Troubleshooting Ofelectrical System (E-Mode)

TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-502

BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE ........................................................... 20-502-1
E-1 Engine does not start (Engine does not rotate) ................................................................................ 20-503
E-2 Engine stops while in operation ........................................................................................................ 20-507
E-3 Engine speed is irregular, or there is hunting ................................................................................... 20-508
E-4 Engine does not stop ........................................................................................................................ 20-510
E-5 Auto-decelerator does not work ........................................................................................................ 20-512
E-6 Auto engine warm-up device does not work ..................................................................................... 20-513
E-7 Preheater does not work................................................................................................................... 20-514
E-8 All work equipment, swing and travel do not move........................................................................... 20-516
E-9 One-touch power maximizing function does not work ...................................................................... 20-518
E-10 No display in monitor panel at all ...................................................................................................... 20-519
E-11 Part of display on monitor panel is missing....................................................................................... 20-520
E-12 Monitor panel displays contents irrelevant to the model ................................................................... 20-520
E-13 Fuel level monitor red lamp lights up while engine is running........................................................... 20-521
E-14 Engine coolant temperature gauge does not indicate correctly ........................................................ 20-522
E-15 Hydraulic oil temperature gauge does not display correctly ............................................................. 20-523
E-16 Fuel gauge does not display correctly .............................................................................................. 20-524
E-17 Swing lock monitor does not display correctly .................................................................................. 20-526
E-18 When the monitor switch is operated, no display appears ............................................................... 20-528
E-19 Windshield wiper does not work ....................................................................................................... 20-530
E-20 Alarming buzzer cannot be cancelled ............................................................................................... 20-532
E-21 "Boom RAISE" is not correctly displayed in monitor function ........................................................... 20-533
E-22 "Boom LOWER" is not correctly displayed in monitor function ......................................................... 20-534
E-23 "Arm DIGGING" is not correctly displayed in monitor function ......................................................... 20-535
E-24 "Arm DUMPING" is not correctly displayed in monitor function ........................................................ 20-536
E-25 "Bucket DIGGING" is not correctly displayed in monitor function ..................................................... 20-537
E-26 "Bucket DUMPING" is not correctly displayed in monitor function.................................................... 20-538
E-27 "SWING" is not correctly displayed in monitor function .................................................................... 20-540
E-28 "TRAVEL" is not correctly displayed in monitor function................................................................... 20-542
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function ..................................... 20-544
E-30 "Service" is not correctly displayed in monitor function..................................................................... 20-546
E-31 Troubleshooting for air conditioner system ....................................................................................... 20-548
E-32 Travel alarm does not sound ............................................................................................................ 20-560
PC200/220(LC)-7
20-501
(11)
TROUBLESHOOTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

a The following information are edited and contained in the "Information Contained in Troubleshooting Table".
You are required to proceed with troubleshooting after fully grasping the contents.
Failure
information
Phenomena occurring on machine
Relative
information
Information on occurred failures and troubleshooting

Cause
<Contents>
The standard values in normalcy by which to judge "good" or "no good" about presumed causes.
References for making judgement of "good" or "no good"
Presumed cause and standard value in normalcy
Standard value in normalcy and references for troubleshooting
Cause for presumed

failure
(The attached No. for
filing and reference
purpose only. It does not
stand for any priority)
<Phenomena of wiring harness fault>

Failure due to disconnection
Defective contact with connector or disconnection of wiring harness has occurred.
Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in contact
with it.
Failure due to short-circuiting
A wiring harness that is not originally connected with a power source circuit (24 V) is
in contact with it.
<Points to remember in troubleshooting>
1) Connector denotation method and handling of T-adapters
Insert or connect T-adapters in the following manner, unless specifically otherwise
instructed.
If there is no indication of (male) or (female) in the connector No., pull off a connector and insert a T-adapter into both sides of male and female.
If there is an indication of (male9 and (female) in the connection No., pull off a connector and insert a T-adapter into only one side of (male) or (female).
2) Description sequence of pin No. and handling of circuit tester leads
Connect the positive lead (+) and negative lead () for troubleshooting in the following manner unless specifically otherwise instructed.
Connect the positive lead (+) to a pin No. marked at the front or wiring harness.
Connect the negative lead () to a pin No. marked at the rear or wiring harness.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
Connector No.: Indicates (Type - numbers of a pin) (color)
Arrow: Roughly indicates the location in the machine where it is installed.
20-502
(1)
PC200/220(LC)-7
TROUBLESHOOTING
BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE
BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE

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

Swing holding brake release switch
Switch power
supply (Fusible
link: A34)
Switch power
supply (Fusible
link: A34)
Switch power
supply (Fusible
link: A34)
Constant power
supply (Fusible
link: A35)
PC200/220(LC)-7
Governor, pump controller (Solenoid power supply)
20A
10A
10A
10A
Horn switch
10A
(Spare)
10A
10A
10A
10
10A
(Spare)
11
20A
Air conditioner unit
12
20A
13
20A
Light switch
14
10A
Service power supply (M32 connector)
15
10A
16
10A
17
20A
Monitor panel
18
10A
Starting switch
19
10A
Room lamp
20
10A
(Spare)
Attachment return switching relay (Coil side and contact side)

Lock switch
Cigarette lighter
Windshield washer motor
Rotary lamp switch

Additional relay (Coil side and contact side)
Light relay (Contact side)
One-touch power maximizing switch
Radio
Starting motor cut-out (Personal code) relay (Coil side)

Monitor panel
Travel alarm
DC/DC converter
Radio
20-502-1
(11)
TROUBLESHOOTING
E-1
E-1 Engine does not start (Engine does not rotate)

Failure
information
The engine does not start (the engine does not rotate).
Relative
information
The following two engine start locking mechanisms are provided in the engine starting circuit.
1) Engine start locking by means of password in the monitor panel
2) Engine start locking by means of lock lever
Cause
1
Shortage in battery
capacity
Fuse Nos. 3 and 18

and Fusible Link A35
fault
Engine starting
switch fault
(Internal
disconnection)
Lock switch fault

(Internal
short-circuiting)
Engine starting
motor cut relay, R11
and R13 defective
(Internal
disconnection or
short-circuiting)

Battery voltage
Battery electrolyte specific gravity
Min. 24 V
Min. 1.26
When a fuse or fusible link is blown, there is a big possibility that grounding fault occurred in
the circuit. (Refer to cause 10)
If a monitor lamp does not light up in the monitor panel, check the power source circuit
between the battery and the specific fuse.
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
H15 (male)
Position
Resistance value
OFF
Min. 1 Mz
Start
Max. 1 z
Between (1) and (4)
S14 (female)
Between (1) and (3)
Lock lever
Resistance value
Release
Min. 1 Mz
LOCK
Max. 1 z
R11 (female) & R13 (male)
Resistance value
Between (1) and (2)
100 500 z
Between (3) and (5)
Min. 1 Mz
Between (3) and (6)
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting. (If all of the power source, grounding (GND), generation signal
and engine start input are normal and yet the engine start output is not normal, the engine
starting motor relay is defective)
Engine starting
motor fault
(Internal
disconnection or
short-circuiting)
Engine starting
motor fault
(Internal disconnection or damage)
Safety relay
Voltage
Power source: Between B terminal and grounding
20 30 V
GND (grounding): Between E terminal and grounding
Connected
Generation signal: Between R terminal (A27 (2)) and

grounding
Start
Max. 1 V
Engine start input: Between S terminal (A27 (1)) and

grounding
20 30 V
Engine start output: Between C terminal and grounding
20 30 V
during the troubleshooting. (If all of the power source, grounding (GND), generation signal
and engine start input are normal and yet the engine start output is not normal, the engine
starting motor relay is defective)
Engine starting motor
Power source: B terminal and grounding
Engine start input: C terminal and grounding
PC200/220(LC)-7
Engine starting switch
Engine startVoltage
ing switch
Start
20 30 V
20 30 V
20-503
(11)
TROUBLESHOOTING
Cause
Alternator fault
(Internal
short-circuit)
E-1

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position or
running during the troubleshooting.
E12 (male)
Voltage
Between (1) and grounding
Max. 1 V
Disconnection of wiring harness

(Disconnection or
defective contact
with connector)
Wiring harness between FB1-18 outlet and H15 (female) (1)
Resistance
value
Max. 1 z
Wiring harness from H15 (female) (4) to J01 to R11 (female)

(5)
Resistance
value
Max. 1 z
Wiring harness between R11 (female) (3) and A27 (female) (1)
Resistance
value
Max. 1 z
Wiring harness between engine starting motor relay C terminal and engine starting motor C terminal
Resistance
value
Max. 1 z
Wiring harness between FB1-3 and S14 (female) (1)
Resistance
value
Max. 1 z
Wiring harness between S14 (female) (3) and R11 (female) (1)
Resistance
value
Max. 1 z
Wiring harness between R11 (female) (2) and R13 (female) (6)
Resistance
value
Max. 1 z
Wiring harness from R13 (female) (3) to J04 to grounding
Resistance
value
Max. 1 z
Grounding fault of
wiring harness
10
(Contact with
grounding circuit)
Short-circuiting of
wiring harness
11
(Contact with 24 V
circuit)
20-504
(1)
Between wiring harness from battery relay B terminal (A23)

to A35 to FB1-18 and grounding
Resistance
value
Min. 1 Mz
Between wiring harness between FB1-18 outlet and H15

(female) (1) and grounding
Resistance
value
Min. 1 Mz
Between wiring harness from H15 (female) (4) to J01 to R11

Resistance
value
Min. 1 Mz
Between wiring harness between R11 (female) (3) and A27

Resistance
value
Min. 1 Mz
Between wiring harness between engine starting motor relay C

terminal and engine starting motor C terminal and grounding
Resistance
value
Min. 1 Mz
Between wiring harness between FB1-3 and S14 (female) (1)

and grounding
Resistance
value
Min. 1 Mz
Between wiring harness between S14 (female) (3) and R11

Resistance
value
Min. 1 Mz
Between wiring harness from R13 (female) (2) to J05 to P02

Resistance
value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Wiring harness between A27 (female) (2) and E12 (female)
(1), or wiring harness from A27 (female) (2) to J02 to D01
(female) (6), or between wiring harness between A27
(female) (2) and P02 (female) (11) and grounding
Voltage
Max. 1 V
PC200/220(LC)-7
TROUBLESHOOTING
E-1
Electrical Circuit Diagram for Engine Start, Stop and Battery Charging
PC200, 200LC-7 Serial No. 200001 250000
PC220, 220LC-7 Serial No. 60001 65000
PC200/220(LC)-7
20-505
(7)
TROUBLESHOOTING
E-1
Electrical Circuit Diagram for Engine Start, Stop and Battery Charging
PC200, 200LC-7 Serial No. 250001 and up
20-506
(7)
PC200/220(LC)-7
TROUBLESHOOTING
E-2
E-2 Engine stops while in operation

Failure
information
The engine suddenly stopped while in operation.
Relative
information
Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
(Code No. 031: governor potentiometer voltage)
Cause
1
Governor potentiometer fault

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

Failure
information
Engine speed is irregular at low idle.

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

(Code No. 010: Engine rotation)
Cause
Model code signal

fault
(Internal failure)

If the monitor display is not normal, proceed to Service Code [E217].
Monitoring Code
Item
Normal display
002
003
Controller model code
200
Governor lever
improperly adjusted
Refer to the section "Special Function of Monitor Panel" in this manual.
Governor motor
improperly working
If the governor motor lever moves smoothly in the following operations, it is judged as normal.
The fuel dial is operated between low idle and high idle.
The engine is stopped with the fuel dial.
Engine fuel control

system defective
Refer to the Engine Shop Manual.
ing harness
(Disconnection or
Wiring harness from C01 (female) (23) to J07 to H15 (female)
Resistance
defective contact
Max. 1 z
(5)
value
with connector)
Grounding fault of
wiring harness
(Contact with
grounding circuit)
Governor pump
As this is an internal failure, troubleshooting cannot be conducted.

(If there is none of the causes from Item 1 to 6 above, the controller is judged as defective)
20-508
(11)
Between wiring harness between C01 (female) (23) to J17

and H15 (female) (5) and grounding
Resistance
value
Min. 1 Mz
PC200/220(LC)-7
TROUBLESHOOTING
E-3
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging
PC200, 200LC-7 Serial No. 200001 250000
PC220, 220LC-7 Serial No. 60001 65000
PC200/220(LC)-7
20-509
(7)
TROUBLESHOOTING
E-3
20-509-1
(7)
PC200/220(LC)-7
TROUBLESHOOTING
E-4
E-4 Engine does not stop

The engine does not stop.
Relative
information
The Governor pump controller drives the battery relay for the min. 4 seconds and max. 7 seconds from
the moment the engine starting switch is turned OFF to the moment the engine completely stops.
It can be confirmed in the monitor function how the battery relay works (ON or OFF)
(Code No. 037: Controller output)
Failure
information
Cause
Battery relay fault
If operating sound is heard from the battery relay contact, when turning the engine starting
switch, the battery relay is judged as normal.
Starting switch OFFoONoOFF
Assembled-type
diode D01 fault
(Internal disconnection)
D01 (male)
Digital type circuit tester
Continuity
Between (5) and (1)
Diode mode
Continued

(Disconnection or
defective contact
with connector)
Governor pump
20-510
(5)
Wiring harness between C03 (female) (4) and D01 (female)

(5)
Resistance
value
Max. 1 z
Wiring harness from D01 (female) (1) to J01 to battery relay

BR terminal (A21)
Resistance
value
Max. 1 z
Wiring harness between battery relay E terminal (A20) and

grounding
Resistance
value
Max. 1 z
C03
Voltage
ONoOFF
20 30 V
(for 4 to 7 seconds)
PC200/220(LC)-7
TROUBLESHOOTING
E-4
PC200, 200LC-7 Serial No. 200001 250000
PC220, 220LC-7 Serial No. 60001 65000
PC200/220(LC)-7
20-511
(5)
TROUBLESHOOTING
E-4
20-511-1
(7)
PC200/220(LC)-7
TROUBLESHOOTING
E-5
E-5 Auto-decelerator does not work

Failure
information
The auto-decelerator does not work.
Relative
information
Rotation of the auto-decelerator is set at 1,400 rpm. If the fuel dial is not set adjusting to this level, the
auto-decelerator does not work.
Confirm the display on the monitor panel, when the engine is running.
Cause
Boom RAISE signal

fault

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

fault
Monitoring code
Item
Normal display
019
Arm DIGGING
Lever operation: ON
Lever NEUTRAL: OFF
Arm DUMPING
signal fault
Monitoring code
Item
Normal display
019
Arm DUMPING
Lever operation: ON
Lever NEUTRAL: OFF
Bucket DIGGING
signal fault
Monitoring code
Item
Normal display
021
Bucket DIGGING
Lever operation: ON
Lever NEUTRAL: OFF
Bucket DUMPING
signal fault
Monitoring code
Item
Normal display
021
Bucket DUMPING
Lever operation: ON
Lever NEUTRAL: OFF
Swing signal fault
Monitoring code
Item
Normal display
019
Swing
Lever operation: ON
Lever NEUTRAL: OFF
Travel signal fault
Monitoring code
Item
Normal display
019
Travel
Lever operation: ON
Lever NEUTRAL: OFF
Attachment signal
fault
Monitoring code
Item
Normal display
021
Service
Lever operation: ON
Lever NEUTRAL: OFF
Governor pump
10
20-512
(5)
As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the
causes listed in Item 1 through 9, the controller is judged as defective.
PC200/220(LC)-7
TROUBLESHOOTING
E-6
E-6 Auto engine warm-up device does not work

The auto engine warm-up device does not work.
Relative
information
The auto engine warm-up device is activated, when the engine coolant temperature is below 30C, and
raise the engine rotation up to 1,200 rpm.
The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.
Presumed cause and standard

value in normalcy
Failure
information
Cause
Engine coolant
temperature signal
fault
Governor pump
PC200/220(LC)-7

If the display on the monitor panel is not normal, proceed to No. E-14
Troubleshooting.
Monitoring code
041
Item
Normal display
Engine coolant
temperature
Compare with the actual

engine coolant
temperature.

(If the fault mentioned in the above item is not found, the Governor pump controller is
judged as defective)
20-513
(11)
TROUBLESHOOTING
E-7
E-7 Preheater does not work

Failure
information (1)
Even if the preheater switch is turned to the PREHEAT position, the preheating monitor lamp does not
light up.
Relative
information
Input of the preheating signal (ON or OFF) can be confirmed in the monitor function.
(Code No. 045: Monitor input 1)

value in normalcy
Cause
Engine starting
switch fault
If preheating does not occur (the heater is not warmed up), refer to Failure Phenomenon (2) below.
Disconnection of wir- a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posiing harness
tion during the troubleshooting.
(Disconnection or
Resistance
defective contact
Max. 1 z
Wiring harness between P02 (female)
and J02
value
with connector)
a Turn the engine starting switch OFF for the preparations.
P02
Monitor panel fault

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

value in normalcy
20-514
(11)
Engine starting
switch fault
Heater relay fault

Electrical intake air
heater

a Turn the engine starting switch OFF for the preparations.
H15 (male)
Between
Resistance value
OFF
Min. 1 Mz
HEAT
Max. 1 z
and
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Heater relay
Continuity and resistance value
Between coil terminal and grounding
Continued
Between contact terminals
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Between heater terminals
Normal if continuity is established.
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posiDisconnection of wirtion during the troubleshooting.
ing harness
Resistance
Wiring harness from H15 (female)
to J02 to heater
(Disconnection or
Max. 1 z
value
relay terminal (A25)
defective contact
Wiring harness between battery relay M terminal (A22)
Resistance
with connector)
Max. 1 z
and heater relay terminal
value
PC200/220(LC)-7
TROUBLESHOOTING
E-7
Electrical Circuit Diagram for Engine Preheater
PC200/220(LC)-7
20-515
(1)
TROUBLESHOOTING
E-8
E-8 All work equipment, swing and travel do not move

Failure
information
All the work equipment, swing and travel do not move.
Relative
information
Cause
Fuse No. 3 fault
Switch lock defective

PPC lock solenoid

fault
(Internal disconnection or short-circuiting)
Assembled-type
diode D01 fault
(Internal short-circuiting)

If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
(Refer to cause 6)
S14 (female)
Between (1) and (2)
Lock lever
Resistance value
Lock
Min. 1 Mz
Release
Max. 1 z
V01 (male)
Resistance value
Between (1) and (2)
20 60 z
Min. 1 Mz
D01 (male)
Resistance value
Between (8) and (4)
Min. 1 Mz
Disconnection of wirWiring harness between FB1-3 outlet and S14 (male) (1)
ing harness
(Disconnection or
defective contact
Wiring harness from S14 (male) (2) to J02 to V01 (female) (1)
with connector)
Wiring harness between V01 (female) (2) and grounding
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
20-516
(11)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Between wiring harness between FB1-3 outlet and S14
(male) (1) and grounding
Resistance
value
Min. 1 Mz
Wiring harness from S14 (male) (2) to J02 to V01 (female)

(1), or between wiring harness between S14 (male) (2) and
D01 (female) (8) and grounding
Resistance
value
Min. 1 Mz
PC200/220(LC)-7
TROUBLESHOOTING
E-8
Electrical Circuit Diagram for PPC Lock Solenoid
PC200/220(LC)-7
20-517
(11)
TROUBLESHOOTING
E-9
E-9 One-touch power maximizing function does not work

Failure
information
The one-touch power maximizing function does not work.
Relative
information
If the knob switch is pressed while the engine is running, the symbol mark is displayed in the monitor
panel.
Input from the knob switch can be confirmed in the monitor function. (Code No. 022: Switch input 1)
Cause
1
Fuse No. 9 fault
One-touch power
max. switch fault

(Refer to cause 4)
M23 (male)
Between (1) and (2)
Knob switch
Resistance value
Release
Min. 1 Mz
Depress
Max. 1 z
Disconnection of wirduring the troubleshooting.
ing harness
Resistance
(Disconnection or
Wiring harness between FB1-9 outlet and M23 (female) (1)
Max. 1 z
value
defective contact
Wiring harness between M23 (female) (2) and C01 (female)
Resistance
with connector)
Max. 1 z
(11)
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Between wiring harness between FB1-9 outlet and M23
Resistance
value
Min. 1 Mz
Between wiring harness between M23 (female) (2) and C01

Resistance
value
Min. 1 Mz
5
Governor pump
C01
Knob switch
Voltage
Release
Max. 1 V
Depress
20 30 V
Electric Circuit Diagram for One-Touch Power Maximizing Function
20-518
(11)
PC200/220(LC)-7
TROUBLESHOOTING
E-10
E-10 No display in monitor panel at all

Failure
information
When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
Relative
information
Cause

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

Part of the display in the monitor panel is missing.
Relative
information
Presumed cause and

standard value in normalcy
Failure
information
Cause
Monitor panel LCD

fault
If all the LCD in the monitor panel light up (i.e. the screen becomes totally white) by the
following switching operation, then the monitor panel is normal.
Switching operation: [ ] + [ A ] (simultaneous switching operation)
Monitor panel
defective
As this is an internal failure, troubleshooting cannot be conducted. (If there is no problem with the above switching operation, the monitor panel is judged as defective)
E-12 Monitor panel displays contents irrelevant to the model

The monitor panels displays contents that have nothing to do with the model on which it is installed.
Relative
information
Presumed cause and

standard value in normalcy
Failure
information
Cause
20-520
(1)
Model code signal

fault
(Internal failure)
Monitor panel
defective

If the display on the monitor panel is normal, proceed to Service Code [E217].
Monitoring code
Item
Normal display
002
003
Controller model code
200
As this is an internal failure, troubleshooting cannot be conducted. (If there is no problem with the above switching operation, the monitor panel is judged as defective)
PC200/220(LC)-7
TROUBLESHOOTING
E-13
E-13 Fuel level monitor red lamp lights up while engine is running
Failure
information
The fuel level monitor red lamp lighted up while the engine was running.
Relative
information
If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
(5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
(Code No. 042: Fuel level sensor)
Cause
1
Fuel level lowered

(system in normal
condition)
Fuel level sensor

fault
(Internal
disconnection)
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)

a Refill fuel.
A60 (male)
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 110 z
Wiring harness between P02 (female) (2) and A60 (female)
(1)
Resistance
value
Max. 1 z
4
Monitor panel
defective
P02 (female)
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 110 z
Electrical Circuit Diagram for Fuel Level Sensor
PC200/220(LC)-7
20-521
(5)
TROUBLESHOOTING
E-14
E-14 Engine coolant temperature gauge does not indicate correctly

Failure
information
The engine coolant temperature rises normally, but the display does not exceed the white range (C).
The engine coolant temperature remains stable, but the display rises to the red range (H).
Relative
information
Input from the engine coolant temperature sensor can be confirmed in the monitor function.
(Code No. 041: Engine coolant temperature)
Cause
Engine coolant temperature sensor fault


E05
Between (1) and (2)
Engine coolant
temperature
10 100 C
Resistance value
90 3.5 kz
Min. 1 Mz
ing harness
Resistance
(Disconnection or
Wiring harness between P02 (female) (1) and E05 (female) (2)
Max. 1 z
value
defective contact
Wiring harness between P02 (female) (13) and E05 (female)
Resistance
with connector)
Max. 1 z
(1)
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Between wiring harness between P02 (female) (1) and E05

Between wiring harness between P02 (female) (1) and E05

Resistance
value
Voltage
Min. 1 Mz
Max. 1 V
5
Monitor panel
defective
P02
Engine coolant
temperature
10 100 C
Resistance value
90 3.5 kz
Min. 1 Mz
Electrical Circuit Diagram for Engine Coolant Temperature Sensor
20-522
(11)
PC200/220(LC)-7
TROUBLESHOOTING
E-15
E-15 Hydraulic oil temperature gauge does not display correctly

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


A61
Between (1) and (2)
Hydraulic oil
temperature
10 100 C
Resistance value
90 3.5 kz
Min. 1 Mz
ing harness
Resistance
(Disconnection or
Max. 1 z
(2)
value
defective contact
Resistance
with connector)
Max. 1 z
(1)
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Between wiring harness between P02 (female) (12) and A61


Resistance
value
Voltage
Min. 1 Mz
Max. 1 V
5
Monitor panel
defective
P02
Hydraulic oil
temperature
10 100 C
Resistance value
90 3.5 kz
Min. 1 Mz
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
PC200/220(LC)-7
20-523
(11)
TROUBLESHOOTING
E-16
E-16 Fuel gauge does not display correctly

Failure
information
Though fuel was refilled, the display does not exceed the red range (E).
Though the remaining fuel level is low, the display does not drop below the green range (F).
Relative
information
Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
(Code No. 042: Fuel sensor voltage)
Cause
Fuel level sensor

fault

A60 (male)
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 110 z
ing harness
(Disconnection or
Resistance
defective contact
Wiring harness between P02 (female) (2) and A60 (female) (1)
Max. 1 z
value
with connector)
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)


Resistance
value
Voltage
Min. 1 Mz
Max. 1 V
5
Monitor panel
defective
P01
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 110 z
Electrical Circuit Diagram for Fuel Level Sensor
20-524
(5)
PC200/220(LC)-7
TROUBLESHOOTING
E-17
E-17 Swing lock monitor does not display correctly

Failure
information
Though the swing lock switch was turned ON, the swing lock monitor does not light up.
Though the swing lock switch was turned OFF, the swing lock monitor lights up.
Relative
information
Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.
Cause
Swing lock switch

fault

X05 (female)
Between (1) and (2)
Swing lock switch
Resistance value
OFF
Min. 1 Mz
ON
Max. 1 z
ing harness
Wiring harness from P02 (female) (17) to J02 to X05 (male)
Resistance
(Disconnection or
Max. 1 z
(1)
value
defective contact
Resistance
with connector)
Wiring harness from X05 (male) (2) to J05 to grounding
Max. 1 z
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Between wiring harness from P02 (female) (17) to J02 to X05

(male) (1), to C02 (female) (38) and grounding
Between wiring harness from P02 (female) (17) to J02 to X05

(male) (1), to C02 (female) (38) and grounding
Resistance
value
Voltage
Min. 1 Mz
Max. 1 V
5
Monitor panel
defective
P02
20-526
(5)
Swing lock switch
Voltage
OFF
20 30 V
ON
Max. 1 V
PC200/220(LC)-7
TESTING AND ADJUSTING
E-17
Electrical Circuit Diagram for Swing Lock Switch
PC200/220(LC)-7
20-527
E-18
E-18 When the monitor switch is operated, no display appears

Failure
information (1)
When operating the working mode changing switch, the working mode monitor does not appear.
Relative
information
Presumed
cause and
standard value
in normalcy
Cause
1
Monitor panel
defective

Failure
information (2)
When operating the auto-decelerator switch, the auto-deceleration monitor does not appear.
Relative
information
If the auto-decelerator itself does not work, either, carry out No. E-5 Troubleshooting.
Presumed
cause and
standard value
in normalcy
Cause
1
Monitor panel
defective

Failure
information (3)
When operating the travel speed shifting switch, the travel speed monitor does not appear.
Relative
information
If the travel speed does not actually change, carry out No. H-21 Troubleshooting.
Presumed
cause and
standard value
in normalcy
Cause
1
Monitor panel
defective

Failure
information (4)
When operating the windshield wiper switch, the windshield wiper monitor does not appear.
Relative
information
If the windshield wiper itself does not work, either, carry out No. E-19 Troubleshooting.
Presumed
cause and
standard value
in normalcy
Cause
1
Monitor panel
defective

Failure
information (5)
When operating the select switch, the adjustment display does not appear.
When operating the LCD monitor adjusting switch, the adjustment display does not appear.
When operating the maintenance switch, the item display does not appear.
Relative
information
Presumed
cause and
standard value
in normalcy
20-528
Cause
1
Monitor panel
defective

PC200/220(LC)-7
TROUBLESHOOTING
E-19
E-19 Windshield wiper does not work

Failure
information
The windshield wiper does not work.
Relative
information
Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.
Cause
Window rear limit

switch fault
Windshield wiper
motor fault

W03 (Switch side)
Between (1) and (2)
Front window
Resistance value
When installed at front
Min. 1 Mz
When retracted at rear
Max. 1 z
W04 (female)
Continuity and resistance value
Between (3) and (1)
Continued
Min. 1 Mz
ing harness
Wiring harness between P01 (female) (9) and W04 (female)
Resistance
(Disconnection or
Max. 1 z
(3)
value
defective contact
Wiring harness between P01 (female) (10) and W04 (female)
Resistance
with connector)
Max. 1 z
(1)
value
Grounding fault of
wiring harness
(Contact with
Resistance
grounding (GND) cir- Between wiring harness between P02 (female) (15) and W03
Min. 1 Mz
(1)
value
cuit)
Monitor panel fault
(Rear limit switch
system)
P02
Front window
Voltage
When installed at front
20 30 V
When retracted at rear
Max. 1 V
Monitor panel fault
(Windshield wiper
motor system)
20-530
(5)
P01
Windshield wiper switch
Voltage
OFF
Max. 3 V
ON
Max. 3 V
20 30 V
(Constant cycle)
PC200/220(LC)-7
E-19
Electrical Circuit Diagram for Windshield Wiper Motor
PC200/220(LC)-7
20-531
E-20
E-20 Alarming buzzer cannot be cancelled

Failure
information
The alarming buzzer cannot be cancelled.
Relative
information
Input from the alarming buzzer cancellation switch (ON or OFF) can be confirmed in the monitor function.
Cause
Alarming buzzer
cancellation switch
fault

Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
P03 (female)
Between
and
Alarming buzzer
cancellation switch
Resistance value
Release
Above 1 M
Depress
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness
Resistance
(Disconnection or
Below 1
Wiring harness between P02 (female)
and P03 (male)
value
defective contact
Resistance
with connector)
Below 1
Wiring harness from P03 (male)
to J05 to grounding
value
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between P02 (female)
(male)
and grounding
and P03
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4
P02
Monitor panel fault

Between
and grounding
Alarming buzzer
cancellation switch
Voltage
Release
20 30 V
Depress
Below 1 V
Electrical Circuit Diagram for Alarming Buzzer Cancellation Switch
20-532
PC200/220(LC)-7
TROUBLESHOOTING
E-21
E-21 "Boom RAISE" is not correctly displayed in monitor function

Failure
information
"Boom RAISE" is not correctly displayed in the monitor function on the monitor panel.
Relative
information
Cause
Boom RAISE PPC

hydraulic switch fault

S06 (male)
Between (1) and (2)
Boom control lever
Resistance value
NEUTRAL
Min. 1 Mz
RAISE
Max. 1 z
ing harness
Wiring harness between C03 (female) (10) and S06 (female)
Resistance
(Disconnection or
Max. 1 z
(1)
value
defective contact
Resistance
with connector)
Wiring harness between S06 (female) (2) and grounding
Max. 1 z
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
Between wiring harness between C03 (female) (10) and S06


Resistance
value
Voltage
Min. 1 Mz
Max. 1 V
a Turn the engine starting switch OFF for the preparations, start engine and carry out troubleshooting.
5
Governor pump
C03
Boom control lever
Voltage
NEUTRAL
20 30 V
RAISE
Max. 1 V
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC200/220(LC)-7
20-533
(5)
TROUBLESHOOTING
E-22
E-22 "Boom LOWER" is not correctly displayed in monitor function

Failure
information
"Boom LOWER" is not correctly displayed in the monitor function on the monitor panel.
Relative
information
Cause
Boom LOWER PPC


S02 (male)
Between (1) and (2)
Boom control lever
Resistance value
NEUTRAL
Min. 1 Mz
LOWER
Max. 1 z
ing harness
Resistance
(Disconnection or
Max. 1 z
(1)
value
defective contact
Resistance
with connector)
Max. 1 z
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)


Resistance
value
Voltage
Min. 1 Mz
Max. 1 V
5
Governor pump
C03
Boom control lever
Voltage
NEUTRAL
20 30 V
LOWER
Max. 1 V
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
20-534
(5)
PC200/220(LC)-7
TROUBLESHOOTING
E-23
E-23 "Arm DIGGING" is not correctly displayed in monitor function

Failure
information
"Arm DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Cause
Arm DIGGING PPC


S04 (male)
Between (1) and (2)
Arm control lever
Resistance value
NEUTRAL
Min. 1 Mz
DIGGING
Max. 1 z
ing harness
Resistance
(Disconnection or
Max. 1 z
(1)
value
defective contact
Resistance
with connector)
Max. 1 z
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)


Resistance
value
Voltage
Min. 1 Mz
Max. 1 V
5
Governor pump
C03
Arm control lever
Voltage
NEUTRAL
20 30 V
DIGGING
Max. 1 V
Electrical Circuit Diagram for Arm DIGGING PPC Hydraulic Switch
PC200/220(LC)-7
20-535
(5)
TROUBLESHOOTING
E-24
E-24 "Arm DUMPING" is not correctly displayed in monitor function

Failure
information
"Arm DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Cause
Arm DUMPING PPC a Turn the engine starting switch OFF for the preparations, and keep the engine running
hydraulic switch
defect
S08 (male)
Arm control lever
Resistance value
(Internal disconnecNEUTRAL
Min. 1 Mz
tion and short-circuitBetween (1) and (2)
ing)
DUMPING
Max. 1 z
ing harness
Resistance
(Disconnection or
Max. 1 z
(1)
value
defective contact
Resistance
with connector)
Max. 1 z
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)


Resistance
value
Voltage
Min. 1 Mz
Max. 1 V
5
Governor pump
C03
Arm control lever
Voltage
NEUTRAL
20 30 V
DUMPING
Max. 1 V
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
20-536
(5)
PC200/220(LC)-7
TROUBLESHOOTING
E-25
E-25 "Bucket DIGGING" is not correctly displayed in monitor function

Failure
information
"Bucket DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Cause
Bucket DIGGING
PPC hydraulic
switch fault
S01 (male)
Bucket control lever
Resistance value
Min. 1 Mz
ing)
DIGGING
Max. 1 z
ing harness
Resistance
(Disconnection or
Wiring harness between C03 (female) (9) and S01 (female) (1)
Max. 1 z
value
defective contact
Resistance
with connector)
Max. 1 z
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)


Resistance
value
Voltage
Min. 1 Mz
Max. 1 V
5
Governor pump
C03
Voltage
NEUTRAL
20 30 V
DIGGING
Max. 1 V
Electrical Circuit Diagram for Bucket DIGGING PPC hydraulic Switch
PC200/220(LC)-7
20-537
(5)
TROUBLESHOOTING
E-26
E-26 "Bucket DUMPING" is not correctly displayed in monitor function

Failure
information
"Bucket DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Cause
Bucket DUMPING
PPC hydraulic
switch fault
S05 (male)
Resistance value
Min. 1 Mz
ing)
DUMPING
Max. 1 z
ing harness
Resistance
(Disconnection or
Max. 1 z
(1)
value
defective contact
Resistance
with connector)
Max. 1 z
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)


Resistance
value
Voltage
Min. 1 Mz
Max. 1 V
5
Governor pump
C03
Voltage
NEUTRAL
20 30 V
DUMPING
Max. 1 V
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
20-538
(5)
PC200/220(LC)-7
TROUBLESHOOTING
E-27
E-27 "SWING" is not correctly displayed in monitor function

Failure
information
"SWING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Cause
Swing PPC hydraulic

switch, left, fault
Swing PPC hydraulic
switch, right, fault

S03 (male)
Between (1) and (2)
Swing control lever
Resistance value
NEUTRAL
Min. 1 Mz
Left
Max. 1 z
S07 (male)
Between (1) and (2)
Swing control lever
Resistance value
NEUTRAL
Min. 1 Mz
Right
Max. 1 z

(Disconnection or
defective contact
with connector)
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)

(1), or wiring harness between C03 (female) (29) and S07
(female) (1)
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Resistance
value
Max. 1 z
Resistance
value
Min. 1 Mz
Voltage
Max. 1 V
6
Governor pump
C03
20-540
(5)
Swing control lever
Voltage
NEUTRAL
20 30 V
Right or left
Max. 1 V
PC200/220(LC)-7
TROUBLESHOOTING
E-27
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
PC200/220(LC)-7
20-541
(1)
TROUBLESHOOTING
E-28
E-28 "TRAVEL" is not correctly displayed in monitor function

Failure
information
"TRAVEL" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
Cause
Travel PPC hydraulic

switch fault

S30 (male)
Between (1) and (2)
Travel control lever
Resistance value
NEUTRAL
Min. 1 Mz
Forward or reverse
Max. 1 z
ing harness
Wiring harness from C03 (female) (39) to J01 to S30 (female)
Resistance
(Disconnection or
Max. 1 z
(2)
value
defective contact
Resistance
with connector)
Wiring harness from S30 (female) (2) to J05 to grounding
Max. 1 z
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
(2), or between wiring harness between C03 (female) (39) and
A43 (female) (2) and grounding
Resistance
value
Min. 1 Mz
Voltage
Max. 1 V
5
Governor pump
C03
20-542
(5)
Voltage
NEUTRAL
20 30 V
Forward or backward
Max. 1 V
PC200/220(LC)-7
TROUBLESHOOTING
E-28
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
PC200/220(LC)-7
20-543
(1)
TROUBLESHOOTING
E-29
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function

Failure
information
"Travel Differential Pressure" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information
When pressure difference is created between the right and left travel PPC circuits (in steering), the travel
differential mechanism is turned ON.
Cause
Travel steering PPC


S31 (male)
Between (1) and (2)
Resistance value
NEUTRAL
Min. 1 Mz
One side of right or left only
Max. 1 z
ing harness
Resistance
(Disconnection or
Max. 1 z
(2)
value
defective contact
Resistance
with connector)
Wiring harness from S31 (female) (2) to J05 to grounding
Max. 1 z
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)


Resistance
value
Voltage
Min. 1 Mz
Max. 1 V
5
Governor pump
C03
20-544
(5)
Voltage
NEUTRAL
20 30 V
One side of right or left only
Max. 1 V
PC200/220(LC)-7
TROUBLESHOOTING
E-29
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
PC200/220(LC)-7
20-545
(1)
TROUBLESHOOTING
E-30
E-30 "Service" is not correctly displayed in monitor function

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

Service (rear) PPC

S10 (male)
Between (1) and (2)
Service pedal
Resistance value
NEUTRAL
Min. 1 Mz
Front
Max. 1 z
S11 (male)
Between (1) and (2)
Service pedal
Resistance value
NEUTRAL
Min. 1 Mz
Rear
Max. 1 z
Resistance
(Disconnection or
Max. 1 z
value
defective contact
(female) (1)
with connector)
Resistance
Max. 1 z
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)
Short-circuiting of
wiring harness
(Contact with 24 V
circuit)
S11 (female) (1) and grounding
Resistance
value
Min. 1 Mz
S11 (female) (1) and grounding
Voltage
Max. 1 V
6
Governor pump
C03
20-546
(5)
Service pedal
Voltage
NEUTRAL
20 30 V
Front or rear
Max. 1 V
PC200/220(LC)-7
TROUBLESHOOTING
E-30
Electrical Circuit Diagram for Service PPC hydraulic Switch
PC200/220(LC)-7
20-547
(5)
TROUBLESHOOTING
E-31
E-31 Troubleshooting for air conditioner system

PC200, 200LC-7 Serial No. 200001 250000
PC220, 220LC-7 Serial No. 60001 65000
The air conditioner does not work.
Relative
information
For the electrical circuit diagram inside the air conditioner unit, refer to the section of STRUCTURE AND
FUNCTION - Air Conditioner in this manual.
Failure
information
Cause
Fuse No. 11 fault
When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
ing harness
Resistance
(Disconnection or
Wiring harness between FB1-11 outlet and M26 (male) (4) (5)
Max. 1 z
value
defective contact
Resistance
with connector)
Wiring harness between M26 (male) (8) and grounding
Max. 1 z
value
Grounding fault of
wiring harness
(Contact with
grounding (GND)
circuit)

defective
Between wiring harness between FB1-11 outlet and M26
(male) (4) (5) and grounding
Voltage
Min. 1 Mz
M26
Voltage
Between (4) (5) and (8)
20 30 V
Electrical Circuit Diagram for Air Conditioner
20-548
(7)
PC200/220(LC)-7
TROUBLESHOOTING
E-31

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

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

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

If multiple Self-diagnosis notices are recorded,
press the UP switch ( ) or DOWN switch ( )
of temperature setting switch (3) to select
another notice.
How to delete Self-diagnosis notice

When reproducing the Self-diagnosis notices
or after removing the cause of a failure, press
the switches on both sides of recirc/fresh air
selector switch (4) simultaneously for 3 seconds
or more, and all the Self-diagnosis notices are
deleted.
Finishing display of Self-diagnosis notice

To finish display of the Self-diagnosis notice,
press OFF switch (1) or turn the starting switch
OFF.
PC200/220(LC)-7
Self-diagnosis
Failure mode
notice
E-No failures
Disconnection in recirculated air
E11
sensor
Short-circuit in recirculated air senE12
sor
Disconnection in coolant temperaE15
ture sensor
Short-circuit in coolant temperature
E16
sensor
E18
Short-circuit in daylight sensor
E43
Abnormality in air outlet damper
E44
Abnormality in air mix damper
Abnormality in recirculated and fresh
E45
air damper
20-549
(11)
TROUBLESHOOTING
Self-diagnosis
notice
Trouble
E-31
Disconnection in recirculated air sensor
E11
Contents of
trouble
Action of
control panel
Disconnection in the recirculated air sensor system is detected.

Fixes the recirculated air temperature for control.
When the following condition is satisfied, the operation returns to normalcy.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
Possible causes and

standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective recirculated
1 air sensor
Disconnection of wiring
harness (Disconnection
2
or defective contact with
connector)
Defective air conditioner

system
Self-diagnosis
notice
Trouble
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
THI (male)
Resistance
Between (1) and (2)
300 z 430 kz
starting switch ON.
Wiring harness between M30 (female) (12) and TH I
(female) (2)
Resistance
Max. 1 z

(female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
may be defective. Refer to CHASSIS COMPONENT, Shop Manual, Air conditioner.
Short circuit in recirculated air sensor
E12
Contents of
trouble
Action of
control panel
Short circuit in the recirculated air sensor system is detected.

Fixes the recirculated air temperature for control.
Related
information
Possible causes and

Cause
Defective recirculated air
1 sensor (Internal short circuit)
2
connector)
20-550
(5)

system

starting switch ON.
THI (male)
Resistance
Between (1) and (2)
300 z 430 kz
starting switch ON.
(female) (2)
Resistance
Max. 1 z

(female) (1)
Resistance
Max. 1 z
PC200/220(LC)-7
TROUBLESHOOTING
Self-diagnosis
notice
Trouble
E-31
Disconnection in coolant temperature sensor
E15
Contents of
trouble
Action of
control panel
Disconnection in the coolant temperature sensor system is detected.

Ignores the warm-up control and fixes the engine coolant temperature at 60C for control.
Related
information
Possible causes and

Cause
Defective coolant tem1 perature sensor (Internal

disconnection)
2
connector)

system
Self-diagnosis
notice
Trouble
starting switch ON.
THW (male)
Resistance
Between (1) and (2)
95 z 455 kz
starting switch ON.
Wiring harness between M30 (female) (14) and THW
(female) (2)
Resistance
Max. 1 z

(female) (1)
Resistance
Max. 1 z
Short circuit in coolant temperature sensor
E16
Contents of
trouble
Action of
control panel
Short circuit in the coolant temperature sensor system is detected.

Ignores the warm-up control and fixes the engine coolant temperature at 60C for control.
Related
information
Possible causes and

Cause
Defective coolant tem1 perature sensor (Internal
short circuit)
2
connector)

system
PC200/220(LC)-7

starting switch ON.
THW (male)
Resistance
Between (1) and (2)
95 z 455 kz
starting switch ON.
(female) (2)
Resistance
Max. 1 z

(female) (1)
Resistance
Max. 1 z
20-551
(11)
TROUBLESHOOTING
Self-diagnosis
notice
Trouble
E-31
Short circuit in daylight sensor
E18
Contents of
trouble
Action of
control panel
Short circuit in the daylight sensor system is detected.

Assumes that the daylight sensor is not installed for control.
Related
information
Possible causes and
Cause
Defective daylight sen1

The daylight sensor may be defective. Check it directly.
sor (Internal short circuit)
2
connector)

system
Self-diagnosis
notice
Trouble
starting switch ON.
Wiring harness between M30 (female) (16) and P15
(female) (2)
Resistance
Max. 1 z

(female) (1)
Resistance
Max. 1 z
Abnormality in air outlet damper
E43
Contents of
trouble
Abnormality in air outlet servomotor system is detected.
Action of
control panel
Stops the air outlet servomotor.

Related
information
a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
the motor output shaft and break the motor coils.
Cause
Possible causes and

Defective air outlet servo1

The air outlet servomotor may be defective. Check it directly.
motor (Internal defect)
starting switch ON.
Disconnection in wiring
2 in wiring harness or
defective contact in connector)
20-552
(5)

system
Wiring harness between MV1 (female) (1) and M30

(female) (3)
Resistance
Max. 1 z

(female) (11)
Resistance
Max. 1 z

(female) (9)
Resistance
Max. 1 z

(female) (8)
Resistance
Max. 1 z

(female) (9)
Resistance
Max. 1 z
If none of causes 1 and 2 is the cause of the trouble, the air conditioner system may
be defective. Refer to CHASSIS COMPONENT, Shop Manual, Air conditioner.
PC200/220(LC)-7
TROUBLESHOOTING
Self-diagnosis
notice
Trouble
E-31
Abnormality in air mix damper
E44
Contents of
trouble
Abnormality in air mix servomotor system is detected.
Action of
control panel
Stops the air mix servomotor.

Related
information
Cause
Possible causes and

Defective air mix servo1

motor (Internal defect)

The air mix servomotor may be defective. Check it directly.
starting switch ON.

system
PC200/220(LC)-7
Wiring harness between MAM (female) (1) and M29

(female) (11)
Resistance
Max. 1 z

(female) (3)
Resistance
Max. 1 z

(female) (2)
Resistance
Max. 1 z

(female) (4)
Resistance
Max. 1 z

(female) (5)
Resistance
Max. 1 z
20-553
(5)
TROUBLESHOOTING
Self-diagnosis
notice
Trouble
E-31
Abnormality in recirculated and fresh air damper
E45
Contents of
trouble
Abnormality in recirculated and fresh air servomotor system is detected.
Action of
control panel
Stops the recirculated and fresh air servomotor.

Related
information
Possible causes and

Cause
The recirculated and fresh air servomotor may be defective. Check it directly.
2 Defective fuse (in unit)
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.
Check the related circuits.
starting switch ON.
20-554
(5)
Defective recirculated
1 and fresh air servomotor
(Internal defect)

system
Wiring harness between MRF (female) (1) and M29

(female) (6)
Resistance
Max. 1 z
Wiring harness between MRF (female) (3) and M29

(female) (7)
Resistance
Max. 1 z
Wiring harness between MRF (female) (7), fuse in unit,

and M33 (female) (3)
Resistance
Max. 1 z
If none of causes 1 3 is the cause of the trouble, the air conditioner system may be
defective. Refer to CHASSIS COMPONENT, Shop Manual, Air conditioner.
PC200/220(LC)-7
TROUBLESHOOTING
E-31
PC200/220(LC)-7
20-555
(5)
TROUBLESHOOTING
E-31
Troubleshooting by failure phenomenon

Trouble
The air conditioner does not operate.
(1) The air conditioner does not operate at all.
Related
information
Cause
1 Defective fuse No. 11

If the fuse is broken, the circuit probably has a grounding fault, etc. (Refer to cause
3.)
starting switch ON.
Possible causes and

Short circuit with chassis

ground in wiring harness
3
(Contact with ground circuit)
Wiring harness between fuse 11 outlet and M33 (male)

(3)
Resistance
Max. 1z
Wiring harness between M27 (female) (14) and M30

(female) (6)
Resistance
Max. 1z
Wiring harness between M33 (male) (3) and chassis

ground
Resistance
Max. 1z
Wiring harness between M29 (female) (12) and chassis

ground
Resistance
Max. 1z
starting switch ON.
Between wiring harness between circuit breaker fuse 11
outlet and M33 (male) (3) and chassis ground
Resistance
Min. 1 Mz
Between wiring harness between M27 (female) (14) and

M30 (female) (6) and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
4

unit
M33
Voltage
Between (2) and (3)
20 V 30 V
If the above voltage is normal and the air conditioner does not operate, the air conditioner is defective.
5 Defective control panel
M30, M29
Voltage
Between M30 (6) and M29 (12)
20 V 30 V
If the above voltage is normal and the air conditioner does not operate, the control
panel is defective.
20-556
(5)
PC200/220(LC)-7
TROUBLESHOOTING
Trouble
E-31
(2) Air does not come out (Air flow is insufficient).
Related
information
Cause
Possible causes and

Defective blower relay

(on coil side)
Defective blower relay

(on contact side)
Defective power transistor (Internal defect)

starting switch ON.
R30 (male)
Resistance
Between (1) and (3)
140 340 z
R30
Fan switch
Voltage
Between (4) and

chassis ground
ON (Operated)
20 30 V
Fan switch
Operate in range of Low, Medium, and
High
If air flow can be changed with fan switch,

power transistor is normal.
5
Defective blower motor

(Internal defect)
MB (female)
Fan switch
Voltage
Between (1) and (2)
ON (Operated)
20 30 V
If the above voltage is normal and the blower motor does not rotate, the blower motor
is defective.
starting switch ON.

system
PC200/220(LC)-7
Wiring harness between fuse 11 outlet, fuse in unit, R30

(3), R31 (female) (1), and M30 (female) (6)
Resistance
Max. 1 z
Wiring harness between M29 (female) (3) and R30

(female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
Wiring harness between MB (female) (1) and R30

(female) (4)
Resistance
Max. 1 z
Wiring harness between MB (female) (2) and PTR

(female) (3)
Resistance
Max. 1 z
Wiring harness between PTR (female) (1) and chassis

ground
Resistance
Max. 1 z
Wiring harness between PTR (female) (2) and M30

(female) (7)
Resistance
Max. 1 z
Wiring harness between PTR (female) (4) and M30

(female) (8)
Resistance
Max. 1 z
20-557
(5)
TROUBLESHOOTING
Trouble
E-31
(3) Air is not cooled (Cooling capacity is low).
Related
information
Cause
Possible causes and

Defective compressor
relay (on coil side)
relay (on contact side)
Defective thermostat
(Internal defect)
Defective high/low pres5 sure switch (Internal disconnection)
starting switch ON.
R31 (male)
Resistance
Between (1) and (2)
140 340 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (Setting of temperature: Highest cooling position).
R31
Fan switch
Voltage
Between (4) and chassis

ground
ON (Operated)
20 30 V
The thermostat may be defective. Check it directly.

starting switch ON.
P17 (male)
Resistance
Between (1) and (2)
Max. 1 z
clutch (Internal defect)
The compressor clutch may be defective. Check it directly.
(Internal defect)
The compressor may be defective. Check it directly.

starting switch ON.
20-558
(5)


system

(female) (1)
Resistance
Max. 1 z
Wiring harness between P17 (female) (2) and chassis

ground
Resistance
Max. 1 z
Wiring harness between fuse 11 outlet, R31 (female)

(2), fuse in unit, R31 (female) (1), and M30 (female) (6)
Resistance
Max. 1 z
Wiring harness between ST1 (female) (1) and R31

(female) (3)
Resistance
Max. 1 z
Wiring harness between M29 (female) (2) and ST1

(female) (2)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
Wiring harness between R31 (female) (4) and M34

(female) (1)
Resistance
Max. 1 z
PC200/220(LC)-7
TROUBLESHOOTING
E-31
PC200/220(LC)-7
20-559
(5)
TROUBLESHOOTING
E-32
E-32 Travel alarm does not sound

Equipped with travel alarm
Failure
information
The travel alarm does not sound while the machine is traveling.
The alarm begins to sound when the machine is at a standstill.
Relative
information
Cause
Fuse No. 15 fault
When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
(Refer to cause 4)
If the monitor display is not correct, proceed to No. E-21 Troubleshooting.
Travel signal fault
Monitoring code
019
Item
Normal display
Travel
Control lever operation: ON

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

Troubleshooting Ofelectrical System (E-Mode)

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TROUBLESHOOTING OF

ELECTRICAL SYSTEM (E-MODE)

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-502

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

Phenomena occurring on machine

Information on occurred failures and troubleshooting

Presumed cause and standard value in normalcy

Standard value in normalcy and references for troubleshooting

Cause for presumed

<Phenomena of wiring harness fault>

Relative Electrical Circuit Diagram

BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE

BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE

Emergency pump drive resistor

Governor, pump controller (Solenoid power supply)

Air conditioner unit

Service power supply (M32 connector)

Attachment return switching relay (Coil side and contact side)

Rotary lamp switch

Starting motor cut-out (Personal code) relay (Coil side)

E-1 Engine does not start (Engine does not rotate)

Presumed cause and standard value in normalcy

Fuse Nos. 3 and 18

Lock switch fault

Standard value in normalcy and references for troubleshooting

Battery electrolyte specific gravity

Between (1) and (4)

Between (1) and (2)

Between (3) and (5)

Between (3) and (6)

Power source: Between B terminal and grounding

GND (grounding): Between E terminal and grounding

Generation signal: Between R terminal (A27 (2)) and

Engine start input: Between S terminal (A27 (1)) and

Engine start output: Between C terminal and grounding

Engine starting switch

Standard value in normalcy and references for troubleshooting

Between (1) and grounding

Presumed cause and standard value in normalcy

Disconnection of wiring harness

Wiring harness between FB1-18 outlet and H15 (female) (1)

Wiring harness from H15 (female) (4) to J01 to R11 (female)

Wiring harness between FB1-3 and S14 (female) (1)

Wiring harness from R13 (female) (3) to J04 to grounding

Between wiring harness from battery relay B terminal (A23)

Between wiring harness between FB1-18 outlet and H15

Between wiring harness from H15 (female) (4) to J01 to R11

Between wiring harness between R11 (female) (3) and A27

Between wiring harness between engine starting motor relay C

Between wiring harness between FB1-3 and S14 (female) (1)

Between wiring harness between S14 (female) (3) and R11

Between wiring harness from R13 (female) (2) to J05 to P02

E-2 Engine stops while in operation

The engine suddenly stopped while in operation.

Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

Governor potentiometer fault

Between (A) and (C)

Between (B) and (A)

Between (B) and (C)

Between (22) and (21)

Between (13) and (21)