Pc200 Testing and Adjusting

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
Q’ty
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 Bosch index: Level 0 – 9
checker
Exhaust gas color B
Commercially
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Engine valve clearance C Commercially
2 Clearance 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 – 5 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, 6, 40, 60 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: 60 MPa {600 kg/cm2}
kit (digital type)
2 799-401-2320 Oil pressure gauge 1 Pressure gauge: 1 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, 6, 40, 60 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: 60 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
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: 60 MPa {600 kg/cm2}
kit (digital type)
2 799-401-3100 Adapter 1 02 size
20-101-1 PC200/220(LC)-7
(14)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Q’ty
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
kit (digital type)
Oil leakage inside Commercially
N Cylinder 1
hydraulic cylinder available
Coolant temperature,
P 799-101-1502 Digital thermometer 1 – 99.9 – 1,299°C
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
(14)
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:
tion of the engine by accident while installing a i) Turn the auto-decelerator OFF.
measurement equipment. ii) Set the fuel dial at high idle (MAX).
iii) Move all the control levers of work
Inspection equipment, swing and travel to the
1. Open up the engine hood and take off cover (1). NEUTRAL position.
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
equipment, swing and travel to the
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

1 795-799-1131 Gear
C
2 Commercial product Clearance 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 clearance 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 clearance gauge C2 inserted
to the extent that clearance gauge C2
4. Turn the crankshaft clockwise with gear C1, can be lightly moved.
then match 1.6 TOP notch "a" of the crank pul- 2) Fix adjusting screw (6) and then tighten lock
ley with pointer (3), and bring up No.1 cylinder to
3 Lock nut: 24±4 Nm{2.45±0.41kgm}
nut (7).
the top dead center.
a When No. 1 cylinder is at the top dead cent- a Check the valve clearance again after
er, its rocker arm can be manually moved as tightening lock nut (7).
much as the valve clearance. If it cannot be a Proceed to the next step once all the adjust-
moved, that means that No. 1 cylinder is not ments of valve clearance indicated with a
yet at the top dead center. In that case, ro- black bullet mark (q) have been completed.
tate it by one more turn.
PC200/220(LC)-7 20-105
(14)
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:

24±4 Nm{2.45±0.41 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.
• Working mode: A mode
• 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

24±4 Nm{2.45±0.45 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 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
(14)
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: 1±1/6 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 1.25–1.75 mm. 2. Loosen lock nut (2), and adjust the belt tension
by shifting the position of compressor bracket
3 Nut: 49.0–68.6 Nm{5–7 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 60 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
(14)
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).
. . Nm . . gm
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).
. . Nm . . gm
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-
nut (10).
3 Locknut:
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 6 MPa {60 kg/cm2}.
20-120 PC200/220(LC)-7
(14)
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 60 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
(14)
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 6 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
(14)
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 60 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
(14)
3) Run the engine and raise the hydraulic oil 5) Detach all the measurement tools after the
temperature to the operating range and mea surement and ma ke sure t hat 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 60 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 p r e s s u re ( a c t u a t o r l o ad e d p r e ssu r e )
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
(14)
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 6 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
(14)
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
Mark Part No. Part Name

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 6 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
(14)
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,
signaling When any of them
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 6 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
(14)
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 locknut (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 locknut (2) to
3 Locknut: 98 – 127 Nm {10 – 13 kgm}

the specified tightening torque.
PC200, 200LC-7 Serial No. 200001 – 202418

PC220, 220LC-7 Serial No. 60001 – 60239
3 Locknut: 69 – 88 Nm {7 – 9 kgm}
PC200, 200LC-7 Serial No. 202419 and up
PC220, 220LC-7 Serial No. 60240 and up
5. Install boot (1).
6. Install work equipment and swing PPC valve

ass'y.
20-132 PC200/220(LC)-7
(14)
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-
7.8–9.8 Nm{0.8–1.0 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:
27.5–35.3 Nm{2.8–3.6 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 ABN NOR
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,
E n t r y a P h o n e n u m b e r in t h e P h o n e
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
(T he insta lled 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
T h e p u m p a b s o r p t io n t o r q u e c a n b e
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)
1 Function of displaying service meter 3 Function of displaying service code [01]

<Operation of switch>
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
(14)
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
monitor panel (2) off the mount.
3 Screw: 2.82 Nm {0.288 kgm}
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
20-180 PC200/220(LC)-7
PC200/220(LC)-7 20-181
(11)
20-182 PC200/220(LC)-7
(1)
Engine (PC220, 220LC) Hydraulic system (PC220, 220LC)
PC200/220(LC)-7
20-183
20-184 PC200/220(LC)-7
PC200/220(LC)-7 20-185
(11)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202

SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...................... 20-218
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-236
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ............................................................................... 20-259
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE ....................................................................... 20-262
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE

"MECHANICAL SYSTEM" ARE INDICATED ...................................................................................... 20-301
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................. 20-501
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) ................................. 20-601
PC200/220(LC)-7 20-201
(14)

Pc200 Testing and Adjusting

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TESTING AND ADJUSTING

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING ........................................................ 20-101-1

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

1 799-205-1100 Tachometer kit 1 Digital indication: 6 – 99,999.9 rpm

Oil pressure gauge Pressure gauge: 2.5, 6, 40, 60 MPa

INSPECTION AND ADJUSTMENT OF ENGINE SPEED

a Engine speed may be detected using a monitor-

3. Measure the engine speed after setting each

5) Engine speed when auto-decelerator is set

4. Detach all the measurement tools after the

2. Adjustment of governor spring

MEASUREMENT OF EXHAUST GAS COLOR

Mark Part No. Part name

k Be careful not to touch the highly heated parts,

1. Measurement with Handy Smoke Checker B1

5) Take out the filtering paper and compare it

ADJUSTMENT OF VALVE CLEARANCE

Mark Part No. Part name

1. Open up the engine hood, and remove the fan

2. Remove all cylinder head covers (1).

5. When No. 1 cylinder is at the top dead center,

3. Take off cap (2) and fit gear C1.

1) Insert clearance gauge C2 in between

6. Turn the crankshaft clockwise with gear C1,

7. When No. 6 cylinder is at the top dead center,

8. After the adjustment, make sure that the

3 Cylinder head cover securing bolt:

24±4 Nm{2.45±0.41 kgm}

MEASUREMENT OF COMPRESSION PRESSURE

Mark Part No. Part name

k Be careful not to get burnt by touching the ex-

1. Adjust the valve clearances.

3. Warm up the engine until the engine oil temper-

4. Detach nozzle holder (1) of a cylinder to be

8. Crank up the engine with the engine starting

60 ± 9 Nm {6.12 ± 0.92 kgm}

MEASUREMENT OF BLOW-BY PRESSURE

1. Fit tool E2 to blow-by hose (1) and connect it

5. Detach the measurement tools after the mea-

2. Start the engine, and lock the travel.

k Insert pin [2] in between the sprocket and

3. Start the engine and keep it running until the

4. Measure the blow-by pressure at high idle and

INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING

3. Turn the crankshaft clockwise with gear F1, then

3 Cylinder head cover securing bolt:

k Do not forget to bring driving gear timing pin

5. Detach the measurement tools after the adjust-

k Before starting the engine again, check that

driving gear timing pin (3) and fuel injection

2. Dismantle the fuel injection pump.

MEASUREMENT OF ENGINE OIL PRESSURE

1. Take off engine oil pressure measurement plug

5. Detach the measurement tools after the mea-

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

3. Start the engine and keep it running until the

ADJUSTMENT OF ENGINE INSPECTION AND ADJUST-

1. Screw in sensor (1) until its tip comes to contact

Gasket sealant (LG-6)