(9)
PC200-7, PC200LC-7 (Serial No. 200001 250000)
PC220-7, PC220LC-7 (Serial No. 60001 65000)
PC200/220(LC)-7 90-17-4
(9)
PC200-7, PC200LC-7 (Serial No. 250001 and up)
PC200/220(LC)-7 90-17-6
(9)
PC200/220(LC)-7 90-17-8
(9)
PC200/220(LC)-7 90-17-10
(9)
PC200/220(LC)-7 90-17-12
(9)
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
PC200-7, PC200LC-7 (Serial No. 200001 250000)
PC220-7, PC220LC-7 (Serial No. 60001 65000)
PC200/220(LC)-7 90-19
(6)
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
PC200/220(LC)-7 90-21
(6)

SM PC200, PC200LC-7

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SEBM024312

MACHINE MODEL SERIAL NUMBER

PC200, 200LC, PC220, 220LC-7 mount the SAA6D102E-2 engine.

10 STRUCTURE, FUNCTION AND

20 TESTING AND ADJUSTING ........................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

90 OTHERS ................................................................................................................................ 90-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

If a part cannot be smoothly removed from the

The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

Used to prevent rubber gaskets, rubber

Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 14.7 1.2 1.5

16 24 235 285 23.5 29.5

27 41 1150 1440 118 147

6 10 5.9 9.8 0.6 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 4.9 2.5 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 63 {3.5 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting