manual PC200(210)(220)(240)-3 SM

'.

SEBM02050309

KOMATSU

www. k omat s upar t s book . c om

PC200,21 0-3

PC220,240-3 -

MACHINE MODEL

SERIAL No.

20001 and up

PC200,200LC-3

K10001 and up

PC21 0,21 OLC-3K PC220,220LC-3

20001 and up

PC240 ,240LC ,240NLC-3

10001 and up

PC240,240LC,240NLC-3K

K10001 and up

NOTE: Please correct the information regarding the applicability of pages 11-1 and following as follows: Present

-

PC200-3

PC220-3

Printed in Japan 07-88(01 )06261

21464 and up

26365 and up

Revised

•

PC200-3

•

PC210-3

• •

PC220-3 PC240-3

21464 and up

26365 and up

00-1 ®

-

CONTENTS No. of page

01 GENERAL

01-1

10 ENGINE 11

STRUCTURE AND FUNCTION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

11-1

12

TESTING AND ADJUSTING

12-1

13

DISASSEMBLY AND ASSEMBLY

13-1

20 POWER TRAIN 21

STRUCTURE AND FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

21-1

22


22-1

23


23-1

24

MAINTENANCE STANDARD

24-1

-

www. k omat s upar t s book . c om 30 UNDERCARRIAGE 31

STRUCTURE AND FUNCTION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

31-1

33


33-1

34


34-1

60 HYDRAULIC SYSTEM 61

STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

61-1

62


62-1

63


63-1

64


64-1

80 ELECTRIC AND ELECTRONIC SYSTEM 81

STRUCTURE AND FUNCTION

81-1

82


82-1

90 OTHERS 93

00-2 ®

DISASSEMBLY AND ASSEMBLy

93-1

PC200, 220-3

-

-

LIST OF REVISED PAGES


The affected pages are indicated by the use of the following marks. It is requested that necessary actions be taken to these pages according to the table below.

Mark

Action required

Indication

0

Page to be newly added

•

Page to be replaced

Add Replace

) Page to be deleted

(

Discard

Pages having no marks are those previously revised or made additions.

-

LIST OF REVISED PAGES Mark

Page

Time of revision

•

00- 1

®

Mark

Page

Time of revision

Mark

Page

01-15-1

00-24

Time of revision

Mark

(1)

Page

Time of revision

11-14-1

@

Mark

Page

Time of revision

13- 4

(I)

www. k omat s upar t s book . c om • •

• • •

00- 2

CV

00-25

01-15-2

(1)

00- 2-1

® ® ® ® ®

00-26

01-16

CV

00-27

01-17

00- 2-2

00- 2-3

00- 2-4 00- 2-5 00- 3

-

@

13- 6

11-14-3

@

13- 7

11-15

(2)

13- 8 13- 9

00-28

01-17-1

(1)

11-16

(2)

00-29

01-17-2

(j)

11-17

(1)

00-30

01-18

(1)

00-31 12- 1

00- 4

-

11-14-2

(7)

® ® (I)

13-10 13-12

(I)

13-13

CD

13-14

CV

12- 2

13-15

11- 2

@

12- 3

13-16

(1)

11- 3

@

12- 3-1

13-17

(I)

(1)

11- 4

12- 4

13-18

(i)

(1)

11- 5

12- 5

13-19

CD

12- 6

13-20

CD

CD

00- 5

01- 1

11- 1

00- 6

01- 3

00- 7

01- 4

00- 8

01- 5

00- 9

01- 6

00-10

01- 7

(1)

11- 6

00-11

01- 7-1

(1)

11- 7

CV

12- 7

00-12

01- 8

(1)

11- 8

(1)

12- 8

13-22

CD

00-13

01- 9

(1)

11- 8-1

(1)

12- 9

13-23

CD

00-14

01- 9-1

(1)

11- 9

@

12-10

(I)

13-24

CD

00-15

01- 9-2

(j)

11-10

(2)

12-11

@

13-25

CD

00-16

01-10

(1)

11-11

(2)

12-12

13-26

(I)

00-17

01-11

(1)

11-11-1

(7)

13-28

®

00-18

01-11-1

(1)

11-11-2

(1)

00-19

01-11-2

(1)

11-11-3

(1)

00-20

01-12

@

11-11-4

@

00-21

01-13

®

13- 1

00-22

01-14

CV CV

11-12 11-13

@

13- 2

00-23

01-15

11-14

CV

13- 3

PC200,220·3

@

•

12-13 12-14

CD

CD

® ®

13-21

13-29

13-31

® ®

®

13-32

(I)

en

13-34

®

13-35

0)

13-30

00-2-1 ®



Mark

Page

Time of revision

13-36 13-37 13-38

Page

Time of revision

@

21-34

@

21-35

CD

21-36

® ® ®

21-37

(~

21-38

($)

13-39 13-40

Mark

Page

Time of revision

23- 8-8

@

24- 1

23- 8-9

@

24- 2

23- 8-10

@

23- 8-11

@

23- 8-12

(4)

Mark

Page

Time of revision

34- 9

(8)

(2)

34-10

(~

24- 4

®

34-11

(8)

24- 5

(2)

34-12

(8)

24- 6

34-13

(8)

Page

Time of revision

Mark

21-39

(2)

23- 9

24- 7

34-14

@

21-40

23-10

24- 8

34-15

(8)

21- 2

(2)

21- 3

($)

21-43

21- 4

21-43-1

21- 5

® ®

® ® ® ® ®

21-44

(2)

23-15

31- 1

21- 6

®

21-45

(2)

23-16

31- 2

61- 4

(2)

21- 7

(2)

21-46

(J)

23-17

31- 3

61- 5

(6)

21- 1

•

@

Mark

®

21-41 21-42

23-11

(I)

24- 9 24-10

23-12

(?)

23-13

61- 1

(2)

23-14

61- 2

(2)

®

61- 3

-

www. k omat s upar t s book . c om 21- 8

21-47

21- 9

®

21- 9-1

®

21- 9-2

(6)

23- 1

(2)

23-20

31- 5-1

23-21

31- 5-2

® ® ® ®

31- 6

(8)

61- 9

23-18 23-19

@

31- 4

(I)

31- 5

61- 6 61- 7

•

®

61- 8

(9)

61- 8-1

®

21-10

®

23- 2

21-11

(2)

23- 3

(I)

23-23

31- 7

(8)

61-10

(2)

21-12

(6)

23- 4

CD

23-24

31- 7-1

61-11

(?)

21-13

(S)

23- 5

(I)

® ®

61-12

(2)

23-22

(I)

23-25

(5)

21-14

23- 6

23-26

'I)

21-15

23- 7

23-27

21-16

23- 7-1

23-28

33- 1

31- 7-2

61-13 61-14

(2)

61-15

(2)

21-18

23- 7-2

(4)

23-29

33- 2

(D

61-16

21-19

23- 7-3

(4)

23-30

33- 3

(f)

61-17

(2)

21-20

23- 7-4

23-31

21-21

23- 7-5

(4)

23-32

21-22

23- 7-6

@

23-33

21-23

23- 7-7

(4)

23-34

21-24

® ®

33- 4

61-18

(2)

33- 5

61-19

(2)

(I)

33- 6

61-20

(2)

61-21

(2)

33- 7

(I)

®

23- 7-8

(4)

23-35

21-26

23- 8

($)

23-36

($)

21-27

23- 8-1

@

23-37

21-28

23- 8-2

(4)

23-38

® ® ® ®

61-22

(2)

61-23

(2)

34- 1

61-25

34- 2

61-26

34- 4

21-29

23- 8-3

@

23-39

21-30

23- 8-4

(Ii)

23-40

21-31

23- 8-5

@

34- 6

21-32

23- 8-6

(4)

34- 7

21-33

23- 8-7

@

34- 8

00-2-2 ®

®

®

34- 5

-

61-27 61-28

® ® ®

61-29 61-30 61-31

PC200. 220-3

-



Mark

Page

Time of revision

Mark

0')

62-11

@

0

® ®

62-12

@

0

62-51-3

61-66

62-13

@

0

62-51-4

61-34-1

61-67

(J)

62-14

(~

0

62-51-5

61-34-2

61-68

(T)

62-16

(~

0

62-51-6

(~

Page

Time of revision

61-64

61-33

® ®

61-65

61-34

(8)

Page

Time of revision

61-32

Mark

61-35 61-36

7

•

61-37

-

Mark

61-69

@

62-17

61-70

®

62-18

($)

61-71

(~

62-19

($)

Page

62-51-2

Time of revision

® ® ® ® ®

Mark

Page

Time of revision

•

62-85

®

(62-86) (62-881 (62-89) (62-90)

62-52

•

(62-91 )

62-53

®

(62-92)

62-54

0)

(62-93)

61-38

(E;)

61-72

(2)

62-20

(~

62-55

@

•

62-94

(2)

62-21

(5)

62-56

(~

62-22

62-57

(~

• •

62-95

61-39

®

61-73

61-40

(J)

61-74

(5)

61-41

(J)

61-41-1

(J)

•

61-41-2

61-75

®

62-23

(~)

62-58

(5)

61-76

(~

62-24

($)

62-59

(5)

61-77

(2)

62-25

(5)

62-60

•

62-96

® ® ®

62-97

@

62-98

®

62-99

(~

www. k omat s upar t s book . c om 61-42

61-78

(5)

62-61

®

61-79

($)

62-27

62-61-1

(J)

61-44

(J)

61-80

(5)

62-28

($)

62-61-2

61-45

(~

61-81

(2)

62-29

($)

62-62

® ®

• •

• •

62-100

(~

62-101

62-105

CS) ® ® ® ®

62-102

62-103

®

61-82

(2)

62-30

($)

62-63

(5)

61-47

(J)

61-83

(2)

62-32

@

62-64

(5)

61-48

(J)

61-84

(D

62-33

@

62-65

(5)

62-106

(5)

61-48-1

(J)

61-85

62-34

($)

62-66

($)

62-107

(5)

61-48-2

(T)

61-86

(2)

62-35

@

62-67

®

62-108

(~

61-49

(T)

61-87

(2)

62-36

(5)

62-68

@

62-109

(£

61-50

®

61-88

(2)

62-37

@

62-69

@

62-110

®

(7)

61-89

®

62-38

(~

62-70

(~

62-111

($)

61-90

(3)

62-39

®

62-71

®

62-112

61-91

(2)

62-40

(~

62-72

(~

• •

61-53-1

62-41

(5)

62-73

($)

•

62-114

® ® ®

61-53-2

62-42

(~

62-74

@

62-115

(5)

(~

62-116

(5)

62-117

@

•

62-118

• •

62-120

® ® ®

61-52 61-53

-

62-26

61-43

61-51

• •

(2)

($)

61-46

-

7'

(D

62-43

C~

62-75

62-44

@

62-76

(5)

62- 3

62-45

@

62-77

($)

62- 4

(~

62-46

@

62-78

62- 5

@

•

62-47

62- 6

@

•

62-48

62- 7

(5)

•

62-49

62- 8

(5)

•

62-50

(2)

62- 9

@

•

62-51

(2)

62-10

@

0

62-51-1

® ® ® ® ® ®

(2)

61-55

(2)

61-56

(2)

61-57

(2)

61-58 61-59

® ®

61-60

(2)

61-61

0)

61-62 61-63

PC200, 220-3

•

® ® (Kl

61-54

62- 1 62- 2

•

62-79

•

62-80

• •

62-81 62-82

•

62-83

® ® ® ® ®

62-84

@

•

•

62-104

62-113

62-121 62-122

(~

62-123

(5)

62-124

®

62-125

(5)

62-126

(J)

00-2-3 ®



Mark

Page

Time of revision

Mark

62-127

@

•

62-128

@

62-129

@

•

62-154

62-130

@

62-155

62-131-1

(J)

62-131-2

(J)

62-131-3

(J)

62-131-4

(J)

• • • • •

62-131-5

(J)

•

62-160

62-131-6

(J)

62-131-7

(J)

62-131-9

(J)

• • •

62-161

Page

Time of revision

62-152

®

Mark

62-156 62-157 62-158 62-159

62-162

Time of revision

63- 9-13

(62-153)

® ® ® ® ® ® ® ® ® ®

Page

•

Mark

®

Page

Time of revision

64- 1

®

81- 5-5

64- 2

(2)

81- 6

64- 3

®

81- 7

CZ)

Page

Time of revision

® ®

63- 9-14

@

63- 9-15

(J)

63- 9-16

®

64- 4

®

81- 8

®

63- 9-17

@

64- 5

®

81- 9

G)

63- 9-18

(~

64- 6

81-10

G)

63-10

CI)

64- 7

81-11

G)

63-11

64- 8

81-12

63-12

64- 9

(~

81-13 81-14 81-15

® ® ® ® ® ® ®

•

63-13

CD

64-10

G)

63-14

(I)

64-11

63-15

(D

64-12

62-131-12 (J)

(62-166)

62-132

(J)

(62-167)

62-133

(J)

62-169

(5)

63-20

CD

64-17

® ® ® ® ® ® ®

62-134

@

62-170

@

63-21

(I)

64-18

62-135

~)

63-22

(I)

64-19

62-136

@

63-23

(I)

64-20

62-137

(~

63- 1

c~

63-24

CD

64-21

62-138

@

63- 2

63-25

(I:';

64-22

62-139

@

63- 3

63-26

(I)

64-23

62-139-1

(J)

63- 4

63-27

(J)

63- 6

63-28

W CD

64-24

62-139-2

CD CD CD CD

62-139-3

(J)

63- 7

(D

63-29

Cc

62-139-4

(J)

63- 8

63-30

62-139-5

(J)

63- 9

CD CD

63-31

62-139-6

(J)

63- 9-1

(~

® ® ® ® ® ® ® ® ® ® ®

63- 9-2

(J)

63- 9-3

@

63- 9-4

(J)

63-36

63- 9-5

(5)

63-37

63- 9-6

(5)

63- 9-7

@

63- 9-8

@

63- 9-9

62-163

Mark

62-131-10 (J)

(62-164)

63-16

(I)

64-13

62-131-11 (J)

(62-165)

63-17

(I

64-14

81-16 81-17 81-18

-


•

62-140

•

62-141

0

62-142

•

62-144

0

62-145

•

62-146

•

62-147

•

62-148

• • •

62-149 62-150 62-151

00-2-4 ®

63-18

64-15

63-19

64-16

82- 1

®

®

82- 2

G)

® ® ® ® ®

82- 3

CD

82- 4

CIi

82- 6

G)

82- 7

@

82- 8

G)

82- 9

(j)

(j)

82-10

0)

64-26

82-11

@

CD

64-28

82-12

0)

64-29

82-13

(3)

63-32

CD CD

64-30

82-14

(5)

63-34

(I)

82-15

(3)

63-35

82-16

G)

G) G)

63-38

CD CD CD CD

63-39 63-40

@

63-41

63- 9-10

@

63-42

63- 9-11

® ®

63-43

63- 9-12

64-25

81- 1

®

82-17

81- 2

®

82-18

81- 3

G)

CD

® ®

82-19

81- 4

82-20

G)

CD

81- 5

G)

82-21

G)

CD CD CD

81- 5-1

(J)

82-22

(5)

81- 5-2

® ® ®

82-23

G)

82-24

G)

82-25

(3)

81- 5-3 81- 5-4

PC200, 220-3

-

-


Mark

Page

Time of revision

82-26

(3)

82-27

@

Mark


Page

Time of revision

Mark

Page

Time of revision

Mark

Page

Time of revision

Mark

Page

Time of revision

82-28 82-30

@

82-31

-

82-32

(3)

82-33

(3)

82-35

82-55

® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ®

91- 1

CD

91- 2

(I)

91- 3

CD

82-36 82-37 82-38 82-39 82-40 82-41

www. k omat s upar t s book . c om 82-42

82-43

82-44

82-45 82-46 82-47 82-48 82-49 82-50

-

82-51 82-52 82-53 82-54

PC200. 220-3

00-2-5 ®

...

-

-


-

~ IMPORTANT

SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed by Komatsu for the purpose.

it

¢

To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

-

LtSAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

www. k omat s upar t s book . c om 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.

-

2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always

-

inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.

PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

00-3

PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug

or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first.

19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21 . When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.

-

www. k omat s upar t s book . c om 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.

24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

-

16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

00-4

-

- - - - - - - - - - FOREWORD - - - - - - - - - This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.

.-

STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included in this section.

www. k omat s upar t s book . c om DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts.

-

NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information.

00-5

HOW TO READ THE SHOP MANUAL

-

HOW TO READ THE SHOP MANUAL (CD ® G) .... )

VOLUMES

REVISED EDITION MARK

Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages.

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume volume to cover all } Attachments volume : models These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready.

DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most upto-date information before you start any work.

REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page.

SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols.

-

www. k omat s upar t s book . c om FILING METHOD

1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume):

21 - 3

t

Unit number (2. Power train) Item number (1. Structure and Function) Consecutive page number for each item.

Example 2 (Engine volume):

Symbol

Item

Special safety precautions are necessary when performing the work.

~ Safety

Extra special safety precautions are necessary when performing the work because it is under internal pressure.

¢

*

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts or systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

12-410 L....if---+--+-- Unit number (1. Engine) L--+-+__ Item number (2. Testing and Adjusting) L-+-__ Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example:

21-4 21-4-1 21 -4-2 21-5

00-6

J--

12-203 112-203-1 Added pages~12-203-2 12-204

Remarks

db ~

~.

Wi • ...:.

-

Places that require special Tightenattention for the tightening ing torque torque during assembly. Coat

Places to be coated with adhesives and lubricants etc.

Places where oil, water or fuel Oil, water must be added, and the capacity.

Drain

Places where oil or water must be drained, and quantity to be drained.

-

-


NETWORK (Disassembly and assembly relationship drawings)

MAINTENANCE STANDARD Standard size, Tolerance

In the shop manual the following network drawings show relationship between work items and sequence for assembly and disassembly.

The way to show this is by a plus or a minus sign with the tolerance in smaller numerals to the right of the standard size.

Ass'y

-

The dimensions of finished parts each differ a little. Therefore, when determining the finished dimensions of parts, a dimension that will be standard is determined provisionally, then the difference allowed from it is indicated. The former is called the standard size, and the latter the tolerance.

Example:

120- 0 .026

-0.126

Utequals 119.874 -

In this network the sequence of disassembly is marked on the top right of each work item so that handling can be easily understood. For example, when taking D of the Ass'y follow the sequence A B- D, when removing E follow the sequence A -E.

119.978 mm)

Moreover, when expressing the dimensions of a hole and the shaft that goes inside it, for the sake of convenience, the standard size for the hole and the shaft are usually taken as the same, and the tolerances changed to indicate the tightness of the fit. For example, the fit of a revolving shaft is indicated as follows, and is shown in the drawing.

www. k omat s upar t s book . c om I

I

F ass'y indicates a further separate disassembly, and indicates the existence of a previous work network. For assembly the sequence is shown using the same kind of network.

0030 Shaft-- 60-0.076

TROUBLESHOOTING CHART

-

N N

<0
C')

0

ci ci

ci Qi u c co

As shown below, the symptoms relating to a particular trouble are described in the line designated "Problems". The probable cause of the trouble is then marked under the "Causes" column.

0

Q) u Qi c uc co co Q)

me

Q;

B

Q)

u u

Q;

x co c:

Q. Q.

:2 ~

::J

<0 ,....

0

0

0

Qi c co

u

ci ci u

Q; Q; Q; Q; ~

0

o

Hole - - .

t: > 0

co "E

.~ C

co

.. -0 ."" . ~

Q. Q.

::J

'~~T' :=1_JL-._

Causes a. E ::l a.

Qi c co

BB ....J

Example: Symptom: Reduced tractive power or slow travel speed.

C')

-_.

Shaft

Q)

N

en "Ui

.51

:; co

>

.s:;

::l

C"

B .E

'"

-" co

Torque converter oil pressure gauge shows lower than

normal pressure. (normal 3 - 4.8 kg/em 2 )

-

.E

.,

0 ."

6

" '" <

0

0

~

Problems

£;

Transmission oil pressure gauge shows lower than normal

::l

FS0002

0

0

pressure. (normal 20 - 23 kg/em 2 )

0

00-7


-

Standard size This is the standard value at the time of design.

Repair limit This is the limit in dimensions which the part can be used. When parts exceed the repair limit, they must be repaired or replaced as specified.

Example: Unit: mm No.

Check item

Criteria Standard size

Remedy Repair limit

-

www. k omat s upar t s book . c om Standard clearance

This is the clearance between new parts after assembly. It is recorded as a range between minimum clearance and maximum clearance. The clearance is adjusted to this value.

Clearance limit This is the maximum clearance allowed. When the clearance exceeds the clearance limit, the parts must be repaired or replaced as specified.

Example: Unit: mm No.

Check item

Remedy

Criteria Standard size

Tolerance Shaft

Hole

-

Standard Clearance clearance limit

00-8

-

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 1. PREPARATIONS BEFORE DISASSEMBLY 1. Washing before taking a machine into the repair shop Thoroughly wash the machine to remove sand, mud and dust before taking it into the shop. Taking a dirty machine into the shop will decrease work efficiency, cause damage to parts, and increase the intrusion of dust and dirt into the machine when it is reassembled.

-

2. Checking the machine before disassembly Before disassembly, study the entire disassembly procedure from beginning to end in the reference materials, and carefully check and record the items listed below. This will help to save unnecessary disassembly and parts costs. It will also give clues on how to prevent recurrence of the trouble. • Machine model, serial number and service meter reading. • Reason for disassembly. (Symptoms, locations, and cause of trouble) • Any dirty air cleaner elements or air leakage. • Properties of fuel used, clogging of fuel filter elements, water mixed in fuel. and leaky or constricted fuel pipes. • Oil capacities, dirtiness of oils (viscosity, color, and any impurities). wat~r mixed in oil. oil leakage, and any clogging of oil filter elements.

2. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 1. During disassembly 1) If the disassembly involves draining oil or lubricants, have containers of suitable capacity on hand. Do not spill any oil or lubricants on the floor. 2) Mark the parts clearly to prevent confusion at the time of reassembly. 3) For disassembly of certain designated parts, use only the special tool prescribed for that purpose. 4) When, after removal of fastening nuts and bolts, a part still can not be removed, never force it. Instead, investigate and correct the cause. 5) Maintain disassembled parts in good order for storage, paying special care not to confuse parts that appear similar. Tag them or mark with ink if necessary. 6) Store standard parts such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss.

www. k omat s upar t s book . c om • Tension of the V-belt and tracks. • Any damaged parts or loose bolts.

-

3. Preparation for disassembly Prepare the required facilities, tools, and space for the disassembly work and rack space for storing the disassembled parts. Make sure that they are all clean.

2. During reassembly 1) Thoroughly clean and examine all parts before reassembly. Repair any scratched or dented surfaces. Foreign matter is especially damaging to sliding surfaces, and will greatly decrease their service life. 2) Clean new parts to remove any rust preventative coating. Solvent: Light oil or trichloroethane

*

3) Carefully align any match marks provided. 4) Use a press or press-fitting tool to assemble bearings, bushings and oil seals. 3. Checks and inspections during disassembly/reassembly 1) During disassembly, watch carefully for evidence of seizing, interference, or improper contact of sliding parts. 2) Measure and record end clearances, gear backlashes, protrusions, and the like during the disassembly/reassembly. Quite often they cannot be measured afterwards.

00-9


3. DETERGENTS

4. NUTS AND BOLTS

1. Precautions for cleaning 1) Thoroughly clean disassembled parts and group them by unit for storage. Be especially sure to remove sludge from oil holes and pipes. 2) Never use dirty solvents to clean important parts. 3) Take extreme care with special chemical agents. Observe the manufacturer's handling instructions and take measures to prevent the agent from coming into contact with your skin or eyes.

Unless otherwise specified in the DISASSEMBLY AND ASSEMBLY, tighten all bolts to a torque of page 00-29. 1) Use bolts having the exact length required for the parts they are to join. If too long, the bolt presses against the bottom of the tapped hole; this pressure makes proper tightening impossible. If too short, the bolt lacks the number of threads necessary to hold the parts together. 2) Tighten each nut and bolt to the specified torque. 3) Tighten bolts evenly and in order.

2. Selection of detergents Tighten mutually opposing bolts alternately. Parts

Detergents

I

Ordinary parts

Kerosene, light oil, or trichloroethane

Finely machined parts (Bearings etc.)

Clean kerosene or neutral dehydrated light oil

Large castings (Cylinder head, cylinder block etc.)

Alkaline detergent, PH 10 - 12. (Immerse in 50 - 70°C detergent for 5 - 10 minutes. Then rinse thoroughly with water,)

Tighten in turn on opposite Sides.

-

4

www. k omat s upar t s book . c om Tighten from the center outwards and on alternate Sides.

3. Detergents for waShing rubber parts (O-rings, oil seals etc.)

~ Detergents

Nitrile rubber

Ester rubber

Silicon rubber

--+---

----r----+-

Fluorine rubber FS0003

COl Or

Trichloroethane

0

0

0

0

Trichloroethylene

0

X

X

0

Gasoline

X

X

X

0

Thinner

X

X

X

X

Light oil

0

0

X

0

Steam

0

X

0

0

0: X:

_

4) The Template Method is prescribed for tightening bolts on certain specific parts of the engine. The Template Method obtains good fittings of bolts with their seats and of bearings with their races to ensure uniform overall tightening. The bolts are tightened in stages, then loosened, and then tightened once more.

Immersion allowed for a short time only Detergent detrimental to rubber

00-10


5. HANDLING LOCKING DEVICES Nuts and bolts which cannot be checked visually from the outside or which are located in vital areas must be firmly locked into position with wires, cotter pins, and lock washers. Never reuse these locking devices.

1. lock wire

4. Thread tightener 1) Wash and degrease the bolt and bolt hole with trichloroethylene and dry. Coat the bolt threads with two or three drops of thread tightener and tighten the bolts. 2) After an hour had passed, the bolt cannot be loosened or tightened any further. If retightening becomes necessary, the bolt must be completely removed. the old thread tightener removed. and a new coat applied.

Bolt loosening direction

. ---0/

~

0-

..

-

The tension in the wire should oppose

I

L.· . .· .

the bolt's tendency to loosen.

U

~

cb

\~ This wire serves no useful purpose.

'--=0.-

'--"

Wrong

Correct

FS0004

www. k omat s upar t s book . c om 2. Cotter pin

Match the holes in the bolt and nut while tightening " Bend the pins ~ perpendicular ~ to the bolt face

-

Pin bent in the

~ . wrong plane

6. PRECAUTIONS FOR PRESS-FITTING

Correct

Wrong

FS0005

Correct

Wrong

FS0006

• Bend the head and ends of the cotter pin upwards as far as possible.

• Coat the surfaces of the parts to be press-fitted with anti-friction grease (molybdenum disulfide) - unless they are tapered. • For taper spline-to-serration fittings 1) Check that the splines and serrations are free from dust, burr, dents and indentations. 2) Insert and align the s'plines and serrations by hand before press-fitting the shaft into the hole. 3) If the spline-serration assembly is loose. disassemble and examine for wear. Replace worn parts with new ones.

FS0007

3. lock washer

[0

-

~

Perpendicular to the nut and bolt

Perpendicular to the nut

~

Not

rTTI1 ~

to the nut and bolt

~. perpendicular

Correct

Wrong

FS0008

00-11


7. PRECAUTIONS FOR ASSEMBLING THE PIN AND SHAFT Before reassembling the pin and shaft, check the positions of the locking device and fastening device on the other side. This is especially important when the shaft is retracted from the inside of the hole as illustrated in the accompanying diagram. To ensure proper reassembly, make sure that the lock pin holes coincide.

Lock pin

2. Push-puller When the screw of the push-puller does not reach the surface of the part to be pushed, insert a spacer. It is also a good idea to insert a plate to prevent the head of the screw from damaging the part.

Pin

www. k omat s upar t s book . c om Line up the lock pin holes

FS0009

8. SERVICE TOOLS 1. Gear puller Fit the gear puller over the gear or bearing and tighten the bolt on the gear puller to remove the part from the shaft.

3. Bearing coupler This can be used two ways: 1) When the bottom 2) When the bottom of the hole is of the hole is not strong enough to strong enough to withstand the withstand the applied force. 'lpplied force.

-

Push-puller Adaptor - Bearing coupler

FSOOll

FS0012

00-12

-


5. Hook wrench A hook wrench has a claw which hooks into the turning sockets of round nuts. The wrench size is defined by the outer diameter of the round nut turned. The accompanying figure shows a hook wrench designed for use with round nuts of two different sizes.

4. Bearing separator

.,.,.

,. ~ ...../ .....//

3-~~. .". .~. ",. .® -

L..L.....::;:.:~.....;::..::..

-

"7";-- -::::-q) .....

-"C ..

Lf

FS0014

Bearing separator

FS0013 FS0015

www. k omat s upar t s book . c om Removal and Installation of the Sprocket Wheel

-

02P-023

FS0016

00-13


12. CENTERING

9.CLEARANCE ADJUSTMENTS Store each set of shims or washers so that they can be installed in their original condition at the time of reassembly.

Centering is very important for interfaces in the power train - for example, between the engine and the transmission and between the bevel gear shaft and the final drives. Incorrect centering only increases the stresses acting on the turning parts, so always make sure that the deviation is within the specified limits.

Engine

10.L1NK RODS

-

1) If it is necessary to change the length of the link rod in order to remove it first record the original length so that the rod can be easily reassembled in its original condition. 2) Remove the link rod at the pins.

www. k omat s upar t s book . c om Rod

0;;;;;11

I~ Yoke

Pin FS0017

Engine Transmission

-

11.SHIMS AND WASHERS 1) Shims are used to center the engine and adjust the action of the bevel gears. Handle very carefully as they get deformed easily. 2) Record the numbers and positions to speed adjustment after reinstallation. 3) Do not reuse any shims or washers that are deteriorated, damaged, bent or deformed. 4) Insert thin shims between thicker ones.

Correct

FS0018

00-14

-

-

MEASURING INSTRUCTIONS


-

PREPARATIONS BEFORE CHECKING

BLOCK GAUGES

1. Cleaning of parts Wash parts to be checked. Special care should be paid to thoroughly remove dust and dirt from the surfaces on which measurements are to be made so that possible errors can be eliminated.

• To bring two blocks into contact, wash each block with benzene to remove rust-preventing oil and wipe with a clean cotton cloth. Put one block on the other, causing a sliding or twisting movement between the two. • If the contact between two blocks feels rough, apply a fine-grade oilstone to the blocks along their edges. (Do not try to rub the' contact surface of the blocks.) • Do not leave the blocks in contact for a long time. Long-time contact will make the blocks difficult to separate or cause black rust to appear on the contact surfaces. • When separating two blocks, slide or twist them. Do not try to pull them apart, by force or strike them with a mallet. • When storing a block gauge, wipe off moisture, dirt and fingerprints, coat with a rust-preventing lubricant such as vaseline, and put the gauge back in its case.

2. Minor repair of part surfaces Remove scratches, dents and rust from parts to be checked. If the surface are rough, the measurements will be inaccurate. When smoothing any surface, be careful not to use an oilstone or sand paper coarser than the finished surface. 3. Preparation of measuring tools Clean the tools and thoroughly remove dust and dirt from the surfaces which contact parts. Check the tools for proper function and zero-point adjustment. Remedy any abnormality.

www. k omat s upar t s book . c om 4. Maintenance of measuring tools Handle all tools with sufficient care and do not subject them to unreasonable force or shocks which can affect their delicate construction. Periodically check the tools for accuracy and, if necessary, calibrate them. Put the tools back into their cases and return them to their fixed storage locations whenever not in use. It is recommended to assign a person to be responsible for the proper storage of measuring tools.

-

MEASURING TOOLS

-

• Repeat each measurement two or three times to eliminate possible errors. Further repetition will be necessary, if there is a large variation in the readings. • When measuring the inside or outside diameter of a cylindrical object, take two readings with the measuring device put in two directions at right angles to each other. Repeat this at several points along the overall length of the object. • Along eye-measurement below the unit of a scale may be used for making a comparison between two approximately equal measurements, the accuracy of such eye-measurements should not be considered as reliable. • At the start of each measurement, select a measuring device having an accuracy appropriate for judging whether the measurement reaches its allowable limit.

VERNIER CALIPERS • At the start of measurement, close the jaws and check that there is no clearance (due to wear) between the jaws and that the "zero" point of the graduation is in exact alignment with the "zero" point of the vernier scale. •

Measuring an outer diameter

Wrong

Correct

FS001S

00-15


DIAL GAUGES

• Measuring an inner diameter

-$--$~-dL Wrong

Wrong

Correct

Correct

FS0020

• Measuring a depth

• Carefully put the gauge contact-point on a surface to be measured to protect the delicate gauge against shock. • Set the zero-point of the gauge with care to keep the movement of the contact-point within its stroke during measurement. • Careless setting of the zero-point may cause the spindle to retract or extend to its limit, thus making measurement impossible. • The measurements of the dial gauge are accompanied by relatively large errors because minute variations of the contact-point (and accompanying errors) are indicated by the dial pointer through an expanding mechanism using gears. The reliability of eye measurements can not be assured below the minimum unit on the scale.

-

• Measuring protrusions. depressions or steps Set the zero-point so that vertical movement of the probe does not exceed its stroke limits, and slide the base of the gauge on a flat surface.

www. k omat s upar t s book . c om Wrong

Correct

Stand FS0021

MICROMETERS • Put the anvil onto an object at a right angle and turn in the spindle until it comes into contact with the object. Rotate the ratchet stop until there are two or three idle rotations, then read the measurement. • When reading a measurement, keep your eyes at a right angle to the graduation on the sleeve. • To turn back the spindle, rotate the thimble with your fingers.

FS0023

• Measuring bending

-

FS0024

Correct

Wrong FS0022

• When storing a micrometer, leave a slight clearance between the anvil and the spindle.

00-16

Read the Total Indicator Reading (T.l.R.) while moving the object back and forth or vertically. Turn the object one complete rotation and read the difference between the maximum and minimum indications of the gauge pointer.

-


•

Measuring end play, looseness or deviation

•

Measuring gear backlash

FS0025

-

Read the T.I.R. while moving the object back and forth or vertically. •

Measuring face runout or radial runout

FS0027

1) Fully mesh one of two gears and place the dial gauge contact-point on a tooth of the other gear. Swing the free gear within the limits of its play in the rotational directions, and read the T.l.R. 2) Use of the lever and fulcrum type dial gauge is recommended for this purpose as the contactpoint placed on the gear is moved tangentially to the gear pitch circle. 3) The lever and fulcrum type dial gauge is suitable for use in a narrow space or for a special measurement which requires placing the contact-point on an object at an angle to the spindle of the gauge. Since the contact-point of this type of gauge has a very narrow measuring range (usually 3 mm or less). the contact-point should be carefully checked for contact with the object during measurement.

www. k omat s upar t s book . c om Radial runout

FS0026

-

1) Read runout at six or more positions during one complete rotation of the object. 2) At the start of each measurement, set the zeropoint at the middle of the assumable range of the spindle movement. Be careful not to confuse positive and negative readings of runout.

Face runout

Radial runout

When the pointer is to the right of "0"

+

-

When the pointer is to the left of "0"

-

+

3) When measuring face runout, place the contact-point on the object along a circle 2 or 3 mm smaller in diameter than the outside diameter of the object.

CYLINDER GAUGES • Install a contact-point having a length approximately equal to the cylinder bore to the measured on the cylinder gauge. Set the zero-point of the test indicator to the bore diameter of the standard cylinder measured with a reference ring gauge or a micrometer. Test indicator

Contact-point

Measuring point

FS0028

00-17

PARTS CHECKING INSTRUCTIONS

-

• Insert the gauge into the bore to be measured and read the minimum indication of the test indicator while giving swings to the gauge about the tip of the detachable rod used as the fulcrum. • When the minimum reading is obtained on the right side of the zero point of the test indicator, and the reading to the standard value to which the zero point is set. When the minimum reading is obtained on the left side of the zero point, subtract the reading from the standard value.

PARTS CHECKING INSTRUCTIONS • Check disassembled parts to see if they are reusable or need repair. If the part failed due to an external source, determine the cause and correct before assembly.

-

3. PITTING

www. k omat s upar t s book . c om 1. GENERAL PRECAUTIONS • Visually inspect parts for cracks, pitting, corrosion, scoring, ridging etc. To ensure proper inspection, every part should be clean before inspection. • If the cause of the defect can be found, it will be a great help to analyze the part condition; whether the defect will progress or not, and the possibility of future trouble. Knowing the cause of the defect, the service man can give good advice to the customer to prevent him from having the same trouble again. • Visual inspection can not find minute or hidden damage. Other methods of inspection are as follows; a) Water-pressure or air-pressure test b) Color check or magnetic damage test

1) Pitting by cavitation

In most cases, cavitation is accompanied by chemical corrosion. After removing rust or scale, carefully inspect the depth of pitting. • When the pitting can not be repaired within the allowable limit, replace the part. • If pitting is not deep, resurface the part after removing the rust and scale. 2) Pitting due to removal of surface • If ball bearing is pitted, replace it. • If more than 1/3 of the contact face is pitted, the part should be replaced. • If pitting is not serious, resurface the part.

-

2. CRACKS • If the part is found to be cracked by visual inspection, it should be replaced or repaired. • If the length or depth of crack exceeds 1/3 of the thickness of the part, it should be replaced instead of repaired. • A part having an internal crack should be replaced.

00-18

-

PARTS HANDLING

PARTS HANDLING 1. OIL SEALS 1. Direction Be careful to install the oil seal with its lips facing in the proper direction, as shown in the figure below.

3) Use a suitable press to press fit the oil seal into the housing. • When installing the oil seal flush with the housing surface ...

+

Main lip

Oil seal nominal outside diameter +(5 - 10)mm

Dust lip

FS0031 FS0029

2. Inspection prior to installation 1) Keep the oil seals free from dust. rust and scratches. Take special care to prevent rust or scratches on the lips. 2) To check the oil seal lip for smoothness, gently slide a wire across its surface. If the wire catches, replace the oil seal with a new one. Make sure that the wire used for this test does not scratch the lip surface. 3) Do not use the oil seal on a shaft where it would come into contact with rust or scratches on the shaft surface. 4) When removing the oil seal, take care not to damage the housing or shaft surfaces.

• When installing housing ...

the

oil

seal

inside

the

r---:--l www. k omat s upar t s book . c om Oil seal nominal outside diameter Oil seal nominal outside diameter + (0.5 - 1.01mm 1-----1 - (0.5 - 1.01mm Oil seal nominal outside diameter + - (05 - 1.0)mm

T

*

-

3. Installing the oil seal 1) Coat the surface to which the oil seal is to be applied with a lubricant or grease. If the lip should double over as the oil seal is being fitted over the shaft, return it to its proper place by rotating the shaft and pulling the oil seal slightly backwards. 2) When installing an oil seal on a shaft machined with a keyway, splines, or threads, use a suitable jig to protect the lip.

FS0032

FS0033

4) After press-fitting the oil seal, check that it has not been installed at an angle to the housing.

*

Max. permissible oil seal slant (H, - H\I/2;:;;a 1/400 FS0034

Lip protection jig

-

FS0030

00-19

PARTS HANDLING

4. Applying grease to the lips Before installing an oil seal, coat it with grease according to the following procedure to prevent friction from burning the seal surfaces while the machine is being started. 1) Single-lip oil seal Place a flat, uniform coating of grease on the surface away from the sealing surface.

FS0035

2) Double-lip oil seal Coat the entire surface between the two lips with grease in the manner shown in the accompanying figures.

2. FLOATING SEALS 1. Handling floating seals 1) Keep each pair of floating seals bundled together with tape to avoid mix-ups when they are reinstalled. 2) Discard the old O-rings. Always use new ones when installing the floating seals. 3) Replace a floating seal if its contact surface is rusted.

2. Installing floating seals 1) Remove all rust and dust from the mounting surfaces of the seal. Use sandpaper to remove any rust that might come into contact with the O-ring. 2) When installing the floating seal, coat the mounting surfaces with oil. Then install the O-ring, taking care not to twist it. Do not coat the O-ring with oil. The floating seal has been correctly installed if the seal ring rotates. 3) After installing the O-ring and seal rings in both housings, mate the two together.

-

* *

www. k omat s upar t s book . c om Grease

Grease Housing FS0036

Seal ring FS0037

5. Applying adhesives Take special care when applying adhesives. to the outer surface of oil seals. Adhesive on the surface of the lip or shaft leads to oil leakage. Since any adhesives on the surface of the press jig will soon transfer to the oil seal lips, clean the jig before use.

*

4) An installer is recommended for inserting the O-rings. Using a screwdriver or other pointed object risks scarring the O-ring. 5) Attempting to mate the two housings together without the O-rings and seal rings in place can damage the O-rings and lead to oil leakage.

-

*

O-ring

Seal ring FS0038

00-20

-

-

PARTS HANDLING

3. O-RINGS

4. GASKETS

1. Handling 1) Discard any O-ring that has been in storage too long or has hardened. 2) Use only the O-rings prescribed for the part in the PARTS BOOK. This is especially important for those rings used with high-temperature engine parts, where heat-resistant and durable materials such as silicon are required. 3) ALWAYS USE NEW O-RINGS.

1. Handling gaskets 1) Always replace packings, gaskets and copper packings with new ones. 2) Make sure that there are no scratches or burrs on the contact surfaces of the gasket. 2. Installing gaskets 1) Make sure that the holes in the gasket match those in the mating part. 2) Apply gasket sealant to the joints so specified in the SHOP MANUAL.

2. O-ring types KOMATSU O-rings are marked with colored dots as shown in the accompanying chart.

Marking

Part Number

Material

Application

3. Precautions for using liquid gasket 1) Remove all scratches, dirt, paint, grease and old gasket sealant before applying a new coat. 2) Coat the specified area evenly and let dry for several minutes. 3) Assemble the mating parts when the gasket sealant is stickly to the touch.

www. k omat s upar t s book . c om -

One blue spot

07000-0····· Nitrile rubber

For low-pressure

Two blue spots

07000-1·

Nitrile rubber

For high-pressure

One green spot

07000-3··

Fluorine rubber

For low-pressure

Two green spots

07000-2·· .. Fluorine rubber

For high-pressure

One red spot

07000-4··

Nitrile rubber

For low-pressure in cold weather

Two red spots

07000-5··

Nitrile rubber

For high-pressure in cold weather

Orange spot

07000-6··

Silicon rubber

For low-pressure in hot weather

3. Inserting O-rings After coating the O-ring with oil, insert carefully so as not to damage it. Silicon rubber O-rings require special care since they tear easily.

5. BEARINGS 1. Handling bearings 1) Shield the bearings from dust and dirt; even the tiniest speck rapidly accelerates wear. Leave the bearings in their protective packaging until just before they are to be installed. 2) Protect a bearing from excessive force and shocks. Never dry a bearing with compressed air after cleaning.

*

*

2. Installing bearings 1) Never drive a bearing onto a shaft by pounding on the outer race or into an opening by pounding on the inner race. Such pounding produces dents in the tracks in the races. 2) When a bearing must be fitted onto a shaft with some interference, press-fit the inner race with the jig shown in the accompanying figure. Jig

-

Press fit

-

FS0039

00-21

PARTS HANDLING

6. PRESS FITTING BUSHINGS 3) If the shaft of opening has considerable interference, heat the bearing before installing. Do not heat above 120°C. 4) When a non-separable bearing must be fitted with interference for both races, press-fit with the jig shown in the accompanying figure.

*

Do not drive in a bushing directly with a hammer. Use a press so that pressure is uniform over the entire circumference. 1) If no press is available, hammer in the bushing using a driving tool so that the force is distributed evenly.

Press fit Bushing

I www. k omat s upar t s book . c om FS0040

5) Thoroughly coat the bearing with oil before installing. 6) Install the bearing, spacer or washer with its chamfered surface facing the step on the shaft.

FS0042

2) If the bushing has an oil hole, bring the hole into exact alignment with the oil hole in the housing.

B"'h~;~I~~k "01 hoi,

---*'~~--+--~

To

'"i''''O"

pump

Oil hole

In a single plane

FS0043

Correct

Wrong

FS0041

-

3) When a bushing has been removed, remove all burrs and foreign matter from the mounting hole, and then clean.

7. REMOVING SNAP RINGS 1) Use snap ring pliers to remove or install snap rings. Do not overexpand them - especially the smaller ones. 2) After installing, check to make sure that the snap ring is firmly in place within its groove.

00-22

-

PARTS HANDLING

8. HYDRAULIC PIPING

~ 1) 2) 3)

4)

-

Precautions for servicing the work equipment hydraulic system Lower the work equipment to the ground and turn off the engine. Loosen the oil filler cap to relieve pressure in the hydraulic oil tank. Operate the control levers 2 or 3 times to eliminate hydraulic pressure remaining in the piping to be disassembled. Support the work equipment on a stand to prevent it from falling when the piping is removed and the hydraulic pressure is released.

2. Installing the hydraulic piping 1) Thoroughly clean each piece of piping with a suitable detergent (for example, light oil, kerosene, trichloroethane) and remove all traces of detergent with compressed air. 2) Repair the sealing faces or, if the scratches and dents are too large, replace. 3) Do not use gasket sealant for hydraulic piping! 4) Install the piping so that all the identification tags match. 5) When a pipe must be joined at both ends, tightening only one end at a time may make it too short. First fit both ends by hand and then tighten the ends by turns. (See figure.)

1. Removing the hydraulic piping 1) Disconnect hydraulic tubes from hoses or other tubes by holding the nut on the spigot (the male side of the joint) with a wrench while loosening the one on the socket (the female side).

www. k omat s upar t s book . c om Tighten gradually and alternately the both ends. FS0045

-

FS0044

2) Seal the ends of the disconnected tubes and hoses and the oil ports to the hydraulic equipment with blind plugs to keep out foreign matter. For the same reason, seal the ports of the hydraulic tank with adhesive tape. 3) Have appropriately-sized containers underneath to catch the hydraulic fluid that will flow out when the piping is disconnected. Clean up all spills immediately. 4) When working under the machine, position yourself out of the way of the oil shower. 5) Tag the ends of all piping removed as well as the ports to which they were attached.

6) To ensure tight-fitting seals, tighten the nuts to 80% of the specified torque, loosen 90°, and then tighten to the full torque. 7) After completing all connections, run the engine at idling speed and operate all the control levers of the hydraulic attachments. Then check the oil level in the hydraulic tank and add oil as necessary.

00-23

PARTS HANDLING

3. Handling high-pressure hoses 1) Do not try to shorten the hose. A hose shorter than the specified length is subject to the defects shown in the accompanying figures. Shorting under pressure increases the tension.

I

I

Too sharp a bend damages the hose.

~= ~ FS0046

FS0047

2) Make sure the hose is not twisted after it is installed.

-

The letters printed on the hose soon reveal any twists.

/

www. k omat s upar t s book . c om FS0048

3) Similarly, the hose must not twist as it moves.

FS0049

Improper connection causes the hose to twist as the pipe moves. FS0050

4) The last figures on this page are examples of poor connections.

-

~1lJW:m~!,\"-- Crimping :--- The hose must have sufficient play to allow it to contract under pressure without crimping. FS0051

...~

FS0052

.

Rubbing

FS0053

00-24

-

-

PARTS HANDLING

4. Handling hoses with self-seal couplings 1) Do not attempt to connect or disconnect or coupling without first relieving the internal hydraulic pressure. The gushing hydraulic fluid will not only soil the surroundings, but the high flow rate may also damage the O-ring of the coupling. 2) Never use a hammer to tighten or loosen a coupling. Such sharp blows can deform the coupling, leading to oil leakage or cracking of the coupling. 3) Protect the disconnected piping from the intrusion of dust and dirt! If it is to remain disconnected for some time, seal by connecting to another coupling or by fitting a dust cap or a blind plug to each end.

*

2) Press the two halves completely together and tighten them uniformly. If they are not held tightly together, they will separate by a distance equivalent to the clearance between the fastening bolts and their holes, forming a pathway for oil leakage.

*

-

FS0057

6. Using sealing tape 1) To prevent oil leakage, wind sealing tape around the tapered thread before inserting the plug into the plug hole. 2) Wrap all but the first 1.5 threads at the tip and then force the tape into the threads with a fingernail. Wind the tape in the same direction as the threads.


During storage Sealing tape

FS0055

5. Handling split flanges 1) Follow the bolt tightening sequence given in the figure.

Leave 1.5 threads bare.

FS0058

FS0056

00-25

PARTS HANDLING

11.PUMP

9. SPRING WASHERS Judging suitability 1) Discard the spring washer if the overlapping portion is worn or damaged.

1) After assembly and before installation, fill the pump with oil through the intake port to provide initial lubrication. 2) Before installing the pump, turn the drive shaft by hand to make sure that it turns smoothly without any catching.

Outlet

FS0059

Inlet

.-

o

0

Inlet port

o 0

2) Discard if the distance P is more than 2t/3.

-

FS0062

3) Test run the installed pump and check for unusual noises and leakage.

www. k omat s upar t s book . c om Bolt head

Washer

12. SEAL RINGS

FS0060

10. SPRING (ROLL) PINS Handling spring pins 1)

A spring pin performs somewhat better when the split is placed facing the load instead of at a right angle to the load.

1) Seal rings are very delicate, so handle and store carefully. 2) Do not reuse rubber seal rings. 3) Avoid excessive stretching when fitting a seal ring over a shaft; it decreases the ring's performance. 4) Remove all sharp edges before fitting a seal ring into a slot on an abutment.

-

Check for sharp edges and scratches

Shaft

FS0061

Seal ring FS0063

00-26

-

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS ~

Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and Assembly section, every part weighing 25 kg or more is indicated clearly with the symbol

&J

-

1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: • Check for removal of all bolts fastening the part to the relative parts. • Check for existence of another part causing interference with the part to be removed.

2. Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

100%

88%

71%

79%

41% FS0064

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. ~ Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

www. k omat s upar t s book . c om Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter (mm)

-

Allowable load (tons)

10

1.0

11.2

1.4

12.5

1.6

14

2.2

16

2.8

18

3.6

20

4.4

22.4

5.6

30

10.0

40

18.0

50

28.0

60

40.0

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°.

M GiJ i::

The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used.

-

2) Sling wire ropes from the middle portion of the hook.

·u

~ 1000

~

co

u

500

.....

"D

co o -'

60 0

90 0

Lifting angle : a FS0065

00-27

HOISTING INSTRUCTIONS

-

• Approximate reduction of allowable load for wire ropes at various hanging angles.

Hanging angle

Reduction in %

30° or less

10%

31 ° -

60°

20%

61 ° -

90°

30%

91° -

120°

50%

3. Hanging bolts

02P-021

~ Hanging angles should not exceed 150°.

-

5) When hoisting several parts as a unit. be careful not to allow any part of the unit to fall. Use a suitable container when hoisting many small parts at a time. 6) Select the most suitable sling device when hoisting a specially-shaped object.


Special hook

Part Number

/""

---:,. Cylinder head

FS0066

7) When using a hoist to turn over a heavy part, observe the following instructions: • Clear as much of the area surrounding the part as possible. • When turning the part over, take special care to prevent the ropes from slackening and the part from slipping when the center of gravity changes. • Gradually slacken the wire ropes after making sure that the part is completely turned over. Slackening the ropes before complete turning of the part may cause the part to fall back to its original position.

00-28

d

Pitch

L

Allowable load (kg)

04530-0815

8

1.25

15

80

04530-1018

10

1.5

18

150

04530-1222

12

1.75

22

220

04530-1628

16

2.0

28

450

04530-2030

20

2.5

30

630

04530-2438

24

3.0

38

950

04530-3045

30

3.0

45

1500

04530-3655

36

3.0

55

2300

04530-4625

46

3.0

25

3400

04530-4870

48

3.0

70

4500

*

The allowable load in the table means the maximum static load which the bolt can withstand. The values of allowable load given in the table should be reduced, taking the necessary safety factors into consideration, as these bolts will be subjected to shocks during actual hoisting operation. The allowable loads in the table are applicable to the bolts slung vertically from a hoist.

-

-

-

STANDARD TIGHTENING TORQUE

-

STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of "Disassembly and Assembly".

Thread diameter of bolt (mm)

-

Width across flat (mm)

@

(jJ

kgm

Nm

6 8 10 12 14

10 13 17 19 22

1.35±0.15 3.2±0.3 6.7±0.7 11.5 ± 1.0 18.0±2.0

13.2±1.4 31.4±2.9 65.7±6.8 112±9.8 177±19

16 18 20 22 24

24 27 30 32 36

28.5±3 39±4 56±6 76±8 94.5± 10

279±29 383±39 549±58 745±78 927 ±98

27 30 33 36 39

41 46 50 55 60

135± 15 175±20 225±25 280±30 335±35

1320±140 1720±190 2210±240 2750±290 3280±340


This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque.

*

Nm (newton meter):

1 Nm ::; 0.1 kgm

2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts.

-

Tightening torque

Thread diameter of bolt (mm)

Width across flats (mm)

kgm

Nm

10 12 16

14 17 22

6.7±0.7 11.5 ± 1 28.5±3

65.7±6.8 112±9.8 279±29

00-29

STANDARD TIGHTENING TORQUE

-

Sealing surface

3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared.

=

FS0068

Tightening torque

Thread diameter of nut part (mm)

Width across flats of nut part (mm)

kgm

Nm

14

19

2.5±0.5

24.5±4.9

18

24

5±2

49±19.6

22

27

8±2

78.5±19.6

24

32

14±3

137.3±29.4

30

36

18±3

176.5 ±29.4

33

41

20±5

196.1±49

36

46

25±5

245.2±49

42

55

30±5

294.2±49

-


...

~

COATING MATERIALS

The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenclature

Komatsu code

Applications

LT-1A

Used to apply rubber pads, rubber gaskets, and cork plugs.

LT-1B

Used to apply resin, rubber, metallic and non-metallic parts when a fast. strong seal is needed.

LT-2*

Preventing bolts, nuts and plugs from loosening and leaking oil.

LT-3

Provides an airtight, electrically insulating seal. Used for aluminum surfaces.

LG-1

Used with gaskets and packings to increase sealing effect.

LG-3

Heat-resistant gasket for precombustion chambers and exhaust piping.

LG-4

Used by itself on mounting surfaces on the final drive and transmission cases. (Thickness after tightening: 0.07 - 0.08 mm)

LG-5

Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter.

Antlfrictlon compound (Lubricant including molybdenum disulfide)

LM-P

Applied to bearings and taper shafts to facilitate press-fitting and to prevent sticking, burning or rusting.

Grease (Lithium grease)

G2-L1

Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and facilitation of assembling work.

Adhesives

-

Liquid gasket

Vaseline

-

Used for protecting battery electrode terminals from corrosion.

*LT-2 is also called LOCTITE in the shop manuals.

00-30

-

-

ELECTRIC WIRE CODE

ELECTRIC

ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.

CLASSIFICATION BY THICKNESS Copper wire Nominal number

-

Cross section (mm')

Cable O.D. (mm)

Current rating (A)

Applicable circuit

Number strands

Dia. of strands (mm)

01

11

0.32

0.88

2.4

12

Starting, lighting, signal etc.

02

26

0.32

2.09

3.1

20

Lighting, signal etc.

05

65

0.32

5.23

4.6

37

Charging and signal

15

84

0.45

1336

7.0

59

Starting (Glow plug)

40

85

0.80

42.73

11.4

135

Starting

60

127

080

63.84

13.6

178

Starting

100

217

080

176

230

Starting

www. k omat s upar t s book . c om 109.1

CLASSIFICATION BY COLOR AND CODE

Priority

~

Starting

Charging

Lighting

Signal

Instrument

Other

Code

B

W

R

G

Y

L

Color

Black

White

Red

Green

Yellow

Blue

Code

BW

WR

RW

GW

YR

LW

Color

Black & White

White & Red

Red & White

Green & White

Yellow & Red

Blue & White

Code

BY

WB

RB

GR

YB

LR

Color

Black & Yellow

White & Black

Red & Black

Green & Red

Yellow & Black

Blue & Red

Code

BR

WL

RY

GY

YG

LY

Color

Black & Red

White & Blue

Red & Yellow

Green & Yellow

Yellow & Green

Blue & Yellow

Code

-

WY

RG

GB

YL

LB

Color

-

White & Yellow

Red & Green

Green & Black

Yellow & Blue

Blue & Black

Code

-

WG

RL

GL

YW

Color

-

White & Green

Red & Blue

Green & Blue

Yellow & White

Classification

-

1

Primary

2

3 Auxiliary

4

5

6

00-31

-

-


-

-

0. GENERAL

General view . . . . . . . . . . . . . . . . . . . . . . .. 01- 3 General assembly drawing 01- 4 Specifications . '. . . . . . . . . . . . . . . . . . . . .. 01- 6 Engine assembly drawing 01- 9 01-10 List of weight List of lubricant and water 01-12

-


PC200. 220-3

01-1

-

-


-

GENERAL

GENERAL VIEW

GENERAL VIEW

1


P205C3001

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Bucket Bucket cylinder Arm Arm cylinder Boom Boom cylinder Sprocket Track frame Idler Track shoe

pe200, 220-3

01-3

GENERAL

GENERAL ASSEMBLY DRAWING

-

GENERAL ASSEMBLY DRAWING PC200·3

9380 2680

6/00

-

www. k omat s upar t s book . c om GL

560

2180

610(lf equipped)

I-------=-=-=..:'---------~. I

I

30/0

2740 2790(lf equipped)

-

,

~ ~ l_~~

9850

Jii9990

*

The mark indicates the dimensions for shovel operation. F205C3001

01-4

PC200. 220-3

-

-

GENERAL ASSEMBLY DRAWING

GENERAL

~~

PC220-3

-

I

~

-

11 v /

I--~

In I

;;t:

I

D~~~

"'=U [Q

-

1390

1205

-

(\ \/

~


I

~80

~40

~O,

61O(lf equipped)

.11

2990 (If equipped)

-

'*

The mark indicates the dimensions for sho\·JI operation. F205C3002

PC200, 220-3

01-5

SPECIFICATIONS

GENERAL

-

SPECIFICATIONS Machine Model

PC200-3

PC220-3

Serial Numbers

20001 and up

20001 and up

18,000

22,000

0.7

0.9

Operating Weight Bucket Capacity

(kg) (m

3

)

Maximum digging depth

(mm)

6,550

6,700

w t9

Vertical wall depth

(mm)

5,965

5,760

« a:

Maximum digging reach

(mm)

9,850

10,180

Maximum digging reach at ground level

(mm)

9,668

10,000

a:

Maximum digging height

(mm)

8,960

9,180

:s:

Maximum dumping height

(mm)

6,255

6,360

10,700

12,700

z

t9

Z

w

u

z

« ~

a: 0

~

0

Maximum digging force

(kg)

Continued swing speed

(rpm)

13

13

Swing maximum slope angle

(deg.)

20

19

Travel speed

(km/h)

Gradeability

(deg.)

LL

a:

w a..

-

www. k omat s upar t s book . c om Overall length (at transportation)

35

0.52 (560 mm)

(mm)

9,380

10,000

Overall width (with standard triple-shoe)

(mm)

2,740

2,940

Track width (with standard triple-shoe)

(mm)

2,740

2,940

Overall height (at transportation)

(mm)

2,940

3,060

Height of cab

(mm)

2,875

2,875

z

Ground clearance of counterweight

(mm)

1,060

1,060

en

z

Minimum ground clearance

(mm)

435

435

~

Radius of upper structure

(mm)

2,700

2,900

Minimum swing radius at front end

(mm)

3,775

3,800

Arm height at minimum swing radius

(mm)

7,390

7,595

Length of track on ground

(mm)

3,070

3,445

Track gauge

(mm)

2,180

2,380

Height of machine hood

(mm)

2,140

2,270

0

(kg/cm

35

2

3.4

0.47 (560 mm)

en

Ground pressure (with standard triple-shoe)

3.5

)

w

-

0

01-6

PC200, 220-3

-

SPEC I FICATlONS

GENERAL

Machine Model

PC200-3

PC220-3

Serial Numbers

20001 and up

20001 and up

60105-1

S60105-1

Engine model Type

4-cycle, in-line vertical, 4-cycle, in-line vertical, water cooled, water cooled, direct injection type direct injection type diesel engine with diesel engine turbocharger

No. of cylinder - bore x stroke

-

w

Z <.:J Z

w

(mm)

6 - 105 x 125

6 - 105 x 125

Total displacement

(cc)

6,494

6,494

Flywheel horsepower

(HP/rpm)

106/2,100

14812,100

Maximum torque

(kgm/rpm)

43/1,600

56.5/1,400

High idling speed

(rpm)

2,300 ± 50

2,300 ± 50

Low idling speed

(rpm)

850 ± 50

850 ± 50

Minimum fuel consumption ratio

(g/HPh)

155

155

www. k omat s upar t s book . c om Starting motor

24V, 7.5 kW

Alternator

24V,25A

Battery

24V (12V x 2) - 110 Ah

Type of radiator core

w <.:J

'
Ootype corrugate fin

Carrier roller

(one side)

1

2

Track roller

(one side)

7

8

Built-up triple grouser


Track shoe

::::>u

a..

Type, number'

Variable displacement piston type x 2 Gear type x 1

:2: ::::>

-

a..

Delivery

U

(Qlmin)

Piston type: 2 x 194 (at rated engine speed)

...J

::::>

Gear type: 50 (at rated engine speed)

cc

:2: w len >en U ...J

::::>
0

>I w ,--'>

20--' oa:

Set pressure

(kg/cm

2

)

Piston type: 320 Gear type: 30

Type, number Control lever operation

4-spool type and 5-spool type Pilot type (Travel control lever: linkage type)

0

:::)
Travel motor

Piston type (with parking brake) x 2

I

>-5:20

Swing motor

Piston type x 1

cc

>-

o

f-

I--'2

Hydraulic cylinder

Double acting piston

Hydraulic tank

Closed box type

Hydraulic filter

Tank return side

Hydraulic cooler

Air cooled

PC200, 220-3

01-7

-

-


-

-

ENGINE ASSEMBLY DRAWING

GENERAL

ENGINE ASSEMBLY DRAWING This figure shows the engine for PC220-3. Turbocharger is not mounted on PC200-3. The other parts for PC200-3 are almost the same with PC220-3.

•

PC220-3

FRONT VIEW

LEFT SIDE VIEW

Unit:mm

l

Direction of wind

Crankshaft center

www. k omat s upar t s book . c om ~>

:1

6-IOXI.5

i

I-

205F2005

205F2006

REAR VIEW

RIGHT SIDE VIEW ~

OJ

-o~

.!: ~ c >OJ UU

-

I

i

I

Oil pres. sensor

Water temp. sensor

j'D»-

To radiator

-...

I

~I

co

~

~o cco '" C ~

OJ

U",

lOX 1.5

8-IOXI.S

I 0 X I .5

235

-

.J

205F2007-1

PC200, 220-3

205F2008·1

01-9

LIST OF WEIGHT

GENERAL

-

LIST OF WEIGHT Unit: kg Machine Model

PC200-3

PC220-3

Serial Numbers

20001 and up

20001 and up

Engine ass'y

830

850

635

655

20

20

178

175

7

10

Radiator ass'y

105

115

Hydraulic tank (without hydraulic oil)

150

150

95

95

1,500

2,255

•

Engine

•

Damper

•

Main piston pump

•

Charging pump

Fuel tank (without fuel) Revolving frame

-

www. k omat s upar t s book . c om Operator's cab (inc!. operator's seat and heater)

395

395

Swing machinery

175

215

Swing motor assembly

70

70

Travel motor assembly (with brake valve)

70

70

165

165

30

30

Counterweight

2,910

3,935

Track frame assembly

3,921

5,090

•

Track frame

1,995

3,030

• •

Carrier roller assembly

24 x 2

24 x 4

Track roller assembly

37 x 14

37 x 16

Recoil spring assembly

135 x 2

135 x 2

Idler assembly

120 x 2

120 x 2

550

560

36 x 2

36 x 2

275

305

4-spool control valve and 5-spool control valve assembly Center swivel joint assembly

• •

•

Final drive assembly

• •

Sprocket Swing circle assembly

-

01-10

PC200, 220-3

-

SPECIFICATIONS

GENERAL

Machine Model

PC220-3

PC220LC-3

Serial Numbers

20001 and up

20001 and up

Engine model

S6D105-1 4-cycle, in-line vertical, water cooled, direct injection type diesel engine with turbocharger

Type

-

No. of cylinder - bore x stroke

(mm)

Total displacement

(cc)

Flywheel horsepower

(HP/rpm)

148/2,100

Maximum torque

(kgm/rpm)

56.5/1,400

High idling speed

(rpm)

2300 ± 50

Low idling speed

(rpm)

850 ± 50

Minimum fuel consumption ratio

(g/HPh)

LU

6 - 105 x 125 6,494

Z (9

Z LU

155

www. k omat s upar t s book . c om 24V, 7.5 kW

Starting motor

24V,25A

Alternator

24V (12V x 2) - 140 Ah

Battery

D-type corrugate fin

Type of radiator core LU

(9 ,« 0:_ LUO:

Carrier roller

(one side)

2

2

Track roller

(one side)

8

10

00:

z«

c..

-


Track shoe

=>u

:2:

=>

c..

u

Variable displacement piston type x 2 Gear type x 1

Type, number Delivery

Piston type: 2 x 194 (at rated engine speed)

(Q/min)

.-J

Gear type: 50 (at rated engine speed)

=>

«0: 0

:2:

LU


Set pressu re

>-

I

(kg/cm 2

)

Piston type: 320 Gear type: 30

f-

(/)

>-

...J

(/)

0 a:w

U

z...J

.-J

=>

0«

u>

«

u

>-

«a: a:o 0>>-0 I:;;

0: 0

I

Type, number

...J

::>

Control lever operation

Pilot type (Travel control lever: linkage type)

Travel motor

Piston type (with parking brake) x 2

Swing motor

Piston type (with swing mechanical brake (if equipped)) x 1

Hydraulic cylinder

-

4-spool type and 5-spool type

>->

Double acting piston

Hydraulic tank

Closed box type

Hydraulic filter

Tank return side

Hydraulic cooler

PC200, 220-3

Air cooled

01-11 (2)

ENGINE ASSEMBLY DRAWING

GENERAL

-

ENGINE ASSEMBLY DRAWING FRONT VIEW

LEFT SIDE VIEW

Unit:mm

Water inlet

Direction of wind

:uI 'I

/

6-IQXI.5

L

www. k omat s upar t s book . c om ~

0>

1239

"O~

.=

~ c >0> U"

205F2006

205F2005

REAR VIEW

RIGHT SIDE VIEW

Water temp. sensor

Oil pres. sensor

~~~v::=::::m;'-----"

Potentiometer (if equipped)

L)"

J)~ -

. -

To radiator

4~IOXI.5

'~"-

~i

1 Engine 0 speed sensor 001 (if equipped) ~

~~~

:"'It ~j

00,

0,

12-IOX 1.5 4-12X I lOX 1.5

235

-.-4-

235

205F2007

01-12 ®

205F2008

PC200, 220-3

-

ENGINE I I STRUCTURE AND FUNCTION

Engine mount and engine attached parts Radiator and cooler Damper Fuel tank and piping Engine control system Auto-deceleration system (If equipped)

-

. . . . .

11-2 11-4 11-5 11-7 11-8 11-9


PC200. 220-3

11-1 CZ)

ENGINE MOUNT AND ENGINE ATTACHED PARTS


-

ENGINE MOUNT AND ENGINE ATTACHED PARTS PC200-3 (Serial No. 20001 - 21463) PC220-3 (Serial No. 20001 - 20365)

~

' _ >V---'-c-ft·-

/ !

I

~. .. .. : ~ _.!!

1',1

,

;

. . • .j

;j.- .'

.___

'i

j

,; ,

1'1

I

, I

-

www. k omat s upar t s book . c om 2

3

4

5

6 9

11

10

12

/

-

Section A-A View Z

11-2 ®

205F2009-1

PC200, 220-3

-


ENGINE MOUNT AND ENGINE ATTACHED PARTS

PC200-3 (Serial No. 21464 and up) PC220-3 (Serial No. 20366 and up)

www. k omat s upar t s book . c om z--

2

F20503101 -----'1 1

I I I,

\ \

-----+- 8 "

F{ \\

LU

-

View Z

PC200, 220-3

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Muffler Exhaust pipe Turbocharger Engine oil filter Intake connector Fuel filter Air cleaner Damper assembly Spacer Engine mount cushion rubber Engine mount bracket Engine mount bolt

11-3 (6)


RADIATOR AND COOLER

-

RADIATOR AND COOLER The radiator has sub-tank (1), so to check the cooling water level it is only necessary to look at the sub-tank. (There is no need to remove the radiator cap.)

The radiator core is a D in-line type. Air is forced out when the fan rotates. The hydraulic oil cooler is installed to the rad iator.

11

4

2

\\ \

/

.~

~~ .

-

7

www. k omat s upar t s book . c om ,

I

'

B

3 ··~10 205F20 I I

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Sub-tank Radiator cap Radiator inlet hose Aeration hose Radiator upper mount Fan guard Radiator outlet hose Valve for heater Drain valve Radiator lower mount Hydraulic oil cooler (air cooled) Hydraulic oil cooler oil-inlet hose Hydraulic oil cooler oil-outlet hose

Specifications

~

Core type

Overall heat radiation area

Radiator

CD-3

23.83 m 2

Hydraulic oil cooler (air cooled)

SF-3

12.47 m 2

Capacity

10Q

5.2Q

11-4

PC200, 220-3


DAMPER

DAMPER PC200-3 (Serial No. 21464 and up) PC220-3 (Serial No. 20366 and up)

PC200-3 (Serial No. 20001 - 21463) PC220-3 (Serial No. 20001 - 20365)

/1

) 4cstic-=-~.\

.

l' .

~.;~.

;.. ~i

:I

,

- ' ,I ~"'/-

.

'1/.1;.'

~ .d,

"

1

1

J'

A

-<,

'L"\ya~<: '-::::<\:

·n". ""

.;

-

.

. /.... · . · . 0 . 0

\,/~' . '"",1'1_

II

'~~f.,.l···III" "/'

00. .'

•••

'."1,'.\'.1"' ...,11.

,"

I'', . \',I ',f.-... A ' · i/,~F I

I

.

' HII I Ijl

'. "':---1 I

'~ I

I,

It, F20503102


3

2

,~

I

5

",

! I

, ,

I

I, \

-L4=E31'

)

I

6

r-'\

Damper assembly Friction plate Cone spring Friction washer Stopper pin Torsion spring Drive plate Hub

7

B

-

1. 2. 3. 4. 5. 6. 7. 8.

205F2010-2

Section A-A

PC200, 220-3

11-5 @


DAMPER

FUNCTION • The rotating torque of the engine is not constant, and there is always a considerable amount of rotational vibration. To prevent this vibration from being transmitted to the gear and piston pumps, a damper is installed to absorb the vibration. • In this way, the durability of the gear and piston pumps are increased by absorbing engine vibration and shock torque generated during sudden acceleration and heavy-duty excavation.

PRINCIPLE OF OPERATION • The torsion spring of the damper acts as a cushion to prevent the vibration of the engine from being transmitted directly to the gear and piston pumps. However, the vibration cannot be removed immediately just by installing a spring, because one spring cannot cushion the vibration completely. For this reason, a cone spring is used in addition to the torsion spring to improve the reduction in vibraton.

STRUCTURE • Drive plate (7) is installed to the engine flywheel and hub (8) is fitted on shaft. There is a torsion spring (6) installed between the drive plate and hub. • Cone spring (3) pushes friction plate (2) and friction washer (4) against the flanged part of the hub. In this way it is structured to generate friction torque. • Even if friction washer (4) is worn, cone spring acts to maintain a constant torque. • The vibration of the engine is absorbed by the torsion spring and friction washer. If any strong twisting force is brought (the transmitted torque becomes large), stopper pin (5) functions to transmit the movement of the flywheel directly to the hub.

2.

When torsion spring and cone spring are used in combination Let us now put a wall to the side of the weight, and use a spring to push a friction plate against the side of the weight. Friction will be generated between the weight and the friction plate. When this happens, the friction generated between the weight and the friction plate will act to stop the free movement (vibration) of the weight comparatively quickly.

www. k omat s upar t s book . c om 1.

When only torsion spring is used If a weight is hung on a spring, as in the diagram below, and is then pulled down and released, it will bounce up and down freely. This bouncing (vibration) will not stop quickly, but will gradually become less over a period of time.

///1/////

Torsion u'" ~Spring

g

~ Friction

~ plate

Torsion spring

~

:~:] L~-'

@w

,r--l, ,

L

__ J

I

'OI---+---+---+-+-hf-L--

~",,~jL---

////t/////

~

.0

_

Cone spring '"

'" u u c

'"uc :> .8 r----+----;.---t----+--

~5

'0

00

u

~.o

~'----------------

o

Time

142F016

Time 142F017

•

'"c

-

In this way, the torsion spring acts to reduce the transmission of vibration. If a cone spring is added, the load of the spring will generate friction torque and this will further improve the vibration absorbing effect.

11-6

PC200, 220-3

-


FUEL TANK AND PIPING

FUEL TANK AND PIPING ,~::;:::::::;::::::;;:::;~~-_ . . _~ '~'1

1!:fl -,

.

T

-

www. k omat s upar t s book . c om z ---

1. 2. 3. 4. 5.

/

-

/

Fuel level gauge (sensor) Sight gauge Fuel tank Filler cap Drain valve

? The fuel level sensor is installed in the fuel tank. When the fuel level monitor indicates EMPTY, there is still 40£ remaining.

ViewZ

5

F205C3003

PC200, 220-3

11-7

ENGINE CONTROL SYSTEM


-

ENGINE CONTROL SYSTEM

3

-

2


F205C3004

1. 2. 3. 4.

11-8

Instrument panel Fuel control lever Fuel injection pump Rod

PC200, 220-3

-

AUTO-DECELERATION SYSTEM


-

-

*

FOR MACHINES EQUIPPED WITH AUTO-DECELERATION SYSTEM

Operation 1. Engine running, control levers at HOLD 1) When fuel control lever (6) is set to the FULL position and the control levers are returned to HOLD, the hydraulic pressure in the ppe circuit does not act on hydraulic switch (9), so the switch is closed. Travel control levers (11) arealsoat NEUTRAL, so limit switch (12) is also closed. For this reason, an electric current flows to timer (7) and the timer sends out an electric current to switch solenoid valve (2). When the solenoid valve is switched, pressure oi I from charging pump (1) acts on decelerator cylinder (3). The cylinder extends and engine control governor lever (5) is moved back to the NO.1 deceleration position. (Fig. 1) When this happens, loose spring (4) is compressed, so fuel control lever (6) is not moved back. The engine speed at this point is 2000 - 2100 rpm (No.1 deceleration speed).

56010& engine

www. k omat s upar t s book . c om Fig. 1

2)

-

When 0.14 seconds have passed after the levers were moved to NEUTRAL, the electric signal from the timer is cut, and solenoid valve (2) is switched. When the solenoid valve is switched, the pressure oil from charging pump (1) and the drain oil from the decelerator cylinder (3) are shut off, so engine control governor lever (5) is held at NO.1 deceleration position for about 4 seconds.

560105 engine

B '"

:; E :J

«""

Fig. 2

PC200, 220-3

F20503051

F20503052

11-11-2 @



*

3)


4 seconds after levers are placed in NEUTRAL, the timer sends out the electric current to switch solenoid valve (2). When the solenoid valve is switched, the pressure oil from the charging pump acts again on decelerator cylinder (3). The cylinder extends and engine control governor lever (5) is moved back to the HALFOPEN (deceleration) position. (Fig. 3) When this happens, loose spring (4) is compressed, so fuel control lever (6) is not moved back. The engine speed at this point is 1150 - 1250 rpm (deceleration speed).

-

-


2.

Engine running, control levers being operated If the work equipment control levers are operated with fuel control lever (6) at the FULL position, the pressure oil in the PPC circuit acts on hydraulic switch (9) and opens the switch. When the travel levers are operated, limit switch (12) is opened. If either of these switches is opened, timer (7) sends an electric signal to excite SOLS. As a result, the pressu re oil from the charging pump does not act on decelerator cylinder (3). The oil at the bottom end of the cylinder is drained, so the force of the cylinder return spring and the force of the loose spring move the engine control governor in the direction of the FULL position. (Fig.4)

F20503053

S6D 105 engine

B

-

CtI

"S

E :J

«""

Fig. 4

F20503054

11-11-3 ®

PC200, 220-3

-


*

3.

-

AUTO-DECE LE RATI ON SYSTEM FOR MACHINES EQUIPPED WITH AUTO-DECELERATION SYSTEM

Engine running, control levers moved from operating position to HOLD If all the control levers are returned to NEUTRA.L when the engine is running, the circu its wi II be set immediately to NO.1 deceleration condition and this condition will be held for about 4 seconds. The set speed for No.1 deceleration is 150 - 250 rpm lower than high idling, and informs that the circuits are now in deceleration condition.

OPERATION TABLE Operation

Neutral

~

Control lever position

Operation

-

www. k omat s upar t s book . c om tJ Decelerator condition

-

Engine speed (Fuel control lever at "Full".)

SOL B Solenoid valve operation (Voltage)

Not operation

No.1 deceleration

Change for load

2,000 2,100 rpm

No.2 deceleration

Not operation

1,150 - 1,250 rpm

Change for load

24V

o

------------- ------------------

SOL A

24V

o

PC200, 220-3

11- 11-4



*


-

1. DECELERATOR CYLINDER

2

3

4

6

5

connecting to - engine governor

-

Drain

www. k omat s upar t s book . c om \

0

----

@

\

@

II

II I /

~

\

205F2018

1.

2. 3. 4. 5. 6.

--

Cylinder Piston Return spring Bushing Nut Stopper

11-12 (4)

PC200, 220-3

ENGINE IZ TESTING AND AD'-'USTING

Testing and adjusting data ... Testing and adjusting tool list . Adjusting valve clearance . . . . Measuring compression pressure .. Measuring blow-by pressure . Testing and adjusting fuel injection timing Measuring exhaust gas color . Testing and adjusting fan belt tension Adjusting fuel control lever .. Adjusting deceleration cylinder

-

12- 2 12- 3 12- 4 12- 5 12- 6 12- 7 12- 9 12-10 12-11 12-14


-

Before performing inspection, adjustment or faultfinding, park the machine on level ground and check the safety pin and chock. When performing joint work, make appropriate signals and allow only authorized personnel near the machine. When checking the water level, allow the engine to cool down before removing the radiator cap to prevent the risk of being scalded by hot water which may spurt out if the engine is hot. Take great care to avoid getting caught in rotating parts such as the fan, etc.

PC200.220-3

12-1 CI)


TESTING AND ADJUSTING DATA

-

TESTING AND ADJUSTING DATA

C lassific ation

Machine model

PC200-3 PC200LC-3

PC220-3 PC220LC-3

Engine model

56D105-B-1

56D105-1

Item

Condition, etc.

Flywheel horsepower

Unit

Standard value

HP/rpm

116/2,100

Permissible value

Standard value

Permissible value

146/2,100 -

l1>

Maximum torque

E

Engi ne speed

u c co

.g

Low idling speed

l1>

kgm/rpm

47/1,600

rpm

800 - 900

-

56.5/1,400 800 - 900 -

High idling speed

rpm

2,250 - 2,350

O°C

rpm

150 min.

-

2,250 - 2,350

"-

Necessary starti ng speed

E

~

~

~

'":::Jco

-'= x

150 min.

_20° C (Using starting aid)

-

rpm

100 min. 162 max.

635 max.

162 max.

635 max.

50 max.

75

50 max.

75

650 max.

650 max.

650 max.

Intake resistance

All speed

mmH 2 0

Inta ke pressu re

All speed

mmHg

Exhaust pressure

All speed

mmHg

Exhaust temperature

All speed !intake air temp.: 20°C)

°c

650 max.

100 min.

-

www. k omat s upar t s book . c om l1>

Quick acceleration

-0

c

Exhaust gas color

co

At high idling

l1>

-'" j'l

-c

Valve clearance at 20°C

Bolch scale

Intake valve

mm

Exhaust valve

mm

5.5 max.

6.0

5.5 max.

6.0

1.0 max.

2.0

1.0 max.

2.0

0.25

0.25

0.25

0.25

0.45

0.45

0.45

0.45 I

Oil temperature: 40 - 60°C

>

kg/cm

2

31.5 min.

22

31.5 min.

22

Compression pressure

-0 0 .0

(E ngi ne speed)

(rpm)

(320 - 360)

mmH 2 0

100 max.

200

100 max.

200

kg/cm 2

3.5 - 5.5

2.5

3.5 - 5.5

2.5

1.0min.

0.8

1.0 min.

0.8

°c

80 - 110

120

80 - 110

120

%

0.5 max.

1.0

0.5 max.

1.0

(320 - 360)

l1>

c

At high idling

'0,

c

Blow-by pressure

LJJ

Oil temperature: min. 80°C E

2l

~

c 0 .;::; co

Oil pressu re (SAE30, Oil temperature: 80°C min.)

:::J

...J

E

At low idling

kg/cm

2

Oil temperature

All speed (Oil in oil pan)

Oil consumption ratio

At continuous rated output (Ratio to fuel consumption)

Fuel injection pressure

Nozzle tester

kg/cm 2

225

180

225

180

Fuel injection timing

B.T.D.C.

Degree

20 ± 1

20

20 ± 1

20

Coolant temperature

All speed (at engine outlet)

°c

70 - 80

100

70 - 80

100

Valve cracking temperature

°c

74.5 - 78.5

74.5 - 78.5

74.5 - 78.5

74.5 - 78.5

Full opening temperature

°c

90

90

90

90

mm

10 ± 0.5

10 ± 0.5

10 ± 0.5

10 ± 0.5

kg/cm 2

0.75 ± 0.1

0.75 ± 0.1

0.75±0.1

0.75 ± 0.1

.~

.n

At high idling

_l1>

-

l1>~

:::J '"

LL~

E

~

Thermostat function

~

Full opening lift

C>

c

"6 0

u

Radiator pressure valve function

Opening pressure (Differential pressure)

Fan speed

At high idling speed

rpm

2,100

2,100

2,100

2,100

Fan belt tension

Deflect when pushed with a force of 6 kg

mm

10

5 -15

10

5 -15

12-2 ®

PC200,220-3

-

TESTING AND ADJUSTING TOOL LIST


TESTING AND ADJUSTING TOOL LIST No.

-

Testing and measuring item

1

Engine speed

2

Battery S.G.

3

Freezing temperature of cooling water

4

Water temperature, oil temperature, air intake temperature

Part No.

Remarks

Multi-tachometer

799-203-8000

Digital reading: 60 - 2,000 rpm (L range) 60 - 19,999 rpm (H range)

Battery coolant tester

795-500-1000

Fault finding tool

1.1 00 - 1.300 -5 - -50°C

0- 200°C ThermIstor temperature gauge

799-101-6000

5

Exhaust temperature

0- 1,000°C

6

Lubrication oil pressure

0- 20 kg/em'

7

Fuel pressu re

0- 50 kg/em'

8

Intake pressure, exhaust pressure

9

Blow-by pressure

0-500mmH20

10

Intake resistance

-1,000 - 0 mmH,

11

Compression pressure

Compression gauge

795-502-1204

0- 70 kg/em'

12

Blow-by pressure

Blow-by checker

799-201-1503

0- 500mmH,O

13

Valve clearance

Feeler gauge

795-125-1330

0.25, 0.45 mm

14

Exhaust gas color

Handy smoke checker

799-201-9000

Dirtiness 0 - 70% with standard color (Dirtiness % x 1/10 ~ Bosch scale)

15

Water and fuel content in oil

Engine oil checker

799-201-6000

Provided with 0.1 and 0.2 water content standard samples

16

Fuel injection pressure Fuel injection nozzle spray condition

Nozzle tester

Commercially available

0- 300 kg/em'

17

Coolant quality

Water quality tester

799-202-7001

PH, nitrite ion concentration

18

Pressure valve function Leakage in cooling water system

Radiator cap tester

799-202-9001

0- 2 kg/em'

19

Radiator blockage (wind speed)

Anemometer (Air speed gauge)

799-202-2001

0- 40 m/s

20

Engine cranking

Cranking kit

795-610-1000

Engine with DC24V starting motor

21

Electrical circuits

Tester

Commercially available

Current, Voltage, Resistance

Engine pressu re measu ring kit

799- 203- 2002

0- 1,000 mmHg

www. k omat s upar t s book . c om ° -

PC200. 220-3

12-3 (6)


ADJUSTING VALVE CLEARANCE

-


*

Adjust clearance between valve and rocker arm as follows: Unit: mm Intake valve

Exhaust valve

0.25

0.45

At 20°C 1) 2)

3)

Remove cylinder head cover (1). Rotate crankshaft in normal direction while watching valve to align "1.6 TOP" mark on crankshaft pulley with pointer (2) when No. 1 cylinder is at compression TOC. While No.1 cylinder is at compression TOC, adjust the valves marked - in the table below: While No.6 cylinder is at compression TOC, adjust the valves marked o. Valve arrangement

-

*

Cylinder No.

1

2

--

4

3

5

-

6

- t -s www. k oma upar t s book . c om Intake valve

Exhaust valve

4)

0

0

0

0

Insert feeler gauge A between rocker lever (3) and valve stem (4) and adjust adjustment screw (5) until feeler gauge A is a sliding fit. Tighten lock nut (6). ~

5)

0

0

Lock nut:

3.2 ± 0.3 kgm

Next, rotate crankshaft one turn in the normal direction and adjust the valves marked o.

*

*

It is also possible to adjust as follows: Adjust valve clearance of No.1 cylinder when it is at compression TOC, then turn crankshaft 120° each time and adjust valve clearances following firing order. Firing order: 1 - 5 - 3 - 6 - 2 - 4 After tightening clearance.

lock

nut,

confirm

4

3

5

6

valve

21KFIOI

12-4 CD

PC200. 230-3

-

-

-


-


MEASURING EXHAUST GAS COLOR

-

MEASURING EXHAUST GAS COLOR Special tool

A

LL *

Part No.

Part Name

Q'tv

799-201-9000

Handy smoke checker

1

When measuring the exhaust gas color, be careful not to touch the exhaust pipe.

Measure the exhaust gas color while engine is warm (Oil temperature: 40 - 60°C)

1) 2)

Insert probe Al in outlet of exhaust pipe and secure to exhaust pipe with cl ip. Connect probe hose and connector hose of accelerator switch to smoke checker A. The pressure of air supply should be under 15kg/cm 2 . Connect power cable to AC1 OOV socket. Check that the power switch is 0 F F before connecting the cable. Loosen cap nut of suction pump and insert filter paper. Turn power switch ON. Accelerate engine suddenly. At the same time, depress accelerator pedal, operate relief valve and

-

* 3)

www. k omat s upar t s book . c om 4)

5) 6)

7)

*

catch exhaust gas color on filter paper. Lay filter paper used to catch exhaust gas color on top of unused filter paper (10 sheets or more) inside filter paper holder, and read indicated value. For details of using the equipment, see the instruction manual supplied with the handy smoke shecker. For the reference value of exhaust gas color, see 12, TESTING AND ADJUSTING DATA.

*

-

*

12-6 CD

PC200, 220-3

-




*

Adjust clearance between valve and rocker arm as follows: Unit: mm Valve

Intake valve

Exhaust valve

0.25

0.45

Engine at cold 1) 2)

-

3)

Remove cylinder head cover (1). Rotate crankshaft in normal direction while watching valve to align "1.6 TOP" mark on crankshaft pulley with pointer (2) when No. 1 cylinder is at compression TOC. While NO.1 cylinder is at compression TOC, adjust the valves marked. in the table below: While No.6 cylinder is at compression TOC, adjust the valves marked o. Valve arrangement

*

Cylinder No.

1

2

4

3

5

6

www. k omat s upar t s book . c om • •

Intake valve

Exhaust valve

4)

•

a

a

a

•

a

a

Insert feeler gauge A between rocker lever (3) and valve stem (4) and adjust adjustment screw (5) until feeler gauge A is a sliding fit. Tighten lock nut (6). ~

5)

•

•

a

Lock nut:

3.2

± 0.3 kgm

Next, rotate cran kshaft one turn in the normal direction and adjust the valves marked o.

*

It is also possible to adjust as follows: Adjust valve clearance of No.1 cylinder when it is at compression TOC, then turn crankshaft 0 120 each time and adjust valve clearances following firing order. Firing order: 1 - 5 - 3 - 6 - 2 - 4 •

4

*

After tightening clearance.

-

lock

nut,

confirm

3

5

6

valve

21KFIOI

PC200.220-3

12-7 CD

MEASURING COMPRESSION PRESSURE


-

MEASURING COMPRESSION PRESSURE

*

If performance tests or troubleshooting shows that the piston, piston ring or cylinder liner may be worn, measure the compression pressure.

Special tool

A

Part No.

Part Name

a'ty

795·502·1204

Compression gauge

1

When measuring the compression pressure, be care· ful not to touch the exhaust manifold or muffler, or to get caught in rotating parts. 1.

-

Adjust valve clearance. For details, see 12 ADJUSTING VALVE CLEARANCE.

*


Warm the engine up. (Oil temperature: 40 - 60°C)

3.

Remove nozzle holder assembly of cylinder to be measured. For details, see section 13, REMOVAL OF NOZZLE HOLDER ASSEMBLY.

* 4.

Install adapter of tool A in nozzle holder mount and tighten to specified tightening torque.

5.

Set the tachometer.

6.

Place fuel confrollever in NO INJECTION position. Crank engine with starting motor and measure compression pressure. When measuring the compression pressure, measure the engine speed to confirm that it is within the specified range. Measure the compression pressure at the point where the pressure gauge indicator remains steady.

-

*

* *

For details of installing the nozzle holder assembly after measuring the compression pressure, see 13 INSTALLATION OF NOZZLE HOLDER ASSEMBLY.

12-8 CD

PC200, 220-3

-

MEASURING BLOW-BY PRESSURE


MEASURING BLOW-BY PRESSURE Special tool

A

* 1.

-

Part No.

Part Name

a'ty

799-201-1503

Blow-by checker

1

Measure the blow-by pressure while engine is warm (Oil temperature: 40 - 60°C) Install adapter of blow-by checker in engine breather hose.

2.

Connect adapter to blow-by checker A with tube.

3.

Run the engine at high idling, and measure the blow-by pressure. Blow-by pressure varies greatly according to the condition of the engine. Therefore, if the blow-by value is considered abnormal, check for problem connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color, and prematurely dirty or deteriorated oil.

*

www. k omat s upar t s book . c om *

For the reference value of the blow-by pressure, see 12 TESTING AND ADJUSTING DATA.

-

PC200. 220-3

12-9 CD

TESTING AND ADJUSTING FUEL INJECTION TIMING


TESTING AND ADJUSTING FUEL INJECTION TIMING TESTING OF FUEL INJECTION TIMING 1. Disconnect hose (1) then remove corrosion resistor (2) together with bracket and move toward radiator. 2. Disconnect fuel injection pipe (3) of No.1 cylinder. 3. Remove delivery valve holder (4). Remove delivery valve (5) and spring (6) from holder, then install holder (4) again. P205C3007

4. Place fuel control lever at FULL position.

-

5. Operate priming pump and rotate crankshaft slowly in normal direction. Examine point where fuel stops flowing from delivery valve holder (4). 0

6. Check that pointer (8) and "20 I.J." line on crankshaft pulley (7) are aligned when fuel stops flowing.

www. k omat s upar t s book . c om * *

BEYOND injection timing line:

Timing RETARDED

BEFORE injection timing line:

Timing ADVANCED

*

*

To adjust injection timing, move position of injection pump. To ADVANCE, move to CYLINDER BLOCK. To RETARD, move to OUTSIDE. When injection timing is incorrect, adjust as follows.

--

12-10 CD

PC200. 220-3


ADJUSTING FUEL CONTROL LEVER

3.

CHECKING FUEL CONTROL LEVER SENSOR

* 1)

After adjustment, check the sensor as follows. Disconnect CN9(10) connector connected the fuel control lever sensor, and connect T-adapter (3 pin) in that place.

205P24 I I

-

2)

Start the engine, and pull fuel control lever all the way to "Full".

3)

Measure the voltage Vl-3 between No.1 and 3 pins of CN9 connector by tester.

*

Correct V 1-3: 4.8 - 5.2 (V) If Vl-3 is out of 4.8 - 5.2 V, check the wiring

To controller ---+-.

\-+--........---1 __~-_;> Fuel control lever sensor

www. k omat s upar t s book . c om of battery, alternator, control box and ground connection.

eNg

205F2415

4)

Measure the voltage Vl-2 between No.1 and No.2 pins of CN9 connector. Vl-2 = (Vl-3/2) ± 0.01 V If Vl-2 is out of specified value, adjust the length of rod (1).

* *

205F2416

PC200, 220-3

12-13 ®

ADJUSTING DECELERATION CYLINDER


-

ADJUSTING DECELERATION CYLINDER Adjustment procedure

1)

Stop the engine and set the fuel control lever to FULL. Check that the lever of the fuel injection pump is in contact with the stopper at the MAX. side, and that lever (1), yoke (2) and rod (3) are fixed in position. 2) Loosen locknut (5) of deceleration cylinder yoke (4), then adjust the clearance (C) between pin (6) and portion ® of the yoke to 0 - 0.75 mm. P (of the yoke) = 1.5, so the adjustment allowance of the yoke half-rotation is 0.75 mm. Therefore, at this point, adjust so that the clearance is the minimum. 3) From the position in 1) and 2), tighten the yoke one turn. P = 1.5, so clearance increases 1.5. Adjustment allowance: (0 + 1.5) to (0.75 + 1.5) mm Clearance = 1.5 to 2.25 mm Target: 2 mm Reference: The difference in speed between No.1 deceleration position and No.2 deceleration position is small (50 - 80 rpm), so adjustment is necessary to make it work properly. The speed increases approx. 50 rpm for every 1 mm in clearance.

*

*

5

4

* *


2 F20503062A

4

2 F20503063A

,. 12-14 ®

PC200.220-3


ADJUSTING FUEL CONTROL LEVER

3.

CHECKING FUEL CONTROL LEVER SENSOR (IF EQUIPPED)

*

1)

After adjustment, check the sensor as follows.

10

Disconnect CN9(10) connector connected the fuel control lever sensor, and connect T-adapter (3 pin) in that place.

205P24I I

-

2)

Start the engine, and pull fuel control lever all the way to "Full".

3)

Measure the voltage Vl -3 between No.1 and 3 pins of CN9 connector by tester.

*

CorrectVl-3: 4.9-5.1 (V) If Vl-3 is out of 4.9 - 5.1V, check the wiring

Fuel control

To controller ---+.

~-----?Ieversensor

www. k omat s upar t s book . c om of battery, alternator, control box and ground connection.

eN9

205F2415

4)

-

Measure the voltage Vl -2 between No.1 and No.2 pins of CN9 connector.

*

*

Vl-2 = Vl-3/2(V) If Vl -2 is out of specified value, adjust the length of rod (1).

205F2416

PC200, 220-3

12-13 @

ADJUSTING DECELERATION CYLINDER


-

ADJUSTING DECELERATION CYLINDER Adjustment procedure 1)

Stop the engine and set the fuel control lever to FULL. Check that the lever of the fuel injection pump is in contact with the stopper at the MAX. side, and that lever (1), yoke (2) and rod (3) are fixed in position. 2) Loosen locknut (5) of deceleration cylinder yoke (4), then adjust the clearance (C) between pin (6) and portion @ of the yoke to 0 - 0.75 mm. P (of the yoke) = 1.5, so the adjustment allowance of the yoke half-rotation is 0.75 mm. Therefore, at this point, adjust so that the clearance is the minimum. 3) From the position in 1) and 2), tighten the yoke one turn. P = 1.5, so clearance increases 1.5. Adjustment allowance: (0 + 1.5) to (0.75 + 1.5) mm Clearance = 1.5 to 2.25 mm Target: 2 mm Reference: The difference in speed between No.1 deceleration position and No.2 deceleration position is small (50 - 80 rpm), so adjustme nt is necessary to make it work properly. The speed increases approx. 50 rpm for every 1 mm in clearance.

*

*

5

4

*

*


2 F20503062A

4

2 F20503063A

12-14 (8)

PC200, 220-3

-

-


TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING FAN BELT TENSION TESTING FAN BELT TENSION

Water pump pulley Approx. 10 mm

Check the amount the fan belt deflects when pushed with a force of 6 kg at a point midway between the water pump pulley and the alternator pulley.

Alternator pulley

205F2417

-

ADJUSTING FAN BELT TENSION 1) 2)

Loosen mounting nut (1) of alternator assembly and belt tension adjustment bolt (2). Using a bar, raise alternator and adjust tension of fan belt (3). Tighten adjustment bolt (2), then tighten mounting bolt (1).


PC200, 220-3

12-15 CD

-

-


-

--

ENGINE I3 DISASSEMBLY AND ASSEMBLY

STARTING MOTOR ASSEMBLY Removal and installation 13- 2 ALTERNATOR ASSEMBLY Removal and installation 13- 3 ENGINE OIL COOLER ASSEMBLY Removal and installation ..... 13- 4 FUEL INJECTION PUMP ASSEMBLY Removal . 13- 6 Installation . 13- 7 WATER PUMP ASSEMBLY Removal and installation . . . . . . . . . . . .. 13- 8 NOZZLE HOLDER ASSEMBLY Removal and installation . . . . . . . . . . . .. 13- 9 TURBOCHARGER ASSEMBLY Removal and installation . . . . . . . . . . . .. 13-10 CYLINDER HEAD ASSEMBLY Removal . . 13-12 Installation . 13-18 RADIATOR ASSEMBLY Removal and installation . 13-25 HYDRAULIC OIL COOLER ASSEMBLY Removal and installation . 13-26 ENGINE, MAIN PUMP ASSEMBLY Removal . 13-28 Installation . 13-34 DAMPER ASSEMBLY Removal and installation . . . . . . . . . . . .. 13-39 AUTO-DECELERATION CYLINDER ASSEMBLY (IF EQUIPPED)

-


Removal and installation . . . . . . . . . . . .. 13-40

*

-

When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and piping, always bleed the air as follows: 1. Start engine and run at low idling. 2. Operate hydraulic cylinder 4 to 5 times, stopping 100 mm from stroke end. 3. Next, operate cylinder 3 to 4 times to stroke end. 4. After doing this, run engine at normal speed.

*

After repair or long storage, follow the same procedure.

PC200. 220-3

13-1 @


STARTING MOTOR

-~

REMOVAL OF STARTING MOTOR ASSEMBLY Disconnect the lead from the negative (-) terminal of the battery. 1.

Open hood.

2.

Remove lower engine cover.

3.

Disconnect wires (1) and (2), and wiring connector (3).

4.

Pull out starting motor assembly (4), then remove below.

INSTALLATION OF STARTING MOTOR ASSEMBLY


Fit a-ring and install starting motor assembly (4) to housing.

2.

Connect wiring connector (3), and wires (2) and (1). Fix the connector securely with the clip.

*

3.

Install lower engine cover.

4.

Close Mod and lock with catch.

5.

Connect lead to negative (-) terminal of battery.

-

13-2 cD

PC200, 220-3

-


ALTERNATOR

REMOVAL OF ALTERNATOR ASSEMBLY

it

-

Disconnect the lead from the negative (-) terminal of the battery.

1.

Open hood.

2.

Disconnect alternator wires (1), (2) and (3).

3.

Remove belt tension adjustment bolt (4), and loosen locknut (5).

4.

Move alternator assembly towards engine to relieve belt tension, then remove belt (6).

5.

Remove locknut (5) and bolt (7), then remove alternator assembly (8).

INSTALLATION OF ALTERNATOR ASSEMBLY


Set alternator assembly (8) on bracket, insert bolt (7), then tighten locknut (5) partially.

2.

Fit belt (6) in pulley groove.

3.

Fit belt tension adjustment bolt (4), and insert bar between engine and alternator. Raise alternator to adjust belt tension. The belt should deflect about 10 mm when pushed with a finger pressure of 6 kg at a point midway between the alternator and the water pump pulley.

* 4. 5.

Tighten belt tension adjustment bolt (4) and locknut (5). Connect alternator wires (3), (2) and (1). Connect the wires as follows. Terminal R: blue Terminal B: white Terminal E: black

*

6.

Close hood and lock with catch.

7.

Connect lead to negative (-) terminal of battery.

02L 05W

-.

05B

PC200. 220-3

205F2301A

13-3 CD


ENGINE OIL COOLER

-

REMOVAL OF ENGINE OIL COOLER ASSEMBLY 1.

Loosen drain valves (1) and (2), and drain cooling water. If the coolant contains antifreeze, dispose of it correctly.

*

2.

Remove fuel injection pump assembly. For details, see 13 REMOVAL OF FUEL INJECTION PUMP.

3.

Remove heater relay (3) together with plate.

4.

Disconnect connector (4) of hydraulic pressure sensor wiring, then remove oil filter (5).

5.

Remove tubes (6) and (7) between oil cooler and adapter.

6.

Remove tube (8) between oil cooler and block.

7.

Remove engine oil cooler assembly (9).

P205C3024

-

www. k omat s upar t s book . c om INSTALLATION OF ENGINE OIL COOLER ASSEMBLY 1.

Fit gasket and install engine oil cooler assembly (9) to block.

2.

Fit O-ring and install tube (8) between oil cooler and block. Insert a flat washer between the tube and the cooler.

-

* 3.

Fit O-rings and install tubes (7) and (6) between oil cooler and adapter.

4.

Fit O-ring and install oil filter (5), then connect connector (4) of hydraulic pressure sensor wiring. Fix the connector securely with the clip.

* 5.

Install heater relay (3) together with plate.

6.

Install fuel injection pump assembly. For details, see 13 INSTALLATION OF FUEL INJECTION PUMP.

7.

Tighten drain valves (2), (1) and add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.

*

13-4 CD

9

P205C3029

PC200, 220-3

-

-

-


-


FUEL INJECTION PUMP

-

REMOVAL OF FUEL INJECTION PUMP ASSEMBLY 1. Open hood. 2. Disconnect fuel control rod (1). 3. Disconnect auto-deceleration cylinder spring rod (3). - (If equipped)

(2) and loose

4. Disconnect fuel supply hose (4).

*

After disconnecting the hose, tie with string or wire to prevent the hose from bending and spilling fuel.

5. Disconnect hoses (5) and (6) between fuel filter and injection pump.

-

6. Remove fuel injection pipe (7). 7. Disconnect lubrication tubes (8) and (9) at pump end. 8. Remove lock bolt (10) of coupling.

www. k omat s upar t s book . c om 9. Remove 4 mounting bolts (11) of fuel injection pump.

10. Move fuel injection pump assembly (12) to rear, and remove.

205P2016

13-6 <4

PC200. 220-3

-


FUEL INJECTION PUMP

INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 1. Align key of drive shaft with keyway, then push in fuel injection pump assembly (12) and tighten 4 mounting bolts (11). 2. Tighten lock bolt (10) of coupling. ~

Mounting bolt: 5.2 ± 0.2 kgm

3. Align fuel injection line on crankshaft pulley (13) with pointer (14), then align line on fuel injection pump with line on coupling.

-

4. Hold in position and tighten 4 mounting bolts (11) uniformly. 5. Fit gaskets on both faces and connect lubrication tubes (9) and (8) at pump end. 6. Install fuel injection pipe (7).


Sleeve nut: 2.4 ± 0.1 kgm

7. Fit gaskets on both faces and connect hoses (6) and (5) between fuel filter and injection pump.

8. Fit gaskets on both faces and connect fuel supply hose (4).

-

9. Connect loose spring rod (3), deceleration cylinder (2) and fuel control rod (1). - (If equipped) * For details of adjusting, see section 12, TESTING AND ADJUSTING, ADJUSTING FUEL CONTROL LEVER and ADJUSTING DECELERATION CYLINDER. 10. Close hood and lock with catch.

PC200, 220-3

13-7 @


WATER PUMP

--

REMOVAL OF WATER PUMP ASSEMBLY 1.

Loosen drain valve (1) and drain cooling water. If the coolant contains antifreeze, dispose of it correctly.

*

2.

Open hood.

3.

Remove belt tension adjustment bolt (2), then remove plate (3).

4.

Loosen alternator locknut (4), move alternator (5) towards engine, and remove belt (6).

5.

Disconnect hose (7) between water pump and radiator at pump end.

6.

Remove hose (8) between water pump and thermostat.

7.

Remove 4 mounting bolts, then remove water pump assembly (9).

-

www. k omat s upar t s book . c om INSTALLATION OF WATER PUMP ASSEMBLY 1.

Fit gasket and set water pump assembly (9) on cylinder head, then tighten 4 mounting bolts.

2.

Install hose (8) between water pump and thermostat.

3.

Connect hose (7) between water pump and radiator at pump end.

4.


5.

Fit plate (3) and belt tension adjustment bolt (2), then adjust belt tension. For details, see TESTING AND ADJUSTING, ADJUSTING FAN BELT TENSION.

-

* 6.

Tighten drain valve (1) and add water through water filler (10) to the specified level. Run the engine to circulate the water through the system. Then check the water level again.

* 7.


13-8 CD

PC200, 220-3


FUEL INJECTION PUMP

INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY (OPTION) 1. Align key of drive shaft with keyway, then push in fuel injection pump assembly (12) and tighten 4 mounting bolts (11). 2. Tighten lock bolt (10) of coupling. ~


3. Align fuel injection line on crankshaft pulley (13) with pointer (14). then align line on fuel injection pump with line on coupling.

-

4. Hold in position and tighten 4 mounting bolts (11) uniformly. 5. Fit gaskets on both faces and connect lubrication tubes (9) and (8) at pump end. 6. I nstall fuel injection pipes (7).



7. Fit gaskets on both faces and connect hoses (6) and (5) between fuel filter and injection pump.

8. Fit gaskets on both faces and connect fuel supply hose (4). 9. Connect fuel control rod (3). For details of adjusting, see 12 ADJUSTING FUEL CONTROL LEVER.

*

-

10. Install corrosion resistor (2). then connect hose (1). 11. Close hood and lock with catch.

PC200, 220-3

13-9 CD


NOZZLE HOLDER

-

REMOVAL OF NOZZLE HOLDER ASSEMBLY 1.

Open hood.

2.

Disconnect spill hose (1), then remove spill pipe (2).

3.

Disconnect fuel injection pipe (3) from nozzle holder to be removed. Remove nozzle holder assembly (4). When removing the nozzle holder, clean around the nozzle holder and fit a blind plug to prevent dust or dirt from entering. Mark the nozzle holders with tags showing the cylinder No. and keep in a safe place. If there is no abnormality in the nozzle holder, install in the same position when assembling.

4.

* *

-

www. k omat s upar t s book . c om INSTALLATION OF NOZZLE HOLDER ASSEMBLY 1.

Install nozzle holder assembly (4) in cylinder head. Tighten the nozzle holder mounting bolts uniformly.

*

~


Connect fuel injection pipe (3).

2.

~


3.

Fit gaskets on both faces and install spill pipe (2), then connect spill hose (1).

4.


-

13-10 CD

PC200.220-3

-


NOZZLE HOLDER

REMOVAL OF NOZZLE HOLDER ASSEMBLY (OPTION) 1.

Open hood.

2.

Disconnect spill hose (1), then remove spill pipe (2).

3.

Disconnect fuel injection pipe (3) from nozzle holder to be removed.

4.

Remove nozzle holder assembly (4). When removing the nozzle holder, clean around the nozzle holder and fit a bl ind plug to prevent dust or dirt from entering. Mark the nozzle holders with tags showing the cylinder No. and keep in a safe place. If there is no abnormality in the nozzle holder, install in the same position when assembling.

*

*

*

When removing No.5 nozzle holder, remove air intake hose (5).

www. k omat s upar t s book . c om INSTALLATION OF NOZZLE HOLDER ASSEMBLY (OPTION) 1.

-

Install nozzle holder assembly (4) in cylinder head. Tighten the nozzle holder mounting bolts uniformly.

*

~

2.


Connect fuel injection pipe (3). ~


3.

Fit gaskets on both faces and install spill pipe (2), then connect spill hose (1).

4.


pe200, 220-3

13-11 CD


WATER PUMP

-

REMOVAL OF WATER PUMP ASSEMBLY 1.

Loosen drain valve (1) and drain cooling water. If the coolant contains antifreeze, dispose of it correctly.

*

2.

Open hood.

3.

Remove belt tension adjustment bolt (2), then remove plate (3).

4.

Loosen alternator locknut (4), move alternator (5) towards engine, and remove belt (6).

5.

Disconnect hose (7) between water pump and radiator at pump end.

6.

Remove hose (8) between water pump and thermostat.

7.

Remove 4 mounting bolts, then remove water pump assembly (9).

P205C3038

-

www. k omat s upar t s book . c om INSTALLATION OF WATER PUMP ASSEMBLY 1.

Fit gasket and set water pump assembly (9) on cylinder head, then tighten 4 mounting bolts.

2.

Install hose (8) between water pump and thermostat.

3.

Connect hose (7) between water pump and radiator at pump end.

4.


5.

Fit plate (3) and belt tension adjustment bolt (2), then adjust belt tension. For details, see 12 TESTING AND ADJUSTING FAN BELT TENSION.

. P205C3040

-

* 6.

Tighten drain valve (1) and add water through water filler (10) to the specified level. Run the engine to circulate the water through the system. Then check the water level again.

* 7.


13-12 CD

PC200, 220-3

-

TURBOCHARGER


REMOVAL OF TURBOCHARGER ASSEMBLY (OPTION)

al'. If'l;

1.

Open hood.

2.

Remove hose (1) between turbocharger and air cleaner.

3.

Loosen intermediate hose clamp of connector, then move hose (2) towards connector.

4.

Remove muffler.

5.

Disconnect turbocharger inlet tube (4) and outlet tube

connector

(3)

between

turbocharger

and

P205C3044

(5).

-

6.

Remove turbocharger assembly (6).

INSTALLATION OF TURBOCHARGER ASSEMBLY (OPTION)


Fit gasket and install turbocharger assembly (6) to exhaust manifold. Fit the gasket with the TOP mark facing up.

*

-

2.

Fit gasket and connect turbocharger outlet tube (5).

3.

Fit O-ring and connect turbocharger inlet tube (4).

4.

Install connector (3) between turbocharger and muffler.

5.

Move hose (2) and connect.

6.

Install hose (1) between turbocharger and air cleaner.

7.


PC200, 220-3

13-13 CD


CYLINDER HEAD

-

REMOVAL OF CYLINDER HEAD ASSEMBLY 1. Draining water 1) Loosen drain valve (1) and drain cool ing water from radiator. 2) Loosen drain valve (2) and drain cooling water from cylinder block.

*

If the coolant contains antifreeze, dispose of it correctly.

2. Hood Open hood.

-

3. Exhaust connector Remove exhaust connector (3). 4. Bracket Disconnect bracket (4) of dipstick guide.

www. k omat s upar t s book . c om 5. Bracket Remove fastening bracket (5) for oil filter mounting bracket.

a

5

6. Intake hose Remove intake hose (6).

__

13-14 CD

lIIlIIIIIIl!!llIIIIIlIIrlllll.!:p~205C30~ PC200. 220-3

-


CYLINDER HEAD

7. Corrosion resistor Disconnect hoses (7) and (8), then remove corrosion resistor (9).

8. Aeration hose

Disconnect aeration hose (10). 9. Radiator inlet hose

Remove radiator inlet hose (11). 10. Bypass hose

www. k omat s upar t s book . c om Remove bypass hose (12).

11. Fuel injection pipe

Remove fuel injection pipes (13).

12. Heater relay

1) 2)

Disconnect wiring connector (14) of water temperature sensor. Disconnect wire (15) between electrical intake air heater and heater relay at heater relay end, then remove heater relay (16) together with plate and move toward pump.

PC200, 220-3

13-15 CD

DISASSEMBl Y AND ASSEMBl Y

CYLINDER HEAD

13. Breather tube

Disconnect breather tube (17). 14. Spill pipe Disconnect spill hose (18), then remove spill pipe (19).

15. Nozzle holder assembly

-

Remove mounting bolts (20), then remove nozzle holder assemblies (21). When removing the nozzle holder, clean around the nozzle holder and fit a blind plug to prevent dust or dirt from entering. Mark the nozzle holders with tags showing the cylinder No. and keep in a safe place. If there is no abnormality in the nozzle holder, install in the same position when assembling.

*

*

www. k omat s upar t s book . c om 16. Cylinder head cover

Remove 4 mounting nuts (22), then remove cylinder head cover (23).

17. Rocker arm assembly

1) 2)

Loosen locknut (24), then loosen adjustment screw (25) 2 to 3 turns. Remove 6 mounting bolts (26), then remove rocker arm assembly (27).

13-16 CD

PC200, 220-3


CYLINDER HEAD

18. Push rod Remove push rod (28).

-

19. Cylinder head assembly 1) Remove 26 mounting bolts (29).


-

Lift off cylinder head assembly (30). If the cylinder head gasket is stuck and the cylinder head assembly will not come off, insert a screwdriver between the bottom face of the cylinder head and the top face of the cylinder block, and lever up carefully.

*

~

Cylinder head assembly: 70 kg

PC200.220-3

13-17 CD


CYLINDER HEAD

INSTALLATION OF CYLINDER HEAD ASSEMBLY Special tool

A

*

Part No.

Part Name

Q'ty

795- 125-1330

Feeler gauge

1

Remove all carbon and dirt from the contact surfaces of the cylinder block and cylinder head. Remove all burrs and damage, and clean out all dirt from inside the cylinder block and cylinder head.

1. Cylinder head assembly 1) Set cylinder head gasket (31) on block. 2) Raise cylinder head assembly (30) horizontally, then using 2 or 3 mounting bolts as guide bolts, set on cylinder block. 3) Tighten 26 cylinder head mounting bolts (29). Tighten the mounting bolts in the order shown and to the following tightening torques.

-

*

www. k omat s upar t s book . c om ~,

i)

Bolt thread and seat face: Anti-friction compound (LM.P)

Order for tightening mounting bolts of cylinder head

Center

Front

-

Rear

20SF2304

ii)

Tightening torque of mounting bolt Molybdenum disulphide

Order Target (kgm)

Range (kgm)

1st step

9

8 - 10

2nd step

13

12 - 14

3rd step

18

17.5-18.5

13-18 CD

PC200, 220-3

-


CYLINDER HEAD

2. Push rod Install push rod (28l. Check that the push rod is fitted completely into the socket of the tappet.

*

-

3. Rocker arm assembly 1) Set rocker arm assembly (27) on cylinder head. Check that the ball of the adjustment screw is fitted properly into the socket of the push rod. 2) Tighten 6 mounting bolts (26). To prevent the push rod from protruding too far and putting strain on the rocker arm when assembling, loosen locknut (24) and turn adjustment screw (25) back 2 to 3 turns.

* *

www. k omat s upar t s book . c om 4. Adjusting valve clearance Adjust clearance between valve and rocker lever as follows.

*

Unit: mm

-

Valve Engine at cold

1)

2)

Exhaust valve

0.25

0.45

\

Rotate the crankshaft in the normal direction to align pointer (32) with the 1.6 TOP mark on crankshaft pulley. When rotating, check the movement of the valves. Insert feeler gauge A between rocker lever and valve stem and turn adjustment screw until clearance is a sliding fit. Then tighten locknut to hold adjustment screw in position. ~

* *

-

Intake valve

Locknut: 3.2 ± 0.3 kgm

After tightening the locknut, check the clearance again. When No.1 cylinder is at compression top dead center, adjust the valves marked •. When No.6 cylinder is at compression top dead center, adjust the valves marked o.

PC200, 220-3

Valve arrangement Cylinder No.

1

•

0

4

3

• •

Intake valve Exhaust valve

2

•

0

•

5

0

6 0

•

° 0

205F2305

13-19 CD


CYLINDER HEAD

5. Cylinder head cover Fit O-ring, and set cylinder head cover (23) in position. Fit packings and washers, then tighten 4 mounting nuts (22). ~

Nut: 0.9 ± 0.1 kgm

6. Nozzle holder assembly Install nozzle holder assembly (21), then tighten mounting bolts (20). When tightening the nozzle holder mounting bolts, fit the spill pipe and fix the position of the nozzle holder, then tighten the nozzle holder mounting bolts uniformly.

-

*



7. Spill pipe 1) Fit gaskets on both faces and install spill pipe (19). 2) Connect spill hose (18).

8. Breather tube Fit O-ring and install breather tube (17).

9. Heater relay 1) Install heater relay (16) together with plate Tighten together with the mounting bolts of the intake manifold. 2) Connect wire (15) and wiring connector (14) of water temperature sensor.

*

13-20 CD

PC200, 220-3

-


CYLINDER HEAD

10. Fuel injection pipe Install fuel injection pipes (13). ~

-


11. Bypass hose Install bypass hose (12). 12. Radiator inlet hose Connect radiator inlet hose (11). 13. Aeration hose Connect aeration hose (10).

www. k omat s upar t s book . c om 14. Corrosion resistor Install corrosion resistor (9), then connect hoses (8) and (7).

15. Intake hose Install intake hose (6).

PC200, 220-3

13-21 CD


CYLINDER HEAD

16. Bracket

Install fastening bracket (5) for oil filter mounting bracket.

17. Bracket Install bracket (4) of dipstick guide.

-

18. Exhaust connector Install exhaust connector (3).

www. k omat s upar t s book . c om 19. Refilling with water Tighten drai n valves of radiator and cylinder block, and add water through water filler (33) to the specified level. Run the engine to circulate the water through the system. Then check the water level again.

*

20. Hood Close hood and lock with catch.

13-22 CD

--

PC200, 220-3

-

-



CYLINDER HEAD

-

REMOVAL OF CYLINDER HEAD ASSEMBLY (OPTION) 1. Draining water 1) 2)

*

Loosen drain valve (1) and drain cooling water from radiator. Loosen drain valve (2) and drain cooling water from cylinder block. If the coolant contains antifreeze, dispose of it correctly.

2. Hood

-

Open hood.

3. Exhaust connector Remove exhaust connector (3).

4. Bracket


Remove fastening bracket (4) for oil filter mounting bracket.

2)

Disconnect bracket (5) of dipstick guide.

5. Turbocharger piping 1) 2)

Remove turbocharger inlet tube (6). Remove turbocharger outlet tube (7).

6. Intake hose Remove intake hose (8) together with bracket (9).

7. Air connector Remove air connector (10).

8. Corrosion resistor Disconnect hoses (11) and (12), then remove corrosion resistor (13).

13-24 CD

PC200, 220-3

-


CYLINDER HEAD

9. Aeration hose Disconnect aeration hose (14). 10. Radiator inlet hose Remove radiator inlet hose (15). 11. Heater hose Disconnect heater hose (16) . .1 2. Bypass hose Remove bypass hose (17).

13. Fuel injection pipe Remove fuel injection pipes (18).

www. k omat s upar t s book . c om 14. Heater relay 1) Disconnect wire (19) between electrical intake air heater and heater relay at heater end. 2) Remove heater relay (20) together with plate.

15. Breather tube Disconnect breather tube (21). 16. Spill pipe Disconnect spill hose (22), then remove spill pipe (23).

PC200, 220-3

13-25 CD


CYLINDER HEAD

17. Nozzle holder assembly Remove mounting bolts (24), then remove nozzle holder assembly (25). When removing the nozzle holder, clean around the nozzle holder and fit a blind plug to prevent dust or dirt from entering. Mark the nozzle holders with tags showing the cylinder No. and keep in a safe place. If there is no abnormality in the nozzle holder, install in the same position when assembling.

* *

18. Cylinder head cover Remove 4 mounting nuts (26), then remove cylinder head cover (27).

-

www. k omat s upar t s book . c om 19. Rocker arm assembly 1) Loosen locknut (28), then loosen adjustment screw (29) 2 to 3 turns. 2) Remove 6 mounting bolts (30), then remove rocker arm assembly (31).

20. Push rod Remove push rod (32).

13-26 CD

PC200,220-3

-


CYLINDER HEAD

21. Cylinder head assembly 1) Remove 26 mounting bolts (33).

-

2)

Lift off cylinder head assembly (34). If the cylinder head gasket is stuck and the cylinder head assembly will not come off, insert a screwdriver between the bottom face of the cylinder head and the top face of the cylinder block, and lever up carefully.

*

riij

www. k omat s upar t s book . c om Cylinder head assembly: 91 kg (incl, turbocharger, exhaust manifold and intake manifold)

-

PC200, 220-3

13-27 CD

DISASSEMBLY AND ASSEMBL Y

CYLINDER HEAD

INSTALLATION OF CYLINDER HEAD ASSEMBLY (OPTION) Special tool

A

*

Part No.

Part Name

Q'ty

795-125-1330

Feeler gauge

1

Remove all carbon and dirt from the contact surfaces of the cylinder block and cylinder head. Remove all burrs and damage, and clean out all dirt from inside the cylinder block and cylinder head.

1. Cylinder head assembly 1) Set cylinder head gasket (35) on block. 2) Raise cylinder head assembly (34) horizontally, then using 2 or 3 mounting bolts as guide bolts, set on cylinder block. 3) Tighten 26 cylinder head mounting bolts (33). Tighten the mounting bolts in the order shown and to the following tightening torques.

*

...o www. k omat s upar t s book . c m ~)

i)

Bolt thread and seat face: Anti-friction compound (LM-P)

J...,_----r---~

...

Order for tightening mounting bolts of cylinder head

Center

Front

___~'e__

-

+- Rear

205F2304

ii)

Tightening torque of mounting bolt Molybdenum disulphide

Order

Target (kgm)

Range (kgm)

1st step

9

8 -10

2nd step

13

12 - 14

3rd step

18

17.5-18.5

13-28 CD

PC200, 220-3

-



ENGINE AND MAIN PUMP

-

REMOVAL OF ENGINE AND MAIN PUMP ASSEMBLY Draining water

I 2

I

Oil stopper

4 Air cleaner ass'y

5 Wiring connector

-

6

I I

Pump piping

j

7

I www. k omat s u pa t s book . c om lr Deceleration cylinder hoses (If

eqUiPped~l\

.AFuel control cable

PC200-3 PC220-3 Hydraulic excavator

--1

3 Hood, covers

~

C,"",n"d wIring connector

N

Starting

~

~

In

16 Engine, mainl pump ass'y

~

moM W;dO:

-

,

I~

Ground connection

.\

r

12/

1

Fuel supply hose

r

13 Spill hose

14 Radiator piping, sub-tank

15 Fan guard 205F2306

13-28 (4)

PC200, 220-3

-

CYLINDER HEAD


2. Push rod I nstall push rod (32). Check that the push rod is fitted completely into the socket of the tappet.

*

-

3. Rocker arm assembly 1) Set rocker arm assembly (31) on cylinder head. Check that the ball of the adjustment screw is fitted properly into the socket of the push rod. 2) Tighten 6 mounting bolts (30). To prevent the push rod from protruding too far and putti ng strai n on the rocker arm when assembling, loosen locknut (28) and turn adjustment screw (29) back 2 to 3 turns.

*

*

www. k omat s upar t s book . c om 4. Adjusting valve clearance

*

Adjust clearance between valve and rocker lever as follows. Unit: mm

-

Valve Engine at cold

1)

2)

Exhaust valve

0.25

0.45

Rotate the crankshaft in the normal direction to align pointer (36) with the 1.6 TOP mark on crankshaft pulley. When rotating, check the movement of the valves. Insert feeler gauge A between rocker lever and valve stem and turn adjustment screw until clearance is a sliding fit. Then tighten locknut to hold adjustment screw in position. ~

* *

-

I ntake valve


After tightening the locknut, check the clearance again. When No.1 cylinder is at compression top dead center, adjust the valves marked •. When No.6 cylinder is at compression top dead center, adjust the valves marked o.

PC200.220-3

,I Valve arrangement Cylinder No.

1

3

• •

Intake valve Exhaust valve

2

•

a

4

•

a

•

5

a

6

a

•

a a

205F2305

13-29 CD

DISASSEMBl Y AND ASSEMBl Y

CYLINDER HEAD

5. Cylinder head cover Fit O-ring, and set cylinder head cover (27) in position. Fit packings and washers, then tighten 4 mounting nuts (26). ~

Nut: 0.9 ± 0.1 kgm

6. Nozzle holder assembly Install nozzle holder assembly (25), then tighten mounting bolts (24). When tightening the nozzle holder mounting bolts, fit the spill pipe and fix the position of the nozzle holder, then tighten the nozzle holder mounting bolts uniformly.

-

*



7. Spill pipe 1) Fit gaskets on both faces and install spill pipe (23). 2) Connect spill hose (22).

8. Breather tube Install breather tube (21).

9. Heater relay 1) Install heater relay (20) together with plate. 2) Connect wire (19) between electrical intake air heater and heater relay.

13-30 CD

PC200. 220-3

-



Special tool

A

-

1.

Part No.

Part Name

Q'ty

796-750-1410

Oil stopper

1

Lower the work equipment- completely to the ground and stop the engine. Operate the control levers several times to release the remain ing pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Disconnect the lead from the negative (-) terminal of the battery. Draining water Loosen drain valve (1) and drain cooling water. If the coolant contains antifreeze, dispose of it correctly.

* 2.

Oil stopper 1) Remove strainer cover (2), then take out strainer (3). 2) Remove strainer and assemble tool A on rod (4). 3) Install rod and tool A inside tank, then fit spring and install strainer cover. When not using tool A, remove drain plug (5) and drain the oil from the hydraulic tank .


•

~

Hydraulic tank: Approx. 150 Q

3.

Hood, covers 1) Open hood. 2) Remove top cover (6) and bottom cover (7). 3) Open side cover.

4.

Air cleaner assembly Sling air cleaner assembly, remove air cleaner band and hose clamp, then remove air cleaner assembly (8).

PC200, 220-3

13-29 CD



5.

Wiring connector Disconnect wiring connector (9) of TVC solenoid valve. Cover the wiring connector with a vinyl bag to protect it from oil or dust.

*

6.

Pump piping

* *

1)

-

After disconnecting, fit blind plugs in the tubes and hoses to prevent dirt or dust from entering. Mark the pilot hoses with tags to show their mounting position. Remove hoses (10) and (11) between pump and control valve, then disconnect branch hoses (12) and (13) together with block.

www. k omat s upar t s book . c om 2) 3) 4)

Disconnect hose solenoid valve. Disconnect hose accumulator. Disconnect hose tank.

(14) between charging pump and (If equipped) (15) between charging pump and (16) between pump and hydraulic

5) 6) 7)

Disconnect hoses (17) and (18) at rear between CO, NC valve and control valve. Disconnect hoses (19) and (20) at front between CO, NC valve and control valve. Disconnect charging pump inlet tube (21) and suction tube (22).

-13-30

PC200, 220-3



7. Deceleration cylinder hoses (If equipped) Disconnect deceleration cylinder hoses (23) and (24). 8. Fuel control cable Disconnect fuel control cable (25).

-

9. Centralized wiring connector Disconnect centralized wiring connector (26). Cover the wiring connector with a vinyl bag to protect it from oil or dust.

*

10. Starting motor wiring Disconnect starting motor wiring (27).

www. k omat s upar t s book . c om 11. Ground connection Disconnect ground connection (28).

-

12. Fuel supply hose Disconnect fuel supply hose (29). After disconnecting the hose, tie with string or wire to prevent the hose from bending and spilling fuel.

*

205P2080

13. Spill hose Disconnect spill hose (30).

PC200, 220-3

13-31 @



14. Radiator piping, sub-tank 1) Disconnect aeration hose (31). 2) Remove radiator inlet hose (32). 3) Disconnect heater hose (33). 4) Disconnect water pump inlet hose (34). 5) Disconnect wiring connector (35) of water temperature sensor, then remove cooling water sub-tank (36) and move towards radiator.

15. Fan guard Remove fan guard (37).

-

www. k omat s upar t s book . c om 16. Engine and main pump assembly 1) Remove 8 mounting bolts (38) of engine at left, right. front and rear.

2)

Using lever block CD, raise engine and main pump assembly (39) horizontally and lift off.

~

Engine and main pump assembly: 870 kg

13-32 CD

PC200, 220·3

-


RADIATOR

REMOVAL OF RADIATOR ASSEMBLY 1. Loosen drain valve (1) and drain cooling water. If the coolant contains antifreeze, dispose of it correctly. 2. Sling hood, disconnect stay (2), then remove 4 mounting bolts and lift off hood (3).

*

~~J

Hood: 55 kg

3. Remove lower cover (4) of radiator. 4. Disconnect radiator outlet tube (5). 5. Disconnect aeration hose (6). 6. Disconnect radiator inlet hose (7). 7. Disconnect hose (8) between sub-tank and radiator. 8. Open side cover, sling radiator assembly, then remove 8 mounting bolts (9) on left and right. 9. Lift off radiator assembly (10).

www. k omat s upar t s book . c om Lk9 J ~-

Radiator assembly: 20 kg

INSTALLATION OF RADIATOR ASSEMBLY

1. Raise radiator assembly (10), set in position on frame, then tighten 8 mounting bolts (9) on left and right. 2. Connect hose (8) between sub-tan k and radiator. 3. Connect radiator inlet hose (7).

-

4. Connect aeration hose (6). 5. Fit a-ring and connect radiator outlet tube (5). 6. Install lower cover (4) of radiator. 7. Raise hood (3) and set in position on frame. Tighten 4 mounting bolts, then connect stay (2). 8. Close side cover. 9. Tighten drain valve (1) and add water through water filler (11) to the specified level. Run the engine to circulate the water through the system. Then check the water level again.

*

10. Close hood and lock with catch.

PC200. 220-3

13-33 CD


HYDRAULIC OIL COOLER

-

REMOVAL OF HYDRAULIC OIL COOLER ASSEMBLY 1.

Loosen oil filler cap slowly to release pressure inside hydraulic tank. Remove drain plug (1) and drain oil from hydraulic tank.

•

..:-. Hydraulic tank: Approx. 150 Q 2.

Sling hood, disconnect stay (2), then remove 4 mounting bolts and lift off hood (3).

~

Hood: 55kg

3.

Open side cover, then disconnect inlet tube (4) and outlet tube (5) of hydraulic oil cooler at hydraulic tank end.

4.

Sling hydraulic oil cooler assembly, remove 4 upper mounting bolts (6) and 4 lower mounting bolts (7).

-

www. k omat s upar t s book . c om Lift off hydraulic oil cooler assembly (8).

5.

~

Hydraulic oil cooler: 36 kg

INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY 1.

Raise hydraulic oil cooler assembly (8), set in position on frame, then tighten 4 upper mounting bolts (6) and 4 lower mounting bolts (7).

2.

Fit a-rings and connect outlet tube (5) and inlet tube (4) of hydraulic oil cooler.

3.

Close side cover.

4.

Raise hood (3) and set in position on frame. Tighten 4 mounting bolts, then connect stay (2).

5.


6.

Tighten drain plug (1) and add engine oil through oil filler (9) to the specified level.

Wi

*

-

Hydraulic tank: Approx. 150 Q Run the engine to circulate the oil through the system. Then check the oil level again.

13-34

CD

PC200, 220-3

-

-


-



INSTALLATION OF ENGINE AND MAIN PUMP ASSEMBLY

-

Fan guard

3 Sub-tank, radiator piping

4 Spill hose

5

I

Fuel supply hose

-

l

6.\

J Ground connection

www. k omat s u p a r t s b o o k . c o m I 1/ 1/

71 \

,AStarting ~ motor wiring 8

PC200-3 PC220-3 Hydraulic excavator

H

1 ~ain

Engine, pump ass y

16

Covers, hood

~ C,,'''''''d'rj 91~ WIring

connector

~ cable Fuel control r

\\,1

10

I

Deceleration cylinder hoses

-

1\ (If equipped)

11

l1

Pump piping

1

12 Wiring connector

13 Air cleaner ass'y

14 Oil stopper

I

15 Refilling with water

I

-

205F2307

13-34

PC200, 220-3

-


1.


Engine and main pump assembly 1) Using lever block (I), raise engine and main pump assembly (39) horizontally, then set in position on frame.

-

2)

Tighten 8 mounting bolts (38) of engine at left, right, front and rear. ~

Mounting bolt: 28 ± 3 kgm


Fan guard Install fan gurard (37).

3.

Sub-tank, radiator piping 1) Install cooling water sub-tank (36) on frame, then connect wiring connector (35) of water temperatu re sensor. 2) Connect water pump inlet hose (34). 3) Connect heater hose (33). 4) Install radiator inlet hose (32). 5) Connect aeration hose (31).

-

pe200, 220-3

13-35 CD



4. Spill hose Connect spill hose (30).

5. Fuel supply hose Fit gaskets on both faces and connect fuel supply hose (29). 6. Ground connection Connect ground connection (28).

7. Starting motor wiring Connect starting motor wiring (27).

-

8. Centralized wiring connector Connect centralized wiring connector (26).

www. k omat s upar t s book . c om 9. Fuel control cable Connect fuel control cable (25). For details of adjustment, see section 12, TESTING AND ADJUSTING, ADJUSTING FUEL CONTROL LEVER. 10. Deceleration cylinder hoses (If equipped) Connect deceleration cylinder hoses (24) and (23). Install hose without twisting or interference.

*

-

*

~

Sleeve nut:

2.5 ± 0.5 kgm (Width across flats: 19 mm)

11. Pump piping Tighten the connections of each hose to the following tightening torques.

*

*

Install hose without twisting or interference. ~

Sleeve nut

Width across flats

13-36 (4)

19mm

2.5 ± 0.5 kgm

27mm

8 ± 2 kgm

32mm

18 ± 3 kgm

PC200. 220-3



1)

Fit O-rings and connect suction tube (22) and charging pump inlet tube (21).

2)

Connect hoses (20) and (19) at front, hoses (18) and (17) at rear between CO, NC valve and control valve. When installing the hoses, connect them to the places marked when the hoses were disconnect-

*

ed.

-

3) 4) 5) 6)

Connect hose (16) between pump and hydraulic tank. Connect hose (15) between charging pump and accumulator. Connect hose (14) between charging pump and solenoid valve. - (If equipped) F it O-rings and set branch hoses (13) and (12) on main pump. Fit O-rings and connect hoses (11) and (10) between pump and control valve.


12. Wiring connector Connect wiring connector (9) of TVC solenoid valve. Fix the connector securely with the clip.

*

13. Air cleaner assembly Raise air cleaner assembly (8) and set in position on bracket. Tighten removed air cleaner band and hose clamp.

PC200, 220-3

13-37 @



14. Oil stopper 1) Remove cover (2), then take out tool A. 2) Remove rod (4) from tool A and assemble strainer (3) on rod (4). 3)

*

Install strainer with rod inside tank, then install spring and cover again. If tool A was not used and the oil was drained from the hydraulic tank, tighten the drain plug and add engine oil through the oil filler (40) to the specified level.

Wi


15. Refilling with water Tighten drain valve and add water through water filler (41) to the specified level.

* *

-

Connect lead to negative (-) terminal of battery. Run the engine to circulate the water through the system. Then check the water level again.

www. k omat s upar t s book . c om 16. Covers, hood 1) Install bottom cover (7) and top cover (6). 2) Close hood and lock with catch. 3) Close side cover.

-

13-38 CD

PC200, 220-3


DAMPER

-.

REMOVAL OF DAMPER ASSEMBLY

-

1.

Remove main pump assembly. For details, see section 63, REMOVAL OF MAIN PUMP ASSSMBLY.

2.

Remove 8 mounting bolts (1) of damper.

3.

Remove damper assembly (2).

INSTALLATION OF DAMPER ASSEMBLY 1.

Set damper assembly (2) in position on flywheel, then tighten 8 mounting bolts (1).

*

Install the damper with the larger boss protrusion on the pump side.


~


~,.

Boss spline: Grease (LM-G)

Install main pump assembly. For details, see section 63, INSTALLATION OF MAIN PUMP ASSEMBLY.

_.

PC200, 220-3

13-39 CD


AUTO-DECELERATION CYLINDER

-

REMOVAL OF AUTO-DECELERATION CYLINDER ASSEMBLY (IF EQUIPPED) 1.

Open hood and disconnect hoses (1) and (2) at cylinder end. Make match marks on the hoses and cylinder before removing.

* 2.

Remove pins (3) and (4), and remove deceleration cylinder assembly (5).

205P2094

-

INSTALLATION OF AUTO-DECELERATION CYLINDER ASSEMBLY (IF EQUIPPED)


Install deceleration cylinder assembly (5) with pins (4) and (3).

2.

Connect hoses (2) and (1), then close hood and lock with catch. ~

* 3.

2.5 ± 0.5 kgm (Width across flats: 19 mm) Install hoses without twisting or interference. Hose nut:

Adjust the deceleration cylinder. For details, see TESTING AND ADJUSTING, ADJUSTING DECELERATION CYLINDER.

*

-

13-40 @

PC200. 220-3



-.

4. Spill hose Connect spill hose (24). 5. Fuel supply hose Fit gaskets on both faces and connect fuel supply hose (23), 6. Ground connection Connect ground connection (22).

-.

7. Starting motor wiring Connect starting motor wiring (21). 8. Wiring connector Connect wiring connector (20).

www. k omat s upar t s book . c om 9. Fuel control cable Connect fuel control cable (19). For details of adjustment, see 12 ADJUSTING FUEL CONTROL LEVER.

*

10. Pump piping Tighten the connections of each hose to the following tightening torques. Install hose without twisting or interference. ~ Sleeve nut

* *

Width across flats

pe200, 220-3

19 mm

2.5 ± 0.5 kgm

27 mm

8 ± 2 kgm

32mm

18 ± 3 kgm

13-41 CD



1)

2)

F it O-rings and connect suction tu be (18) and charging pump inlet tube (17). Connect hoses (16) and (15) at front, hoses (14) and (13) at rear between NC· CO valve and control valve. When installing the hoses, connect them to the places marked when the hoses were disconnected.

*

3) 4) 5) 6)

Connect hose (12) between pump and hydraulic tank. Connect hose (11) between control valve and accumulator. Fit O-rings and set branch hoses (10) and (9) on main pump. Fit O-ring and connect hoses (8) and (7) between pump and control valve.

-

www. k omat s upar t s book . c om 11. Air cleaner assembly Raise air cleaner assembly (6) and set in position on bracket. Tighten removed air cleaner band and hose clamp,

12. Oil stopper 1) Remove cover (2), then take out tool A. 2) Remove rod (4) from tool A and assemble strainer (3) on rod (4). 3) Install strainer with rod inside tank, then install spring and cover again. If tool A was not used and the oil was drained from the hydraulic tank, tighten the drain plug and add engine oil through the oil filler (33) to the specified level.

*

Wi 13-42 CD


PC200, 220-3

-



13. Refilling with water Tighten drain valve and add water through water filler (34) to the specified level. Connect lead to negative (-) terminal of battery. Run the engine to circulate the water through the system. Then check the water level again.

* *

14. Cover, hood 1) Install top cover. 2) Close hood and lock with catch. 3) Close side cover.

-


PC200, 220-3

13-43 CD



-

REMOVAL OF ENGINE AND MAIN PUMP ASSEMBLY (OPTION) Special tool

A

Part No.

Part Name

Q'ty

796-750-1410

Oil stopper

1

Lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Disconnect 'the lead from the negative (-) term inal of the battery.

-

1. Drai ni ng water Loosen drain valve (1) and drain cooling water. If the coolant contains antifreeze, dispose of it correctly.

*

www. k omat s upar t s book . c om 2. Oil stopper 1) Remove strainer cover (2), then take out strainer (3).

2) 3)

Remove strainer and assemble tool A on rod (4). Install rod and tool A inside tank, then fit spring and install strainer cover. When not using tool A, remove drain plug (5) and drain the oil from the hydraulic tank.

*

• ...:..

-


3. Hood, cover 1) Open hood. 2) Remove top cover. 3) Open side cover.

6

4. Air cleaner assembly 81 ing air cleaner assembly, remove air cleaner band and hose clamp, then remove air cleaner assembly (6).

13-44 CD

PC200, 220-3

-



5. Pump piping After disconnecting, fit blind plugs in the tubes and hoses to prevent dirt or dust from entering. Mark the pilot hoses with tags to show their mounting position. 1) Remove hoses (7) and (8) between pump and control valve, then disconnect branch hoses (9) and (10) together with block. 2) Disconnect hose (11) between control valve and accumulator. 3) Disconnect hose (12) between pump and hydraulic tank.

*

*

-

4) 5)

Disconnect hoses (13) and (14) at rear between CO·NC valve and control valve. Disconnect hoses (15) and (16) at front between CO·NC valve and control valve.


Disconnect charging pump inlet tube (17) and suction tube (18).

P205C3089

6. Fuel control cable Disconnect fuel control cable (19).

PC200,220-3

13-45 Q)

DISASSEMBL Y AND ASSEMBL Y


7. Wiring connector Disconnect wiring connector (20).

8. Starting motor wiring Disconnect starting motor wiring (21).

9. Ground connection

-

Disconnect ground connection (22).

10. Fuel supply hose Disconnect fuel supply hose (23). After disconnecting the hose, tie with string or wire to prevent the hose from bending and spilling fuel.

*

www. k omat s upar t s book . c om 11. Spill hose Disconnect spill hose (24).

12. Radiator piping, sub-tank 1) 2) 3) 4) 5)

Disconnect aeration hose (25). Remove radiator inlet hose (26). Disconnect water pump inlet hose (27). Removesub-tank (28) and move towards radiator. Disconnect heater hose (29).

13-46 CD

PC200, 220-3



13. Fan guard 1) Remove fan guard (30). 2) Remove upper shroud (31).

14. Engine and main pump assembly 1) Remove 8 mounting bolts (32) of engine at left, right, front and rear.


Using lever block CD, raise engine and main pump assembly (33) horizontally and lift off.

-

PC200. 220-3

13-47 CD



-

INSTALLATION OF ENGINE AND MAIN PUMP ASSEMBLY (OPTION) 1. Engine and main pump assembly 1)

Using lever block CD, raise engine and main pump assembly (33) horizontally, then set in position on frame.

2)

Tighten 8 mounting bolts (32) of engine at left, right, front and rear. ~ Mounting bolt: 28 ± 3 kgm

-

www. k omat s upar t s book . c om 2. Fan guard 1) 2)

Install upper shroud (31). Install fan guard (30).

3. Sub-tank, radiator piping 1) 2) 3) 4) 5)

Install sub-tank (28) on frame. Connect water pump inlet hose (27). Install radiator inlet hose (26). Connect aeration hose (25). Connect heater hose (29).

13-48 CD

PC200, 220-3

-



4. Spill hose Connect spill hose (24). 5. Fuel supply hose Fit gaskets on both faces and connect fuel supply hose (23). 6. Ground connection Connect ground connection (22).

-

7. Starting motor wiring Connect starting motor wiring (21). 8. Wiring connector Connect wiring connector (20).

www. k omat s upar t s book . c om 9. Fuel control cable Connect fuel control cable (19). For details of adjustment, see 12 ADJUSTING FUEL CONTROL LEVER.

*

10. Pump piping Tighten the connections of each hose to the following tightening torques. Install hose without twisting or interference.

* *

~ Sleeve nut

Width across flats

PC200, 220-3

19 mm

2.5 ± 0.5 kgm

27 mm

8 ± 2 kgm

32 mm

18 ± 3 kgm

13-49 CD

DISASSEMBL Y AND ASSEMBLY


1) 2)

Fit O-rings and connect suction tube (18) and charging pump inlet tube (17). Connect hoses (16) and (15) at front, hoses (14) and (13) at rear between NC·CO valve and control valve. When installing the hoses, connect them to the places marked when the hoses were disconnected.

*

3) 4) 5) 6)

Connect hose (12) between pump and hydraulic tank. Connect hose (11) between control valve and accumulator. Fit O-rings and set branch hoses (10) and (9) on main pump. Fit O-ring and connect hoses (8) and (7) between pump and control valve.

-

www. k omat s upar t s book . c om 11. Air cleaner assembly Raise air cleaner assembly (6) and set in position on bracket. Tighten removed air cleaner band and hose clamp.

12. Oil stopper 1) Remove cover (2), then take out tool A. 2) Remove rod (4) from tool A and assemble strainer (3) on rod (4). 3) Install strainer with rod inside tank, then install spring and cover again. If tool A was not used and the oil was drained from the hydraulic tank, tighten the drain plug and add engine oil through the oil filler (33) to the specified level.

*

ttl 13-50 CD

-


PC200, 220-3

-



13. Refilli ng with water Tighten drain valve and add water through water filler (34) to the specified level. Connect lead to negative (-) terminal of battery. Run the engine to circulate the water through the system. Then check the water level again.

* *

14. Cover. hood 1) Install top cover. 2) Close hood and lock with catch. 3) Close side cover.

-


PC200. 220-3

13-51 CD


DAMPER

-

REMOVAL OF DAMPER ASSEMBLY 1.

Remove main pump assembly. For details, see 63 REMOVAL OF MAIN PUMP ASSEMBLY.

2.

Remove 8 mounting bolts (1) of damper.

3.

Remove damper assembly (2).

INSTALLATION OF DAMPER ASSEMBLY 1.

-

Set damper assembly (2) in position on flywheel, then tighten 8 mounting bolts (1). Install the damper with the larger boss protrusion on the pump side.

*

~


~,~

Boss spline: Grease (LM-G)


Install main pump assembly. For details, see 63 INSTALLATION OF MAIN PUMP ASSEMBLY.

-

-' 13-52 CD

PC200,220-3

POWER TRAIN 2. STRUCTURE AND FUNCTION

Power train . . . . . . . . . . . . . .. . . . . . . . . .. 21- 2 Travel and brake system 21- 4 1. Outline 21-4 2. Travel control circuit 21- 6 3. Center swivel joint 21- 7 4. Travel motor (with parking brake) and brake assembly 21- 8 Final drive system 21-18 Swing system 21-20 1. Outline 21-20 2. Swing control circuit 21-21 3. Swing motor and safety valve assembly 21-24 4. Swing machinery 21-30 5. Swing circle 21-32

-


-

PC200, 220-3

21-1


POWER TRAIN

-

POWER TRAIN OUTLINE

3


F205C3005

1. Hydraulic tank 2. Engine 3. Main pump 4. L.H. final drive

•

5. 6. 7. 8.

L.H. travel motor Control valve assembly Swing circle Center swivel joint

-

9. Swing machinery 10. Swing motor 11. R.H. travel motor 12. R.H. final drive

The mechanical power from engine (2) is converted to hydraulic power by main pump (3). The hydraulic power from main pump (3) is divided to each actuator by control valve (6). It then goes to travel motors (5) and (11), swing motor (10) and the hydrC1ulic cylinders, and is converted back to mechanical power. This actuates the travel, swing and work equipment circuits.

21-2

PC200, 220-3

-

POWER TRAIN


Engine

-

Swing motor Damper

L. H. travel

Swing

Boom-La

Boom-Hi

Bucket

Service

Arm-Hi

Arm-La

www. k omat s upar t s book . c om Control valve assembly

-

Final drive

F20503001

-

Power from the engine is transmitted to the damper. The damper is mounted with the main pump for traveling, swing and working, and with charging pump. When the main pump runs, hydraulic oil is delivered to both left and right travel motors via the travel control valves. In this way, the travel motors rotate. The main pump consists of the front main pump and rear main pump, and each pump flows oil to the right and left travel motors independently. The speed of travel motor is reduced with the final drive system, and the motor torque is transmitted to each sprocket. And both sprockets start running.

PC200, 220-3

The main pump is a swash plate variable displacement type pump. Travel speed is controlled by the fuel control lever. The straight-travel valve is installed to travel the machine straight when operating the swing, boom, arm or bucket control lever during traveling. The left and right travel levers are each Iinked to the spool of the left and right travel control valves. The machine can travel forward or rearward and steering can also be controlled with these two travel levers.

21-3 @


TRAVEL AND BRAKE SYSTEM

-

TRAVEL AND BRAKE SYSTEM 1. OUTLINE

7

2

-

www. k omat s upar t s book . c om 9 205F2027

1. 2. 3.

•

Center swivel joint R.H. travel motor R.H. final drive

4. 5. 6.

Hydraulic tank Travel shuttle valve Control valve assem bly

The travel control system consists of the following components. Travel levers: These are used by the operator to steer the machine and to select FORWARD or REVERSE. Travel control valve (6) (interconnected with travel levers): This regulates the direction of flow of the oil from main pumps (7). The oil from travel control valve (6) flows through center swivel joint (1) to travel motors (2), (9). A parking brake is installed to the travel motor. Final drives (3), (8): This reduces the travel motor speed and transmits to sprocket.

21-4 ®

•

•

•

7. 8. 9.

-

Main pumps L.H. final drive L.H. travel motor

Straight-travel valve (built-in control valve (6)): This acts to prevent the machine from deviating when the machine is traveling, and the operator uses the swing, boom, arm or bucket circuit. The function of travel brake is carried out by the travel motor itself. When travel levers are moved from "TRAVEL" position to "NEUTRAL", the inlet and outlet ports to motor are closed, so the machine stops. For operation of the travel control levers and direction of travel, see OPERATION & MAINTENANCE MANUAL. For details of main pumps (7) and control valves (6), see Section 61 HYDRAUUC SYSTEM.

PC200, 220-3

-



(1) TRAVEL CONTROL CIRCUIT SCHEMATICS Engine running, travel levers at "Neutral" R.H. travel motor

Brake valves

L.H. travel motor

PPC valve actuated:

~~~iOOlilrn"--Bucket, boom

-

ISl1

PPC valve

1l@'l=m1-- Swing PPC valve

www. k omat s upar t s book . c om illillillill!--- Arm PPC

Main relief valve Hydraulic control valve (4-spool)

Hydraulic filter

-

Travel shuttle valve

Main relief valve

Main pump (front)

1. 2. 3.

R. H. travel control valve L. H. travel control valve Straight-travel valve

PC200, 220-3

Hydraulic tank

F20503002

21-5 C?l


TRAVEl- AND BRAKE SYSTEM

2. TRAVEL CONTROL CIRCUIT This diagram shows the condition with the travel control lever at forward, and the work equipment control lever or swing lever operated. (Straight-travel valve actuated)

Control valve (5-50001) IR.H. travefconti'Olvallle-

. 1 Travel motor

-

PR i

To PPC valve

3 To OLSS circuit

Charging pump

lB,

Front main pump

I I

Center swivel joint


I I

I I

Rear main pump

I I I I

Pc

I

T'

I I I I I I I I

Hydraulic filter

Ie - ...------.

i, •

L

L

I I I

I P3 - - - - - - - - - - - I L

:

J 205F2028

•

When operating the travel control lever, the travel control valve spool is moved via the linkage. This happens, the pressure oil from front and rear main pumps flows to right and left travel control valves (1), (2) from ports PL and PR, then flows to right and left travel motors in the undercarriage through center swivel joint (3). The drain oil from right and left travel motors flows to travel control valves through center swivel joint, and then flows to hydraulic filter, oil cooler through the port T. And this oil is drained to

•

•

• •

•

The setting pressure for main relief valve is 320 kg/cm 2 • In travel circuit, the straight-travel valve is provided to travel the machine straight even if operating swing, boom, arm or bucket while traveling. When travel control lever is in "NEUTRAL", parking brake (4) built in the travel motor is applied to stop the machine.

hydraulic tank.

21-6 @

PC200, 220-3

-



(1) STRAIGHT-TRAVEL SYSTEM This system acts to prevent the machine from deviating when the machine is traveling (FORWARD and REVERSE), and the operator uses the swing, boom, arm or bucket circuits.

R.H. travel motor

Brake valve

-

Main relief valve

Front main pump

www. k omat s upar t s book . c om Center swivel joint

Rear main pump

Charging lamp

1 1

I I I I

Brake valve

-

Straight-travel valve

I I

i

I

_H_T--~--------------.J

P

: L-_'--r---~t~--~ Travel

t-~II

shu~;;-e-v~i-;;; ~J 1

L_

L.H. travel motor

PI

I

:

1

:

LJ:::--1--lJ I +--------1 I1

I:

:

L_J'-.?

1 L P4

L __ J'..?

•

•

_.

When traveling in forward, the pilot pressure from the left travel circuit acts on the left port (P1) of travel shuttle valve. When traveling in reverse, the pilot pressure from the left travel circuit acts on the right port (P2) of travel shuttle valve. When this happens, if the swing, boom, arm or bucket are operated, the PPC valve moves accordingly. The pilot pressure from the PPC valve passes through travel shuttle valve and pushes the spool of straight-travel valve. This switches the spool.

PC200, 220-3

From boom, bucket PPCvalve From swing PPC valve From arm PPC valve

•

F20503003

When the spool is switched, the left and right travel circuits are connected, so the same pressure is supplied to the left and right travel motors. Therefore, the left and right travel motors both turn at the same speed, so the machine travels in a straight line.

21-7 ®



1)



Port P3

Port P4

/

Port P5

/ /

I

n~

t

Port P4a

\

A

EC:

-

Port P5a \

/

www. k omat s upar t s book . c om /

Port T

/

Port Pl

o

Port Po

Port P2

205F2C530

-

0

Section A-A Section C-C

Section B-B

21-8 ®

205F2031

Section D-D

1. 2. 3. 4.

Cover Spool return spring Body Spool

PC200, 220-3

-

-



Function • The travel shuttle valve is installed on top of the 4-spool control valve (See 21-12). When the machine is traveling, the pilot pressure oil from the left travel circuit actuates the travel shuttle valve, and the spool is switched. Therefore, if the swing, arm, boom or bucket are operated, a corresponding pilot pressure goes from the shuttle valve of the PPC valve. it flows to the straight-travel valve and switches the straight-travel valve.

-

Operation Travel lever at "FORWARD" (other levers at "HOLD") • Pilot pressure oil flows to (Pi) port from the left travel circuit and pushes the spool to the right. Therefore, ports (P3), (P4), (Ps) and (Po) are connected through the groove in the spool, and are also connected to the straight-travel valve. However, there is no flow of pilot pressure oil from the shuttle valves of the PPC valves, so the straighttravel valve is not actuated. (When operating in "REVERSE", pressure oil is sent to port (P2), and pushes the spool to the left.)

PI

Po

•

.1&

From L.H. travel To straightFORWARD circuit travel valve

www. k omat s upar t s book . c om 'ill'

From shuttle valve of arm PPC valve

P4 From shuttle From shuttle valve of boom, valve of swing PPC v.,.Jve bucket PPC valve

-

-

When arm control lever is operated during travel • Pilot pressure oil flows from the left travel circuit to port (Pi) and pushes the spool to the right. • When the arm control lever is operated, pilot pressure oil is sent from the shuttle valve of arm PPC valve to port (P3). It passes along the groove of the spool and flows to port (Po)' and then it flows to the straight-travel valve to switch the straighttravel valve.

*

(The pilot pressure from the shuttle valve of the swing PPC valve flows as follows: Port (Ps) -+ Port (Po) -+ straight-travel valve; the pilot pressure from the shuttle valve of the boom, bucket PPC valve flows as follows: Port (P4) -+ Port (Po) -+ straight travel valve) For details of the shuttle valve of the PPC valve, see p. 61-14

205F2032

PI

From L.H. tratl FORWARD ciiircjju.it• • • • •

P3t From shuttle valve of arm PPC valve

P,

'ill'

From shuttle From shuttle valve of valve of swing PPC valve boom, bucket PPC valve

205F2033

PC200, 220-3

21-9 ®



-

PC200-3 (Serial No. 25418 and up) PC220-3 (Serial No. 21402 and up) Port P6

/

:Qj

\

Port P 3

Port p.

PortP 5

~

A

-

Port P 5 ,

Port P.,

/

\

www. k omat s upar t s book . c om B

L=J--I----+t-

\ PortT

/

PortP j

o

\

Port Po

\

Port P2

-

0

Section A-A Section D-D

Section C-C

2

3

4 1. 2.

Cover Spool return spring

3. 4.

Body Spool

F20503104

_

Section B-B

21-9-1 (6)

PC200, 220-3



Function • The travel shuttle valve is installed on top of the 4-spool control valve (See 21·12). When the machine is traveling, the pilot pressure oil from the left travel circuit actuates the travel shuttle valve, and the spool is switched. Therefore, if the swing, arm, boom or bucket are operated, a corresponding pilot pressure goes from the shuttle valve of the PPC valve. It flows to the straight-travel valve and switches the straight-travel valve.

-

Operation Travel lever at "FORWARD" (other levers at "HOLD") • Pilot pressure oil flows to (Pi) port from the left travel circuit and pushes the spool to the right. Therefore, ports (P3), (P4), (Ps) and (Po) are connected through the groove in the spool, and are also connected to the straight-travel valve. However, there is no flow of pilot pressure oil from the shuttle valves of the PPC valves, so the straighttravel valve is not actuated. (When operating in "REVERSE", pressure oil is sent to port (P2), and pushes the spool to the left.)

www. k omat s upar t s book . c om To

autO-deCelerati:~

oil pressure switch

U P\ From shuttle valve of arm PPC valve

-

When arm control lever is operated during travel • Pilot pressure oil flows from the left travel circuit to port (Pi) and pushes the spool to the right. • When the arm control lever is operated, pilot pressure oil is sent from the shuttle valve of arm PPC valve to port (P3). It passes along the groove of the spool and flows to port (Po)' and then it flows to the straight-travel valve to switch the straighttravel valve.

From shuttle From shuttle valve of boom, valve of swing bucket PPC PPC valve valve 205F2032-1

p,

t

From L.H. travel FORWARD circuit

4m~"iii;i" P jZillillillZ2: 6

*

-

(The pilot pressure from the shuttle valve of the swing PPC valve flows as follows: Port (Ps) .... Port (Po) .... straight-travel valve; the pilot pressure from the shuttle valve of the boom, bucket PPC valve flows as follows: Port (P4) .... Port (Po) .... straight travel valve) For details of the shuttle valve of the PPC valve, see p. 61-14

PC200, 220-3

To auto-deceleration oil pressure switch

I>

Plt From shuttle valve of arm PPC valve

From shuttle From shuttle valve of valve of swing PPC valve boom, bucket PPC valve 205F2033-1

21-9-2 (6)



2) Straght-travel valve (built-in control valve) Functions • While operating the swing, boom, arm, or bucket when traveling, the pressure oil flowing to the R.H. and L.H. travel circuits branches into the swing, boom, arm, or bucket circuit. Since the supply of pressure oil in a branched travel circuit is less than that in the circuit before the branch, the motor naturally slows down, resulting in a turn. When the straight-travel valve is switched over to establish continuity between the R.H. and L.H. travel circuits, this undesired turning is prevented by equalizing the supply of pressure oil to the R.H. and L.H. travel motors so that they rotate at the same speed.

*

-

www. k omat s upar t s book . c om Operation When traveling only: • Since no pilot hydraulic oil flows from the shuttle valve in the PPC valve, no hydraulic oil flows from the travel shuttle valve to the straight-travel valve. • Therefore, the circuit between port PR (R.H. travel circuit) and port PL (L.H. travel circuit) remains closed and both circuits remain independent.

From

PR

port

To arm throttle valve

From port PL

From travel shuttle valve

From port PL

From port PR

205F2034

While operating the swing, boom, arm, or bucket when traveling: • While operating the swing, boom, arm, or bucket when traveling, the pilot pressure oil flows from the shuttle valve in the PPC valve for the specific concurrent operation into the spool end in the straght-travel valve, pushing the spool to the right. Port PR and port PL then become connected to each • other and an equal amount of pressure oil is supplied to the R.H. and L.H. travel motors, allowing both motors to rotate at the same speed. The machine travels thus in a straght line.

From

From travel shuttle valve

PR

...

port

To arm throttle valve

From port PL

...

From port PL

From port PR

205F2035

21-10 @

-

PC200, 220-3

-

-



3.

TRAVEL CONTROL VALVE

Port Pl ,

Port P4 PortP1Al

Port PAA

E Port B1L


-

\ \ Port P3Al Port B3l Port B2l

Port A3l

A

Port P3BA

B

Port A2l

5-spool valve

4-spool valve

The travel control valve, swing control valve and all other control valves consist of a 4-spool valve and a 5-spool valve as shown in the diagram above. In addition, there is also a travel shuttle valve (1). The L.H. travel control valve is in the 4-spool valve, and the R.H. travel control valve is in the 5-spool valve.

1.

F20503004


PC200, 220-3

21-11 (2)



•

4-SPOOL VALVE (LEFT TRAVEl CONTROL VALVE) 1. 2. 3. 4. 5. 6. 7.

Spool (L.H travel) Spool (boom-Lo) Spool (bucket) Spool return spring Spool (arm-Hi) Valve body Orifice for jet sensor (for rear main pump) 8. Relief valve for jet sonsor (for rear main pump)


/

6

/

8

9

Section A-A

10

11

12 14

9

~15

3

-

13

Section C-C Section G-G

1. 9. 10. 11. 12.

Spool (L.H. travel) Spool (straight-travel valve) Spool (swing priority valve) Spool (swing) Suction valve (swing)

21-12 (6)

F20503005

9. Spool (straight-travel valve) 3. Spool return spring valve 13. Spool (arm throttle valve) 14. Main relief valve (4-spool) 15. Spool return spring

PC200, 220-3

-

-



•

5-SPOOL VALVE (RIGHT TRAVEL CONTROL VALVE)

16. 17. 18. 19. 20. 21. 6. 22.

Spool return spring Spool (for swing) Spool (for boom-Hi) Spool (for service) Spool (for arm-Lo) Spool (for R.H. travel) Valve body Jet sensor orifice (for front pump) 23. Jet sensor relief valve (for front pump)

16~.

17 18

20


6

23

22 Section B-B

24

-

24. Main relief valve (5-spool) 25. Spool return spring 10. Spool (swing priority valve)

25

10

Section D-D F20503006

PC200, 220-3

21-13 (~



MAIN RELIEF VALVE

9

1.

2. 3. 4. 5. 6. 7. 8. 9.

Main valve Main valve spring Valve seat Pilot valve Pilot valve spring Lock nut Plug Holder Lock nut

F20503032

-

Function The main relief valve is in the circuit between the pump and the control valve. This valve acts to protect the pump from damage from any abnormal oil pressure. When abnormal pressure is produced or when the hydraulic cylinder reaches the end of its stroke during operations, the oil sent from the pump is relieved through the main relief valve. (It sets the maximum high pressure in the circuit during operations)

www. k omat s upar t s book . c om Flow of the oil • Chamber A forms a pump circuit and chamber C forms a tank drain circuit. The oil flows into chamber B through the main relief valve orifice to keep the chamber filled. Pilot valve is set in the valve seat. F20503033

•

-

If the pressure in chamber B reaches the pilot valve spring force (set pressure), the pilot valve moves, allowing the oil in chamber B to flow into chamber C. In addition, the oil flows from chamber A to B through orifices. F20503034

•

If the oil flows through the orifice of valve (ll, a differential pressure occurs between the chambers A and B, moving main valve (1) to the right. This allows the oil in chamber A to flow into chamber C.

F20503035

21-14 @

PC200, 220-3

-



1)

Counterbalance valve

Function When driving the machine downhill, the sprocket rotates mdre quickly than the revolution of travel motor due to its own weight, thus tending to accelerate motors. However, with the employment of the counterbalance valve, load is applied to the motor so that the machine will travel in confirmity with the engine speed.

-

Operation When oil starts flowing: When the travel control lever is changed either to "F" or "R", oil from the main pump enters the PA port via the travel control valve, and pushes check valve (CI ).

c,

c MA

MB

When the hydraulic pressure applied to check valve (CI) is increased, check valve (CI) is moved and oil flows to motor outlet port (MB) via motor inlet port (MAl, and then to the opposing side of the spool. However, the outlet (Ps port) is closed with check valve (C2); therefore, the oil flow stops. As a result, the travel motors do not rotate.

205F2041

www. k omat s upar t s book . c om And the oil pressure is further increased, the oil pressure in chamber (Ed at the left of spool (1), increases. When the oil pressure is boosted to 7.3 - 9.7 kg/cm 2 , spool (1) moves to the right, allowing the oil to flow out from D2 of spool (1) to Ps port. The oil finally returns to the hydraulic tank. In this way, the travel motor starts rotating.

MA

MB

205F2042

-

When the machine is traveling downhill: Due to its own weight, the travel motor rotates quickly than the revolution of motor normally with the oil. Therefore, the oil pressure on the inlet side (MA) of the motor decreases. When the oil pressure in chamber (EI) decreases to less than 7.3 - 9.7 kg/cm 2 , spool (1) moves to the left, thus blocking the oil from flowing out from D2 of spool (1). As a result, the oil pressure on the outlet side (Ms) of the motor rises. As this oil pressure works as a resistance to the motor, the machine is prevented from travelling at a speed higher than the engine speed. As it is clear from the above, the machine cannot travel at a higher speed other than that conforms to the regulated engine speed.

MA

MB

205F2043

PC200, 220-3

21-15



2)

Safety valve Function When stopping the machine or driving downhill, the circuit for motor outlet port is closed or throttled by the counterbalance valve, but the motor trys to rotate by inertia so that the oil pressure on the outlet side of the motor rises. And this may damage the motor and piping. So the oil pressure on the motor outlet side relieves to the motor inlet side.

Setting pressure 320

~~ kg/cm 2 (at 5 Q/min)

Control valve

-

www. k omat s upar t s book . c om F20503021

Operation • When stopping the machine or driving downhill, the circuit for motor outlet port (E) is closed or throttled by the counterbalance valve, but the oil pressure of motor outlet port (E) rises by the inertia of motor. • When the pressure in chamber (E) reaches the safety valve spring force (set pressure), a differential pressure occurs between chamber E and G (according to the difference between D 1 and D2), moving safety valve (11) to the right. This allows the oil in chamber E to flow into chamber (F).

205F2044

11

205F2045

G

21-16

PC200, 220-3

-

-

-


-


FINAL DRIVE SYSTEM

-

FINAL DRIVE SYSTEM


4

3 1. Coupling 2. Shaft

'I -

8~ 9"

" 10~

3. Hub

4. 5. 6. 7.

~

~

Sprocket Gear (72 teeth) No.2 ring gear (72 teeth) No.1 ring gear 76 teeth PC200-3 only: 77 teeth \

12

8. Carrier 9. Cover 10. Sun gear 14 teeth PC200-3 only: 13 teeth

13/ /

11. 12. 13. 14. 15.

11--

-

1

/ 14

15

17

16 Section A-A

21-18

205F2046

Button Oil level plug Lock nut Pin Planet gear 31, 27 teeth PC200-3 on Iy: 32,27 teeth \ 16. Drain plug 17. Floating seal

PC20D,220-3

-

FINAL DRIVE SYSTEM


STRUCTURE • • •

Sun gear (10) is meshed with planet gear (15), and is supported by button (11). Planet gear (15) is assembled to carrier (8) through bearings and pin (14). No. 1 ring gear (7) is connected to cover (9) and hub (3) by bolt. No.1 ring gear (7) is meshed with the large gear of planet gear (15), and the small gear is meshed with No.2 ring gear (6).

•

In addition, No.2 ring gear (6) is meshed with gear (5), and gear (5) is fixed to shaft (2) by bolt.

•

In this way, a 2-stage planetary system is formed by sun gear (10), planet gear (15), pin (14), No. 1 ring gear (7), and No.2 ring gear (6).

FUNCTION • The final drive system reduces the speed of the travel motor and increases the travel power. In this way it provides a suitable travel speed.

Reduction ratio: 1

PC200-3:

32

72

32

72

31

72

31

72

+13 x n

-69.892

1 - 27 x 7i 1

PC220-3:

+14x2j

1 - 27 x

-78.714

m

OPERATION • The rotation of the travel motor passes through coupling (1) and is transmitted to sun gear (10). •

No.1 ring gear (7) is connected to cover (9) and hub (3) by bolts, so when sun gear (10) rotates, planet gear (15) rotates about its own axis and moves in orbit along No.1 ring gear (7).

www. k omat s upar t s book . c om •

Planet gear (15) is assembled to carrier (8), so carrier (8) rotates together with the orbit of planet gear (15).

•

At the same time the small gear of planet gear (15) is meshed with No. 2 ring gear (6), so it also tries

Volume of lubricating oil (each side): 4£

(engin~ oil CLASS-CD SAE30)

to rotate about its own axis and move in orbit. However, it is meshed with No. 1 ring gear (7) with a different number of teeth so it tries to rotate more quickly. As a result it tries to rotate No. 2 ring gear (6) but No.2 ring gear (6) is fixed

-

to shaft (2), so No.1 ring gear (7) rotates relatively. •

Sprocket (4) is joined by hub (3) and forms one unit with No. 1 ring gear (7) so the sprocket also rotates.

-

205F2047

PC200, 220-3

21-19


SWING SYSTEM

-

SWING SYSTEM 1. OUTLINE

-

2


F205C3008

1. 2. 3. 4. 5. 6. 7.

Swing circle Center swivel joint Swing machinery Swing motor Hydraulic tank Swing control valve Main pumps

-

The hydraulic excavator has a swing mechanism which allows the work equipment to swing 360 degrees. Thus digging work and loading dump trucks can be done without moving the machine. The swing mechanism consists of swing motor (4) which rotates the upper structure, reduction gears (swing machinery) (3), swing circle (1), and center swivel joint (2) through which the hydraulic oil is delivered from the revolving upper structure to the undercarriage.

*

As for CENTER SWIVEL JOINT, see page 21-7.

21-20

PC200, 220-3

-

2.

-



Travel control lever moved back from "travel" to "neutral": The flow of oil from the travel control valve to the travel motor and travel brake valve stops, so the counterbalance valve spool of the travel brake valve tries to return to the neutral position. When this happens, the pressure in parking brake pressure chamber (F) drops and brake piston (2) is pushed back by springs (12). When brake piston (2) is pushed back, a gap is formed between the brake piston and housing (1).

12

Counterbalance valve spool

The output port of throttle (C) is connected to the inside of housing (1), and the oil is drained. (The inside of the housing is connected to the tank drain circuit.) For this reason, brake piston (2) is pushed back by springs (12), and plates (3) and discs (4) are pushed against the brake case. As a result, output shaft (6) cannot rotate and the brake is applied.

2

F

3 (Plate)


(Disc)

6

Travel brake valve

c 205F2039

PC200, 220-3

21-21 ~



(2) TRAVEL BRAKE VALVE

This valve prevents the speed of the motor from being increased by the weight of the machine when going downhill.

~,

I~j I

I~' ill.

•

-

~I

':j

l 'I'CC C--1 -10

F20503007

www. k omat s upar t s b/ook . c om 6

7

8

9

10

11

\

-

°

/ / - - ......

--,OJ' ~_/

Section 0-0

Section C-C

The brake valve consists of the counterbalance valve and the safety valve. Rated flow: 177 Q/min Safety valve set pressure: 360

+g kg/cm

2

(at 5 Q/min) 2

Spool switching pressure: 8.5 ± 1.2 kg/cm (Cracking pressure)

21-22 (6)

1. 2. 3. 4. 5.

Spool switching spring Counterbalance valve spool Housing Check valve spring Check valve

6. 7. 8. 9. 10. 11.

_-

205F2040

Adjustment screw Lock nut Sleeve Safety valve spring Pilot piston Safety valve

PC200, 220-3

-



1)

Counterbalance valve

Function When driving the machine downhill, the sprocket rotates mdre quickly than the revolution of travel motor due to its own weight, thus tending to accelerate motors. However, with the employment of the counterbalance valve, load is applied to the motor so that the machine will travel in confirmity with the engine speed.

-

Operation When oil starts flowing: When the travel control lever is changed either to "F" or "R", oil from the main pump enters the PA port via the travel control valve, and pushes check valve (Cl ).

c MA

MB

When the hydraulic pressure applied to check valve (Cl) is increased, check valve (Cl) is moved and oil flows to motor outlet port (MB) via motor inlet port (MAL and then to the opposing side of the spool. However, the outlet (Ps port) is closed with check valve (C2); therefore, the oil flow stops. As a result, the travel motors do not rotate.

205F2041


And the oil pressure is further increased, the oil pressure in chamber (E d at the left of spool (1), increases. When the oil pressure is boosted to 7.3 - 9.7 kg/cm 2 , spool (1) moves to the right, allowing the oil to flow out from D2 of spool (1) to Ps port. The oil finally returns to the hydraulic tank. In this way, the travel motor starts rotating.

205F2042

-

When the machine is traveling downhill: Due to its own weight, the travel motor rotates quickly than the revolution of motor normally with the oil. Therefore, the oil pressure on the inlet side (MA) of the motor decreases. When the oil pressure in chamber (El) decreases to less than 7.3 - 9.7 kg/cm 2 , spool (1) moves to the left, thus blocking the oil from flowing out from D2 of spool (1). As a result, the oil pressure on the outlet side (Ms) of the motor rises. As this oil pressure works as a resistance to the motor, the machine is prevented from travelling at a speed higher than the engine speed. As it is clear from the above, the machine cannot travel at a higher speed other than that conforms to the regulated engine speed.

Dl

MB

205F2043

PC200, 220-3

21-23



2)

Safety valve Function When stopping the machine or driving downhill, the circuit for motor outlet port is closed or throttled by the counterbalance valve, but the motor trys to rotate by inertia so that the oil pressure on the outlet side of the motor rises. And this may damage the motor and piping. So the oil pressure on the motor outlet side relieves to the motor inlet side.

Setting pressure 360 ~~ kg/cm 2 (at 5 Q/min)

Control valve


-

Operation • When stopping the machine or driving downhill, the circuit for motor outlet port (E) is closed or throttled by the counterbalance valve, but the oil pressure of motor outlet port (E) rises by the inertia of motor. • When the pressure in chamber (E) reaches the safety valve spring force (set pressure), a differential pressure occurs between chamber E and G (according to the difference between Dl and D2), moving safety valve (11) to the right. This allows the oil in chamber E to flow into chamber (F).

205F2044

11

205F2045

G

21-24 (6)

PC200, 220-3

-

-

SWING SYSTEM


2

I I I I

I I I I


3

4

7

6

5

B

Section A-A

1. 2. 3. 4. 5. 6. 7. 8.

Housing Case Center shaft Valve plate Pistons Cylinder block Center ball Output shaft

F205C3013

*

Theoretical delivery: 87.8 cc/rev

PC200, 220-3

21-25


SWI NG SYSTEM

(1) SWING BRAKE AND SAFETY VALVE

The swing motor itself acts as the swing brake when the swing control lever is moved from "SWI NG" to "NEUTRAL", the circuits of the inlet and outlet ports of the swing motor are closed, so the motor

stops. When this happens, the pressure at the outlet port of the motor becomes extremely high, so there is a safety valve to let the oil flow from the outlet port to the inlet port.

2

_---3

-

4

----5 6


Section B-B (See page 21-24.)

B

9

Section C-C (See page 21-24.)

1. 2. 3. 4. 5.

Adjustment screw Lock nut Sleeve Safety valve spring Piston

21-26

6. 7. 8. 9.

Safety valve Housing Check valve Check valve spring

-

205F2055

The safety valve consists of the check valve and the safety valve. +5 2 • Setting pressure: 275 a kg/cm (at 100 £/min)

PC200, 220-3


SWING SYSTEM

Function • When swing operation is stopped, the outlet circuit of the swing motor is closed by the swing control valve. However, the swing motor keeps running by the force of inertia, causing the pressure in the swing motor outlet circuit to go too high. This causes damage to the swing motor. To prevent such damage, this excessively high pressure oil of the motor outlet side must be relieved to the motor inlet side (low pressure side).

-

Operation 1. When operating the swing ·control "Neutral" to "SWING RIGHT":

lever

•

Compared with a counterbalance valve type (equipped to traveling circuit), the safety valve type does not allow the pressure to be trapped in the outlet circuit when swinging is slowed down. Consequently, no rattle occurs during deceleration, resulting in improved control of swinging.

from

Cs Return oil from another circuit

www. k omat s upar t s book . c om MA

MB Control valve 205F2056

•

-

When the swing control lever is placed in "SWING RIGHT" position, the pressure oil from the front main pump flows 'to port MA through the swing control valve.

PC200, 220-3

•

Thereby, the pressure at port MA goes up and driving torque is generated in the motor, causing the motor to start running.

•

The oil from the motor outlet flows from port MB back to the tank through the control valve,

21-27


SWING SYSTEM

2.

When returning the swing control lever to "Neutral":

Cs Return oil from another circuit

B

A

www. k omat s upar t s book . c om Cs

MB

MA Control valve

205F2057

•

•

•

When the swing control lever is returned in uN EUTRA L" position, the pressure oil from the front main pump does not flow to port MA. Since the motor outlet drain circuit to the tank is closed by the control valve, the oil pressure at port MB in the motor outlet goes up and produces rotational resistance against the motor. This starts to apply the brake. The oil pressure at port MB goes up to the set pressure of safety valve B and the high brake torque acts on the motor, causing the motor to stop.

•

•

-

While safety valve B is functioning, the relief oil from safety valve B and the oil from port S are supplied through check valve CA to port MA. At this time, the pressure of the return oil from the other circuit is kept constant (low pressure) by check valve CS. Thus, the suction performance of check valve CA is insured, preventing the occurrence of cavitation in port MA.

21-28

PC200, 220-3


SWI NG SYSTEM

2. SWING CONTROL CIRCUIT (1) Operating to "SWING LEFT"

r---

5-spool control valve

Accumulator

I

I r'ARt--:

L.H. PPC valve

lj!

I

I

-

!

+-

I

I

I

I,

I

- - +- '-j

:

I~P1BRl

1

I

,

I

I

:

: I

l- __ I

C·,

I

I I I

I

I

I

I

I

- -r- ~'_JI I

Swing motor safety valve

Main relief valve

I

Set pressure 320 kg/em'

I

I I

I

Shuttle valve

-tn

I

Charging pump

I I I

--Jtr :

I

I

JJ

PC200 (Serial No. 25924 and up) PC220 (Serial No. 21402 and up)

II

www. k omat s upar t s book . c o m ~ I Rear main pump: ._..J

,------<>----...-+_

I Hydraulic. filter

D

L

P5a

- --------r-;;;----

Oil cooler

L-

-

-

_

II

I


I Hydraulic tank

IP5

I

Solenoid valve for swing mechanical brake

I I

t - - -----1 I

205F2049-2

Note These parts and circuit are installed only on machines with swing mechanical brake. Starting swing • When the swing control lever is moved to "SWI NG LEFT", the spool of the PPC valve (which is connected directly to the control lever) is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) flows from the charging pump to the pilot case (port P1BR) at the side of the spool of the swing control valve, and moves the spool. • In this way, the pressure oil from the front main pump goes along the following circu it: Port PR ->- swing control valve ->- Port A1 R, and flows to port MA of the swing motor to rotate the motor. • The return oil flows along the following circuit: MB ->-B1 R->-swing control valve ->- port T, and is drained to the hydraulic tank. • At the same time, the pilot pressure oil which merges from the shuttle valve flows P5 ->- port P5a, actuates the swing priority valve, and regulates the

PC200, 220-3

pressure oil which flows to the arm-La control valve. This improves the ease of operation when using the swing and arm at the same time. Stopping swing • When the swing control lever is returned to "neutral", the supply of pressure oil from the front main pump to port MA is stopped. • The return circuit to the hydraulic tank is closed at the swing control valve, so the return oil raises the pressure at port MB. This produces resistance to the rotation of the motor and the brake begins to take effect. • The pressure at port MB rises to the set pressure of the safety valve. In this way it applies high braking torque to the motor and this stops the motor. In other words, the swing motor itself has the function of swing brake.

21-29 (~)


SWING SYSTEM

(2) Operating to "SWING RIGHT"


1--

Accumulator

~1.AR}

;- _ ____ __ _,

+------------.'~

I

_

i

I

i-fIr'--i :' :

LH. PPC valve

I

,

tf>lB~ ~

Swing

-~

I

•

~J

-t

"

-t - - -- -- ~"-

Shutti~'valve:

Charging pump

L

-

L

-

-

~~;~ i""'

-

'

-

-

-

-

, -

-

priority

:

:

valve

:,

I

i

:

i

:

I,

"

PR

'L__

-,

,

:

,

,

---H

i

MB

I

I

Front main pump

Swing motor safety valve

"m-lo ,o",m' ",'" I

T,---'~

:

I

-

0

nf-<~~}_+__-----1-,-S'-w-':-'mg

I

1~

Swing control valve

, , ,

i, LU

i' I h J

-

II

PC200 (Serial No. 25924 and up)1 PC220 (Serial No. ! 21402 a.nd up~

www. k o mat s upar t s book . c om _j Rear main pump

, ___ .J

I -r-----<:>----~__;.--'

! 1

!

I . I Hydraulic filter

Oil cooler


I Hydraulic tank

'------

Note

,,

-1-

:PS _

I I

1

1

.......-i/-.__._ _.__._••-

I

.J

--~

1


__ J 205F2050-2

Y

" :

21-30

-

These parts and circuit are installed only on machines with swing mechanical brake.

Starting swing • When the swing control lever is moved to "SWING RIG HT" the spool of the PPC valve (which is connected directly to the control lever) is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) flows from the charging pump to the pilot case (port P1 A R) at the side of the spool of the swing control valve, and moves the spool. • In this way, the pressure oil from the front main pump goes along the following circuit: Port PR -+ swing control valve -+ Port B1 R, and flows to port MB of the swing motor to rotate the motor. • The return oil flows along the following circuit: MA -+ A1 R -+ swing control valve -+ port T, and is drained to the hydraulic tank. • At the same time, the pilot pressure oil which merges from the shuttle valve flows P5 -+ port P5a,

(6)

~-----

PSa'

I I

L

I

1

,

L __

, , , ,

,

I

actuates the swing priority valve, and regulates the pressure oil which flows to the arm-La control valve. This improves the ease of operation when using the swing and arm at the same time. Stopping swing • When the swing control lever is returned to neutral, the supply of pressure oil from the front main pump to port MB is stopped. • The return circuit to the hydraulic tank is closed at the swing control valve, so the return oil raises the pressure at port MA. This produces resistance to the rotation of the motor and the brake begins to take effect. • The pressure at port MA rises to the set pressure of the safety valve. In this way it applies high braking torque to the motor and this stops the motor.

PC200, 220-3

-

-

SWING SYSTEM


FUNCTION

STRUCTURE

•

•

Sun gear (9) is meshed with planet gears (11), and is supported by the mounting bolt of plate (7) through button (5).

•

Planet gears (11) are assembled to carrier (6) through needle bearings (13) and pins (10).

•

No.1 ring gear (12) is connected to cover (4) and case (8) by bolts. NO.1 ring gear is meshed with the large gears of planet gears (11), and the small gears is meshed with NO.2 ring gear (14). In addition, No.2 ring gear (14) is meshed with gear (15), and gear (15) is fixed to swing pinion shaft (17) by a spline.

The swing machinery reduces the speed of the swing and increases the swing power. In this way it provides a suitable swing speed (together with the swing circle).

1 + l.!-

Reduction ratio:

~-::-::_~7-::c5_~_ 21 19 21 27 x 67 x 75

x

\~O = 182.225

Continuous swing speed: 13 rpm Volume of lubricating oil: 7.8 Q (Engine oil CLASS-CD SAE30)

•

•

In this way, a 2-stage planetary system is formed by sun gear (9), planet gears (11), pins (10), carrier (6), No.1 ring gear (12), and No.2 ring gear (14).

www. k omat s upar t s book . c om OPERATION •

-

•

•

No.1 ring gear (12) is connected to cover (4) and case (8) by bolts, so when sun gear (9) rotates, planet gears (11) rotate about its own axis and moves in orbit along No.1 ring gear (12). Planet gears (11, are assembled to carrier (6), so carrier (6) rotates together with the orbit of planet gears (11). At the same time the small gears of planet gears (11) are meshed with No.2 ring gear (14), so they also try to rotate about its own axis and move in orbit. However, the large gears of planet gears are meshed with No. 1 ring gear with a different number of teeth of No.2 ring gear, so they try to rotate more quickly. As .a result, No.2 ring gear (14) rotates relatively. Swing pinion shaft (17) also rotates through gear (15), so the swing circle rotates.

-

205F2065

PC200, 220-3

21-31


SWING SYSTEM

5. SWING CIRCLE

Machine front

-

-


-Pm:

Section B-B

Upper structure

1 2-~tp~~==~~~~~~

-

/

3--

V/) /

Undercarriage

1. 2. 3. 4. 5.

21-32

Swing circle inner race Ball bearing Swing circle outer race Seal Swing pinion

5 Section A-A

F205C3014

Grease volume: 18.7S

PC200, 220-3

-


SWING SYSTEM

12. Main relief valve (5-spool) 13. Spool return spring 14. Spool (swing priority valve)

12

13

14

-

www. k omat s upar t s book . c om Section 0-0

8

16

14

4

17

\

8. 16. 14. 4. 17.

Spool (for R.H. travel) Spool (travel-straight valve) Spool (for swing priority valve) Spool (for swing) Suction valve (swing)

-

4-spool valve

5-spool valve Section G-G

F20503010

PC200, 220-3

21-33 (fD


SWI NG SYSTEM

-

4. SWING MOTOR AND SAFETY VALVE ASSEMBLY There are two types of swing motor: one equipped with a swing mechanical brake; the other without a swing mechanical brake.

Port S

-

2

www. k omat s upar t s book . c om -z

-

PortMA

Port MB

ViewZ

1. 2.

Swing motor Swing mechanical brake (if equipped)

The swing motor and safety valve assembly consists of the following. • Swing motor • Safety valve

21-34 CZ)

Port T

*

Port C

205F2053

The principle and operation of the swing motor is the same as for the travel motor. For details, see TRAVEL MOTOR Page 21-17 and 21-18.

PC200, 220-3

-

SWING SYSTEM


Function • When swing operation is stopped, the outlet circuit of the swing motor is closed by the swing control valve. However, the swing motor keeps running by the force of inertia, causing the pressure in the swing motor outlet circuit to go too high. This causes damage to the swing motor. To prevent such damage, this excessively high pressure oil of the motor outlet side must be relieved to the motor inlet side (low pressure side).

.-

Operation 1. When operating the swing control "Neutral" to "RIGHT SWING":

lever

•

Compared with a counterbalance valve type (equipped to traveling circuit), the safety valve type does not allow the pressure to be trapped in the outlet circuit when swinging is slowed down. Consequently, no rattle occurs during deceleration, resulting in improved control of swinging.

from

Return oil from another circuit


MB Control valve

201F5042

•

-

When the swing control lever is placed in "SWI NG RIGHT" position, the pressure oil from the front main pump flows to port MA through the swing control valve.

PC200, 220-3

•

Thereby, the pressure at port MA goes up and driving torque is generated in the motor, causing the motor to start running.

•

The oil from the motor outlet flows from port MB back to the tank through the control valve.

21-37

SWING SYSTEM


2.

When returning the swing control lever to "Neutral":

Return oil from another circuit

A

B

www. k omat s upar t s book . c om Cs

MB Control valve

201F5043

•

•

•

When the swing control lever is returned in "N EUTRAL" position, the pressure oil from the front main pump does not flow to port MA. Since the motor outlet drain circuit to the tank is closed by the control valve, the oil pressure at port MB in the motor outlet goes up and produces rotational resistance against the motor. This starts to apply the brake. The oil pressure at port MB goes up to the set pressure of safety valve B and the high brake torque acts on the motor, causing the motor to stop.

•

•

-

While safety valve B is functioning, the relief oil from safety valve B and the oil from port S are supplied through check valve CA to port MA. At this time, the pressure of the return oil from the other circuit is kept constant (low pressure) by check valve Cs. Thus, the suction performance of check valve CA is insured, preventing the occurrence of cavitation in port MA.

21-38

PC200, 220-3

SWING SYSTEM


-

*

FOR MACHINES EQUIPPED WITH SWING MECHANICAL BRAKE

SWING MECHANICAL BRAKE (IF EQUIPPED) The swing mechanical brake is installed so that the weight of the work equipment does not swing the upper structure when the swing control lever is at "N EUTRAL" and other controls are being used, or when the machine is parked on a slope.

Timer

-

~I,"O":~ ~{-: I

for swing f------------,chanical brake

I

www. k omat s upar t s book . c om I I I

Front main pump

I

I

I I

I I I I I I I I

-

I

L

9

Accumulator' 1

I I I I I I

r----------l I

~--------------'~--.---~-------

l_Ia-:~a~g~n~~~r:~l

Engine running, all control levers at "Neutral"

I I

Note:

,-----, <--_ ---.i :

•

-

•

Rear main pump

I

I I

These parts and this circuit are installed only on machines with swing mechanical brake.

When operating the swing control lever, the pressure oil in the swing PPC circuit pushes the oil pressure switch to "OFF", and the no current flows to the swing solenoid valve. The solenoid valve is switched and the pressure oil from the charging pump flows to the swing mechanical brake. The oil pushes the brake piston to release brake. After releasing the swing mechanical brake, the swing motor starts to rotate because of the stroke of control lever.

PC200, 220-3

205F2058A

•

*

When the swing control lever is moved back to "Neutral", no oil in the PPC circuit flows to the oil pressure switch (ON). The current flows to the timer, and the switch of timer is off after 6 seconds, then the current flows to the solenoid valve. This switches the solenoid valve, so that the pressure oil in the brake pressure chamber is drained. Brake is "actuated". The structure of the brake is the same as for the travel parking brake, so for details, see p. 21-19.

21-39 ®


SWING SYSTEM

*


PC200-3 (Serial No. 20001 - 25923) PC220-3 (Serial No. 20001 - 21401) 1)

-

Application of swing mechanical brake •

3

2

When operating the swing control lever: Operating the swing control lever allows the pressure oil in the swing PPC circuit to push the oil pressure switch at the bottom of the lever, and no cu rrent flows to the swing solenoid valve. The swing solenoid valve is switched and the pressure oil from the charging pump will flow into port C and go to swing mechanical brake chamber F. The oil in F pushes brake piston (3) against brake spring (2). The brake piston travel will release the swing mechanical brake and allows the motor to start running.

-

www. k omat s upar t s book . c om 205F2059

•

When the swing control lever is at neutral: When the swing control lever is moved back to "Neutral", no oil in the PPC circuit flows, restoring the oil pressure switch to the original position (ON). Thereby, the solenoid valve is back to original position. The pressure oil from the charging pump does not flow to port C any more. Since port C is connected to the tank as the drain circuit, the pressure in the swing mechanical brake pressure chamber F goes down. Brake piston (3) is pushed back by brake spring (2), which presses plates (4) and discs (5) against each other, causing the swing mechanical brake to be applied.

2

3

4

5

-

Frompump" • • • 205F2060

21-40

PC200, 220-3

-

-

SWING SYSTEM


PC200-3 (Serial No. 25924 and up) PC220-3 (Serial No. 21402 and up) 1)

Application of swing mechanical brake • When the swing control lever is at neutral: When the swing control lever is moved back to "Neutral", no oil in the PPC circuit flows, restoring the oil pressure switch to the original

2

4

3

position "OFF". Thereby, the solenoid valve is back to original position. The pressure oil from the charging pump does not' flow to port C any more. Since port C is connected to the tank as the drain circuit, the pressure in the swing mechanical brake pressure chamber F goes down. Brake piston (3) is pushed back by brake spring (2), which presses plates (4) and discs (5) against each other, causing the swing mechanical brake to be applied.

-

www. k omat s upar t s book . c om From charging pump

•

When operating the swing control lever: Operating the swing control lever allows the pressure oil in the swing PPC circuit to push the oil pressure switch at the bottom of the lever, and the current flows to the swing solenoid valve. The swing solenoid valve is switched and the pressure oil from the charging pump will flow into port C and go to swing mechanical

2

207F2030

3

brake chamber F. The oil in F pushes brake piston (3) against brake spring (2). The brake piston travel will release the swing mechanical brake and allows the motor to start running.

-

From charging pump

207F2031

21-41 (6)


SWING SYSTEM

*

2)


-

Solenoid valve

PortB

Port T

= , --,

= ,,

-, , -

Port P

Port A

8

9

-

// www. k omat s upar t s book . c om I

/

, , ,

/

, ,

-r",

:

'

C

,

, , , ,

/

= - ,,

,

Port A

Port B Port P 205F2061

1. 2. 3. 4. 5. 6. 7. 8. 9.

Solenoid ass'y Push pin Spring Spring retainer Spool Valve body Spring retainer Spring Plug

-

FUNCTION • The solenoid valve is installed at the side of the control valve. When the swing control lever is operated, the oil pressure switch, which is interconnected with the contro I lever, come 0 FF, and no electric signal is sent to the solenoid valve. This switches the solenoid valve, so the pressure oil from the charging pump flows to the swing mechanical brake.

21-42 @

-

SWING SYSTEM


*


PC200-3 (Serial No. 20001 - 25923) PC220-3 (Serial No. 20001 - 21401) OPERATION 1. When swing control lever is at "Neutral". If control lever is at "Neutral", the oil pressure switch, which is interconnected with the control lever, come ON, and an electric signal is sent to the solenoid valve. When this happens, valve (1) is excited and push pin (2) pushes spool (5) to the right. This closes the circuit between port P and port A, and opens the circuit between port P and port B, and opens the circuit between port A and port T at the same time.

The oil from the charging pump flows from port P to port B and stops. When opening the circuit between port A and port T, the brake piston is pushed by the brake spring and the oil from port A, that is, the oil from swing mechanical brake chamber, enters port T and is drained to the tank, so the brake is actuated.

-

From oil pressure switch

2

From charging pump

T

From swing mechanical brake oil chamber

205F2062


-

When swing control lever is at "Operated". The oil pressure switch is OFF and solenoid (1) is deactivated. Spool (5) is pushed back to the left by spring (8). This closes .the circuit between port P and port B, and opens the circuit between port P and port A. The oil from the charging pump flows from port P to port A and enters the swing mechanical brake oil chamber. The pressure oil pushes the brake piston, and the brake is released.

From oil pressure switch

From charging pump

To swing mechanical brake oil chamber

205F2063

PC200, 220-3

21-43 ®


SWING SYSTEM

*



-

OPERATION 1. When swing control lever is at "Neutral". The oil pressure switch is OFF and solenoid (1) is deactivated. Spool (5) is pushed back to the left by spring (8). This closes the circuit between the charging pump and port C and opens the circuit between port C and the tank. When opening the circuit between port C and the tank, brake piston is pushed by brake spring and the oil from port C, that is, the oil from swing mechanical brake chamber F, enters the tank port and is drained to the tank, so the brake is actuated.

-


A

8

P

From charging pump

2.

207F2032

When swing control lever is at "Operated". The oil pressure switch, comes ON, and an electric signal is sent to the solenoid valve. When this happens, solenoid (1) is excited and push pin (2) and spool (5) to the right. This closes the circuit between port C and the tank port, and opens the circuit between the pump and port C at the same time. The oil from the charging pump flows to port C and enters the swing mechanical brake oil chamber F. The pressure oil pushes brake piston, and the brake is released.

-

2

5

p

From charging pump

207F2033

21-43-1 (~)

PC200, 220-3

-

-


-

SWING SYSTEM


-

5. SWING MACHINERY

tA

Section B-B

-

www. k omat s upar t s book . c om Swing motor

2

3

o

4 8

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

1. 5

.

----13 4

5 8-· /

6

-------17

Section A-A

21-44 ®

Gauge Filler Relief valve Cover Button Carrier Plate Case Sun gear (21 teeth) Pin Planet gear (27, 17 teeth) No.1 ring gear (75 teeth) Needle bearing No.2 ring gear (67 teeth) Gear (67 teeth) Drain valve Swing pinion (13 teeth)

-

-

205F2064

PC200, 220-3

POWER TRAIN 23 DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT ASSEMBLY Removal . Installation . Disassembly . Assembly . TRAVEL MOTOR ASSEMBLY Removal . Installation . Disassembly . Assembly . SWING MOTOR ASSEMBLY Removal and installation . Disassembly . Assembly . SWING CIRCLE ASSEMBLY Removal . Installation . SWING MACHINERY ASSEMBLY Removal and installation . Disassembly . Assembly . SOCKET Removal and installation . TRAVEL MOTOR, FINAL DRIVE ASSEMBLY Removal . Insta lIati on . FINAL DRIVE ASSEMBLY Disassembly . Assembly .

-

23232323-

2 3

4 5

23- 6 23- 7 23-7-1 23-7-4


*

-

23-7-8 23- 8 23-8-3 23- 9 23-13 23-17 23-18 23-22 23-27 23-28 23-29 23-30 23-35

When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and piping, always bleed the air as follows: 1. Start engine and run at low idling. 2. Operate hydraulic cylinder 4 to 5 times, stopping 100 mm from stroke end. 3. Next, operate cylinder 3 to 4 times to stroke end. 4. After doing this, run engine at normal speed. After repair or long storage, follow the same procedure.

*

PC200, 220-3

23-1 @


CENTER SWIVEL JOINT

-

REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY Lower the work equipment completely to the ground and stop the engine. Operate the control lever several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1.

Disconnect upper drain hose (1) of travel motor.

*

Fit a blind plug in the hose.

2.

Disconnect upper travel hoses (2), (3), (4) and (5).

3.

Pull out pin and disconnect plate (6).

4.

Disconnect lower drain hoses (7) and (8) of travel

-

motor. Fit a blind plug in the hose.

* 5.

Disconnect lower travel hoses (9), (10), (11) and (12).

6.

Remove tee (13) at bottom of swivel joint.

7.

Using eye bolts CD (Dia. = 8 mm, Pitch = 1.25 mml, sling center swivel joint assembly (14) and remove 4 mounting bolts (15).

8.

Lift off center swivel joint assembly (14) .

www. k omat s upar t s book . c om .}

(~g·l

Center swivel joint assembly: 30 kg

-

-23-2 CD

PC200, 220-3

CENTER SWIVEL JOINT


INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLV A 1.

Using eyebolts (Dia. = 8 mm, Pitch = 1.25 mml, raise center swivel joint assembly (14). Align stamped marks A, B, C and D on port with positions shown in diagram on right, then set on frame.

c

Front _ Sprocket

2.

Tighten 4 mounting bolts (15).

3.

Fit a-ring and install tee (13) at bottom of swivel joint.

4.

Fit O-rings and connect lower travel hoses (12), (11), (10) and (9). Install hose without twisting or interference.

B

D

205F2308

* -

5.

Connect lower drain hoses (8) and (7) of travel motor. ~

*

Sleeve nut:

5 ± 2 kgm (Width across flats: 24 mm)

Install hose without twisting or interference.

6.

Install plate (6) with pin.

7.

Fit a-rings and connect upper travel hoses (5), (4), (3) and (2).

8.

Connect upper drain hose (1) of travel motor.


*

* *

-

*

5 ± 2 kgm (Width across flats: 24 mm) Install hose without twisting or interference. Sleeve nut:

Start the engine and bleed the air from the travel motor. For details, see 62 BLEEDING AIR FROM TRAVEL MOTOR. After bleeding the air, add oil to the hydraulic tank to the specified level.

PC200. 220-3

23-3 CD


CENTER SWIVEL JOINT

-

DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1.

Remove cover (1).

2.

Remove snap ring (2).

3.

Using push tool CD, remove swivel rotor (4) and ring (3) from swivel shaft (5).

4.

Remove snap ring (6), then remove oil seal (7) and 5 slipper seals (8).

1

-

_{'.~.~ ~) 0 .

.0

.

-1-----------

0

I

o www. k omat s upar t s book . c om 2~-O

_1:0 7

4

205F2309

205P2104

23-4 CD

PC200, 220-3

-

-


CENTER SWIVEL JOINT

ASSEMBLV OF CENTER SWIVEL JOINT ASSEMBLV

*

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil or grease (G2-L1) before installing.

1.

Assemble 5 slipper seals (8) in swivel rotor (4).

2.

Using push tool @ (outside diameter: 110 mm), press fit oil seal (7) in swivel rotor (4), then install snap ring (6). Oil seal lip: Grease (G2-L1)

-

3.

205P2105

Set swivel shaft (5) on block, then using push tool ® (outside diameter: 130 mm), tap swivel rotor (4) with a plastic hammer to install. When installing the rotor, be careful not to damage the lip of the slipper seals or oil seal.

*

7 4.

Install ring (3), then secure with snap ring (2).


Fit a-ring and install cover (1).

205P2101

PC200, 220-3

23-5 CD


TRAVEL MOTOR

-

REMOVAL OF TRAVEL MOTOR ASSEMBLY Lower the work equipment completely to the ground and stop the engine. Operate the control lever several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1.

Set machine so that drain plug (1) of final drive case is at bottom. Remove drain plug (1) and drain oil from case .

•

...:... 2.

Final drive case: Approx. 3.7 Q {each side)

-

Remove cover (2).


Disconnect drain hose (3) between travel motor and swivel joint at travel motor end. Fit a blind plug in the drain hose.

* 4.

Disconnect hoses (4) and (5) between travel motor and swivel joint at travel motor end.

*

Fit a blind plug in the travel hoses.

5.

Remove 2 mounting bolts (6).

6.

Fit guide bolt

CD

(Dia.

= 10 mm,

Pitch

= 2 mm,

-

Length

= 300 mm), remove travel motor assembly (7).

Using eyebolts CV (Dia. = 10 mm, Pitch = 1.5 mm), remove travel motor assembly (7).

7.

~~

Ckg]

Travel motor assembly: 70 kg

23-6 CD

PC200, 220-3

-


TRAVEL MOTOR

INSTALLATION OF TRAVEL MOTOR ASSEMBLY

-

®,

1.

Fit O-ring, then using lifting tool assembly (7) by crane.

2.

Using a bar, make travel motor assembly horizontal. Align with spline for coupling of final drive case, and set in position.

3.


4.

Fit O-rings and connect hoses (5) and (4) between travel motor and swivel joint.

5.

Connect drain hose swivel joint.

(3)

raise travel motor

between travel motor and


Sleeve nut:


6.

Install cover (2).

7.

Tighten drain plug (1) and add engine oil through oil filler (8) to the specified level.

'Wi *

-

* *

Final drive case: Approx. 3.7 Q (each side)

Run the engine to circulate the oil through the system. Then add oil to the hydraulic tank to the specified level. Bleed the air from the motor. For details, see section 62, TESTING AND ADJUSTING, BLEEDING AIR FROM TRAVEL MOTOR. After bleeding the air, check the oil level again.

PC200, 220-3

23-7 CD


TRAVEL MOTOR

7. Cylinder block Remove four big springs (16) and four small springs from housing (15), then remove center shaft (17) and cylinder blocks (18).

-

8. Plate Remove plate (19).

www. k omat s upar t s book . c om 9. Counterbalance valve, check valve 1) Remove plate (20), then remove spool switching spring (21), retainer (22) and counterbalance valve 2)

spool (23). Remove seat (24), then remove check valve spring (25) and check valve (26).

10. Safety valve Remove safety valve (27).

23-7-3

PC200, 220-3


TRAVEL MOTOR

ASSEMBLY OF TRAVEL MOTOR ASSEMBLY Special tools Part number

-

1.

Part name

a'ty

A

790-501-5000

Unit repair stand

1

Al

790-901-2230

Plate

1

B

795-630-1803

Torque wrench set

1

BI

796-720-2220

Socket

1

B2

796-730-2120

Screw driver

1

C

796-730-2000

Wrench

1

D

796-751-2900

Holder (travel motor)

1

Safety valve Fit O-ring and backup ring, and install safety valve assembly (27). ~

Safety valve: 26 ± 3.0 kgm


-

Counterbalance valve, check valve 1) Assemble check valve (26) and spring (25), then fit backup ring and O-ring to seat (24) and install. 2) Assemble counterbalance valve spool (23) and retainer (22), then fit D-ring and install plate (20). ~

3.

Bolt: 6.75 ± 0.75 kgm

Plate Turn over housing, align dowel, then install plate (19).

PC200,220-3

23-7-4 @


TRAVEL MOTOR

4.

Cylinder block 1) Install cylinder block (18), assemble center shaft (17), then use tool D to secure center shaft. Coat end face of cyl inder block with engine oil. 2) Install four big springs and four small springs in housing.

*

5.

Bearing 1) Press fit bearing (28) on shaft (9).

28

www. k omat s upar t s book . c om P20502037 2)

Press fit outer races (29) and (30) in brake case.

3)

Assemble output shaft (9) in brake case, then press fit bearing (14) and oil seal (15). Fit spacer (11), then install snap ring (10). Fit O-ring and install ring (12), then partially tighten nut (8).

4) 5)

~,

Oil seal face: Grease (G2- L1)

23-7-5 (If)

PC200, 220-3

-

TRAVEL MOTOR


6.

Nut and pre-pressure adjustment Tighten up the nut (8) using tool while measuring the rotation torque using tool B. Rotate the shaft at the rate of about one revolution every five seconds. If the rotational torque becomes higher than the specified value, slacken off the nut completely to make the rotational torque zero, then retighten the nut. Rotational torque of shaft: 0.45 ~ 0.60 kgm After adjusting the rotational torque, bend the lock plate. If the lock does not line up with the groove in the nut, either tighten up the nut with in the range of the specified rotational torque or slacken it.

* *

* * *

-

7.

Piston assembly 1) Install holder (31) on piston (7) and set assembly on retainer (6). 2) Install center ball (32) and holder (33) on shaft. Clean the spherical face of the shaft and coat lightly with engine oil. 3) Assemble piston (7) to retainer (6), align with holder and set on shaft. Coat the hole in the retainer for the mounting bolt with thread tightener (LT-2). then completely remove any thread tightener or oil from the side of the retainer. 4) Following the order in 206F255, tighten retainer mounting bolts with wrench to the following tightening torque.

*


~

Retainer mounting bolt kgm

* * * *

1st time

Max. 0.1 (temporary tightening)

2nd time

0.5 ± 0.1

3rd time

1.0 ± 0.1

Completely remove all oil or grease from the mounting bolts before installing. After tightening the mounting bolts, check that the piston moves freely and falls under its own weight. If the piston does not move smoothly. loosen the mounting bolts, then tighten and check again. No thread tightener should come out after the bolts are tightened.

-

206F255

PC200, 220-3

23-7-6 @


TRAVEL MOTOR

8. Disc, plate Install plates (5) and disc (4).

9. Brake piston Fit O-ring and install brake piston (3).

-

www. k omat s upar t s book . c om 10. Brake case assembly Fit O-ring, then using eye bolt (Dia. 10 mm, Pitch 1.5 mml, lift brake case assembly (2). Align piston assembly with cylinder block and install. 0 Set housing at about 25 • Remove tool D after installing the brake case assembly.

* *

-

23-7-7 @

PC200, 220-3

-


SWING MOTOR

REMOVAL OF SWING MOTOR ASSEMBLY

its' 1.

2.

3.

-

4. 5. 6.

Lower the work equipment completely to the ground and stop the engine. Operate the control lever several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove intermediate U-bolt (1), then remove tube (2) between swing motor and tank. Disconnect hoses (3) and (4) between control valve and swing motor. Disconnect hose (5) between swivel joint and swing motor. Disconnect hose (6) between swing motor and tank. Disconnect hose (7) between solenoid valve and swing motor. Remove 2 mounting bolts, then using eye bolts CD (Dia. = 12 mm, Pitch = 1.75 mm), remove swing motor assembly (8).


Swing motor assembly: 65 kg

INSTALLATION OF SWING MOTOR ASSEMBLY

-

Tighten the hose joints to the following tightening torque. Install hose without twisting or interference.

* *

~

1.

2. 3. 4. 5. 6.

*

5 ± 2 kgm (Width across flats: 24 mm) Fit O-ring, then using eye bolts CD (Dia. = 12 mm, Pitch = 1.75 mml, raise swing motor assembly (8) and install to swing machinery. Connect hose (7) between solenoid valve and swing motor. Connect hose (6) between swing motor and tank. Connect hose (5) between swivel joint and swing motor. Fit O-rings and connect hoses (4) and (3) between control valve and swing motor. Fit O-ring and install tube (2) between swing motor and tank, then secure with intermediate U-bolt (1). Sleeve nut:

Run the engine to circulate the oil through the system. Then add oil to the hydraulic tank to the specified level.

PC200.220-3

23-7-8 @


SWING MOTOR

-

DISASSEMBLY OF SWING MOTOR ASSEMBLY (WITHOUT SWING MECHANICAL BRAKE) Special tools No.

Part No.

Part Name

a'ty

A

790-501-5000

Unit repair stand

1

Al

790-901-2230

Plate

1

B

795-630-1 803

Torque wrench set

1

BI

796-720-2220

Socket

1

B2

796-730-2120

Screwdriver

1

C

796· 730-2000

Wrench

1

D

796-750-1500

Holder (Swing motor)

1

-

Preparatory work Using a block, set the swing motor assembly (1) at an angle of 25°.

www. k omat s upar t s book . c om P0202230

1.

Case assembly Using eye bolt (Thread dia. = 10 mm, Pitch = 1.5 mm), lift off case assembly (2).

P020223I

2.

Piston assembly 1) Set case assembly on unit repair stand A, then remove retainer (3) using tools B, BI and B2. 2) Remove both piston assembly (4) and holder.

23-8 (4)

PC200, 220-3

-

-


3.

Drive shaft Turn over unit repair stand A, remove nut (5) with tool C, then remove drive shaft (6).

4.

Bearing 1) Remove snap ring (7), then remove spacer (8) and ring (9). 2) Remove oil seal (10) and bearing (11).

SWING MOTOR


Cylinder block Remove center shaft (13) and cylinder blocks (14) from housing (12).

12

-6.

Valve plate Remove valve plate (15).

PC200, 220-3

23-8-1 @

SWING MOTOR

DrSASSEMBL Y AND ASSEMBLY

7.

Safety valve Remove safety valve (20).

20

F0202226

8.

Check valve Remove plug (21), then remove spring (22) and valve

-

(23).


-'

23-8-2 :4)

PC200, 220-3

-


SWING MOTOR

ASSEMBLY OF SWING MOTOR ASSEMBLY (WITHOUT SWING MECHANICAL BRAKE) Special tools Q'ty

No.

Part No.

A

790-501-5000

Unit repair stand

1

Al

790-901-2230

Plate

1

B

795-630-1803

Torque wrench set

1

BI

796-720-2220

Socket

1

2

796-730-2120

Screwdriver

1

C

796-730-2000

Wrench

1

796-750-1 500


1

B

D

1.

Part Name

22

23

21

Check valve Assemble valve (23) and spring (22), then fit G-ring and install plug (21 l.


Plug:

8 ± 1 kgm

F0202227

2.

Safety valve Fit G-ring, and install safety valve (20). ~

Safety valve:

20

26 ± 3 kgm

F0202226

3.

Valve plate Turn over housing, align dowel, then install valve plate (15).

PC200, 220-3

23-8-3


SWING MOTOR

4.

Cylinder block Install cylinder block (14) in housing (12), assemble center shaft (13), then use tool D to secure center shaft. Coat end face of cylinder block with engine oil.

12

*

P20503067

5.

P20503068

Bearing 1) Press fit outer races (32) and (33) in case.


Press fit bearing (34) on drive shaft (6).

6

P20503071

3)

Assemble drive shaft (6) in case, then press fit bearing (11) and oil seal (10). Coat oil seal face with grease lightly. Fit O-ring and ring (9) and spacer (8), install snap ring (7), then partially tighten nut (5).

* 4)

23-8-4 (4)

PC200, 220-3

-

6.

Preload adjustment of drive shaft Install case assembly to unit repair stand A. Tighten up the nut (5) using tools Band C. ~

*

-

SWING MOTOR


7.

Rotational torque of shaft:

0.45 - 0.60 kgm

Rotate the shaft at the rate of about one revolution every five seconds.

Piston assembly 1) Install holder (34) on piston assembly (4) and set assembly on retainer (3). 2) Install center ball (34) and holder on shaft. 3) Assemble piston assembly to retainer, align with holder and set on shaft.

34


Following the order in 206F255, tighten retainer mounting bolts with tools B, B1 and B2, to the following tightening torque. ~

Retainer mounting bolt

kgm 1st time

*

-

* * 8.

P20503075

Max.O.l (temporary tightening)

2nd time

0.5

3rd time

1.0 ± 0.1

±

0.1

Completely remove all oil or grease from the mounting bolts before installing. After tightening the mounting bolts, check that the piston moves freely and falls under its own weight. If the piston does not move smoothly, loosen the mounting bolts, then tighten and check again.

206F255

Case assembly Fit O-ring, then using eye bolt (Thread dia. = 10 mm, Pitch = 1.5 mm), lift case assembly (2). Align piston assembly with cylinder block and install. Set housing at about 25°. Remove tool D after installing the case assembly.

* *

-

P020223I

PC200, 220-3

23-8-5 (4;


SWING MOTOR

-

DISASSEMBLY OF SWING MOTOR ASSEMBLY (WITH SWING MECHANICAL BRAKE) Special tools No.

Part No.

A

790-501-5000

Unit repair stand

1

Al

790-901-2230

Plate

1

B

795-630-1803

Torque wrench set

1

BI

796-720-2220

Socket

1

B2

796-730-2120

Screwdriver

1

C

796-730-2000

Wrench

1

796-750-1500


1

D

Part Name

Q'ty

-

Preparatory work Using a block, set the swing motor assembly (1) at an angle of 25°.


1.

Brake case assembly Using eye bolt (Thread dia. = 10 mm, Pitch lift off brake case assembly (2).

= 1.5 mm),

P020223I

2.

Brake piston Set brake case assembly on unit repair stand A, then remove brake piston (3).

23-8-6 (4)

PC200, 220-3

-

-


3.

Disc, plate Remove disc (4) and plate (5).

4.

Piston assembly 1) 2)

SWING MOTOR

Using tool B, Bl and B2, remove screw, then remove retainer (6). Remove both piston assembly (7) and holder.


Drive shaft Turn over unit repair stand A, remove nut (8) with tool C, then remove drive shaft (9).

6.

Bearing

1) 2)

Remove snap ring (10), then remove spacer (11) and ring (12). Remove oil seal (13) and bearing (14).

PC200, 220-3

23-8-7

SWING MOTOR


7. Cylinder block Remove spring (16) from housing (15), then remove center shaft (17) and cyl inder blocks (18).

F0202225 8. Valve plate Remove valve plate (19).

-

www. k omat s upar t s book . c om 9. Safety valve Remove safety valve (20).

20

F0202226 10. Check valve Remove plug (21), then remove spring (22) and valve (23).

23

22

21

F0202227

23-8-8 @

PC200, 220-3

-

-

SWING MOTOR


ASSEMBLY OF SWING MOTOR ASSEMBLY (WITH SWING MECHANICAL BRAKE) Special tools Part Name

Q'ty

No.

Part No.

A

790-501-5000

Unit repair stand

1

Al

790-901-2230

Plate

1

B

795-630-1803

Torque wrench set

1

Bl

796-720-2220

Socket

1

B2

796-730-2120

Screwdriver

1

C

796-730-2000

Wrench

1

796-750-1500


1

-

D

1.

22

23

21

Check valve Assemble valve (23) and spring (22), then fit O-ring and install plug (21).


Plug:

8±1 kgm

F0202227

2.

Safety valve Fit O-ring, and install safety valve (20). ~

Safety va Ive:

20

26 ± 3 kgm

F0202226

3.

Valve plate Turn over housing, align dowel, then install valve plate (19).

PC200, 220-3

23-8-9 @


SWING MOTOR

4.

Cylinder block

1)

Install cylinder block (18), assemble center shaft (17), then use tool D to secure center shaft. Coat end face of cylinder block with engine oil. Install springs (16) in housing (15).

* 2)

5.

Bearing 1) Press fit bearing (28) on shaft (9).

28


2)

Press fit outer races (29) and (30) in brake case.

3) 4) 5)

Assemble drive shaft (9) in brake case, then press fit bearing (14) and oil seal (13). Fit spacer (11), then install snap ring (10). Fit O-ring and ring (12), then partially tighten nut (8).

*

Coat oil seal face with grease lightly.

23-8-10 (4)

PC200, 220-3


SWING MOTOR

6.

Preload adjustment of drive shaft 1) Install brake case to unit repair stand A. 2) Tighten up the nut (8) using tools Band C. ~

*

7. _

Rotational torque of shaft: 0.45 - 0.60 kgm

Rotate the shaft at the rate of about one revolution every five seconds.

Piston assembly 1) Install holder (31) on piston (7) and set assembly on retainer (6). 2) Install center ball (32) and holder (33) on shaft. Clean the spherical face of the shaft and coat lightly with engine oil. 3) Assemble piston to retainer, align with holder and set on shaft.

*


4)

Following the order in 206F255, tighten retainer mounting bolts with tools B, B1 and B2, to the following tightening torque. ~

Retainer mounting bolt kgm 1st time

* *

-

*

Max.O.l (temporary tigh1ening)

2nd time

0.5

±

0.1

3rd time

1.0

±

0.1

Completely remove all oil or grease from the mounting bolts before installing. After tightening the mounting bolts, check that the piston moves freely and falls under its own weight. If the piston does not move smoothly, loosen the mounting bolts, then tighten and check again.

PC200, 220-3

206F255

23-8-11 (4)


SWING MOTOR

-8. Disc, plate Install plates (5) and disc (4).

9. Brake piston Fit O-ring and install brake piston (3).

-

www. k omat s upar t s book . c om 10. Brake case assembly Fit O-ring, then using eye bolt (Thread dia. = 10 mm, Pitch = 1.5 mm l, lift brake case assembly (2). Align piston assembly with cylinder block and install. Set h ousi ng at about 25°. Remove tool D after installing the brake case assembly.

* *

--

23-8-12

pe200, 220-3


SWING MOTOR

REMOVAL OF SWING MOTOR ASSEMBLY Lower the work equipment completely to the ground and stop the engine. Operate the control lever several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

-,

1.

Remove tube (1) between swing motor and tank.

2.

Disconnect hoses (2) and (3) between control valve and swing motor.

3.

Disconnect hose (4) between swivel joint and swing motor.

4.

Disconnect hose (5) between swing motor and tank.

5.

Remove 2 mounting bolts, then using eyebolts CD (Dia. 12 mm, Pitch = 1.75 mml, remove swing motor assembly (6).

www. k omat s upar t s book . c om =

~

Swing motor assembly: 65 kg

P205C3114.

INSTALLATION OF SWING MOTOR ASSEMBLY

-

* *

Tighten the hose joints to the following tightening torque. Install hose without twisting or interference.

1.

Sleeve nut: 5 ± 2 kgm (Width across flats: 24 mm) Fit a-ring, then using eyebolts CD (Dia. = 12 mm, Pitch = 1.75 mml, raise swing motor assembly (6) and install to swing machinery.

2.

Connect hose (5) between swing motor and tank.

3.

Connect hose (4) between swivel joint and swing motor.

4.

Fit a-rings and connect hoses (3) and (2) between control valve and swing motor.

5.

Fit a-ring and install tube (1) between swing motor and tank.

~

*


PC200, 220-3

23-9 CD


SWING CIRCLE

-

REMOVAL OF SWING CIRCLE ASSEMBLY 1.

Work equipment assembly Remove work equipment assembly. For details, see 63 REMOVAL OF WORK EOUIPMENT ASSEMBLY.

2.

Boom cylinder assembly 1) Set boom cylinder on stand @. Disconnect boom cylinder hoses (1) and (2).

2)

Sling boom cylinder assembly (3), and remove lock plate (4). Using forcing screw CD (Dia. = 12 mm, Pitch = 1.75 mm), pull out pin (5), then remove boom cylinder assembly (3). ~ 6!!J

-

.

Boom cylinder assembly: 185 kg


3.

Remove the other boom cylinder assembly in the same way.

Counterweight Sling counterweight (6), remove 4 mounting bolts, then lift off counterweight.

~

Counterweight: 3000 kg

4.

Hood 1) Sling hood, pull out pin and disconnect stay (7). 2) Remove 4 mounting bolts and lift off hood (8) /~.~

~k9--"J

23-10 CD

Hood: 55 kg

PC200, 220-3

-

SWING CIRCLE


5.

Drain hose Disconnect drain hose (9) at swivel joint end.

6.

Swivel joint piping Disconnect swivel joint upper hose (10) at swivel joint end.

7.

Plate Pullout pin (11). then remove plate (12) from swivel joint.

8.

Battery cover Remove battery cover (13).

9.

Battery 1) Disconnect 3 battery wires (14). Disconnect the lead from terminal of the battery first. 2) Remove 2 batteries (15).

*

the negative (-)

www. k omat s upar t s book . c om 10. Revolving frame assembly 1) Remove mounting bolts (16) of revolving frame

2)

assembly, leaving 2 or 3 mounting bolts at front and rear. Sling revolving frame assembly (17). The wire is hooked to the mounting frame of the counterweight and will contact the engine, so fit the blocks securely in position. At the front, hook the wire to the boom cylinder bottom mount. Use lever block (2) at the front and adjust the length of the wire. This makes it easier to center the load. The load is extremely heavy, so check that the lifting tool is free from damage.

*

*

LL 3)

In this position, loosen remaining mounting bolts, then raise revolving frame assembly and check that load is center to front, rear, left and right.

* 4)

If the load is not centered, tighten the mounting bolts and adjust the length of the wire again. Repeat Step 3), and when load is centered, remove remaining mounting bolts and lift off revolving frame assembly. _A,

Ck~J

Revolving frame assembly: 4465 kg

PC200, 220-3

23-11 CD


SWING CIRCLE

11. Swing circle assembly 1) Remove 36 mounting bolts (18).

2)

Using eyebolts (3) (Dia. = 22 mm, Pitch lift off swing circle assembly (19).

r:k9-I ~

= 2.5 mm),

-

Swing circle assembly: 260 kg


-

23-12 CD

PC200, 220-3

-

SWING CIRCLE


INSTALLATION OF SWING CIRCLE ASSEMBLY 1.

Swing circle assembly 1) Using eyebolts ® (Dia. = 22 mm, Pitch = 2.5 mm), raise swing circle assembly (19). Align with inner teeth soft zone as shown in diagram, then set in position on frame. The "S" marks stamped on inner and outer soft zones.

*

-

Front

t Outer teeth soft zone


2)

2.

Tighten 36 mounting bolts (18). ~,

Mounting bolts: Thread tightener (LT-2)

~


~

Inner teeth of circle: Grease (G2-L1)

Revolving frame assembly 1) Raise revolving frame assembly (17) horizontally. The wire is hooked to the mounting frame of the counterweight and will contact the engine, so fit the blocks securely in position. At the front, hook the wire to the boom cylinder bottom mount. Use lever block (l) at the front and adjust the length of the wire. This makes it easier to center the load.

*

*

-

The load is extremely heavy, so check that the lifting tool is free from damage.

PC200, 220-3

23-13 CD


SWING CIRCLE

2)

Lower revolving frame assembly slowly, align swing pinion with circle gear, then align with dowel pin and set in position. Tighten 2 or 3 mounting bolts (19) at front and rear. ~=J

3)

3.

Top face of swing circle: Gasket sealant (LG-1 ) Tighten all 26 mounting bolts (16). ~)

Mounting bolt: Thread tightener (LT-2)

~

Mounting bolt: 76 ± 8.5 kgm

Battery 1) Install 2 batteries (15). 2) Connect 3 battery wires (14). Connect lead to positive (+) terminal of battery first.

*

4.

Battery cover Tighten 4 mounting bolts of battery cover (13).

5.

Plate Set plate (12) on swivel joint, then install pin (11).

6.

Swivel joint piping Fit G-ring and connect swivel joint upper hose (10). Install hose without twisting or interference.

www. k omat s upar t s book . c om * 7.

~

* 8.

-

Drain hose Connect drain hose (9). 5 ± 2 kgm (Width across flats: 24 mm) I nstall hose without twisting or interference. Sleeve nut:

Hood Raise hood (8) and set in position on frame. Tighten 4 mounting bolts, then connect stay (7).

23-14 CD

PC200, 220-3

_.


9.

SWING CIRCLE

Counterweight Raise counterweight (6) and set in position on frame, then tighten 4 mounting bolts.

-

10. Boom cylinder assembly 1)

Raise boom cylinder assembly (3). and set in position on frame. Knock pin at bottom end, then secure with lock plate (4),

*

Adjust with spacers so that the clearance between the revolving frame and boom cylinder bottom is less than 1 mm.


Set boom cylinder on stand (4), Fit O-rings and connect boom cylinder hoses (2) and (1). Install the other boom cylinder assembly in the same way.

*

-

11. Work equipment assembly Install work equipment assembly. For details see 63 INSTALLATION OF WORK EQUIPMENT ASSEMBLY.

*

*

For details, see 62 BLEEDING AIR FROM TRAVEL MOTOR. After bleeding the air, add oil to the hydraulic tank to the specified level.

PC200, 220-3

23-15 CD


SWING CIRCLE

-

REMOVAL OF SWING CIRCLE ASSEMBLY (OPTION) 1.

Work equipment assembly Remove work equipment assembly. For details, see 63 REMOVAL OF WORK EQUIPMENT ASSEMBLY.

2.

Boom cylinder assembly 1) Set boom cylinder on stand cyl inder hoses (1) and (2).

2)

0.

Disconnect boom

Sling boom cylinder assembly (3), and remove lock plate (4). Using forcing screw CD (Dia. = 12mm, Pitch = 1.75 mml, pull out pin (5), then remove boom cylinder assembly (3).

~

-

Boom cylinder assembly: 185 kg


3.

Remove the other boom cylinder assembly in the same way.

Counterweight Sling counterweight (6), remove 4 mounting bolts, lift off counterweight. .~

~

Counterweight: 3000 kg

4.

Hood 1) Sling hood, pull out pin and disconnect stay (7). 2) Remove 4 mounting bolts and lift off hood (8).

r1t'1

23-16 CD

Hood: 55 kg

PC200, 220-3

SWING CIRCLE


-

-

5.

Drain hose Disconnect drain hose (9) at swivel joint end.

6.

Swivel joint piping Disconnect swivel joint upper hose (10) at swivel joint end.

7.

Plate Pull out pin (11), then remove plate (12) from swivel joint.

8.

Battery cover Remove battery cover (13).

9.

Battery 1) Disconnect 3 battery wi res (14). Disconnect the lead from terminal of the battery first. 2) Remove 2 batteries (15).

*

the negative (-)


-

10. Revolving frame assembly 1) Remove mounting bolts (16) of revolving frame assembly, leaving 2 or 3 mounting bolts at front and rear. 2) Sling revolving frame assembly (17). The wire is hooked to the mounting frame of the counterweight and will contact the engine, so fit the blocks securely in position. At the front, hook the wire to the boom cylinder bottom mount. Use lever block (.2) at the front and adjust the length of the wire. This makes it easier to center the load.

*

*

The load is extremely heavy, so check that the lifting tool is free from damage.

3)

In this position loosen remaining mounting bolts, then raise revolving frame assembly and check that load is center to front, rear, left and right. If the load is not centered, tighten the mounting bolts and adjust the length of the wire again. Repeat Step 3), and when load is centered, remove remaining mounting bolts and lift off revolving frame assembly.

* 4)

-

li
Revolving frame assembly: 4465 kg

PC200, 220-3

23-17 CD


SWING CIRCLE

11. Swing circle assembly 1)


2)

Using eyebolts ® (Dia. = 22 mm, Pitch lift off swing circle assembly (19).

I~j

= 2.5

mm).

-

Swing circle assembly: 260 kg


-

23-18 CD

PC200, 220-3


SWING CIRCLE

INSTALLATION OF SWING CIRCLE ASSEMBLY (OPTION) 1.

Swing circle assembly 1) Using eyebolts ® (Dia. = 22 mm, Pitch = 2.5 mm), raise swing circle assembly (19). Align with inner teeth soft zone as shown in diagram, then set in position on frame.

*

The "S" marks stamped on inner and outer soft zones.

-

Front

t Outer teeth soft zone


2)

2.

Tighten 36 mounting bolts (18). ~~,

Mounting bolts: Thread tightener (LT-2)

~


~

Inner teeth of circle: Grease (G2-L1)

Revolving frame assembly 1) Raise revolving frame assembly (17) horizontally. The wire is hooked to the mounting frame of the counterweight and will contact the engine, so fit the blocks securely in position. At the front, hook the wire to the boom cylinder bottom mount. Use lever block @ at the front and adjust the length of the wire. This makes it easier to center the load. The load is extremely heavy, so check that the lifting tool is free from damage.

*

*

Lt

PC200. 220-3

23-19 CD


SWING CIRCLE

2)

Lower revolving frame assembly slowly, align swing pinion with circle gear, then align with dowel pin and set in position. Tighten 2 or 3 mounting bolts (19) at front and rear. ~.,

Top face of swing circle: Gasket seal ant (LG-1 ) Tighten all 26 mounting bolts (16).

3)

3.

~

Mounting bolt: Thread tightener (L T-2)

~

Mounting bolt: 76 ± 8.5 kgm

Battery 1) Install 2 batteries (15). 2) Connect 3 battery wires (14).

*

4.

-

Connect lead to positive (+) terminal of battery fi rst.

Battery cover Tighten 4 mounting bolts of battery cover (13).


Plate Set plate (12) on swivel joint, then install pin (11).

6.

Swivel joint piping Fit D-ring and connect swivel joint upper hose (10).

* 7.

Install hose without twisting or interference.

-

Drain hose Connect drain hose (9). ~

* 8.

5 ± 2 kgm (Width across flats: 24 mm) Install hose without twisting or interference. Sleeve nut:

Hood Raise hood (8) and set in position on frame. Tighten 4 mounting bolts, then connect stay (7).

23-20 CD

PC200, 220-3

-


9.

-

SWING CIRCLE

Counterweight Raise counterweight (6) and set in position on frame, then tighten 4 mounting bolts.

10. Boom cylinder assembly 1) Raise boom cylinder assembly (3), and set in position on frame. Knock pin at bottom end, then secure with lock plate (4). Adjust with spacers so that the clearance between the revolving frame and boom cylinder bottom is less than 1 mm.

*


*

Set boom cylinder on stand (1). Fit O-rings and connect boom cylinder hoses (2) and (1). Install the other boom cylinder assembly in the same way.

11. Work equipment assembly Install work equipment assembly. For details, see 63 INSTALLATION OF WORK EQUIPMENT ASSEMBLY.

* *

For details, see 62 BLEEDING AI R FROM TRAVEL MOTOR. After bleeding the air, add oil to the hydraulic tank to the specified level.

PC200, 220-3

23-21 Q)

-

-


-

-

_.


SWING MACHINERY

REMOVAL OF SWING MACHINERY ASSEMBLY 1.

Remove swing motor assembly. For details, see 23 REMOVAL OF SWING MOTOR ASSEMBLY.

2.


3.

Lift off swing machinery assembly (2).

" (kgj

-

Swing machinery assembly: 190 kg

INSTALLATION OF SWING MACHINERY ASSEMBLY


Fit O-ring and raise swing machinery assembly (2). Lower slowly, align pinion and inner teeth of swing circle and set in position on frame.

2.


3.

Install swing motor assembly. For details, see 23 INSTALLATION MOTOR ASSEMBLY.

OF

SWING

-

PC200, 220-3

23-23 CD


SWING MACHINERY

-

DISASSEMBLY OF SWING MACHINERY ASSEMBLY· 1.

Draining oil Loosen drain valve (1) and drain oil from swing machinery case .

•

~

2.

Swing machinery case: Approx. 7 Q

Cover 1) 2)

Remove 12 mounting bolts (2). Remove cover (3).

-


Ring gear Remove ring gear (4).

4.

Spacer Remove spacer (5).

5.

Thrust washer Remove thrust washer (6).

6 6.

7

Sun gear Remove sun gear (7).

23-24 Q)

PC200, 220-3

-


2)

SWING MACHINERY

Install gear assembly (13) on shaft. Check that the bottom of the gear is securely fitted in the spacer pilot.

*

10. Plate, bolt Fit plate (12), then tighten mounting bolt (11). 11. Spacer Install spacer (10).

-

12. Carrier assembly, sun gear Remove 3 mounting bolts of carrier shaft. Using eye bolts CD (Dia. = 12 mm, Pitch = 1.75 mm) in mounting bolt holes, align marks of carrier assembly (9) as shown in diagram below, then fit sun gear (7) and install. Always match the stamped numbers. If the gears are assembled in the wrong combinations, the gears may be damaged.

10

*

When assembling the planetary gear, set the th ree 11 marks facing in the same direction, and check that the lines of the sun gear and planet gears are centered and meshed as shown in the figure before installing. If the stamped numbers cannot be al igned at the center, rotate the planet gear which cannot be aligned 0 120 to the left or right, and the numbers to be aligned will appear.


205F232I

9

The stamped number on the sun gear comes between the stamped numbers on the planet gears. F20803009

13. Thrust washer Install thrust washer (6).

-

14. Spacer Install spacer (5).

PC200, 220-3

23-25 ®

SWING MACHINERY


15. Ring gear Coat gasket sealant on mounting face, then install ring gear (4). ~

*

Contact face: Gasket sealant (LG-6) Check that the condition in Step 12 is correct before installing the ring gear.

16. Cover Coat gasket sealant on both mounting faces, then set cover (3) on ring gear, and tighten 12 mounting bolts (2).

-

~c-,

*

Contact face: Gasket sealant (LG-6) Set the oil filler as shown in the diagram below when installing the cover.

www. k omat s upar t s book . c om Oil filler

205P2215

Front of . . machine

2 17. Refilling with oil Tighten drain valve, pull air bleed valve (36), and add engine oil through oil filler (37) to the specified level.

205P2216

'Wl

*

Swing machinery case: Approx. 7 Q Check the level again at the specified place after installing the swing machinery assembly to the machine body.

23-26 CD

PC200, 220-3


SWING MACHINERY

16. Gear assembly 1) 2)

Remove gear assembly (30) together with upper and lower thrust washers (31) from carrier (32). Remove bearings (34) and (35) from gear (33).

32

34

I

35 31

I

f

II 205P2198

-


PC200, 220-3

23-27 CD


SWING MACHINERY

-

ASSEMBLY OF SWING MACHINERY ASSEMBLY

* 1.

32

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Gear assembly 1) Assemble bearings (35) and (34) on gear (33). 2) F it upper and lower thrust washers (31), then set gear assembly (30) on carrier (32).

205P2198

2.

205P2199

Shaft 1) Align bolt holes of shaft and carrier, then tap with a plastic hammer to install shaft (29). Rotate the planet gear and be careful not to damage the th rust washer when install ing. 2) Install mounting bolts (28).

28

*

-

www. k omat s upar t s book . c om 205P2200

3.

205P2195

Oil seal Using push tool @ (outside diameter: 155 mm), press fit oil seal (26) in case (27). /' -

Oil seal lip:

Grease (G2-L1) (Fill 40 - 60%)

205P2201

4.

Bearing Set case in a press, then using push tool diameter: 200 mm), press fit bearing (24).

®

205P2202

(outside

205P2204

23-28 CD

PC200.220-3

-

-


5.

SWING MACHINERY

Snap ring I nstall snap ring (23). Check that snap ring is fitted securely in the groove.

*

6. -

Shaft 1) Fit O-ring, then using push tool ® (inside diameter: 105 mm), install spacer (21) on shaft (19). 2) Fit case (20) on shaft (19), then set in press. Using push tool (j) (inside diameter: 95 mm), press fit bearing on shaft. Be careful not to damage the oil seal when installing.

*


Spacer Assemble spacer (22). Assemble the spacer with the chamfered side at the bottom.

*

8.

Bearing Using push tool ® (outside diameter: 215 mm), press fit bearing (25) in case.

PC200, 220-3

23-29 CD

DISASSEMBL Y AND ASSEMBL Y

SWING MACHINERY

9.

Gear assembly 1) Assemble gear assembly as follows. i) Set inner gear (16) on outer gear (17), then fit plate (15) and tighten mounting bolts (14). Bend lock plate securely. ii) Using push tool ® (inside diameter: 120 mm), press fit bearing inner race (18).

*

2)

Install gear assem bly (13) on shaft. Check that the bottom of the gear is securely fitted in the spacer pilot.

*

-

10. Plate. bolt Fit plate (12), then tighten mounting bolt (11).

www. k omat s upar t s book . c om 11. Spacer Install spacer (10).

10

12. Carrier assembly. sun gear Remove 3 mounting bolts of carrier shaft. Using eyebolts CD (Dia. = 12 mm, Pitch = 1.75 mm) in mounting bolt holes, align marks of carrier assembly (9) as shown in diagram below, then fit sun gear (7) and install.

*

When assembling the planetary gear, set the three 11 marks facing in the same direction, and check that the lines of the sun gear and planet gears are centered and meshed as shown in the figure.

-

9

23-30 CD

PC200.220·3

-

FINAL DRIVE


1.

Draining oil Remove drain plug (1) and drain oil from final drive case .

•

....:...

Final drive case: Approx. 3.7 Q

205F231 I

-

2.

Travel motor assembly 1) Remove 2 mounting bolts (2). 2) Using eye bolts CD (Dia. = 10 mm, Pitch = 1.5 mm), lift off travel motor assembly (3).


3.

Coupling, sun gear 1) Remove coupling (4). 2) Remove sun gear (5).

4.

Cover 1) Make match marks on cover (7), ring gear (9) and hub (20).

205P2121

-.

2) 3)

7

8

Remove mounting bolts (6), then remove cover (7). Remove button (8) from cover.

Mat.ch marks

205P2124A

PC200, 220-3

205P2125

23-31 ®


FINAL DRIVE

5.

Ring gear Remove ring gear (9).

9

6.


7.

Carrier assembly Using eye bolts CD (Dia. = 10 mm, Pitch lift off carrier assembly (11).

1.5 mml.



2

9.

Gear assembly 1) Remove 18 mounting bolts (13). 2)

Take out gear assembly (14). There are dowel pins fitted in the gear assembly, so if it is difficult to remove the assembly, put a block in contact with the dowel pin position and fit with a hammer to remove.

*

13

205P2130

23-32 (Q)

205P2131

PC200. 220-3

-

-


TRAVEL MOTOR. FINAL DRIVE

REMOVAL OF TRAVEL MOTOR, FINAL DRIVE ASSEMBLV Lower the work equipment completely to the ground and stop the engine. Operate the control lever several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

-

1.

Remove track shoe assembly. For detials, see 33 REMOVAL OF TRACK SHOE ASSEMBLY.

2.

Using hydraulic jack

3.

Remove 20 mounting bolts (1) of sprocket (2). then remove sprocket.

~

CD

(30 t), raise track frame.

3

Sprocket: 40 kg


Remove cover (3).

5.

Disconnect drain hose (4) between travel motor and swivel joint. F it a blind plug in the drain hose.

* 6.

-

Disconnect hoses (5) and (6) between travel motor and swivel joint. Fit a blind plug in the hoses.

* 7.

Sling travel motor and final drive assembly (7), then remove 18 mounting bolts (8).

8.

Lift off travel motor and final drive assembly (7). ~-

CS
*

Travel motor, final drive assembly: 340 kg

Be carefu I not to let the travel motor hit the track frame.

PC200. 220-3

23-33 CD


TRAVEL MOTOR, FINAL DRIVE

-

INSTALLATION OF TRAVEL MOTOR, FINAL DRIVE ASSEMBLY 1.

Raise travel motor and final drive assembly (7) with crane, and set on track frame.

* 2.

Be careful not to let the travel motor hit the track frame.

Tighten 18 mounting bolts (8). ~


3.

Connect hoses (6) and (5) between travel motor and swivel joint.

4.

Connect drain hose (4) swivel joint. ~

Hose nut:

between travel

-

motor and



Install cover (3).

6.

Set sprocket (2) in position, then tighten 20 mounting bolts (1).

3

CD

7.

Slowly release hydraulic jack frame to original position.

8.

Install track shoe assembly. For details see 33 INSTALLATION OF TRACK SHOE ASSEMBLY.

*

*

(30 t), and return track

For details, see 62 BLEEDING AIR FROM TRAVEL MOTOR. After bleeding the air, add oil to the hydraulic tank to the specified level.

23-34 CD

PC200, 220-3

FINAL DRIVE


ASSEMBLY OF FINAL DRIVE ASSEMBLY

PC200-3 PC220-3 Carrier

, . . - - - - - - - - - _ To A

PC200-3 PC220-3

Shaft

~---'- ToB

www. k omat s upar t s book . c om A----------------------l

B ---1------1

-

205F2312

Special tool Part No.

*

Part Name

Q'ty

B

790-102-1831

Nut wrench

1

C

790-431-2100

Plate assembly

1

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

PC200, 220-3

23-35 (8)


FINAL DRIVE

1.

Gear assembly 1) Using push tool ® (outside diameter: 90 mm), press fit bearing outer race (38) on gear (34).

34 205P21

2)

Assemble bearing (36), spacer (37), and bearing (35) on gear (34), then set gear assembly (32) on carrier (33).

-

33 35 37

34

I I I

36

If

.J.t. www. k omat s upar t s book . c om I

r

I

205P2144

2.

205P2148

Pin Set carrier assembly in a press, then using push tool (j) (outside diameter: 54 mm), press fit pin (31).

*

When press fitting the pin, rotate the gear, and pay careful attention to the angle of the pin.

3.

Collar Assemble collar (29) and lock washer (27).

4.

Nut 1) Using tool B, tighten nut (28). 2)

-

~ Nut: 35 ± 5 kgm Bend lock washer (27) securely.

23-36 (:5)

PC200. 220-3

FINAL DRIVE


5.

Bearings, floating seals 1) Using push tool (outside diameter: 310 mm), press fit bearings (25) and (24) on hub (26). 2) Install floating seal (23). 3) Install floating seal (22) on shaft (21). Clean all oil and grease from the O-ring and the face in contact with the O-ring, then dry before installing the floating seals. When assembling the floating seals, coat the sliding face of the seal th inly with oil and be careful to keep them free of dust.

25

24

21 !

*

*

205P2138

6.

, 22

26

23

205P2137

Hub assembly 1) Using eye bolts 3) (Dia. = 16 mm, Pitch = 2.0 mm), set hub assembly (20) on shaft (21). 2) Usign push tool (inside diameter: 240 mm), tap bearing to press fit.


Adjusting bearing clearance 1) Rotate the hub 2 - 3 turns to settle the bearing. 2) Using tool C, hold the bearing and press fit the shaft securely. ~ Plate mounting bolt: 1.25 ± 0.25 kgm Adjusting shim type i) Using a depth micrometer, measure stepped difference "h" from the end face of the shaft to the end of the bearing inner race. When measuring stepped difference "h", measure at three places around the circumference and take the largest value. ii) Take value h measured in Step i) and select a shim to give a value of (h + 0.10) - (h + 0.15) mm. After assembling the set of shims, check the thickness with calipers. 30349) (PC200-3 Serial No. 20001 (PC220-3 Serial No. 20001 22628) Adjusting spacer type i) Using a depth micrometer, measure stepped difference "h" from the end face of the shaft to the end face of the bearing inner race. When measuring stepped difference "h", measure at three places around the circumference and take the smallest value. ii) Take value "h" measured in Step i) and select a spacer to give a value of (h - 0.10) - (h -0.15) mm. There are seven types of spacer. Select the spacer to give the above thickness. (PC200-3 Serial No. 30350 and up) (PC220-3 Serial No. 22629 and up) 3) Assemble selected shim or spacer (19).

*

-

20 205P2151

/

c c

L

*

( 205F2468

205F2313-1

205F2313-2

205P2134

*

*

PC200, 220-3

23-37 (8)

DISASSEBMLY AND ASSEMBLY

FINAL DRIVE

8. Gear assembly 1) Assemble gear assembly as follows. i) Assemble inner gear (17) to outer gear (18). ii) Fit plate (16), then tighten mounting bolts (15). 2) Set gear assembly (14) in hub, then knock in 2 dowel pins. i) Align position of dowel pin of gear assembly. ii) Temporarily tighten with 2 mounting bolts (13). iii) Knock in 2 dowel pins. When installing, be careful that the shim does not slip out of position.

*

3)

18

205P2132

205P2133

Tighten 18 mounting bolts (13). /~-

Thread of bolt: Thread tightener (L T-2)

~

Mounting bolt: 29.75 ± 1.75 kgm (PC200-3 Serial No. 20001 (PC220-3 Serial No. 20001 39 ± 2 kgm (PC200-3 Serial No. 25868 (PC220-3 Serial No. 21531

-

13 25867) 21530) and up) and up)


4)

205P2130

Check adjustment of bearing clearance again. Hook spring balance in the tap hole for the sprocket mounting bolt, rotate the hub against the shaft, and measure the starting force. Starting force: Max. 30 kg If the starting force is above the standard value, there is a preload on the bearing, so adjust again.

* *

205F2469

23-38

PC200.220-3

FINAL DRIVE


9. Spacer Install spacer (12). 10. Carrier assembly Using eye bolts CD (Dia. = 10 mm, Pitch = 1.5 mm), raise carrier assembly (11). Align as shown in diagram below, then fit sun gear (5) and install.

*

Always match the stamped numbers. If the gears are assembled in the wrong combinations, the gears may be damaged.

-

When assembling the planetary gear, set the three 11 marks facing in the same direction, and check that the lines of the sun gear and planet gears are centered and meshed as shown in the figure before installing. If the stamped numbers cannot be aligned at the center, rotate the planet gear which cannot 0 be aligned 120 to the left or right, and the numbers to be aligned will appear.

www. k omat s upar t s book . c om 205F23 I 4

The stamped number on the sun gear comes between the stamped numbers on the planet gears.

F20803009


10

12. Ring gear Coat mounting surface with gasket sealant, align match marks made when disassembling, and install ring gear (9) .

.re-'.

*

Contact face: Gasket sealant (LG-6) Remove sun gear (5) assembled in step 10 to align teeth. 2Q5P2127

PC200, 220-3

205P2154

23-39


FINAL DRIVE

13. Cover 1) Install button (8) on cover. 2)

7

Coat mounting surface with gasket sealant, align match marks made when disassembling, then set cover (7) on ring gear and tighten mounting bolts (6). ~,-

Contact face:

Gasket sealant (LG-6)

~

Mounting bolt:

28 ± 3 kgm

205P2155

205P2125

14. Sun gear, coupling 1) 2)

Install sun gear (5). Install coupling (4).

-

www. k omat s upar t s book . c om 15. Travel motor assembly

CD

= 10 mm,

= 1.5 mm),

1)

Using eye bolts

2)

raise travel motor assembly (3). Fit G-ring and install on shaft. Tighten 2 mounting bolts (2).

(Dia.

Pitch

205P2121

205P2120

16. Refilling with oil Tighten drain plug (1) and add engine oil through oil filler (39) to the specified level.

'Wi

*

Final drive case: Approx. 3.7 Q Check the level again at the specified place after installing the final drive case assembly to the machine

39

body. ,

,I

205F2315

23-40 (8

PC200, 220-3

-

-


4.

Nut 1)

Using tool B, tighten nut (28). ~

2)

-

5.

FINAL DRIVE

Nut: 60 ± 5 kgm Bend lock washer (27) securely.

Bearings, floating seals 1) Using push tool (outside diameter: 310 mm), press fit bearings (25) and (24) on hub (26). 2) Install floating seal (23). 3) Install floating seal (22) on shaft (21). Clean all oil and grease from the O-ring and the face in contact with the O-ring, then dry before installing the floating seals. When assembling the floating seals, coat the sliding face of the seal thinly with oil and be careful to keep them free of dust.

B

\

24

25

21

*


205P2138

6.

-

205P2137

22

Hub assembly 1) Using eye bolts ® (Dia. = 16 mm, Pitch = 2.0 mm), set hub assembly (20) on shaft (21). 2) Usign push tool (inside diameter: 240 mm), tap bearing to press fit.

20 205P2151

7.

-

Shim 1) Adjust shim thickness as follows. i) Rotate hub 2 or 3 times to fit bearing. ii) Using plate ®, hold bearing, and press fit securely on shaft. iii) Using depth micrometer @, measure difference "h" between end face of shaft and end face of bearing inner race. iv) Using value "h", select shim so that shim is h to h +0.1 mm. 205P2152

pe200.220-3

205F2313

23-41 CD


FINAL DRIVE

2)

Assemble shim (19).

8. Gear assembly 1)

16

Assemble gear assembly as follows. i) Assemble inner gear (17) to outer gear (18). ii) F it plate (16), then tighten mounting bolts (15).

/

-

www. k omat s upar t s book . c om 1B

2) 3)

205P2133

Set gear assembly (14) in hub, then knock in 2 dowel pins. Tighten 18 mounting bolts (13). ,("

Mounting bolt:

Thread tightener (LT-2)

~

Mounting bolt:

38.5 ± 2.5 kgm

205P2132

13

205P2131

205P2130


12

23-42 CD

PC200. 220-3

-

DISASSEBML Y AND ASSEMBLY

FINAL DRIVE

10. Carrier assembly Using eyebolts Q) (Dia. = 10 mm, Pitch = 1.5 mml. raise carrier assembly (11). Align as shown in diagram below, then fit sun gear (5) and install.

When assembling the planetary gear, set the three 11 marks facing in the same direction, and check that the lines of the sun gear and planet gears are centered and meshed as shown in the figure before installing.

www. k omat s upar t s book . c om 11. Spacer Install spacer (10).

-

12. Ring gear Coat gasket sealant on both mounting faces, then install ring gear (9).

"c-.

*

Contact face: Gasket sealant (LG-6) Check that the condition in Step lOis correct before installing the ring gear.

205P2127

13. Cover 1) Install button (8) on cover. 2) Coat gasket sealant on both mounting faces, then install cover (7) and tighten mounting bolts (6). /:

Contact face:

Gasket sealant (LG-6)

~

Mounting bolt:

28 ± 3 kgm

-

7

B

205P2125

PC200. 220-3

205P2154

205P2155

23-43 CD


FINAL DRIVE

14. Sun gear, coupling 1) Install sun gear (5). 2) Install coupling (4).

15. Travel motor assembly 1) Using eye bolts CD (Dia. = 10 mm, Pitch = 1.5 mm), raise travel motor assembly (3). Fit O-ring and install on sl1aft. 2) Tighten 2 mounting bolts (2).

-


205P2120

16. Refilling with oil Tighten drain plug (1) and add engine oil through oil filler (39) to the specified level.

'Wi

*

Final drive case: Approx. 3.7 Q Check the level again at the specified place after installing the final drive case assembly to the machine body.

39~

-

23-44 CD

PC200,220-3

POWER TRAIN 24 MAINTENANCE STANDARD

Travel motor Final drive Travel shuttle valve Swing motor Swing machinery Swing circle

·.·

24- 2 24- 4 24- 6 24- 7 24- 8 24-10


PC200. 220-3

24-1


TRAVEL MOTOR

-

TRAVEL MOTOR 3,

~

6

www. k omat s upar t s book . c om No.

Check Item

Criteria

Standard size

1

Spool selector spring

205F2202

Section 0-0

Section C-C

Unit: mm

Remedy

Repair limit

Free length x 0.0.

Installed length

Installed load

Free length

Installed load

51 x 29.5

34.7

28.5 kg

47.7

22.8 kg

51.4x17.3

30.5

0.2 kg

47.2

0.16 kg

2

Check valve spring

3

Tightening torque for plug

1.8 ± 0.2 kgm

4


3.5 ± 0.5 kgm

5


8 ± 1 kgm

6


7

Tightening torque for cover mounting bolt

8

Tightening torque for safety valve

Replace if any damage or deformation is found.

-

Tighten

24-2

14.5 ± 2 kgm

7 ± 0.5 kgm

26 ± 3 kgm

PC200, 220-3

-

-


-


FINAL DRIVE

-

FINAL DRIVE

B

7

B--------+ftt:~

--T-r , I

I '

I

-


-

2

3 --'----'--"-----

-

------

205F2203A

24-4

PC200, 220-3

FINAL DRIVE


-

www. k omat s upar t s book . c om Unit: mm

No.

1

Check Item

Criteria

Backlash between su n gear and planet gear

PC200: 2

Clearance limit

0.19-0.51

1.00

0.22 - 0.60

1.10

--

0.20 - 0.59

1.10 Replace

3

Backlash between planet gear and NO.2 ring gear

0.22 - 0.60

1.10

4

Backlash between NO.2 ring gear and gear

0.22 - 0.63

1.20

5

End play of sprocket shaft

6

Amount of wear on sprocket tooth

7

-

Standard clearance

Backlash between planet gear and NO.1 ring gear PC220:

-

Remedy

Width of sprocket tooth

-

0-0.1

Repair limit:

6

Standard size

Repair limit

71

68

I-----

8

Tightening torque of sprocket mounting bolt

25 ± 6.5 kgm

9

Tightening torque of oil filler plug

15.5 ± 2.5 kgm

Tightening torque of drain plug

15.5 ± 2.5 kgm

10

PC200, 220-3

Repair by build-up welding or replace rims.

Tighten

24-5


SWING MOTOR

-

SWING MOTOR

-

3


205F2204

Section C-C Section B-B

Unit: mm

No.

Check Item

Criteria

Remedy

Standard size

1

Check valve spring

Repair limit

Free length x 0.0.

Installed length

Installed load

Free length

62.5 x 20.0

37.0

0.33 kg

57.1

2


29 ± 4 kgm

3

Tightening torque for safety valve

26 ± 3 kgm

4


13 ± 1.5 kgm

24-6

---..

Installed load

Replace if any damage or deformation is fou nd.

0.26 kg

Tighten

PC200, 220-3

-

-


-

-


SWING MACHINERY

-

SWING MACHINERY

,--cd--

I

_s

~-.~._-.-.----~-

B


3 4 6

9

-

rrL-=--------,- -- - - -

5

205F2206

24-8

PC200, 220-3

-

SWING MACHINERY


-


No.

Check Item

Criteria

Standard clearance 1

-

-~

Backlash between sun gear and planet gear

e---

Remedy

Clearance limit

0.13 - 0.49

1.00 Replace

2


0.16 - 0.58

1.10

3


0.15 - 0.53

1.00

4

Backlash between NO.2 ring gear and gear

0.2 - 0.6

1.10

5

Backlash between output shaft (pinion) and swing circle

0.24 - 1.29

2.00

6

End play of swing pinion

1.78 - 2.22

-

Standard size

Repair limit

7

Wear of output shaft collar surface contacting with oil seal

8

9

Clearance between sun gear and swing motor output shaft spline in rotating direction.

Clearance between output shaft and idle gear spline in rotating direction

PC200. 220-3

Adjust

.. -

<1>125

0 -0.100

124.7

Standard clearance

Clearance limit

0.06-0.15

...

0.09 - 0.27

Apply hard-chrome plating, recondition or replace

Replace

-

24-9


SWING CIRCLE

-

SWING CIRCLE

Machine front -

I

TT-

Machine center

SA

-

www. k omat s upar t s book . c om Section B-B

2

\ Section A-A

No.

1

2

Tightening torque of outer race mounting bolt

3

Tightening torque of inner race mounting bolt

4

Grease

F205C3015 Unit: mm

Remedy

Criteria

Check Item

Clearance of bearing in axial direction

\

4

Standard clearance

Clearance limit

0.15-0.35

1.0

Replace

76 ± 8.5 kgm Tighten

24-10

56 ± 6 kgm

Grease must not be badly contaminated or fould in white (capacity: 162)

Replace

PC200, 220-3

-

UNDERCARRIAGE 3I STRUCTURE AND FUNCTION

-

Track group Recoil spring Idler Track roller Carrier roller Trackshoe

'.'

31-2 31-3 31-4 31-5-1 31-6 ·31-7-1


31-1 (8)

TRACK GROUP


-

TRACK GROUP

2

\

-


/

7

1. 2. 3. 4. 5. 6. 7.

8.

31-2

6

Idler Track frame Carrier roller Track roller Center guard Recoil spring Front guard Track

\\\ 5

\

\

4

205F2067

The tracks which bear and spread the weight of the machine on the ground convert the driving power transmitted from the sprockets into tractional force. The track group includes a pair of right and left track frames (2), front idlers (1), carrier rollers (3) and track rollers (4) are mounted. The track (8) looped around each track frame is driven by the sprocket wheel and its rolling is guided by the front idler, carrier roller and track rollers. The track roller guards (4) and (7) attached on the bottom surface of each track frame prevents the track from slipping off due to intrusion of stones.

PC200, 220-3

-

-

RECOI L SPRING


RECOIL SPRING

-


4

3

F205030 I I

The idler cushion is mounted on the track frame between the front idler and the sprocket wheel. It performs the following functions: 1) Maintaining proper track tension 2) Absorbing shocks which the front idler is subjected to during traveling of the machine. One ene of the rod (1) is connected to the idler yoke and the other end to the support (2). The recoil spring support (2) and the piston (3) are always pushed toward the forward part of the machine by the recoil spring (4), and the rod is also pushed forward by force from the piston through the grease filling the cylinder. When the front idler, connected to the recoil spring through the adjusting cylinder, is subjected to an impact exceeding the initial preload of the recoil spring, the recoil spring will retract to absorb the shock. Also, when mud, stones or snow get lodged between the track and the sprocket wheel, the recoil spring will absorb the shock caused by a sudden increase of track tension, thus preventing damage to the track, sprocket or other rollers.

PC200, 220-3

The adjusting cylinder is provided with the lubricator. Feeding grease through the lubricator causes the cylinder piston to push the idler forward so that track tension is increased. On the other hand, track tension is decreased by loosening the lubricator to discharge the grease. To loosen track tension, loosen the lubricator by one turn. If grease does not ooze out easily, try moving the machine back and forth a short distance. Do not loosen the lubricator more than one complete turn in order to prevent dangerous spurting of grease under high pressure. Although the protector is provided to prevent the lubricator from flying out, this precaution should be kept in mind for safety.

Lt

31-3

IDLER


-

IDLER PC200·3 (Serial No. 20001 - 33477) PC220-3 (Serial No. 20001 - 23219)

4

-


5

3

1. 2. 3. 4.

Idler Support Lubricating plug Floating seal

5. 6.

Idler shaft Bushing

205F2068

The front idler (1) mounted at the front-end of each track frame is supported on the idler shaft (5) through the guide and bushing (6). The idler assembly including the yoke, which is connected to the idler shaft bearings, is sl idable back and forth along the track frame by the guideplates attached to the underside of the bearings and the cover so that smooth rolling of the track can always be maintained.

31-4

Lubricating oil (engine oil) enters the oil hole provided in the shaft to lubricate the sliding surface of the bushing. Each end of the bushing is provided with a floating seal to prevent both leakage of oil and inclusion of mud and water. To improve its wear-resistant property, the idler is made of siliconmanganese steel casting, the tread of the idler which the track link contacts, is hardened by highfrequency harden ing treatment.

PC200, 220-3

-

-

IDLER



4 2

5


6

------~ 205F2451

1. 2. 3. 4. 5. 6.

PC200, 220-3

Idler Support Lubricating plug Floating seal Idler shaft Bushing

31-5


TRACK ROLLER

-

TRACK ROLLER PC200-3 (Serial No. 20001 - 33477) PC220-3 (Serial No. 20001 - 23219)

2

3

4

5

6

Section

A~A

1 1

-


--tJ,L1

------=- - --------- .-

i

__ J 205F2069

1. 2. 3. 4. 5. 6.

31-5-1 ($)

Lubricating plug Collar Floating seal Track roller Bushing Shaft

Track rollers are arranged under each track frame, they distribute the machine weight evenly onto the tracks on which the track rollers rotate. The track roller assembly consists of the roller (4), bushing (5), floating seal (3), shaft (6) and collar (2). The roller is made of special alloy steel and is treated by quenching and tempering. Two kinds of rollers are provided: one bearing only the outside flange and the other with both inside and outside flange and the other with both inside and outside flange. These receive thrust load (load in the axial direction) and are arranged alternately. The shaft is provided with an oil hole to feed lubricating oil (engine oil) to the sliding surface of the bushing. Each end of the bushing is provided with a floating seal to prevent both leakage of oil and inclusion of mud and water.

PC200, 220-3

-

-

-

TRACK ROLLER



2

3

5

4

\

6 II I

:

I

-

J

www. k omat s upar t s book . c om [

F

~~----

------

------

_. . . . .

_

..

_-

~~ 205F2452

1. 2. 3. 4. 5. 6.

Lubricating plug Collar Floating seal Track roller Bushing Shaft

PC200, 220-3

31-5-2


CARRIER ROLLER

-

CARRIER ROLLER PC200-3 (Serial No. 20001 - 33477) PC220-3 (Serial No. 20001 - 23219)

2

3

4

5

6

-


205F2070

1. 2. 3. 4. 5. 6.

31-6 (8)

Shaft Cover Floating seal Carrier roller Bushing Cover

Carrier rollers are arranged above each track frame, th is acts to support the upper half of the track loop in the proper rolling condition, preventing the track from dangling by its own weight. The roller made of special alloy steel is hardened by heat treatment of its tread and flanges. The flanges are provided for receiving thrust load (load in the axial direction), thus preventing the track from slipping off the carrier rollers. The shaft is provided with an oil hole to feed lubricating oil (engine oil) to the sliding surface of the bushing. Each end of the bushing is provided with a floating seal to prevent both leakage of oil and inclusion of mud and water.

PC200, 220-3

-

CARRIER ROLLER



2

-

___ ~

/I~+-----------!

3

~

5

4

----I_~

~_-.-------/-

6

..J

-


1.

Shaft

2.

Collar Floating seal Carrier roller Ring Cover

3. 4. 5. 6.

PC200, 220-3

31-7 @


TRACK SHOE

-

TRACK SHOE PC200-3 (Serial No. 20001 - 33762) PC220-3 (Serial No. 20001 - 23302)

1 2 3

-

www. k omat s upar t s book . c om Relation of idler

Relation of carrier roller

Relation of sprocket

-

Relation of track roller

Swamp shoe (OP)

1. 2. 3. 4. 5. 6. 7. 8. 9.

Master bushing Master dust seal Master pin Regular bushing Regular pin Regular dust seal Shoe Link Shoe bolt

206F023

Standard shoe specifications 610 mm triple-shoe PC200-3

Link pitch: 190 mm j Number of shoe: 90 610 mm triple-shoe

PC220-3

Link pitch: 190mm j Number of shoe: 94

710 mm triple-shoe PC200LC.3j Link pitch: 190 mm Number of shoe: 98 710 mm triple-shoe PC220LC-3j Link pitch: 190 mm Number of shoe: 102

31-7-1 (8)

PC200, 220-3


TRACK SHOE

PC200-3 (Serial No. 33763 and up) PC220-3 (Serial No. 23303 and up) ii

II

II

~~~,

O//'JU,iV~\

www. k omat s upar t s book . c om _

9

(~JIT:nUIT'TIl

\

8

Relation of idler

Relation of carrier roller

Relation of sprocket

Relation of track roller

Swamp shoe (OP)

205F2454

1. 2. 3. 4. 5. 6. 7. 8. 9.

Master bushing Master dust seal Master pin Regular bushing Regular pin Regular dust seal Shoe Shoe bolt Link

PC200. 220-3

Standard shoe specifications 700 mm triple-shoe

600 mm triple-shoe PC200-3

1

Link pitch: 190 mm

Number of shoe: 90

600 mm triple-shoe PC220-3

Link pitch: 190 mm \ Number of shoe: 94

PC200LC-3

1

Link pitch: 190 mm

Number of shoe: 98

700 mm triple-shoe PC220LC-3 \ Link pitch: 190 mm Number of shoe: 102

31-7-2 @

-

-


-

-

UNDERCARRIAGE 33 DISASSEMBLY AND ASSEMBLY

IDLER, RECOIL SPRING ASSEMBLY Removal 33-3 Installation .. . . . . . . . . . . . . . . . . . . . . . 33-3 RECOIL SPRING ASSEMBLY Disassembly 33-4 Assembly 33-5 TRACK ROLLER ASSEMBLY Removal 33-6 Installation 33-6 CARRIER ROLLER ASSEMBLY Removal 33-7 Installation 33-7 TRACK SHOE ASSEMBLY Removal 33-8 Installation 33-8


PC200. 220-3

33-1 CD

-

-


-

-


IDLER, RECOIL SPRING

-REMOVAL OF IDLER, RECOIL SPRING ASSEMBLY 1.

Remove track shoe assembly. For details, see section 33, REMOVAL OF TRACK SHOE ASSEMBLY.

2.

Using eyebolts CD (Dia. = 16 mm, Pitch = 2 mm), raise idler and recoil spring assembly (1), and pull out to front.

Lfu

Idler, recoil spring assembly: 270 kg

®,

3.

Fix recoil spring on block crane.

4.

Remove 4 mounting bolts (2), then disconnect idler assembly (3) and recoil spring assembly (4). Make match marks on the contact faces of the idler and recoil spring before removing.

and sling idler with

*

Lfu Lfu

Idler assembly: 130 kg

www. k omat s upar t s book . c om Recoil spring assembly: 140 kg

INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY

-

1.

Fix recoil spring assembly (4) on block ®, then raise idler assembly (3) with crane, and tighten 4 mounting bolts (2).

2.

Raise idler and recoil spring assembly (1), and push into track frame.

* 3.

205P2218

Install so that the oil filler plug of the idler is on the right.

Install track shoe assembly. For details, see 33 INSTALLATION OF TRACK SHOE ASSEMBLY.

PC200, 220-3

33-3 CD


RECOIL SPRING

-

DISASSEMBLY OF RECOIL SPRING ASSEMBLY Special tools Part No.

1.

Part Name

a'ty

A

791-685-8003

Compressor kit

1

Al

790-101-1600

Cylinder ass'y (70 t)

1

A2

790-101-1102

Pump ass'y

1

Divide into recoil spring assembly (1) and cylinder assembly (2).

2.

Set recoil spring assembly (1) on tool A.

-

A The spring is under high installed load, so be careful to set correctly. Installed load of spring: 11,700 kg

* 3.

Apply hydraulic pressure slowly to compress spring, then remove lock (3) and nut (4).


4.

Compress the spring until the nut is loose.

Release hydraulic pressure slowly to remove tension

of spring.

* 5.

Free length of spring: 583 mm

Disassemble into yokes (5) and (8), spring (6), spacer (7), and shaft (9).

6.

Remove plate (11) from cylinder (10), then remove lubricator (12).

7.

Remove G-ring, then pull out piston assembly (13).

8.

Remove ring (14) from piston (15), then remove snap ring (17), and packing (16).

-

33-4 CD

PC200, 220-3

RECOIL SPRING


ASSEMBLY OF RECOIL SPRING ASSEMBLY 1.

Fit ring (14) on piston (15). then assemble packing (16) and secure with snap ring (17). Be careful to install the packing in the correct direction. Push piston assembly (13) into cylinder (10), then assemble O-ring. Be careful not to damage the lip of the packing when pushing the piston assembly in. Tighten lubricator (12) and install plate (11). Set yokes (5) and (8), spring (6). spacer (7). and shaft (9) in tool A.

* 2.

* 3. 4.

~

5.

The spring is under high installed load, so be careful to set all the parts correctly in tool A. Apply hydraulic pressure slowly to compress spring. When the standard installed length is reached, tighten nut (4) and install lock (3). Installed length of spring: 460 mm

*

www. k omat s upar t s book . c om 460mm

205F2324

6. 7.

-

Remove recoil spring assembly (1) from tool A. Install cylinder assembly (2) in recoil spring assembly (1). Set so that the lubricator mounting position is at the side. When installing the cylinder assembly, check that the piston inside the cylinder is at the outside end face of the cylinder.

* *

205P2.225

PC200. 220-3

33-5 CD


TRACK ROLLER

-

REMOVAL OF TRACK ROLLER ASSEMBLY 1.

Lower the work equipment completely to the ground. Loosen lubricator (1) to relieve track tension. The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the track tension is not relieved, move the machine backwards and forwards.

2.

Remove 4 mounting bolts (2) of track roller.

3.

Use work equipment to raise machine, then remove track roller assembly (3).

~

-

Track roller assembly: 40 kg

INSTALLATION OF TRACK ROLLER ASSEMBLY


Set track roller assembly (3) on track link. Set the track roller with the oil filler plug on the outside.

*

2.

Use work equipment to raise boom, then partially tighten mounting bolts (2).

3.

Lower machine completely to ground, then fully tighten mounting bolts (2).

4.

Install lu bricator (1). then pump in grease to adjust track tension. Adjust the track tension to give a clearance of 60 - 100 mm between the contact surfaces of the track link and track roller at the 4th roller from the sprocket when the track is raised from the ground.

205P2227

-

*

205P2229

33-6 CD

PC200. 220-3


CARRIER ROLLER

REMOVAL OF CARRIER ROLLER ASSEMBLY

-

CD

1.

Using hydrau lie jack

(10 ton). push up track.

2.

Remove 2 mounting bolts (1), then remove carrier roller assembly (2).

INSTALLATION OF CARRIER ROLLER ASSEMBLY CD

1.

Using hydraulic jack

(10 ton). push up track.

2.

Install carrier roller assembly (2), then tighten 2 mounting bolts (1).

3.

Release hydraulic jack original position.

www. k omat s upar t s book . c om CD

slowly to return track to

PC200, 220-3

33-7 CD

TRACK SHOE


-

REMOVAL OF TRACK SHOE ASSEMBLY Special tools Part No.

Part Name

Q'ty

A

791-630-3000

Remover & installer

1

Al

790-101-1300

Cylinder (100 ton)

1

A2

790-101-1102

Pump

1

1.

Stop machine with master pin midway between idler and carrier roller. Make sure that there is enough space to layout the track shoe behind and in front of the machine. Lower the work equipment completely to the gound. Loosen lu bricator (1) to relieve track tension.

* 2.

-

The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the track tension is not relieved, move the machine backwards and

www. k omat s upar t s book . c om 3. 4.

forwards. Using tool A, remove master pin. Remove tool A and move machine forward so that

5.

temporary pin is in front of idler, then set block CD in position. Remove temporary pin ® and move machine in reverse to remove track (2).

INSTALLATION OF TRACK SHOE ASSEMBLY 1.

Position track under track frame, fit link bushing in sprocket, then move machine slowly forward to wind on track (2). Assemble the track with the link bushing at the front. Set block CD in position, assemble dust seal (3) on link, then insert temporary pin ®. Move machine in reverse, and stop when temporary pin is midway between idler and carrier roller. Using tool A, press fit master pin. I nstall lubricator (1), then pump in grease to adjust

-

* 2. 3. 4. 5.

track tension. Adjust the track tension to give a clearance of 60 - 100 mm between the contact surfaces of the track link and track roller at the 4th roller from the sprocket when the track is raised from the ground.

*

33-8 CD

PC200,220-3

UNDERCARRIAGE 34 MAINTENANCE STANDARD

Track frame and recoil spring Idler Track roller . . . . . . . . . • . . . . . . . . . . . . . . Carrier roller . . . . . . . . . . . . . . . . . . . . . . . . T rack shoe

34- 2 34- 4 34- 8 34-10 34-1 2


PC200, 220-3

34-1 (8)


TRACK FRAME AND RECOIL SPRING

--

TRACK FRAME AND RECOIL SPRING

-


205F2207

Unit: mm No.

1

2

Check Item

Vertical width of idler gUide

Criteria

Remedy

Standard size

Repair limit

Track frame

107

111

Idler support

105

103

Track frame

250

255

Rebuild or replace

Rebuild or replace

Horizontal width of idler guide Idler support

247

245

Standard size

3

Recoil spring

34-2

-

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

583

460

11,700 kg

-

9,360 kg

Replace

PC200, 220-3

-

-

-



IDLER

-

IDLER PC200-3 (Serial No. 20001 - 33477) PC220-3 (Serial No. 20001 - 23219)

-


-

3

5

4 205F2208

34-4 @

PC200, 220-3

IDLER


-

Unit: mm No.

Check Item

Criteria

Remedy

www. k omat s upar t s book . c om Standard size

1

Outside diameter of protrusion

2

Outside diameter of tread

3

Width of protrusion

4

Total width

5

Width of tread

Clearance between shaft and bushing

Clearance between shaft and support

65

Standard size 8

Interference between idler and bushing 72

9

10

-

520

508

85

73

Rebuild or replace

156

45.5

39.5

65

7

560

164

Standard size 6

Repair limit

Tolerance

Standard clearance

Clearance limit

1.5

Shaft

Hole

-0.250 ~0.350

+0.044 -0.035

0.215 0.394

-0.250 -0.290

-0.110 -0.220

0.030 0.180

Tolerance Shaft

Hole

+0.062 +0.032

-0.006 -0.072

Standard interference

-

Replace bushing

Replace

Interference limit

0.038 0.134

Standard clearance

Clearance limit

0.165 - 0.395

1.5

-

Replace bushing

Side clearance of idler (each)


PC200.220-3

21 ± 5 kgm

Tighten

34-5 ®

IDLER



4

3

5

-


20 +- 6kglll

2

-

---I -------~ 205F2470

34-6 (81

PC200, 220-3

-

IDLER


Unit: mm


Criteria

Check Item

Standard size

1

-


3

Width of protrusion

4

Total width

5

Width of tread

508

85

-

164

-

Tolerance

Standard clearance

Clearance limit

+0.074 -0.036

0.214 0.424

1.5

-0.110 -0.220

0.030 0.180

-0.250 -0.350

65

-0.250 -0.290

Interference between idler and bushing

Rebuild or replace

45.5

65

72

9

520

Hole

Standard size

8

-

Shaft


Clearance between shaft and support

552

39.5

Standard size

7

Repair limit

Outside diameter of protrusion

2

6

Remedy

Tolerance Shaft

Hole

+0.089 +0.059

-0.006 -0.072


-

Replace bushing

Replace

Interference limit

0.065 0.161

Standard clearance

Clearance limit

0.39 - 1.00

1.5

-

Replace bushing

Side clearance of idler (both)

PC200, 220-3

34-7


TRACK ROLLER

-

TRACK ROLLER PC200·3 (Serial No. 20001 - 33477) PC220·3 (Serial No. 20001 - 23219)

8 \

9

21

I

1205F2209

-

Unit: mm


Check Item

Criteria

Standard size

Remedy

Repair limit

...

1

~

Outside diameter of flange (outside)

193

2


3

4

5

160

148

Width of tread

47

55

Width of flange

30

23


Standard size

Tolerance Hole

Shaft -0.215 -0.315

+0.195 0

Standard size Interference between roller and bushing

7

8


9

Tightening torque of mounting bolt

__._.._- _..

....

_~

0.215 0.510

__. -

1.5

Standard ',nterference

Shaft

Hole

+0.153 +0.053

+0.030 0

Interference limit --

67

Side clearance of roller (each)

-

Clearance limit

Replace bushing

Tolerance

6

Standard clearance ._,.

60

Rebuild or replace

0.023 0.153

Standard clearance

Clearance limit

0.26 - 0.90

1.5

-

Replace

21 ± 5 kgm Tighten

34-8 (8)

28.5 ± 3.0 kgm

-PC200. 220-3

-

TRACK ROLLER



7

~ 28.S±3kgrn ---------

f

' ,

6

~lJ __

www. k omat s upar t s book . c om F=-

~----

- - _..- -..--- - - - - +

3

No.

Check Item

1


___.I

- - - - . --+-----;;;---+---.-+-

-----

4

205F2471

Criteria

Unit: mm

Remedy

Standard size

Repair limit --

186

-

-

2


3

Width of tread

44.5

52

4

Width of flange

24.5

-

5

Clearance between shaft and bu sh i ng

154

Standard size

60

Standard size

6

Interference between roller and bushing

67

7

Side clearance of roll er (both)

PC200. 220-3

Rebuild or replace

142

Tolerance

Standard clearance

Shaft

Hole --

-0.215 -0.315

+0.195 0

-----

Clearance limit ----

0.215 0.510

1.5 Replace bushing

Tolerance Shaft

Hole

+0.153 +0.053

+0.030 0


Interference limit

0.023 0.153

Standard clearance

Clearance limit

0.41 - 0.95

1.5

-

Replace

34-9 18


CARRIER ROLLER

CARRIER ROLLER

II .


3

2

5

-


Unit: mm No.

Check Item

Criteria

Standard size

1

Remedy

Repair limit


169

2


3

Width of tread

144

124

47

55 Tolerance

Standard size

4

Clearance between shaft and bush i ng

50

Standard size Interference between roller and bushing

5

63

Shaft

Hole

-0.15 -0.20

+0.185 0

Rebuild or replace

Standard clearance

Clearance limit

0.15 0.385

1.0


Interference limit

Tolerance Shaft

Hole

+0.083 +0.053

+0.03 0

0.023 0.083

Standard size

Repair limit

0.32 - 0.61

1.5

Replace bushing

-

Side clearance of roller (each)

6

34-10 (8\

PC200, 220-3

-

CARRIER ROLLER



-~ ~28.5

-

www. k omat s upar t s book . c om 205F2472 Unit· mm

No.

1

Check Item

Criteria

Standard size

Repair limit

165

-

140

128

43

50


2


3

Width of tread

Tolerance

Standard

size

4

Remedy


Shaft

Rebuild or replace

Standard clearance

Clearance limit

-0.012 0.016

-

Hole

---

50

0 -0.016

0 -0.012

Tolerance Standard size

5

Interference between roller and bushing

80

-

6

Shaft

Hole

0 -0.013

-0.021 -0.051


Interference limit

0.008 0.051

Standard size

Repair limit

0-0.18

1.5

Replace bushing

-

Side clearance of roller

PC200, 220-3

34-11 (8)


TRACK SHOE

-

TRACK SHOE PC200-3 (Serial No. 20001 - 33762) PC220-3 (Serial No. 20001 - 23302)

1

r--~~ i --~-·---l[

1

If

I I

"rll~·····i 'I

i

I

-


___----'u.

11

_

4

9

,--,,__l Swamp shoe lOP)

206F029

34-12 (8)

PC200, 220-3

-

-

TRACK SHOE


Unit: mm Criteria

Check Item

No.

Remedy


2

Standard size

Repair limit

190.25

193.25

59.48

56.48

Link pitch

Outside diameter of bushing

Repair limit

Standard size

3

15

Triple: 26

Height of grouser

Turn or replace

-Semi double: Swamp:

4

Height of link

48 102.5

25 90.5

Tolerance


Interference limit

+0.074 0

0.190 0.304

0.1

+0.172 +0.072

+0.062 0

0.210 0.372

0.14

+0.230 +0.200

+0.062 0

0.138 0.230

0.08

Standard 5

6

Interference of pin and link

7

Interference of master pin and link

8

-

9

Shaft

Hole

55

+0.304 +0.264

Shaft: 38 Hole: 37.8

37.8

Interference of bushing and link

Clearance of link matching surface

Tightening torque of shoe bolt

PC200. 220-3

Rebuild or replace

97

105

size

Lug welding, rebuild or replace

Standard clearance (one side)

Standard clearance (both sides)

Clearance limit (both sides)

0-0.9

0-1.8

-

Replace

Replace with larger one

Replace

Initial tightening torque: 40 ± 4 kgm Additional tightening angle: 120 ± 10°

Tighten

34-13 (8)

TRACK SHOE


PC200·3 (Serial No. 33763 and up) PC220·3 (Serial No. 23303 and up)

t-----f,.-----,[ ---~

----TTl

'-1

I

I

-

www. k omat s upar t s book . c om ...

\9

-

{I)=ID 205F2473

34-14 @

PC200, 220·3

-


TRACK SHOE

Unit: mm Check Item

No.

Criteria

Remedy


2

Standard size

Repair limit

190.25

194.25

59.3

54.3

Link pitch

Outside diameter of bushing

Repair limit

Standard size ~-

3

-

Height of grouser

'.

..

__. . .

- - - - -- - - - -

Swamp: 102.5

4

Height of link

size

6

7

8

9

Interference of master pin and link

Clearance of link matching surface

Tightening torque of shoe bolt

PC200.220-3

Rebuild or replace

97

Tolerance


Shaft

Hole

59

+0.304 +0.264

+0.074 0

0.190 0.304

Shaft 38 Hole: 37.8

+0.172 +0.072

+0.062 0

0.210 0.372

37.8

+0.230 +0.200

+0.062 0

0.138 0.230

Interference of bushing and link

Interference of pin and link

90.5

105

Standard 5

Lug welding, rebu ild or replace

16

Triple: 26

_

Turn or replace

Interference limit !

0.1

Replace

0.14

I

I

0.08

Standard clearance (one side)

Standard clearance (both sides)

Clearance limit (both sides)

0-0.9

0-1.8

-

Replace with larger one

Replace

Initial tightening torque: 40 ± 4 kgm Additional tightening angle: 120 ± 10°

Tighten

34-15

-

-


-

-

HYDRAULIC SYSTEM 6. STRUCTURE AND FUNCTION

Hydraulic piping Hydraulic schematics Hydraulic circuit diagram Work equipment control Hydraulic tank Front main pump and rear main pump assembly . OLSS (Open center Load Sensing System) Hydraulic control valve Accumulator Hydraulic cylinder Work equipment Attachment Attachment list

-

. . . . .

61- 2 61- 4 61- 5 61- 7 61-22 61-23 61-40 61-51 61-60 61-62 61-64 61-65 61-68

www. k omat s upar t s book . c om NOTE OLSS: TVC valve: CO valve: NC valve: PPC valve:

-

. . . . . .

Open center Load Sensing System Torque Variable Control Valve Cut-Off Valve Negative Control Valve Proportional Pressure Valve

PC200, 220-3

61-1


-

HYDRAULIC PIPING •

Hydraulic pumps driven by the engine consist of two main pumps (variable displacement piston type) and one charging pump (gear pump type). The main pumps deliver the oil from the hydraulic tank to the control valves, while the charging pump delivers the oil to the PPC valve.

•

When the OLSS system is used, the main pumps help save energy and keep the hydraulic pressure loss to a minimum.

•

The travel, steering, swing, and work equipment operations are all hydraulically controlled by operating the corresponding hydraulic motor and hydraulic cylinder, when control lever in the operator's cab is operated to change the oil flow in circuit.

•

Each control valve has a main relief valve, a safety valve, and a suction valve. The main relief valve is in the circuit between the hydraulic pump and the control valve, it keeps the maximum pressure of the oil delivered from the hydraulic pump at the preset value. The safety valve, located in the circuit between the control valve and the actuators (hydraulic motor, hydraulic cylinder, etc.), protects the hydraulic equipment from external overloading when the control valve is in NEUTRAL, and ensures operational safety. The suction valve prevents the occurrence of negative pressure in the circuit.

•

-


• •

In addition, an oil cooler is provided in the hydraul ic circuit to prevent the oil from getting too hot and to minimize the degradation of the oil.

•

The oil flows in the circuit in one direction. All of the oil passes through a filter in the tank in order to protect the hydraulic equipment. Each boom and arm circuit forms a two-pump merged circuit. When the arm and the swing operations are performed concurrently, the arm circuit from one of the pumps is restricted so that the swing circuit is given priority.

•

61-2

-

PC200, 220-3

HYDRAULIC CIRCUIT DIAGRAM

Note:

These parts are installed only on machines equipped with auto-deceleration system, swing mechanical brake, and 3-stage mode selector

OLSS.

--l

-I I I

I

I

I

I

I

I

I

I

I

I

I

+-+---------1'-----1'-

I

--I I

-4 I

I

I

I

I I

I I

I

I

I

I

I I

:

I

-1'----'T'---

"I

5-spool contl-ol valve

I

t I I I I I I

I

j 4-spool contr_ol valve Arm cylinder

I I I

¢130 x ¢95

1570

Bucket cylinder

¢11O x ¢75 - 1120

;--


Boom cylinder (L.H.)

¢120x¢851260

Boom cylinder (R.H.)

¢120 x ¢85 - 1260

-----~------

-

- - -

---------

--------

- -

... J


205F2235-2

61-8-1 @

HYDRAULIC CIRCUIT DIAGRAM

LlI~~uRAM

Note:

These parts are installed only on machines equipped with auto-deceleration system, swing mechanical brake, and 3-stage mode selector

PC200-3 (Serial No. 24684 - 25417), PC220-3 (Serial No. 21135 - 21401) - ___ _ - - - = -_- -=-=-=-= -= - - - - == ...... --_____ 'r=---=- ==~-=::-~-= =- -= ====== - ==- =-= -- - -- --- === =========:~-~-==----i

r- : I

~~

-

-

-

-

-

-

-

----

-~-

-

-- -

,I II

1

1

-

--

_

I I

,I I,

, I:

-

I

- ¥ - - ......

,1

+_~----I ,

---------------~---_t-t-----------------

: : I : II I I

I

OLSS.

----I I

I I I

-------, I

---4----,

I

II I I

I

I

II II

:

I

-~~~~-------==-::==:=~~+~i=---

iii i

,---------.-----.-----1'--+----

I 1'1

II I I

'

II I , II II

II

I I I I

I

I

--+1----------------t--1-------=:L==~!fJ==

+1

r--

l1~~~~~~~~~~~~~~-~-~-~-~-~-~-~-~-~-~~~====~=======~===1==r~~~~~~F====ll ! II I,


4-spool control __v__a __lv__e

'-~~

I:

1 ,

Arm cyl inder 11 11

¢130 x ¢95 -1570

1I11

IIII I I II I I II :: II II I I I I II 11 I I II I: II I,ll I'll I II

Bucket cylinder

¢110 x ¢75 - 1120


1

Boom cylinder (L.H.)

¢120 x ¢85 - 1260

II

II II II I' II

Boom cylinder (R.H,)

¢120 x ¢85 - 1260 I I I

I

I II

I III I III III , I, : II I 1L/J'----j---+---+---7--llU!:J,_·I.Tt

I I I

II II I I

II I I

II I

--

- -

-......------... -

-

- - - - - - - - - --

----~------------------

Strainer Solenoid valve for Hydraul ic tank

swing mechanical brake

205F2236-2 Oil pressure switch

61

HYDRAULIC SCHEMATICS

No. 24684

, PC220-3 (Serial No. 21135 22. Control valve (5-spool side) 22A. Jet sensor 22B. For R.H. travel 22C. For arm-La 220. For service 22E. For boom-Hi 22F. For swing 22G. Main rei ief valve 22H. Swing priority valve 23. Control valve (4-spool side) 23A. Jet sensor 23B. For arm-Hi 23C. For bucket 230. For boom-Lo 23E. For L.H. travel 23F. Main rei ief valve 23G. Arm th rattle valve 23H. Straight-travel valve 24. Solenoid valve for swing mechanical brake (if equipped) 25. Travel shuttle valve 26. 0 iI pressu re swi tch 27. Arm cylinder 28. Bucket cylinder 29. Boom cylinder 30. Center swivel joint 31. R.H. travel motor 32. L.H. travel motor 33. Swing motor


Note:

*

These parts are installed on machines equipped with auto-deceleration system swing mechanical brake.


61-5


13

14

6

-

WORK EQUIPMENT CONTROL


WORK EQUIPMENT CONTROL There are two types of work equipment control lever: • Wrist control type • Long lever control type This section also deals with the swing control.

*

1. WRIST CONTROL TYPE To reduce the operating force for wrist control type levers, PPC valve is installed for each control lever except the travel levers.

PPC: Proportional Pressure Control The travel control lever is connected to the valve spool by a linkage system.

*

c~~

~~

www. k omat s upar t s book . c om /~

///'j

3

~,

4

-

5

B

205F2141A

7. L.H. work equipment control valve Control valve (arm/swing control lever) Swing mechanical brake solenoid (if equipped) 8. PPC'valve Swing motor 9. PPC shuttle valve R.H. work equipment control lever 10. Accumulator (boom/bucket control lever) 11. Main pumps 5. PPC valve 6. PPC shuttle valve 1. 2. 3. 4.

-

PC200, 220-3

61-9 (5)



(1) PPC VALVE

www. k omat s upar t s book . c om Port T

-

Port P4B

Port P2

Port P3A

Port P4A

Port P,

Port P3B 205F2158

61-10 (2)

PC200. 220-3

-

-



3.

-

Control lever moved back from sl ightly operated position to neutral (Fine control) (Fig. 3): When disc (2) starts to be pushed back, piston (4) is pushed up by a force corresponding to the force of centering spring (8) and the pressure at port PI. At the same time, fine control hole (f) of valve (10) is connected to drain chamber D, so the oil at port PI escapes. If the pressure at port PI drops too far, valve (10) is pushed down by spring (9). Fine control hole (f) is shut off from drain chamber D, and at almost the same time it is connected to pump pressure chamber Pp. The pump pressure is supplied until the pressure at port Al returns to a pressure equivalent to the position of the lever. Whenthe spool of the control valve returns, the oil in drain chamber D flows in from fine control hole (f') of the valve which has not moved. The extra oil then flows through port P2 to chamber A2.

2 4

8 o

9 f

f'

Pp

www. k omat s upar t s book . c om Control valve

Fig.3

4.

-

Control lever operated to end of travel (F ig. 4): Disc (2) pushes piston (4) down, and piston (4) forcibly pushes in valve (10). Fine control hole (f) is shut off from drain chamber D, and is connected to pump pressure chamber Pp. Therefore, pressure oil from the charging pump passes through fine control hole (f), and flows from port PI to chamber Al to push the spool of the control valve. The oil returning from chamber A2 flows from port P2 through fine control hole (f') to drain chamber D.

205F2162

2 4

o f

f'

10

Pp

Control valve

Fig.4

205F2163

PC200, 220-3

61-11



(2) PPC shuttle valve • For L.H. ppe valve

Port P1B

Port PB(TB)

Port Ps

Port P2A

Port P2B

Port PA(TA)

Port P1A

.D

0

0 0

-

0

TI Port TB(PB)

Port P4B

Port Pa

Port P3B

Port P4A

Port P3A

PortTA(PA)

www. k omat s upar t s book . c om ~ ® ~ 2

3

Section A-A 205F2164

1. 2. 3.

-

Plug Ball Block

61-12

PC200.220-3



•

For R.H. PPC valve

PortP1A

Port P3A

PortPA(TA)

Port PB(TB)

PortP1B

Port P3B

Port Ps

Port P2A

Port P4A

Port TB(PB)

Port TA(PA)

2

Port P4B

Port P2B

4

3

www. k omat s upar t s book . c om o

-

Section B-B

Section A-A

205F2165

1. 2. 3. 4.

Valve Plug Ball Block

PC200, 220-3

61-13



Function

When the swing or work equipment circuits are operated, the pilot pressure from the PPC valve is supplied to swing priority valve or arm throttle valve (built into the control valve) and actuates them. Operation

When pilot pressure flows in from the PPC valve, ball (3) is pushed and the low pressure circuit is closed. Therefore, pilot pressure oil from the PPC valve on the side being actuated is suppl ied to the ports of the travel shuttle valve.

From PPC valve

To travel shuttle valve

3

o o

-


To travel shuttle valve

From PPC valve 205F2166

-

61-14

PC200, 220-3



(3) a.

Operation of arm control lever Arm control lever operated to ARM IN:

Safety valve Set pres. 340 kg/cm 2

Accumu lator

t-----------;,'--'~-

- - - - -- - --: I

L.H. PPC valve

I

~>--- _ _ R4~_

_____

o

I

I

~

I

I

I

I I , I

Swing priority valve I - - - - - - - - ....... -

:

~--

switch,

---+---

- -

I I

1 I

For swing PPC shuttle valve

I

I

I

Shuttle valve

I ~

I

__L_-~----I-tJCharging pump Front main pump

0

I

t ----r~1~:;~~ I

,

valve

~

I

I I

-

~

(

I

I

I

I

I

----- -----/i'--1

f"',,"-

I

I I

I

I

:

I

I

I

I

Main relief I valve ~ PR Set pres. *---------~r--~~l--~-----l 320 kg/cm 2

I

I

I

I

I I I

I


r-----------------'I-I ( (

I I I

I

I

I I

,

_.J

I

L

PL

(

r - - I

--I

~

~

- - - - - --

I

_---l

T Hydraulic Hlter

I

~ ~}

I

I

COla.

Oil cooler

_ _ _ _-'--_, Hydraulic tank

-

L-

-'

I

.._ Control valve (4-spool) F205C3021

•

•

•

-

.- ~ > ~ 0~ I~

When the arm control lever is operated to "A RM IN", the spool of the PPC valve connected directly to the control lever is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) from the charging pump flows from port P4AR. It acts on the tip of the spool of the arm-Lo and arm-Hi control valves, and moves the spools. When this happens, the pressure oil from the front main pump and rear main pump enters port PR and port PL, passes through arm-La and arm-Hi control valves, and merges. The oil from port B4R acts on the bottom end of the arm cylinder, and extends the arm cyl inder. The oil returning from the arm cyl inder head passes through port A4 R to port T. It then flows through the hydraul ic filter and oil cooler, and is drained to the hydraul ic tank.

PC200, 220-3

•

•

When the arm control lever and swing control lever are operated at the same time, the pilot pressure from the PPC valve (for swing) actuates the swing priority valve. This regulates the flow of pressure oil to the arm-La control valve. Therefore priority is given to supply of oil to the swing circuit. This im'proves ease of operation when using arm and swing together. If the arm control lever is operated to "ARM IN" when there is no load, the weight of the arm and bucket will make the cylinder move more quickly than oil can be supplied to the cylinder bottom, so negative pressure will be formed at the bottom end of the cylinder To prevent this, there is a throttle (modified spool) in the return circuit of the arm-La control valve.

61-15



b.

Arm control lever operated to ARM OUT:

Control valve (5-spool)

A'R

Safety valve Set pres. 340 kg/cm 2

AccumUlator

B'R

j-----~----I

.----------_+_~

I

I I

Arm cylinder

frt ----t-- _!,-'~R_ ~-----

From swing PPC - ~ shuttle valve

~ To oil - - - -r-+-- pres. : -, I

I

-

switch

I

~--~~-I-

~ P4BR - - - - -rl-- - - - - - I

Charging pump

Shuttle valve Front main pump

I

I

Main relief valve Set pres. ~---------~r__~--+'~~_ _--..J 320 kg/cm 2 :

~

L-Jr--r-L'--'--_-'

PR

www. k omat s upar t s book . c om I I I

Rear main pump

I

I

I l

PL

I

I

I

r-,,

..I

T

I

I

I

I

r

r---- ----- -

•

I

1~

I

r--

I ------~ '---.J

I

------~---------~

Arm throttle valve

I

I

'-

Hydraulic filter N

"Qj

~ c

•

•

•

:--~I

c.~

'co ~ a;~

Oil cooler

L-....:......_ _

OJ

E ~~

::;;; > Ul M ' - - - - - - - - - - '

I I

Hydraulic tank

When the arm control lever is operated to "AR M OUT", the spool of the PPC valve connected directly to the control lever is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) from the charging pump flows from port P4B R. It acts on the tip of the spool of the arm-Lo and arm-Hi control valves, and moves the spools. When this happens, the pressure oil from the front main pump and rear main pump enters port PR and port PL, passes through arm-Lo and arm-Hi control valves, and merges. The oil from port A4R acts on the head end of the arm cylinder, and retracts the


•

F205C3022

When the arm control lever and swing control lever are operated at the same time, the pilot pressure from the PPC valve (for swing) actuates the swing priority valve. This regulates the flow of pressure oil to the arm-Lo control valve. Therefore priority is given to supply of oil to the swing circuit. This improves ease of operation when using arm and swing together.

arm cylinder. The oil returning from the arm cylinder bottom passes through port 84 R to port T. It then flows through the hydraulic filter and oil cooler, and is drained to the hydraulic tank.

61-16

-

PC200, 220-3



c.

Arm throttle valve Function • When the arm control lever and boom control lever are operated at the same time, most of the pressure oil flows to the arm circuit, where the load is less. The amount of oil flowing to the boom circuit drops, so the arm speed is faster than boom speed. This makes combined operations difficult. (Particularly when using "ARM OUT" and "BOOM RAISE" at the same time.) When this happens, the arm throttle valve is switched and the flow of oil to the arm-Hi control valve is restricted. This regulates the arm speed and makes combined operations easier.

-

•

The arm is actuated by the merged oil flow from two pumps, and the bucket is actuated by the flow from one pump. For this reason, when the arm and bucket are operated together, the flow of oil to the arm circuit is greater, so the arm moves much faster than the bucket. This makes combined operations difficult. (Particularly when using" ARM OUT" and "BUCKET CURL" at the same time.) When this happens, the arm throttle valve is switched and the flow of oil to the arm-Hi control valve is restricted. This regulates the arm speed and makes combined operations easier.

www. k omat s upar t s book . c om Operation • When only arm control lever operated: Pilot pressure oil from the boom and bucket PPC shuttle valve does not flow to the arm throttle valve, so the arm throttle valve is not actuated. Pressure oil from the rear main pump passes through port PL and then flows to the arm-Hi control valve.

-

•

To arm-Hi control valve

...

From swing PPC shuttle valve

c;),,""""

...

When arm control lever and boom (or bucket) control lever operated together: The pilot pressure oil from the boom and bucket PPC shuttle valve passes from port P4 to port P4 a. It acts on the right end of the spool of the arm throttle valve, and pushes the spool to the left. When this happens, the pressure oil flowing from the rear main pump to the arm-Hi control valve is restricted, and the arm speed is regulated to make combined operations easier.

From port PL

From boom. bucket PPC shuttle valve

20SF21S0


l' From swing PPC shuttle valve

Throttle

*", ':"'. t From port PL

From boom, bucket PPC shuttle valve

20SF21S1

PC200, 220-3

61-17



(4) Operation of bucket control lever

a.

Bucket control lever operated to BUCKET CURL

1--Control valve (5-spool)

Accumulator

r------------,

t - - - - - - - - - - - + -, '., R.H. PPC valve

:

~ck~t--r=i ~

-n

I I

I

-----~~~-:

Safety-suction valve Set pres. 340 kg/cm 2

I I I

I I

I I

:

_ i---i~J l~ Charging pump

Shuttle valve

Front main pump

I

~~Ll

______ _

..I

V

'-

Bucket control valve

,-''--...,.--'-----,

,

~

---

1----1---- CU R L

~~~~--~3I'cl

Bucket cylinder

I

-

: I

To arm-Hi control valve Arm throttle valve

,I

t

I

I

www. k omat s upar t s book . c om l t I

----'

I

'--,

I I

I

Rear main pump

I I I I

PL

L

I

,--------------1

T

I

r

Main relief valve Set pres.

I

Hydraulic filter

I I

I I

320 kg/cm:-----------i'

I I

I I

Oil cooler

, , ,

Control

I I

V~;;(4-SPOOI)! ~f>"-t----l I

, ,

_____-'1

Hydraulic tank

---

--------r-

L~

~

P.

F205C3023

•

•

•

When the bucket control lever is operated to "BUCKET CURL", the spool of the PPC valve connected directly to the control lever is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) from the charging pump flows from port P3 AL and acts on the tip of the spool of the bucket control valve, and moves the spool. When this happens, the pressure oil from the rear main pump enters port PL and passes through the bucket control valve. The oil from port B3 R acts on the bottom end of the bucket cylinder, and extends the bucket cyl inder. The oil returning from the bucket cylinder head passes through port A3 R to port T. It then flows through the hydraul ic filter and oil cooler and is drained to the hydraulic tank.

61-18

•

•

-

The pilot pressure oil divided from the shuttle valve passes through port P4 to port P4a, and actuates the arm throttle valve. This regulates the flow of pressure oil to the arm-Hi control valve. This improves ease of operation when using the arm and bucket together. If the bucket control lever is operated to "BUCKET CU RL" when there is no load, the weight of the bucket will make the cylinder move more quickly than oil can be suppl ied to the cyl inder, so negative pressure will be formed at the bottom end of the cylinder. To prevent this, there is a throttle (modified spool) in the return circuit of the bucket control valve.

PC200, 220-3



b.

Bucket control operated to BUCKET DUMP

Control valve (5-spool) Accumulator

,----------,

,

t----------_+___ 1 R. H. PPC valve

I

Bucket

,

:

,'

~--r- -:-m-----i~--~ ~

"

I

-

L

, I

I

j'

-----ri : : I I

:

I I

~

IP3BL

L

-

J

Safetysuction valve Set pres. 340 kg/cm 2

_

CURL

~-1- --t--~ ----~.~:~ __f>3~L

-------

I

I

Shuttle valve Charging pump Front main pump

,I

,

,

, , I I

Bucket cylinder

I

, ,

To arm-Hi control valve Arm throttle valve

I I , I I

, , ,I

- -

---'

'--,

www. k omat s upar t s book . c om Rear main pump

I

,I ,

, ,

l

I

PL

,

,I , , ,I ,I

(

I

1 Hydraulic filter:

Contr-;;I-;;~Ive

Oil cooler

(4-spool)

;--i-------=-n~-I ~f>,~t--:

-----+- -_ . --

'---

'--_1

L_

'p,

.J

~

Hydraulic tank

-

F205C3024

•

•

•

-

When the bucket control lever is operated to "BUCKET DUMP", the spool of the PPC valve connected directly to the control lever is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) from the charging pump flows from port P3 BL and acts on the tip of the spool of the bucket control valve, and moves the spool. When this happens, the pressure oil from the rear main pump enters port PL and passes through the bucket control valve. The oil from port A3 L acts on the head end of the bucket cylinder, and retracts the bucket cyl inder. The oil returning from the bucket cylinder bottom passes through port B3 L to port T. It then flows through the hydraulic filter and oil cooler and is drained to the hydraulic tank.

PC200, 220-3

•

The pilot pressure oil divided from the shuttle valve passes through port P4 to port P4a, and actuates the arm throttle valve. This regulates the flow of pressure oil to the arm-Hi control valve. This improves ease of operation when using the arm and bucket together.

61-19



(5) a.

BOOM CONTROL Boom control lever operated to BOOM RAISE

Accumulator Control valve (5-spool)

:------T-------iB~~HT~trOivi~=-~It-----------+,

I

'

I

:: I

__J

I

'

~,I t~, -----1 I

I

~

+--l i

I

._ LJ=d--hJ-tl i I

L

tI

:

Main relief valve

"----~~~.L ~

;.-p':':'R';-'+---)----;;>--.=:.._...J

I

Charging Shuttle valve I pump Front main pump I I

I

L i

Set pres.

}3~_k~/~r.r2~_

-- -

+---+-~~~

--._._-

RAISE

p~j- -~~~%IL~a~v~----...-----4---+4-JL.*=----4

~

P'AL

-

I

I

Boom cylinder

www. k omat s upar t s book . c om To arm-Hi control valve

Rear main pump

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ JI

Ll\J:~j~.Q!.!~~'!!~-- - - l

T

I

Main relief val/ve 320 kg cm

I

Control valve

Oil cooler

~~-P!.~"---------J

:

I

(4~s~~;;I)T

I

1

Lp·~t---l

~_------------------

J

P. t -~

Hydraulic tank F205C3025

•

•

When the boom control lever is operated to "BOOM RAISE", the spool of the PPC valve connected directly to ~ the control lever is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) from the charging pump flows to port P2 BLand acts on the tip of the spool of the boom-Lo and boom-Hi control valve, and moves the spool. When this happens, the pressure oil from the rear main pump enters port PL, passes through the boom-Lo. control valve, and goes to port A2L. At the same time, the pressure oil from the front main pump enters port PR, passes through the boom-Hi control valve, and goes to port A2 L. The oil acts on

•

•

the bottom end of the boom cylinder, and extends the boom cylinder. The oil returning from the boom cylinder head passes through port B2 L to port T. It then flows through the hydraulic filter and oil cooler and is drained to the hydraulic tank. The pilot pressure oil divided from the shuttle valve passes through port P4 to port P4a, and actuates the arm throttle valve. This regulates the flow of pressure oil to the arm-Hi control valve. This improves ease of operation when using the arm and boom together.

61-20

PC200, 220-3



b.

Boom control lever operated to BOOM LOWER

Accumulator

1-


,-----, I

I I I

l

.-

I I I

!l-----, I

I

I

I

I

I I

+_,

-

l____ ,-1 J

8l i!

I L;,-

Charging Shuttle valve pump Front main pump I I I

I I

I

I

I I

I I

p~,_

-

- - - - - - - - - - - - - '--"'---I

Bo-;;-m~L~

- - - - - - - - - -

RAISE

~

cont rol va~.lrver+.l_r_rrTT"_rr"..

P'AL

Boom cylinder


I I

Rear main pump

I

I I

I

__________________ J

--,

I

L~r!!:,..!hIP!!I~I/il~e ~IL+---..,

T

Main rei ief valve Set pres.

320 k,lcm'

Con~rol Oil cooler

r

I

valve

,

~

(4-~-

Lp'1---: I

I

'

J

L I

'j.

I ,

-- -----

H

__

p.

Hydraulic tank

-

F205C3026

•

•

-

•

When the boom control lever is operated to "BOOM LOWER", the spool of the PPC valve connected directly to the control lever is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) from the charging pump flows to port P2A L and acts on the tip of the spool of the boom-Lo, and moves the spool. When this happens, the pressure oil from the rear main pump enters port PL, passes through the boom-Lo control valve, and goes to port B2 L. The oil acts on the head end of the boom cylinder, and retracts the boom cylinder. The oil returning from the boom cylinder bottom passes through port A2 L to port T. It then flows

PC200, 220-3

•

•

through the hydraulic filter and oil cooler and is drained to the hydraulic tank. The pilot pressure oil divided from the shuttle valve passes through port P4 to_port P4a, and actuates the arm throttle valve. This regulates the flow of pressure oil to the arm-Hi control valve. This improves ease of operation when using the arm and boom together. For BOOM LOWER there is a throttle (modified spool) in the return circuit. This controls the lowering speed of the work equipment and also acts to prevent negative pressure from being formed at the head end of the boom cylinder.

61-21


HYDRAULIC TANK

-

HYDRAULIC TANK

]

2 To oil cooler

From oil cooler

. ,From filter

<0 '

Q

~

To tank

F20503036 Section A-A

Section B-B

4

3

\

-

5

www. k omat s upar t s book . c om [lJ

rcJ1 ~ To pump -

/ B

*

•

When checking the oil level, fully retract the arm and bucket, lower the bucket to the ground as shown in the drawing, and stop the engine.

Pressure to open the bypass valve: 1.27 ± 0.3 kg/cm 2

•

Pressure valve Pressure to open the valve: 0.39 ± 0.15 kg/cm 2 Operating pressure on vacuum valve: o to 0.046 kg/cm 2

61-22

1. 2. 3. 4. 5. 6: 7. 8. Tank capacity • Specified: • Refilled:

F205C3027

Filler cap Bypass check valve Bypass valve Filter element Tank Sight-gauge Drain plug Strainer

250£ 150£

PC200, 220-3

FRONT MAIN PUMP AND REAR MAIN PUMP


FRONT MAIN PUMP AND REAR MAIN PUMP ASSEMBLY Port Pt

Port Pt

Port Pd

/

ViewZ

2

6

www. k omat s upar t s book . c om z ---

I

3

F205C3028

1. 2. 3. 4. 5. 6.

OUTLINE

• •

-

•

These pump assemblies consist of two variabledisplacement swash-plate type pumps, two servo valve units, and impeller pump (built in between the front main pump and the rear main pump), a charging pump and a rei ief valve. These pump assemblies are installed to the damper. Each main pump has a servo valve, an NC and CO valve assembly. The NC and CO valve assembly have a TVC valve. The front main pump serves 5-spool valve.

PC200.220-3

Front main pump servo valve Rear main pump servo valve Front main pump Rear main pump Charging pump Relief valve

•

The rear main pump serves 4-spool valve.

•

The charging pump serves to boost the oil pressure in the control valve, and control the OLSS.

61-23



1.

FRONT MAIN PUMp· REAR MAIN PUMP

@

~.

@ @@ @

---V @

B

C0

@ @

B

@

-

View X

www. k omat s upar t s book . c om ---x A

1

Port PsV1B

\ /

\

/

\

Port PSVl

Port PsV1A View Z

•

Port Pa2

Port PSVl

View Y 205F2073

The front main pump and rear main pump are variable-displacement swash-plate type pumps and are installed in tandem.

61-24

•

The front main pump is installed to the damper.

PC200, 220-3

-



2. LONG LEVER CONTROL TYPE In order to reduce the operating force for the long lever type of control lever, the following two valves are installed. PPC (Proportional Pressure Control) valve: Swing control lever Arm control lever Bucket control lever

The difference from the wrist control type is in the boom control lever. Long lever control type: In-line servo installed Wrist control type: PPC valve installed The swing, arm and bucket controls are all the same at "1. Wrist control type", so for details, see P. 61-9 to P. 61-21.

In-line servo valve: Boom control lever The travel control lever is connected to the valve spool by a linkage system.

*

-

~>~) ,U)

// 2

C'~

r

~ ')

www. k omat s upar t s book . c om 3 ~

11

8 1. Control valve 2. Solenoid valve (For swing mechanical brake (if equipped)) 3. Swing motor 4. R.H. work equipment lever (For boom, bucket) 5. PPC valve

PC200, 220-3

205F2139A

6. L.H. work equipment lever (For swing, arm) 7. PPC valve 8. Accumulator 9. PPC shuttle valve 10. PPC shuttle valve 11. Main piston pump

61-25 (~



(1) PPC (Proportional Pressure Control) VAL VE

(in swing, arm, bucket control circuits)

c

A

B

www. k omat s upar t s book . c om o

z_ Port T

Port P

-

Port P4B

Port pz

Port P4A

Port P3A

Port P,

@

View Z

Port P3B 20SF21S6

61-26 ®

PC200, 220-3

-



-

2

3 4 ~~---5

-

6 7

8


Section B-B

Section A-A

-

Section D-D 205F2157

Section C-C

PC200, 220-3

1. 2. 3. 4. 5.

Bolt Piston Plate Collar Retainer

6.

7. 8. 9.

Center spring Spring Valve Body

61-27 ®



(2) IN-LINE SERVO VALVE (in boom control circuit) •


The boom control has an in-line servo valve to reduce the operating force of the boom control lever. The in-line servo valve is better than the PPC valve for fine control operations. Operations on slope faces. or scraping operations are performed using the boom. These operations require fine control. so this valve is used. 1)

In-line servo valve Port P

Port Tz

Port Tl

www. k omat s p ar t s book . c om lu Jh~

~

)''-1----,I( ~''''J

o

2

3

4 5

6

7

Section A-A

1. Input spool 2. Plate 3. Holder 4. Spring 5. Spacer

61-28 @

8

9

205F2152

6. Pilot spool

7. Piston (Outlet spool) 8. Body

-

9. Plate 10. Joint

PC200. 220-3

-



SERVO VALVE UNIT FOR REAR MAIN PUMP

Main pump pressure PPI port

Charging pump pressure Pp port

-

---------- Main pump pressure PP2 port ..- Servo actuator port

Servo actuator port _.~ Filter View Z


-

Jet sensor outlet pressure Pd port

2

\

3 /

TVC valve output pressure Pt2 port

, \

, Jet sensor inlet pressure Pt port

z ..-.

\

i

CO • NC valve output pressure port

\

4

F205C3029

1. 2. 3. 4.

PC200, 220-3

Connector TVC valve CO, NC valve assembly Servo valve

61-29



(1) SERVO VALVE

Servo actuator port

Charging pump pressure Pc IN Port

Servo actuator port

/

r*+-----,-

A B

Main pump pressure PP2 IN port

Main pump pressure Ppl IN port CO + NC valve output pressure Pi IN port

D Main pump pressure Main pump pressure PP2 OUT port Ppl OUT port

-

www. k omat s upar t s book . c om CO + NC valve drain Pa2 IN Port

o

Section D-D

Section B-B

E

F

Section C-C

o

@ o@

°

Section E-E

Section F-F

Section G-G

Section H-H

Section J-J 205F2087-1

61-30

PC200.220-3

-


-

c.


When operating the boom control lever at engine stop

6

7

10

c

D


•

When the boom control lever is moved to BOOM RAISE, input spool (1) is pulled. Pilot spool (6) is also pulled and when clearance C (1.5 mm) becomes "0", pilot spool (6) and piston (7) are interconnected. When input spool (1) is pulled further, piston (7) also moves, so joint (10) is also moved. As a result, the two spools of the boom control valve (connected to joint (10) by a cable) are also pulled. When the boom control lever is moved to BOOM LOWER, input spool (1) is pushed. Pilot spool (6) is also pushed and when clearance D (1.5 mm) becomes "0", pilot spool (6) and joint (7) are interconnected.

PC200, 220-3

205F2155

When input spool (1) is pushed further, pilot spool (6) also moves, so joint (10) is also moved. As a result, the two spools of the boom control valve (connected to joint (10) by a cable) are also pushed. •

In this way, in-line servo valve can operate even when the engine is stopped. However, it is constructed so that the two spools of the boom-Lo and boom-Hi control valves are actuated together. Therefore, if there is no hydraulic power, manual operating force is needed to operate the in-line servo valve and also the two control valve spools. This increases the operating force considerably.

61-31 (2)



(3) BOOM CONTROL a. Boom control lever operated to "BOOM RAISE"


Accumulator

R.H. PPC valve 1

Boo~--

I

-~----1~1- l-t~-----''\=1i..I.J:iJJ..:rl1+4+1

t

i-,

i

I

Main relief valve Set pres. 320 kg/em'

I

-.J

I I

--l I I

1

I I

PR

i

Shuttle valve Front main pump

RAISE

__ =_=_-==-_---.J

W===~

I I I I I I

"=r-C:=-

__ L__ Charging pump

I

I I I I

LOWER

-

I L I

I I

www. k omat s upar t s book . c om To arm-Hi control valve

Rear main pump

___ ~

,

J----~-----j

HY,ldrauli<:_filter

r----<)-*-~, +--=T+M~a-i-n-re""'.I~ie.....Jf valve : i

I Set

'---'--_--'~I

•

•

Hydraulic tank

U~~~~~' j=!'

..

61-32 (liJ

r---

-

I

I P, !

i

L--"-[---l

,I

:

I

L--C-;;~t~ol~aIV;(4!::I)

cooler_J ...J In-line servo valve PC200-3 (Serial No. 20001 - 24683) PC220-3 (Serial No. 20001 - 21134)

When the boom control lever is operated to "BOOM RAISE", the spool of the in-line servo valve (connected to the control lever by cable) is actuated. This hydraulic pressure actuates the cable which is connected to the boom-Lo and boom-Hi control valves, and moves the spools of both control valves. When this happens, the pressure oil from the rear main pump enters port PL, passes through the boom-Lo control valve, and goes to port A2 L. At the same time, the pressure oil from the front main pump enters port PR, passes through the boom-H i control valve, and goes to port A2 L. The oil acts on

i4-'--~

tt ----: L~._ -vaive----.-1.

p..::s. 320 kg/Crr'------~-----J

-

'--

Arm throttle

I

..

Lt=--=-~-_-----.:..i-----i

Oil

,I

•

205F2144-1

-

the bottom end of the boom cylinder, and extends the boom cylinder. The oil returning from the boom cylinder head passes through port B2 L to port T. It then flows through the hydraulic filter and oil cooler and is drained to the hydraulic tank. The pilot pressure oil divided from the shuttle valve passes through port P4 to port P4 a, and actuates the arm throttle valve. This regulates the flow of pressure oil to the arm-Hi control valve. This improves ease of operation when using the arm and boom together.

PC200. 220-3

-

-



b.

Boom control lever operated to "BOOM LOWE R"


1----

Accumu lator

I

Boom-Hi control valve

----~-r=r-

-f

I I

-

1<1 !

I

I _ _ --,

iII

I

I

II I

_L_~J~-~t-~

LOWER

RAISE

I

l!

Charging pump Front main pump

I

I!


Rear main pump

I I


I

I

I

I

,--------

_ ~

LArm throttle

___l

valve~4-----,

I I T ! Main relief valve ~~~~~~~~-~-_J I I I Set pres. 320 k9/c~2 -

L~

------, ~--:-:::==i_ -

I I P4

Ili~~~~~r

1-I

'

L

JP4 Control valve (4-spool)

- --

In-line servo valve PC200-3 (Serial No. 20001 - 24683) PC220-3 (Serial No. 20001 - 21134)

•

•

•

When the boom control lever is operated to "BOOM LOWER", the spool of the in-line servo valve (connected to the control lever by cable) is actuated. This hydraulic pressure actuates the cable which is connected to the boom-Lo and boom-Hi control valves, and moves the spools of both control valves. When this happens, the pressure oil from the rear main pump enters port PL, passes through the boom- La control valve and port B2 L, and acts on the head end of the boom cylinder to retract the arm. The oil returning from the boom cylinder bottom passes through port A2 L to port T. It then flows

PC200, 220-3

I

L-~r---l

I

cooler L Oil Hydraulic tank

I

----I

•

205F2142

through the hydraulic filter and oil cooler and is drained to the hydraul ic tank. The pilot pressure oil divided from the shuttle valve passes through port P4 to port P4 a, and actuates the arm throttle valve. This regulates the flow of pressure oil to the arm-Hi control valve. This improves ease of operation when using the arm and boom together. For "BOOM LOWER", there is a throttle (modified spool) in the return circuit. This controls the lowering speed of the work equipment and also acts to prevent negative pressure from being formed at the head end of the boom cylinder.

61-33 ®


HYDRAULIC TANK

-

HYDRAULIC TANK PC200-3 (Serial No. 20001 - 26400) PC220-3 (Serial No. 20001 - 21728)

-

Section A-A

4

3

5


To pump -

i

7

8

*

When checking the oil level, fully retract the arm and bucket, lower the bucket to the ground as shown in the drawing, and stop the engine.

•

Pressure to open the bypass valve: 1.27 ± 0.3 kg/cm 2

•

Pressure valve Pressure to open the valve: 0.39 ± 0.15 kg/cm 2 Operating pressure on vacuum valve: o to 0.046 kg/cm 2

61-34 (8)

1. 2. 3. 4. 5. 6. 7. 8.

205F2071B

Filler cap (with lock device (if equipped)) Bypass check valve Bypass valve Filter element Tank Sight-gauge Drain plug Strainer

Tank capacity • Specified: • Refilled:

250£ 150£

PC200, 220-3

-

HYDRAULIC TANK



2 ,From filter

To oil cooler

From oil cooler

-

Section B-B

Section A-A

4

3

5


F20503106

1. 2. 3. 4. 5. 6. 7. 8.

Filler cap (with lock device (if equipped)) Bypass check valve Bypass valve Filter element Tank Sight-gauge Drain plug Strainer

PC200.220-3

61-34-1 (6)

-

-


-

-

-


-



(3) CO, NC VALVE ASSEMBLY

TVC valve output ,------''-,--;;+--r'--, pressure Pt2 F-R connection port Charging pump pressure '0 C!l Pc OUT port

Jet sensor inlet pressure Pt IN port

TVC valve output pressure Pt2 I N port TVC valve drain Pd2 IN port

--- Z


Main pump pressure PPI (F) OUT port Main pump pressure PP2 (F) OUT port

Jet sensor outlet pressure Pd IN port

CO + NC valve output pressure OUT port

,-!_ _-.L---,PI

Charging pump pressure Pc IN port

o

CO + NC valve drain Pd2 OUT port

-

Main pump pressure Pp. (F) IN port

o Section A-A

Section B-B

o

Main pump pressure PP2 (F) IN port

Section C-C

View Z 205F2092-1

61-36

PC200, 220-3



2

3

4

5

7

6

9

8

7

\

6

5

i

I

4'

10 11

/

Front main pump

Rear main pump

14

Section A-A

12

13


15 205F2074-1

1. 2. 3. 4. 5. 6. 7.

-

Shaft (front) Cradle (front) Case (front) Rocker arm Shoe Piston Cylinder barrel

8. 9. 10. 11. 12. 13. 14. 15.

Valve plate Impeller Cradle (rear) Shaft (rear) Case (rear) End cap (rear) End cap (front) Servo piston

Section C-C

PC200, 220-3

61-37 ®



-' 2

4

\

5

6

7

8

9

Coupling

1. 2. 4. 5. 6. 7. 8. 9.

Shaft (front) Cradle (front) Rocker cam Shoe Piston Cyl inder barrel Valve plate Impeller

-

www. k omat s upar t s book . c om 205F2075-1

•

13

• Rod

• •

2 4 A Cylinder barrel

• "c

'-'I

;>""';

142F034

The tip of piston (6) is spherical. Shoe (5) is swaged around the ball at the piston tip to form one un it with the piston. Piston (6) and shoe (5) from a spherical bearing. Rocker cam (4) has surface A. Shoe (5) is always pushed against this surface and slides in a circle on surface A. Rocker cam (4) slides on the concave face of cradle (2) which is fixed to the case. Pistons (6) move in an axial direction inside each cylinder of cylinder barrel (7). Cylinder barrel (7) rotates while pushing valve seat (8). This seals the oil while rotating. The oil inside each cyl inder chamber on the rotating side (cylinder barrel (7)) goes in and out of the ports on the fixed side (valve seat (8)). Delivery control (Rocker cam angle control) Servo piston (15) changes the angle of the rocker cam. Servo piston (15) moves in a reciprocal linear movement according to the commands of the servo valve. This linear movement moves rod and rocker cam (4). Rocker cam (4) slides around the spherical surface of cradle (2).

-

61-38 (6)

PC200, 220-3

-



OPERATION 1.

Operation of pump • When shaft (1) rotates because of the engine, cylinder barrel (7) also rotates. Shoe (5) rotates on face A of rocker cam (4). When rocker cam (4) moves on concave face B, the angle ex of rocker cam (4) changes. ex is called the rocker 1)

-

7

B

cam angle. When rocker cam (4) has a rocker cam angle ex, piston (6) reciprocates inside cylinder barrel (7). As a result, a difference between volume E and volume F inside cylinder barrel (7) appears. When this happens, an amount of oil equal to this difference in volume is sucked in from port ®, and the same amount of oil is pumped out

4

5

A

E

F 205F2077

from port ®. In other words, cylinder barrel (7) rotates and volume F gradually becomes smaller. While the volume F approaching volume E, oil is pumped out. After it passes the situation in volume E and approaches volume F, the oil is sucked in.


7

-

E

(A) . . .

142F036A·1

F

2)

When the angle of rocker cam (4) is 0, there is no difference between volume E' and volume F', so no oil is sucked in or pumped out. (no pumping action)

-

F' 205F2078

PC200, 220-3

61-39 ®



2. SERVO VALVE UNIT • •

The servo valve unit is installed on top of the main pump. There are two servo valve units: one for the front main pump and the other for the rear main pump.

•

The 1. 2. 3. 4.

servo valve unit consists of the following parts. Servo valve TVC valve CO'NC valve assembly Connector

SERVO VALVE UNIT FOR FRONT MAIN PUMP

$

Main pump pressure,~~ PPI IN port

Charging pump pressure Pc IN port

~

/

-

~ Servo actuator port

Main pump pressure _,,_ Pp. IN port

www. k omat s upar t s book . c om Servo actuator port

Filter

ViewZ

TVC valve output pressure Pt, port (Serial No. PC200. 220-3 • -)

TVC valve output pressure Pt. T -R connection port

TVC valve output pressure Pt. port (Serial No. PC200, 220-3 20001 - .)

-

Jet sensor or outlet pressure Pd I N port

---z

2

co . NC valve output pressure Pi port

1. 2.

61-40 (~

co' NC valve assembly Servo valve

205F2085-1

PC200.220-3

-

-

OLSS


•

HYDRAULIC SCHEMATICS

-

12 -spool side)

1. Relief valve for charging pump 2. Charging pump (BAR25) 3. Rear main pump 4. Front main pump 5. Servo piston (rear) 6. Servo valve (rear) 7. Servo valve (front) 8. Servo piston (front) 9. CO'NC valve ass'y (rear) 9A. NC valve 9B. CO valve 10. TVC valve 11. CO, NC valve ass'y 11 A. NC valve 11 B. CO valve 12. Jet sensor (rear) 13. Jet sensor (front)


-

4

M

-

side)

F205C3034

PC200, 220-3

61-41


2.

FUNCTION OF OLSS

Effective using of engine horsepower

Saves energy (Low fuel f----consumption)

Constant torque control

,-----

Relief loss savi ng

Hydraulic loss saving

Cut-off control

Neutral loss saving

r------~

Flow control

Fine control loss saving

-


Effective using of engine horsepower:

In order to use the engine horsepower effectively, the delivery of the pumps automatically decreases as the load pressure on the pumps goes up and increases as the load pressure goes down. That is, the constant torque control function is applied to keep the load imposed on the engine constant by means of the automatic speed change action.

2)

HYDRAULIC LOSS SAVING

Cut-off control (CO val~) Relief loss When bucket hits something hard during digging operations, a large quantity of oil is uselessly drained to the hydraulic tank to protect hydraulic equipment from damage.

205F2097 Flow control (NC valve) Neutral loss Unused hydraulic oil is drained to the hydraulic tank when waiting for successive dumps and control levers are positioned in neutral.

205F2098 Flow control (NC valve) Fine control loss During precise controls, oil flow is regulated by a control lever. The regulated oil is drained uselessly.

205F2099

61-42

PC200, 220-3

-

-


OLSS

3. BASIC CIRCUIT

I-~--

~~---,

I

I I

I I

I

1

I

t

I

I I

I

I

I

I

-

1

J

)-~---"

I

I

I

I

I

I I

j

I

I I I I I I

I I

r L~

~+----

I

I

,- __ - - ---J+\"""" ___ l

I I

I

1

t

I

I

I Pt

I

t

I

I

1

I Pd

I

t

I

I I

Pd I

I P,

I

I

I I I

I I

I I

I

I

I

I

I

I

I

l

I--l-~,

I

I

I

~-$ S--~-

www. k omat s upa r t s book . c om ,$~ l~ I

'

I

I

1

I

I

I I

I

I

I

I

I

L____ -,

--~-~i'---.J I I Pi l

L_~+,-

___

~

I \... ____ ..J

I

, I

Pi'l

I I

P,L.....

......- - ,

-

-

F205C3035

a.

Constant torque control (Oil pressure sensing system) This system automatically controls the delivery of the pumps for the working conditions. It consists of the following components. TVC (Torque Varialbe Control) valve Servo valve

b.

Cut-off control This system reduces the swash plate angle to the minimum when the pump output pressure is near relief pressure. It consists of the following components. CO (Cut-Off) valve Servo valve

PC200. 220-3

c.

Flow control This system controls the swash plate angle of the pump in accordance with the stroke of the control valve. It consists of the following components. NC (Negative Control) valve Servo valve Jet sernsor PPC valve

61-43

OLSS


4.

FUNCTION

a.

Constant torque control

TVC valve

d~b

Pi

Hill

~

~I

NC valve

~I

valve

1

Ptz

Servo valve

•• ~

~:1€9

I

I

.J:

-:t:t-'

7

L.j

co

l

DU'~OO(

h-Ppz

PPI

p;"oo

T-

[[Jl~oo

L.L-/'

LJ

p ~

J

r-

0

~ I:~ s,~

Pc

CJ

"'------L

:~~1tIb

nt LQ-=

-

CJ

www. k omat s upar t s book . c om Decrease ___

Control valve

PPI

I

R ~

Control valve

Ppz

~

Increase

I Discharge

Pc

M F205C3036

Constant torque control is achieved by controlling the engine load at a constant level by decreasing the pump discharge when the pump pressure increases because of an increase in operating load and by increasing the pump discharge when the operating load is reduced. With an increase in discharge pressure PPI of the main pump, output pressure Pt of the TVC valve is reduced. The servo valve then operates in such a way that the main pump discharge is reduced. If main pump discharge pressure PPI (or PP2) decreases, TVC valve output pressure Pt increases. Then, the servo valve will operate to increase the main pump discharge.

Max.

:;-

~ u

2

OJ

~

'"

.<:

~

1J D.

E :J

Min.

D.

c

'"

:2;

o Main pump discharge pressure (kg/em')

Fig. 1

61-44

F205C3037

PC200, 220-3

-

FRONT MAIN PUMP AND REAR M,l),IN PUMP


OPERATION 1.

Increasing of delivery amount (swash plate angle changes to the left)

14

f

h

Pi

www. k omat s upar t s book . c om From main pump

20

•

•

The input signal pressure Pi enters from port i and acts on chamber C of the control piston. In addition, pressure Pc from charging pump is sent to port j. If Pi now rises slightly, the oil pressure acting on chamber C will rise slightly, so control piston (4) will move (to the left) to a position where the force of spring (7) and the oil pressure in chamber Care balanced. When this happens, the angle of arm (5) changes because the bottom tip of the arm does not change position at it is held by servo piston (20). The servo piston (20) cannot move because it is held by balancing the oil pressure and the spring. As a result, guide spool (14) moves to the left.

205F2089-1

•

The movement of this guide spool (14) connects port j and port h, so pressure Pc passes through port I and flows into chamber e of the servo piston (20). It pushes servo piston (20) to the left and increases

•

the swash plate angle of the main piston pump to increase the delivery amount. Because of this, arm (5) rotates clockwise about pin (6), so guide spool (14), moves to the right. This closes port j and port h, port k and port f, so the delivery amount only increases by an amount corresponding to input signal pressure Pi.

PC200, 220-3

61-45 ®



2.

Decreasing of delivery amount (swash plate angle changes to the right)

14

f

+-Pc

h

Charging pump

Pi

-


5

C chamber

From main pump

21

20 205F2090-1

•

If the input signal pressure Pi now lowers slightly, the oil pressure acting on chamber C will lower slightly, so control piston (4) will move (to the right) to a position where the force of spring (7) and the oil pressure in chamber C are balanced. When this happens, the angle of arm (5) changes because the bottom tip of the arm does not change position as it is held by the servo piston. The servo piston cannot move because it is held by balancing the oil pressure and the spring. As a result, guide spool (14) moves to the right.

•

•

-

The movement of this guide spool (14) connects port j and port k, so control pressure Pc passes through port g and flows into chamber b of the servo piston (20). It moves servo piston (20) to the right and decreases the swash plate angle of the main piston pump to decrease the delivery amount. Because of this, arm (5) rotates counterclockwise about pin (6), so guide spool (14) moves to the left. This closes port j and port k, port hand f, so the delivery amount only decreases by an amount corresponding to input signal pressure Pi.

61-46 ([)

PC200, 220-3

-

OLSS


Operation

1)

When the main pump discharge pressure is lower than the relief pressure: Since spool (2) is pushed downward by the force of spring (1), port a and port b are open to each other and TVC valve output pressure Pt is equal to the CO valve output pressure. CO valve output pressure Peo is then maximized and the main pump discharge is also increased to the maximum with the swash plate angle maximized by the operation of the servo valve.

2

·E..·EEI$q~1

To NC - - - ill""·,·ill· ..

valve

-

'.'

3


F0202145

2)

-

When the main pump discharge is higher than the rei ief pressu re: When main pump discharge pressure Pp comes close to the relief pressure owing to an increase in the load, piston (3) is pushed by main pump discharge pressure PP2 and at the same time piston (4) is pushed by CO valve output pressure Peo. When the forca of.spring (1) is overcome by the pressing force of the pistons, spool (2) moves upward. As a result, the spool land restricts the oil flow from port a to port b and at the same time the opening areas of port b and port e (drain port) are made larger. With angle reduced by the operation of the servo valve, the main pump discharge is reduced.

2

ToNC~---"""

valve

3 4 F0202146

PC200, 220-3

61-47


OLSS

c.

Flow control

co

valve

Pb TVC Pc

valve

-

www. k omat s upar t s book . c om Servo

piston

F205C3041

•

•

•

The flow control is achieved by controlling the main pump discharge according to the movement of the control valve spool, and serves to improve the operation of the pump as well as save energy. When the control lever is in neutral, the pump discharge is regulated to the minimum by the operation of the NC valve and the jet sensor to minimize the redundant oil flow. When operating the control lever, it increases the main pump discharge according to the depth of the lever stroke. This helps minimize the redundant oil flow that occurs when fine control is performed.

•

•

-

At the same time, the fine control performance is improved with the optimum controllability of the main pump discharge accordi ng to the lever stroke. The NC valve is controlled by balancing the sum of jet sensor output pressure Pt and CO valve output pressure Pea against the sum of the spring force in the NC valve and jet sensor output pressure Pd. The jet sensor detects the flow of oil retu rning to the tank through the control valve, and gives signal pressures Pt and Pd to the NC valve.

61-48

PC200, 220-3

OLSS


Operation 1) When the control valve is in NEUTRAL: The differential pressure (Pt - Pd) of the jet sensor reaches the maximum and jet sensor output pressure Pt acting on piston (1) becomes greater than the sum of the force of spring (3) and jet sensor output pressure Pd acting on the lower end of spool (2). As a result, spool (2) is pushed downward, causing a restriction of the oil flow between port c and port b and in turn opening port b and port a (drain port). Output pressure Pt of the NC valve is then reduced to the m.inimum and the main pump discharge is also reduced to the minimum with the swash plate angle minimized through the operation of the servovalve.

From Jet sensor

Pt

==~'" b~;;;;;;.1

To servo - - - - --------...,---.....,(I!-.,.lj.'r-:......t"1 valve Pi

2 ~t;;t.;;;:"'J.-~Peo

"""''''''''''''',:':','"",':From CO valve

3


2)

-

When the control valve is operated: With the jet sensor differential pressure (Pt ~ Pd) reduced according to the operation of the control valve, spool (2) is pushed upward, fully opening port c and port b. Thus, the NC valve output pressure increases. Together with the increase in the main pump swash plate angle through the servovalve operation, the main pump discharge is also increased. That is to say, the pump discharge increases as the stroke of the lever increases.

From Jet sensor

Pt

.......,....,..........l...+ihJ:::;;~

~ilbi~~~I+-

To servo - - Pi - ]",',6',""2"""8'· valve .

2 Peo

""""'==--From CO valve

3

F0202148

PC200, 220-3

61-49

-

-


-

-



•

RELIEF VALVE

6

-

1. 2. 3. 4. 5.

Adjustment screw Lock nut Pilot valve spring Pilot valve Main valve spring

6.

Main valve

205F2081

www. k omat s upar t s book . c om Function The relief valve is built- in the body of charging. It relieves the oil delivered from the pump when the PPC valve is placed in Neutral.

-

Flow of the oil • Chamber A forms a pump circuit and chamber C forms a tank drain circuit. The oil flows into chamber B through the main relief valve orifice to keep the chamber filled. Pilot valve is set in the valve seat. •

205F2082

If the pressure in chamber B reaches the pilot valve spring force (set pressure). the pilot valve moves, allowing the oil in chamber B to flow into chamber C. In addition, the oil flows from chamber A to B through orifices.

•

205F2083

If the oil flows through the orifice of valve (6). a differential pressure occurs between the chambers A and B, moving valve (6) to the left. This allows the oil in chamber A to flow into chamber C.

-

6

PC200,220-3

205F2084

61-51 ®


2-STAGE AND 3-STAGE MODE SELECTOR OLSS

-

2-STAGE AND 3-STAGE MODE SELECTOR OLSS (Open center Load Sensing System) (MODE SELECT TYPE) 1. OUTLINE

10


I

15 14

13 Detail P

1. Mode selector switch 2. Control valve 3. Engine 4. Potentiometer (if equipped) 5. Engine speed sensor (if equipped) 6. Main pump assembly 7. Controller (if equipped) 8. Jet sensor (for front main pump) 9. Jet sensor (for rear main pump)

61-52 @

10. 11 . 12. 13. 14.

Front main pump Rear main pump Charging pump TVC valve CO· NC valve assembly (for rear main pump) 15. Servo valve (for rear main pump) 16. CO· NC valve assembly (for front main pump) 17. Servo valve (for front main pump)

OLSS (Open center Load Sensing System) is an energysaved system to reduce the fuel consumption by means of controlling the swash plate angle (delivery) of the variable-displacement swash-plate type piston pump. Therefore this system acts to reduce the hydraulic loss during operation, to increase the fine control and to control the pump delivery .. There are two types of OLSS: 2-stage and 3-stage. Check the mode selector switch to see which type is installed.

s

s

2-stage

3-stage

PC200, 220-3

-

-

HYDRAULIC CONTROL VALVE


20

21

22 18

-

23

19

Section C - C

www. k omat s upar t s book . c om Section 0 - 0

24

-

25

Section E - E

F205C3044

18. 19. 20. 21.

PC200, 220-3

Spool return spring Spool (arm throttle valve) Main relief valve (4-spool) Main relief valve (5-spool)

22. 23. 24. 25.

Spool return spring spool (swing priority valve) Check valve Check valve spring

61-53



23

10

26

-

www. k omat s upar t s book . c om Section G - G

Section F - F

27

2

28

29

11

30

-

33 1. 23. 10. 26.

61-54

Spool (l.H. travel) Spool (swing priority) Spool (swing) Suction valve (swing)

Section H - H

27. Safety valve (boom cylinder bottom) 2. Spool (boom-Lo) 28. In-line check valve spring 29. In-line check valve

F205C3045 11. Spool (boom-Hi) 30. Suction valve (boom cylinder bottom) 31. Safety valve with suction valve (boom cylinder head)

PC200, 220-3

-



4

32

19

14

12

www. k omat s upar t s book . c om Section K - K

Section J - J

33

5

24

13

34

32. Safety valve with suction valve (bucket cylinder head) 4. Spool (bucket) 19. Spool (arm throttle valve) 12. Spool (service) 33. Safety valve with suction valve (bucket cylinder bottom) 5. 24. 13. 34. 35.

Spool (arm-Hi) Check valve Spool (arm-Lo) Safety valve (arm cylinder he,ad) Safety valve with suction valve (arm cylinder bottom) 14. Spool (R.H. travel)

-

Section L - L

PC200, 220-3

35

F205C3046

61-55



MAIN RELIEF VALVE

2

3

4

5

B

7

8

9

1.

2. 3. 4. 5. 6. 7. 8. 9.


-

F20503032 Function The main relief valve is in the circuit between the pump

and the control valve. This valve acts to protect the pump from damage from any abnormal oil pressure. When abnormal pressure is produced or when the hydraulic cylinder reaches the end of its stroke during operations, the oil sent from the pump is relieved

www. k omat s upar t s book . c om through the main relief valve. (It sets the maximum high pressure in the circuit during operations)

Flow of the oil • Chamber A forms a pump circuit and chamber C forms a tank drain circuit. The oil flows into chamber B through the main relief valve orifice

to keep the chamber filled. Pilot valve is set in the valve seat.

F20503033

•

-

If the pressure in chamber B reaches the pilot valve spring force (set pressure), the pilot valve moves, allowing the oil in chamber B to flow into chamber C through orifice. In addition, the oil flows from chamber A to B through orifices.

F20503034

•

If the oi I flows through the orifice of valve (1 L a differential pressure occurs between the chambers A and B, moving valve (1) to the right. This allows the oil' in chamber A to flow into chamber C.

F20503035

61-56

PC200, 220-3

-



Operation

2

The TVC valve is controlled by balancing the sum of main pump discharge pressure PPl and PP2 and TVC valve output pressure Pt 2 against the force of spring (1). 1)

-

When the main pumps are in operation without load (when the mode selector switch is turned to STANDARD), spool (2) is pressed downward by spring (1) because of the low discharge pressure PPl and PP2 of the main pumps. As a result, charging pump discharge pressure Pc is made equal to TVC valve output pressure Pt 2 · Since TVC valve output pressure Pt2 reaches the maximum value at this stage and the servo valve will increase in the main pump swash plate angle through the servo valve operation, the main pump discharge is also increased. That is to say, the pump discharge increases as the stroke of the increase angle of the main pump, the main pump discharge is raised to the maximum. (Fig.2)

3


2)

-

When the main pumps are in operation under load (when the mode selector switch is turned to STANDARD), an increase in main pump discharge pressure PPl (or PP2) will cause piston (4) to be pressed and spool (2) to move upward. As a result, the oil flow from port a to port b is restricted by the spool land, while the openings of port b and port c (drain port) are made larger. As the lowered TVC valve output pressure Pt 2 reduces the main pump swash plate angle through the operation of the servo valve, the discharge of the main pump is also reduced. (Fig.3)

2 Pc

To CO valve _

illZ~~~.~~~t_mm~ 3

4 3)

When the mode selector switch is turned to LIGHT DUTY, piston (5) is pushed upward by shaft (6) on solenoid valve (7). As a result, the setting pressure of spring (1) is made higher and the control is effected as shown in Fig. 1.

5 6 7

F0202144

Fig.3 PC200. 220-3

61-57 G)


2-STAGE AND 3-STAGE MODE SElECTOR OLSS

b.

Cut-off control

CO valve

Pi

NC valve

TVC

• • • •~ valve

Pc

-


205F21 I I

* *

-

Cut-off control is a function which minimizes the relief loss by reducing the pump discharge through the operation of the CO valve when the main pump discharge pressure comes near the relief pressure. The CO valve is controlled by balancing the sum of main pump discharge pressure Pp. and CO valve output pressure Pea against the force of the spring.

61-58 ®

PC200. 220-3



Operation 1) When the main pump discharge pressure is lower than the rei ief pressure: Since spool (2) is pushed downward by the force of spring (1), port a and port b are open to each other and TVC valve output pressure Pt 2 is equal to the CO valve output pressure. CO valve output pressure Peo is then maximized and the main pump discharge is also increased to the maximum with the swash plate angle maximized by the operation of the servo valve.

2

From TVC valve To NC . - - valve

illll!EEEilltm!::1

3


F0202145

2)

When the main pump discharge is higher than the relief pressure: When main pump discharge pressure Pp comes close to the relief pressure owing to an increase in the load, piston (3) is pushed by main pump discharge pressure PP2 and at the same time piston (4) is pushed by CO valve output pressure Pco. When the force of spring (1) is overcome by the pressing force of the pistons, spool (2) moves upward. As a result, the spool land restricts the oil flow from port a to port b and at the same time the opening areas of port b and port e (drain port) are made larger. With angle reduced by the operation of the servo valve, the main pump discharge is reduced.

2

To NC _ _ ...................;.....I,.-!. valve

3 4 F0202146

PC200, 220-3

61-59 ®



c.

Flow control

co valve

Pb TVC Pc valve

-

www. k omat s upar t s book . c om Servo piston

205F21 14

•

•

•

The flow control is achieved by controlling the main pump discharge according to the movement of the control valve spool, and serves to improve the operation of the pump as well as save energy. When the control lever is in neutral, the pump discharge is regulated to the minimum by the operation of the NC valve and the jet sensor to minimize the redundant oil flow. When operating the control lever, it increases the main pump discharge according to the depth of the lever stroke. This helps minimize the redundant oil flow that occurs when fine control is performed.

•

•

-

At the same time, the fine control performance is improved with the optimum controllability of the main pump discharge according to the lever stroke. The NC valve is controlled by balancing the sum of jet sensor output pressure Pt and CO valve output pressure Pco against the sum of the spring force in the NC valve and jet sensor output pressure Pd. The jet sensor detects the flow of oil returning to the tank through the control valve, and gives signal pressures Pt and Pd to the NC valve.

61-60 (2)

PC200, 220-3

-

-


Operation 1) When the control valve is in NEUTRAL: The differential pressure (pt - Pd) of the jet sensor reaches the maximum and jet sensor output pressure Pt acting on piston (1) becomes greater than the sum of the force of spring (3) and jet sensor output pressure Pd acting on the lower end of spool (2). As a result, spool (2) is pushed downward, causing a restriction of the oil flow between port c and port b and in turn opening port b and port a (drain port). Output pressure Pt of the NC valve is then reduced to the minimum and the main pump discharge is also reduced to the minimum with the swash plate angle minimized through the operation of the servo valve.


To servo - - - - -~-r~--IU-ll"'..........r1 valve Pi

2

3


2)

-

When the control valve is operated: With the jet sensor differential pressure (Pt - Pd) reduced according to the operation of the control valve, spool (2) is pushed upward, fully opening port c and port b. Thus, the NC valve output pressure increases. Together with the increase in the main pump swash plate angle through the servovalve operation, the main pump discharge is also increased. That is to say, the pump discharge increases as the stroke of the lever increases.

2 Peo

~~iii!E.TI-----From CO valve

3

F0202148

PC200, 220-3

61-61 @



*

FOR MACHINES EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS

4. 3-STAGE MODE SELECTOR OLSS

s

This OLSS is used to select either the H-mode (for heavy-duty operations), S-mode (for standard operations) or L-mode (for light-duty operations). This allows the engine output to match the work conditions, resulting in lower fuel consumption. •

-

FUNDAMENTALS

1-----.-_....1

-II I I

I

S6D1 05 engine

I I

Fuel control lever

}

Swash plate pump

-

I I I I

Engine speed sensor Potentiometer

I I

\.J

I

www. k omat s upar t s book . c om I I

I I I I

Pump control system

I I Mode selector switch L _ _ ,

I

,---

I

I

I

I

I

I I

I I

Ordinary control circuit

Controller

_____;.

19 J

I

-

I I

I

Prolix circuit

-------~-------~-----~ Resistor

a.

Engine speed' oil pressure sensing system control (Constant torque control) 1) Engine speed sensing system (H-mode) This system acts to control the load pressure (swash plate angle) of the pump in order to keep the engine load (engine speed) constant even when the load changes during operation. It consists of the following components. • TVC (Torque Variable Control) valve • Servo valve • Electronic control system (potentiometer, engine speed sensor, electronic controller)

61-62 ®

2)

205F2100-1

Oil pressure sensing system (S-mode, L-mode) In L-mode during light load operations, the system controls to a low delivery pressure by "oil pressure sensing system". This is selected by the mode selector switch. To ensure that it operates properly even if the controller and sensors should break down, there is a "prolix circuit". It uses "oil pressure sensing system".

b.

Cut-off control

c.

Flow control The function of these two systems is the same as for the 2-stage mode selector OLSS. For details, see page 61-58 to 61-61.

PC200, 220-3

-

-

HYDRAULIC CYLINDER


3.

Bucket cylinder

3

2

-

5

7

8

9

10

15

13

11

16

www. k omat s upar t s book . c om "i'f---------Cf""",'3.

I

F205C3054

1. 2. 3. 4. 5. 6. 7. 8. 9.

Dust seal Busning Head side tube Bottom side tube Piston rod Snap ring Dust seal Cylinder head Bushing

10. Rod packing 11. Cylinder 13. 14. 15. 16.

Piston Slipper seal Wear ring Piston nut

Unit· mm Item

Arm

Bucket

Model

Boom

PC200

85

95

75

PC220

90

95

90

PC200

120

130

110

PC220

130

140

130

PC200

1.260

1.570

1.120

PC220

1.240

1.635

995

PC200

3,050

3,680

2.800

PC220

3.020

3.825

2.575

PC200

1.790

2.110

1.680

PC220

1,780

2.190

1.580

PC200

85

95

85

PC220

95

95

95

Rod 0.0.

Cylinder I.D.

Stroke

Max. length

Min. length

-

P iston nut w idth across flats

PC200, 220-3

61-63


WOR K EQUI PMENT

-

WORK EQUIPMENT

4

2


Side cutter (if equipped) 205F2174

1. 2. 3. 4. 5. 6.

-

Arm Bucket cylinder Arm cylinder Boom Boom cylinder Bucket

61-64

PC200. 220-3



*


Operation

As a result, the signal current from the controller, and the delivery pressure (load) and delivery volume of the pump give the following curve. P x Q = constant where P = Delivery pressure (load) of pump Q = Delivery volume of pump

The operation differs according to whether the 3-stage mode selector switch has been SWitched, or whether the controller has broken down. Engine speed sensing: • When using H-mode Oil pressure sensing: • When using S-mode and L-mode • When using prolix circuit

1.

-

Mode selector switch at H-mode with engine at full throttle: • When the engine speed is above the set speed, the signal current from the controller to the TVC valve solenoid is at its minimum. Therefore the swash plate angle of the pump is at the maximum. • When the engine speed is below the set speed, the signal current from the electronic controller increases, the TVC valve moves, and the swash plate angle of the pump becomes smaller. The relationship between the engine speed and the signal current sent to the controller is as follows.

i

;;:

= min

o

LL

Px

Q =

Constant

(cc/rev)

Pressure (kg/em 2

)

F20503037

In other words, a signal current matching the drop in the engine speed is sent by the electric controller to the solenoid so that the delivery volume of the pump matches delivery pressure.

www. k omat s upar t s book . c om PC200: 1900 rpm PC220: 1950 rpm

(A)

2.

1.01-------< ~

~ 0.78

"

u OJ ;::

0.5

~

OJ

Q)

W 0.18

OL--------+---'------

-

1900 2100 Eng; ne speed (rpm)

205F2102-1

The relationship between the signal current sent from the controller to the TVC valve, and the suction torque of the pump is as follows.

(kgm) Q)

"cr

8c

.g " OJ

3.

Mode selector switch at H-mode with engine at partial speed: When the engine speed is 1500 - 2100 rpm, a signal for a speed (set speed) corresponding to the amount the fuel control lever is pulled is sent by the potentiometer to the controller. The pump delivery volume is controlled according to the difference in the set speed and actual speed in the same way as when the engine is at full throttle. When the engine speed is below 1500 rpm, the controller acts to prevent the engine from stalling. Mode selector switch at S-mode and L-mode with engine at full throttle: A constant signal current is sent from the controller to the TVC valve regardless of the actual speed of the engine. When this happens, the TVC valve detects the delivery pressure of the pump and controls the flow (oil pressure sensing). The relationship between the delivery pressure and delivery flow of the pump is as follows.

(f)

o

(ee/rev)

0.5 Electric current

!

205F2103

In other words, it is controlled by the controller to give the curve shown in the graph above.

PC200, 220-3

Pressure

(kg/cm 2

)

205F2105

61-65 (8)



*

4.


-

Using prolix circuit: When the controller breaks down, if the prolix circuit switch is turned ON, a fixed current flows to the TVC valve in the same way as when using the S mode or L mode. (However, when the S mode or L mode are used, the current is output from the controller. When the prolix circuit is used, the current flows in the following circuit: fuse resistor - TVC valve.) The pump then detects the discharge pressure and controls the flow. The relationship between the pump delivery pressure and pump delivery amount for engine speed sensing and oil pressure sensing is as follows.

-

H-mode Prolix circuit

;;:

o

:;::

switched on S-mode L-mode


61-66

(a,

PC200, 220-3

ATTACHMENT


ATTACHMENT Name

Specification

Application

Style

PC200-3 Capacity (m 3

Used for digging narrow trenches or for digging hard ground beyond ability of standard bucket

Narrow bucket

-

)

Bucket width (mm)

Weight (kg)

PC220-3

0.33

0.45

0.7

560

750

900

410

440

612

Yes

Yes

No

Reversible

PC200-3 Capacity (m 3

)

0.8

0.9

PC220·3

1.0

1.2

1.0

1 .1

www. k omat s upar t s book . c om Used for loadi ng a large quantity of relatively light material

Light-duty bucket

Bucket width

1,200 1,330 1,450 1,680 1,300 1,400

(mm)

Weight

590

(kg)

Reversible

Capacity (m 3

-

Used for digging

Trapezoidal bucket PC200 PC220

trapezoidal channels in farms and paddy fields

Yes

620

Yes

Yes

774

769

Yes

Yes

Ditching angle (deg.)

38

40

45

Bucket width (mm)

(3,310)

(3,280)

3,165

830 (inc!. side plate 220 kg)

Weight (kg)

Compaction area

(m 2

)

2.00

Compaction width (mm)

2,000

Capacity (m 3

0.35

Suitable for slope forming work

Weight (kg)

-

Yes

710

0.5

)

206F264

Slope finishing bucket PC200 PC220

660

)

700

206FI31

PC200, 220-3

61-65


ATTACHMENT

Name

Style

Clamshell bucket PC200 PC220

/

Application

Capacity (m 3

~ I

•

\~~~~, \\

\~ r,.'~.' /r(

\~

",

,

"

000

' .• •

Specification

Suitable for digging and loading work in a restricted spot such as bridge girder foundation digging work

\

//

',-,.//~//

Loading type

Digging type

0.60

0.60

)

Bucket width (mm)

866

865

Opening width (mm)

1,782

1,860

Weight (kg)

1,140

1.205 0

0

360 manual slide

360 manual slide

Opening time (sec.)

2.0

1.0

Closing time (sec.)

1.2

2.0

Rotation type

-

'yo

206FI32

!

/& - t www. k oma s upar t s book . c om /

/

I

Ripper bucket PC200 PC220

Capacity (m 3 )

0.56

Bucket (mm)

950

Weight (kg)

935

Reversible

No

4

~~';!A

~"~u

Used for digging hard ground rockbed and pavements

~(l

206FI33 l-shank

3-shank

76

50

Shank width (mm)

/:c; Ripper PC200 PC220

~

Su itable for digging rocks and pavements and tree roots

PC200

PC220

PC200

pcno

Ripper digging force (bucket) (kg)

-

12,700 15,400 12,800 15,500

\

~'@ Weight (kg)

206FI34

Short arm

~fT

~\:I}

Arm length (Overall) (mm) Suitable for digging on general purpose

Maximum digging (mm) depth

Weight (kg)

363

620

PC200-3

PC220-3

1,800

2,400

2,000

2,500

5,425

6,035

5,665

6,165

580

520

650

640

206FI35A

61-66

PC200, 220-3


ATTACHMENT

Application

Style

Name

Specification

Arm length

Long arm (PC220 only)

Used for deep excavation work

.<:

'c0>

(mm)

Max. digging depth (mm)

3,500

7,160

Q)

E

«

-

Weight

(kg)

Arm length (total length)

(mm)

760

206F265A

1\

1,130 (1,725)

www. k omat s upar t s book . c om Used for a wide range of Iight load opera-

Extension arm (PC200 only)

tions, such as slope face operations of drainage canals


Weight

(kg)

7,680

450

206F266

-

PC200, 220-3

61-67

ATTACHMENT LIST


-

ATTACHMENT LIST PC200-3 Attachment name

Standard long arm

Short arm 1.8 m 2.4 m

Extension arm

(bucket width 560 mm)

0

0

0

0


0

0

0

0


0

0

0

X


6

6

6

X


X

6

6

X


X

6

6

X


X

6

6

X

Slope finishing bucket

0

0

0

X

Trapezoidal bucket (variable slope type)

0

0

0

X

Ripper bucket (bucket width 950 mm)

X

0

0

X

Clamshell bucket

0

0

0

X

Narrow bucket Standard bucket

Light-duty bucket

-

www. k omat s upar t s book . c om 1-shank ripper

0

0

0

X

3-shank ripper

0

0

0

X

PC220-3 Attachment name

Standard arm

Short arm 2.0 m

2.5 m

Long arm

Narrow bucket


0

0

0

0

Standard bucket


0

0

0

6

Light-duty bucket (bucket width 1300 mm)

6

6

6

X

Light-duty bucket (bucket width 1400 mm)

6

6

6

X

_.~----

-

-~~._._-

Slope finishing bucket

0

0

0

0

Trapezoidal bucket (bucket width 3370 mm)

0

0

0

0

Ripper bucket


0

0

0

X

Clamshell bucket


0

0

0

0

1-shank ripper

0

0

0

X

3-shank ripper

0

0

0

X

0:

6: X:

For normal operation For light-duty operation Unattachable

61-68

PC200, 220-3



HYDRAULIC CONTROL VALVE (4-spool valve and 5-spool valve) 1. WRIST CONTROL TYPE LONG LEVER CONTROL TYPE PC200-3 (Serial No. 24684 -), PC220-3 (Serial No. 21135 -) Port PL

Port P 3

-

Port P,

Port P 4

Port P R

Port PRL

Port PRR

Port P ,AR

Port A 'R

Port B 'R

www. k omat s upar t s book . c om Port B"

Port A"

Port N CBR

Port NCAR

Port N CBR

Port A'R

Port P 18R

2

Port T

Port B'R

Port P 2BL

Port NCAR

F20503016

1. 2.

Travel shuttle valve Connecting bolt of control valve

OUTLINE •

•

PC200, 220-3

This control valve consists of a 4-spool valve and a 5-spool valve. In addition, it also has a travel shuttle valve. It has a built-in straight-travel valve, arm throttle valve and swing priority valve. The 4-spool valve and 5-spool valve are connected by bolts to form one unit. The oil flow merges inside the valve, so the valve is compact and provides excellent ease of maintenance.

61-69 ®



2

3 4 1. Spool (L.H. travel) 2. Spool (Boom-Lo)

5

3. 4. 5. 6. 7.

Spool (bucket) Spool return spring Spool (arm-Hi) Valve body Orifice for jet sensor (for rear pump) Relief valve for jet sensor (for rear pump) Spool return spring Spool (swing) Spool (boom-Hi) Spool (service) Spool (arm-Lo) Spool (R.H. travel) Valve body Orifice for jet sensor (for front pump) Relief valve for jet sensor (for front pump)

-


B

Section A - A

7

8. 9.

10. 11 . 12. 13. 14. 15. 16.

9

17.

10 11

-

12 13 14

16

61-70 ®

Section B - B

17

-

F20503017

PC200, 220-3



-.

21

23

18

2419

-

22

,-;-

25

20

Section C-C

www. k omat s upar t s book . c om Section D-D

26

-

27

Section E-E F20503018A

18. 19. 20. 21. 22.

PC200, 220-3

Spool (straight-travel) Spool return spring Spool (arm throttle valve) Main relief valve (4-spool) Spool return spring

23. 24. 25. 26. 27.

Main relief valve (5-spool) Spool return spring Spool (swing priority valve) Check valve Check valve spring

61-71 (5)



25

18

10

28

-

www. k omat s upar t s book . c om Section G - G

Section F - F

29

2

30

31

11

32

-

33 1. 18. 25. 10. 28.

61-72 ~

Spool (L. H. travel) Spool (straight-travel) Spool (swing priority) Spool (swing) Suction valve (swing)

Section H - H F20503019

29. Safety valve (boom cylinder bottom) 2. Spool (boom-Lo) 30. In-line check valve spring 31. In-line check valve

11. Spool (boom-Hi) 32. Suction valve (boom cylinder bottom) 33. Safety valve with suction valve (boom cylinder head)

PC200. 220-3

-



4

34

14

12

20

-


SectionJ - J

35

5

26

13

36

34. Safety valve with suction valve (bucket cylinder head) 4. Spool (bucket) 20. Spool (arm throttle valve) 12. Spool (service) 35. Safety valve with suction valve (bucket cylinder bottom) 5. 26. 13. 36. 37.

Spool (arm-Hi) Check valve Spool (arm-Lo) Safety valve (arm cylinder he,ad) Safety valve with suction valve (arm cylinder bottom) 14. Spool (R.H. travel)

-

Section L - L

PC200. 220-3

37

F20503020

61-73 CZ)



2.

LONG LEVE R CONTROL TYPE

PC200·3 (Serial No. 20001 - 24683) PC220-3 (Serial No. 20001 - 21134)

Port PL

\

\

Port P3

Port P5

Port P4

E

Port PRL

PortP1AL PortA1R

Port PRR

B

/

-

PortB1R

Port A3R

\~~~~

www. k omat s upar t s book . c om Port B3L Port B2L

A

Port A3L Port A2L Port Pd

Port P3BR Port Pt

Port A5R Port Pd Port P1BR

Port B5R

2

/

Port Pt

View Z

1.

2.

205F2117

Travel shuttle valve Connecting bolt of control valve

61-74 (5)

PC200, 220-3



-

2

3 4

-

5

1. 2. 3. 4. 5. 6. 7.

Spool (L.H. travel) Spool (boom-Lo) Spool (bucket) Spool return spring Spool (arm-Hi) Valve body Orifice for jet sensor (for rear pump) Relief valve for jet sensor (for rear pump) Spool return spring Spool (swing) Spool (boom-Hi) Spool (service) Spool (arm-Lo) Spool (R.H. travel) Valve body Orifice for jet sensor (for front pump) Rei ief valve for jet sensor


8

Section A-A

7

8.

9. 10. 11. 12. 13. 14. 15. 16.

9

17.

(for front pump)

10 11 12 13

14

15

17

16 Section B-B

PC200, 220-3

205F2118

61-75 ®



21

23

18

24 19

22

25

-

20

Section C-C

www. k omat s upar t s book . c om Section D-D

26

-

27

Section E-E

18. 19. 20. 21.

61-76

Spool (straight-travel) Spool return spring Spool (arm throttle valve) Main relief valve (4-spool)

22. Spool return spring 23. Main relief valve (5-spool) 24. Spool return spring

F20503013A

25. Spool (swing priority valve) 26. Check valve 27. Check valve spring

PC200, 220-3

-



MAIN RELIEF VALVE

2

-

3

4

5

B

7

8

9

1. 2. 3. 4. 5. 6. 7. 8. 9.


F20503032

Function The main relief valve is in the circuit between the pump and the control valve. This valve acts to protect the pump from damage from any abnormal oil pressure. When abnormal pressure is produced or when the hydraulic cylinder reaches the end of its stroke during operations, the oil sent from the pump is relieved through the main relief valve. (It sets the maximum high pressure in the circuit during operations)


Flow of the oil • Chamber A forms a pump circuit and chamber C forms a tank drain circuit. The oil flows into chamber B through the main relief valve orifice to keep the chamber filled. Pilot valve is set in the valve seat. F20503033

•

If the pressure in chamber B reaches the pilot valve spring force (set pressure), the pilot valve moves, allowing the oil in chamber B to flow into chamber C through orifice. In addition, the oil flows from chamber A to B through orifices. F20503034

•

If the oi I flows through the orifice of valve (1), a differential pressure occurs between the chambers A and B, moving valve (1) to the right. This allows the oir in chamber A to flow into chamber C.

F20503035

PC200, 220-3

61-79 (~



SAFETY-SUCTION VALVE

2

3

4

For boom cylinder head, arm cylinder bottom and bucket cylinder 1. 2. 3. 4.

5

B

5. 6. 7.

Main valve Suction valve Sleeve Lock nut

Main valve spring Pilot piston Suction valve spring

-

7 205F2131

Function

Setting pressure: • Boom cylinder head (Lo circuit): 250 kg/cm 2 (at 1 - 2Q/min.)

www. k omat s upar t s book . c om The safety-suction valves are located in circuits between the control valve and the boom cylinders, arm cylinders and bucket cylinders. If abnormal pressure occurs in the cylinder due to any shock, this valve relieves oil into tank to prevent each cylinder from damage.

•

Arm cylinder bottom (Lo circuit)) 340 kg/cm2

•

Bucket cylinder

(at 1 - 2Q/min.)

Operation

As a safety valve • Chamber A forms the cylinder circuit and chamber B forms the tank drain circuit. Oil in chamber A flows to chamber D through the hole of the piston, and to chamber C through the clearance between main poppet (1) and piston (6). The piston is secured to the suction valve with nut

c

-

(4).

This valve has a relationship of d2 •

> dl > d3 > d4.

If abnormal pressure occurs in chamber A., ~he suction valve is not moved because d2 > dl . But, as d3 is larger than d4, the fC'~ce which pushes the main poppet to the left is generated. When th is force exceeds to the main poppet spring force, the main poppet moves, and the oil in chamber A flows to chamber B (tank drain circuit).

205F2132

c

205F2133

61-80 ®

PC200, 220-3

-

-

ATTACHMENT


Specification

Application

Style

Name

Loading type

Digging type

0.60

0.60

Capacity (m')

Bucket width (mm) 866 865 Suitable for digging 1 - - - - - - - - - - 1 - - - - - - - + - - - - - - and loading work in Opening width (mm) 1,782 1,860 a restricted spot such as bridge Weight (kg) 1,140 1,205 girder foundation 0 0 digging work 360 360 Rotation type manual sl ide manual slide

Clamshell bucket PC200 PC220

-

206FI32

Opening time (sec.)

2.0

1.0

Closing time (sec.)

1.2

2.0

Capacity (m')

0.56

www. k omat s upar t s book . c om Used for digging hard ground

Ripper bucket PC200 PC220

rockbed and pavements

Bucket (mm)

950

Weight (kg)

935

Reversible

No

206FI33 1-shank

3-shank

76

50

Shank width (mm)

-

Su itable for digging rocks and pavements and tree roots

Ripper PC200 PC220

PC200

PC220

PC200

PC220

Ripper digging force (bucketl (kg) 12,700 15,400 12,800 15,500

Weight (kg)

206FI34

'T ~·~. \1 IIJ';5, .

Arm length (Overall I (mm)

i.;

Short arm

\\

\

I.

\ ',' \ '.

····1···· .....

Ie "

-

Suitable for digging on general purpose

Maximum digging (mm) depth

363

620

PC200,200LC

PC220, 220LC

1,800

2,400

2,000

2,500

5,425

6,035

5,665

6,165

580

520

650

640

-~

E

«

Weight (kg)

"f

206FI35A

PC200.220-3

61-89 @


ATTACHMENT

Application

Style

Name

Specification

Arm length

Long arm (PC220 only)

Used for deep excavation work

-5Cl

(mm)


3,500

7,160

c

~

E

~

Weight

(kg)

760

206F265A

Arm length (total length)

I \

(mm)

1,130 (1,725)

-

www. k omat s upar t s book . c om Used for a wide range of Iight load opera-

Extension arm (PC200 only)

tions, such as slope face operations of drainage canals


Weight

(kg)

7,680

450

206F266

-

61-90 Q)

PC200. 220-3

HYDRAULIC SYSTEM 62 TESTING AND AD,"-,USTING

Table of judgement standard value Table of electrical judgement standard value . Troubleshooting tools . Testing travel and operating force Measuring hydraulic oil temperature Air bleeding

-

62- 2

. . .

Testing and adjusting hydraulic pressure (Work equipment, swing, travel circuits) Testing and adjusting pressue of charging circuit . Testing and adjusting control pressure of main pump . . . . . . . . . . . . . . . . . . .. Method of locating defective equipment when there is travel deviation

.62-32 .62-42 .62-43 .62-45 .62-46

www. k omat s upar t s book . c om Measuring oil leakage of swing, travel motor Checking and adjusting travel motor pertorman~ . Testing method using visual and functional check . Troubleshooting .

PC200,220-3

62-47

62-50

62-51-1 62-53 .62-54 .62-55 . .. 62-58 . .. 62-59

62-1 ®


TABLE OF JUDGEMENT STANDARD VALUE

-


*

Standard value and permissible value in following table are the value when 2-stage mode selector switch is at S position.

Classification

-E -e-0 OJ OJ

~ OJ c

Item

Permissible value

Standard value

Engine low idling speed

• Engine oil pressure:

Engine high idling speed

• Engine water temperature: in correct range

incorrect range

730 - 830

-

2250 - 2350

-

• Hydraulic oil temperature: 45 - 55°C Engine speed when one or two main pump circuit oil is relief

• Engine coolant temperature: incorrect range • Engine oil pressure:

2150 - 2250

incorrect range

Min.2150

• At one pump relief: Bucket circuit relief

C>

c

LU

Condition

Engi ne rated speed Engine speed when auto-deceleration acts. (If equipped)

• At two pump relief: Bucket and arm circuits relief

-

2100

• Fuel control lever at "Full" • Work equipment control lever at "Neutral"

1200 ± 50

I

Boom control valve

a

1200 ± 50

b

I

a

b

-

Arm control valve

www. k omat s upar t s book . c om Bucket control valve

-E E

OJ > ~

£

Swing control valve

L. H. travel control valve

~~

u..

00

~

-

0 0 0-

(/)

R. H. travel control valve

.,..,.. 'In

()

°oC~

I

35

9.5 ± 0.5 9.5 ± 0.5

35

9.5 \ 0.5 9.51 0.5

205F2401

Boom-Hi control valve


Service valve Neutral ~ Raise and Lower

65 ± 10

65 ± 10

Neutral ~ Arm IN and OUT

65 ± 10

65 ± 10

Neutral ~ Curl and Dump

65 ± 10

65 ± 10

Neutral -+ R.H. and L.H. Swing

65 ± 10

65 ± 10

Neutral ~ Forward and Reverse

130 ± 15

130 ± 15

F

45 ± 5

45 ± 5

R

40 ± 5

40 ± 5

Stop .... Low idling

45 ± 20

45 ± 20

Low idling .... Full speed

175 ± 30

175 ± 30

Boom control lever Arm control lever

-E

Bucket control lever

OJ >

Swing control lever

E

• At center of lever knob

• Measure at end of travel

~

~

Q;

Travel control lever • Do not start engine

> .!"

eC

Travel pedal

0

u

Neutral ~ Forward and Reverse

-

Fuel control lever

62-2 (8)

PC200, 220-3



Classification

Standard value

Condition

Item Boom control

30+0·5 · -0.8

3.4

Arm control

25+0·5 · -0.8

2.7

Buc ket control

25+0·5 · -0.8

2.7

3 0 +0.5 · -0.8

3.4

Forward

2.5 ± 1.0

3.8

Reverse

2.5 ± 1.0

3.8

Forward

5.5 ± 1.1

8.3

Reverse

6.0 ± 1.2

9

C,

::£

'" OJ

.2

Swing control

Ol

c .;::; co

Permissible value

Travel control

Q;

Q.

• At engine full speed • Hydraulic oil tem peratu re : 45 - 55°C • Hook pushpull scale on center of lever knob to measure

0 ~

'" ~ >

e ~

c 0

Lever

Pedal

u Low idling ... Stop

12.0~~:g

Low idling ... Full speed

10.0~~:~

Fuel control lever

15

www. k omat s upar t s book . c om Boom circuit

Arm circuit

• Hydraulic oil temperature: 45 - 55° C

Bucket circuit

Travel circuit

320 +10 -6

320 +25 0

297 +15 -10

275 +25 0

30 +5 0

30 ± 3

• Relief pressure at engine full speed (Be relieved oil in only measuring circuit)

Swing circuit Charging circuit

-

"'E -.<::

C>

-"'"

TVC valve outlet pressure

• Hydraulic oil temperature: 45 - 55°C • At engine full speed

E

~ '"C-

Lever at neutral At one pump relief (320 kg/cm 2 ) Average pressu re of two pump (160 - 170 kg/cm 2

PC200-3

PC220-3

PC200-3

PC220-3

23 ± 1

24 ± 1

Min.18

Min.18

16 ± 1

17 ± 1

15 ± 1.5

16 ± 1.5

)

.>!

-::l co

-0 I

>-

NC valve outlet pressure


Max. 7

Max. 7

Min.18

Min.18

Lever at neutral

15 ± 1.0

15 ± 1.0

Lever at full stroke

Max. 2

Max. 2

Max. 5

Max. 5

Lever at neutral Lever at stroke end Raise track on one side then rotate sprocket

Difference pressure of jet sensor


Lowered hydraulic pressure

• Hydraulic oil temperature: 45 - 55°C • Difference oil relief pressure between at engine full speed and at engine a half speed (Measure pressure in one circuit only) .

PC200, 220-3

62-3 @

-

._~----------------------


Classification


Item

Standard val ue

Condition

PC200-3 PC220-3

• Engine speed: Full speed • Hydraulic oil temperature: 45 -55°C

(sec,)

• Bucket unloaded • Arm and bucket cylinder fully retracted • Measure time taken from bucket tooth touching the ground to cylinder fully extended (RAISE) • Measure time taken from cylinder fully extended to bucket tooth touching the ground (LOWER)

(sec.)

• Top of boom is in horizontal, and bucket cylinder fully extended • Measure time taken from cylinder fully retracted position to cylinder fully extended position (I N) • Measure time taken cylinder fully extended position to cylinder fully retracted position (OUT)

Boom

Permissible value PC200-3

PC220-3

w (fl

3.2 ± 0.3 3.4 ± 0.3

4.0

4.1

s: o

2.8 ± 0.3

3.4

4.2

z

4.0 ± 0.4 5.0 ± 0.5

5.1

5.9

3.2 ± 0.3 3.2 ± 0.3

3.5

3.9

a::

a::

w

3.3 ± 0.3

...J

'0 Q) Q)

...,~ c: Q)

E

c.

Arm

:::J

0Q)

,>,(.

o

s:

www. k omat s upar t s book . c om Bucket

..., c:

(sec.)

Q)

• Top of boom is in horizontal, and arm cylinder fu II y retracted • Measure time taken from cylinder fully retracted position to cylinder fully extended position (CURL) • Measure time taken from cylinder fully extended position to cylinder fully retracted position (DUMP)

...J

a::

:::>

3.5 ± 0.4 4.2 ± 0.4

4.4

5.0

2.3 ± 0.2

2.8

3.6

u

2.6 ± 0.3

[1--+--------+--------------+-----l.---L----1I------'----

.:;

0-

Q)

Bucket cylinder fully extended

,>,(.

o

s:

Top of boom horizontal I Arm cylinder

1~~~,,,

Total work equipment

(Fig. 2)

Max. 600

Max. 960

Max. 30

Max. 45

Max. 110

Max. 165

Max. 20

Max. 30

205F575

• Engine speed: Stopped • Hydraulic oil temperature: 45 - 55°C • Bucket unloaded • Work equipment in posture in Fig. 2 • Measure amount bucket tooth moved down (distance "a") in 15 min. • Measure immediately after setting (mm) Boom cylinder

(mm)

Arm cylinder

(mm)

Bucket cylinder (mm)

62-6 @

• Measure amount each cylinder retracted in 15min.

PC200, 220-3



Classification

Item

Condition

Standard value

Permissible value

0

1.2 (Time lag is 0 sec, run the engine at min 1500 rpm)

• Engine speed: Low idling • Hydraulic oil temperature: 45 - 55°C Boom

C OJ

(sec.)

E

• Bucket unloaded • Arm and bucket cylinder fully retracted • Measure time taken from bucket tooth touching the ground to the machine raised

Cl

c.

~

:J

OJ

0-

• Top of boom is in horizontal, bucket cylinder fully retracted

E

OJ

i=

.>t.

0

Arm

s:

-

(sec.)

• Measure time taken from arm stopped when arm came into vertical to arm moved again

(sec.)

• Arm is in vertical • Measure time taken from bucket stopped when bucket tooth came in bottom to bucket moved again

Bucket

OJ

u c co

• Engine speed: Full speed • Hydraulic oil temperature: 45 - 55°C

Cl

c

.~

E

2.8 (Time lag is 0 sec, ru n the engi ne at min 1500 rpm)

0


0

PC200-3

PC220-3

PC220-3

PC200-3


-0

c co c 0 .;::;

OJ

C.

c 0 .;::;

~

~

OJ

c.

OJ

c.

0

0

E co

c 0 .;::; co c

0 E

:0

Arm and Swing 90°

• Bucket unload • Arm is in vertical and boom cylinder is extended fully • Operate at "Boom raise" and in "Swing" at the same time, and measure the time taken and the amount arm top pin moved up when swing for 90°

E 0

Time

3.5 ± 0.4

3.5 ± 0.4

(sec.)

Height of arm top pin (mm) Time

3700 ± 370

4400 ± 440

Min. 2700

Min. 3400

(sec.)

Height of arm top pin (mm)

0 0 aJ

U

-

Boom and Swing 90°

• Engine speed: 2100 rpm • Hydraulic oil temperature: 45 - 55°C • Relief pressure is 30 kg/cm 2

Charging pump discharge

Min. 44.5

40.5

Max. 100

Max. 1.00

Max. 100

Max. 100

Max. 120

Max. 120

Max. 120

Max. 120

Max. 120

Max. 120

(li/min.) Hydraulic oil temperature

• Oil levels and coolant level within specifications • Convert the atmospheric temperature reading in ° F to ° C, using the formula ~ (F - 32) = C.

Engine coolant temperature OJ

u c co co .n co ~

Engine oil temperature

OJ

I

Swing gear case oil temperature

Final drive case oil temperature

Estimate the temperature inside the cab on the basis of the known temperature difference between the atmospheric temperature • Drain the antifreeze and use a forcibly open type thermostat. • Wind velocity, maximum 5 m/sec.: Do not conduct the test in extremely bad weather • Surface conditions: Flat and sandy soils with Nd Value 10 - 20 Nd: niobium .With engine running at full speed, dig a ditch whose width is about the same as the machine and whose depth is about 2/3 the max. digging depth, swing 90°, and dump. Continue until the heat balance is achieved. • As far as possible, keep the oil pressure below the set pressure of the relief valve and use simultaneous operations while digging.

PC200, 230-3

62-7 @



FLOW CONTROL FEATURE TVC VALVE

*

The following table shows the reference values for use when troubleshooting.

Classification

Item

Condition

S position

Posture of work equipment

L position

PC200-3

PC220-3

PC200-3

PC220-3

3.6 ± 0.4

3.6 ± 0.4

3.8 ± 0.4

3.8 ± 0.4

OJ

<.>

c co

E

.E Q;

0.

c

,2 ~

E OJ

Boom and swing 90°

0.

a c a

~

205F2407

•. Engine speed: Full speed

-

• Hydraulic oil temperature: 45 - 55°C

~

co c

:0 E a u (sec.)

• Bucket loaded • Operate at "Boom raise" and in "Swjng" at the same time, and measure the time taken when swing for 90°

www. k omat s upar t s book . c om Posture of work equipment

l~)

j)f>f

,,-);:i

V

Minimum engine speed (rpm) at boom raise, and boom raise speed

~

3co

.e -

e

(sec.)

205F242I


3.2 ± 0.3 (2050 ± 50)

3.5 ± 0.3 (2150±50)

3.8 ± 0.4 (2190 ± 50)

4.0 ± 0.5 (2200 ± 50)

3.5 ± 0.5

3.4 ± 0.5

4.0 ± 0.5

3.9 ± 0.5

• Measure time taken from bucket tooth touching the ground to cylinder fully extended (RAISE)

~

c

a<.>


:5: a u.. Note. Bucket dump speed when relieving oil in swing circuit

~S;

-;:7=~=

(_l

--~)

-

205F2426

(sec.)

Note:


With the control performance check of the TVC valve, it becomes the control position (approximately position A on the curve) when (swing relief pressure 297

o

~~5 + bucket operation

pressure) -:- 2

=

average pressure.

S, L position

:5: a

;;::

'0 ~

c

:>

a

E

-

Pump delivery pressure P

62-10 (5)

PC200, 220-3

-,



MAIN PISTON PUMP PERFORMANCE PC200-3 Main piston pump (S mode)

150 c

-

-E. D<

d

... C ::J

0

E co

100

~

OJ

,~

Qi

www. k omat s upar t s book . c om "0

0-

E ::J

"-

50

oL..-I......J.---l......l..~....L...l-..l.-l.-J---l......l..~....L...L...L...l.-.L....JL......J---l.---l.~.....L......i......L..L....JL......J.....L.....L....L...L...L..J

50

-

-

150

200

Pump delivery pressure

250

P, + P, 2

300

(kg/em' )

Standard value for delivery Q (new machine) (Q/min)

Check point

Test pump del ivery pressure (kg/em' )

Other pump delivery pressure (kg/em' )

Average pressure (kg/em' )

Judgement standard for delivery Q (Q/min) (bottom level)

(1)

P,

P,

P, + P, --2-

See graph

(2)

320

0-20

Note

15 +30 -10

0

(3)

280

320

300

55 ± 20

35

(4)

180

320

250

80 ± 20

60

(5)

300 - 280

0-20

150

140 ± 20

120

(6)

0-20

0-20

0-20

195 + 5 -10

185

See graph

Note: The CO valve is working, so the average pressure is unnecessary.

PC200. 220-3

62-11 (5)



PC200-3 Main piston pump (L mode)

200

~"~":~."~":~."~"liii\1\--1----1----1----I----t---1

150 c

.§. 0<

-

d

C :J

0

E co

100

~

OJ

> a;

www. k omat s upar t s book . c om -a c. E :J

c..

50

Pump del ivery pressure

PI + P2

2

(kg/em 2 )

Check point

Test pump del ivery pressure (kg/em 2 )

Other pump delivery pressure (kg/em 2 )

Average pressure (kg/em 2 )


Judgement standard for del ivery Q (Q/min) (bottom level)

(1)

PI

P2

PI + P2 --2-

See graph

See graph

(2)

320

0-20

Note

15 +20 -10

0

(3)

180

320

250

50 ± 20

30

(4)

200 - 180

0-20

100

130 +30 -20

110

(5)

120 - 100

0-20

60

170 +30 -20

150

(6)

0-20

0-20

195 + 5 -10

185

0:... 20

-


62-12 ®

PC200, 220-3

-



PC220-3 Main piston pump (5 mode)

150 c

-

~ 0< d

..., C

::J

a

E co

100

>

'"

.~

a:;

www. k omat s upar t s book . c om "0

0.

E ::J

a..

50

OL.-.l...-L......J---'---l.---l.--'---L.--'--'--'---'--.l...-.l--L......J---l.---l.---l......L--'---'---L.--'--'--'---'--.l--L......JL......J---l.---l.---l.....J

50

100

1 50

200


P, + pz

-

2

250

300

350

(kg/em Z )



--2-

See graph

See graph

0-20

Note

27 ± 20

0

280

320

300

70 ± 20

50

(4)

180

320

250

100 ± 20

80

(5)

300 - 280

0-20

150

170 ± 20

150

0-20

0-20

0-20

195 + 5 -10

185

Check point

Test pump del ivery pressure (kg/em Z )

Other pump del ivery pressure (kg/em Z )

Average pressure (kg/em Z )

(1)

PI

Pz

(2)

320

(3)

(6)

P, + pz


PC200, 220-3

62-13 @




150 1 - - - - - - 1 - - - -

-

d

C ::l o E

100 f - - - - - I - - - - - - t - - - - - - t - - - - =

r:'" ~

www. k omat s upar t s book . c om a; "'C

Co

E ::l

c..

501-----f-----t-----+-------j------1"


P, + P, 2

(kg/em' )

Check point

Test pump delivery pressure (kg/em' )

Other pump del ivery pressure (kg/em' )




(1)

P,

P,

PI + P, --2-

See graph

See graph

(2)

320

0-20

Note

27 ± 20

0

(3)

280

320

300

40 ± 20

20

(4)

80

320

200

100 ± 20

80

(5)

100 - 80

0-20

100

160 +30 -20

140

(7)

0-20

0-20

0-20

195 + 5 -10

185

-

Note: The CO valve is working, so the average pressure is unnecessary_

62-14 ®

PC200, 220-3

TROUBLESHOOTING Circuit diagram 62-16 62-19 Connection table for connector pins Connector position for troubleshooting 62-21-1 Troubleshooting procedure 62-22 62-23 Checks before troubleshooting Troubleshooting (except troubleshooting for machine monitor) 62-24 62-24 1) How to use the judgement table 2) Judgement table 62-26 3) Method of using the troubleshooting chart. . . . . . . . .. 62-28 Troubleshooting for electric system (E1 - E6) 62-29-1 Troubleshooting for hydraulic and mechanical 62-76 system (H1 - H16)

-

www. k omat s upar t s book . c om Failure mode and components

62-105

-

PC200, 220-3

62-15 Q)

TROUBLESHOOTING

CIRCUIT DIAGRAM

-

CIRCUIT DIAGRAM E. OLSS AND AUTO-DECELERATION SYSTEM (IF EQUIPPED) PC200-3 (Serial No. 20001 - 21463) PC220-3 (Serial No. 20001 - 20364) CN33 Engine speed sensor Swing oil pressure sensor

CN32

Potentiometer

Limit switch (neutral)

TVC solenoid

eNII 02n

Auto-decelerator

028

Control box

solenoid

-

www. k omat s upar t s book . c om Battery relay

:Mode selec-:

~S_~i~

Auto"decelerator switch

D5W

Fuse box CN40

PC200-3 (Serial No. 21464 and up) PC220-3 (Serial No. 20365 and up) 02YB 02 02LG 02LG

CN33

-

Potentiometer

Control box

~ai=n~===J~CN38 02P 02V

OlP 02V

Resistor

02W

028

Mode selector switch connection OPPOSlW term",,,1 No

~'E

Battery relay

Q.5W

Fuse box

62-16 @

OFF

0

ON

o

M

H

0

F20503064

PC200, 220-3

-

-.

-


-



-


*

Standard value and permissible value in following table are the value when 3-stage mode selector switch is at H position.

Classification

Item

Condition

Standard value

Permissible value

Engine low idling speed

• Engine oil temperature: in correct range

730 - 820

-

Engine high idling speed

• Engine water temperature: in correct range

2250 - 2350

-

2150 - 2250

Min.2150

-E

-e"0 Q) Q)

~ c: '", c: w Q)

• Hydraulic oil temperature: 49 - 55°C

Engine speed when one or two main pump circuit oil is relief

Engi ne rated speed

Engine speed when auto-deceleration acts.

Boom control valve

• Engine coolant temperature: incorrect range • Engine oil pressure: incorrect range • At one pump relief: Bucket circuit relief • At two pump relief: Bucket and arm circuits relief • Fuel control lever at "Full" • Work equipment control lever at "Neutral"

e

1200 ± 50

1200 ± 50

A) R.H. and L.H. travel control lever spool (Linkaged type)

Arm control valve

-

2100

Q

b

a

Q

b

a

-

www. k omat s upar t s book . c om r------

Bucket control valve

E E a; >

0

Cl. Cfl

I

I

'

i I

--~4Jr

Swing control valve

Neutral

L.H. travel control valve

....~

-0

-....,

a ' b r--+---j

R. H. travel control valve

204F 173

35

B) Control lever spools excepting A) (With PPC valve) Q

9.5 ± 0.5 9.5 ± 0.5

35

9.5 ± 0.5 9.5 ± 0.5

~~ Boom-Hi control valve 00


Il'"

°OO~

r

Service valve

205F2401

Li n kaged tYpe With PPC valve Linkaged type With PPC valve Boom control lever

Arm control lever

E E a; >

....~ ~

Q)

>

• At center of lever knob

Bucket control lever Swing control lever Travel control lever

~

• Measure at end of travel • Do not start engine

-

g c: 0

Neutral .... Raise and Lower

150 ± 15

65 ± 10

150 +30 0

65 ± 10

Neutral .... Arm I N and OUT

110 ± 15

65 ± 10

110 +22 0

65 ± 10

Neutral .... Curl and Dump

110 ± 15

65 ± 10

110 +22 0

65 ± 10

Neutral .... R.H. and L.H. Swing

150 ± 15

65 ± 10

150 +30 0

65 +10 0

Neutral .... Forward and Reverse Neutral .... Forward and Reverse

Travel pedal

u

Stop -

Low idling

130 ± 15

130 ± 15

F

45 ± 5

45 ± 5

R

40 ± 5

40 ± 5

45 ± 20

45 ± 20

175 ± 30

175 ± 30

-

Fuel control lever Low idling - Full speed

62-16

PC200. 220-3

-

CIRCUIT DIAGRAM

TROUBLESHOOTING

SWING BRAKE SYSTEM (IF EQUIPPED)

Timer

Swing mechan ical "--'-_ _---' brake solenoid

02Yf.,

Oil pressure sensor

1J)(jY

-

I --~I--~

L...:.""----
'-t----+-"'-"---C:E:l----I,,?.-J

I·

battery re ay term Ina

I

Swing brake caution lamp


PC200.220-3

62-16-1 @

-


-

--



Class ification

rn

-""'-

Standard value Item

.2

2.3 ± 0.5

30+ 0 .5 · -0.8

2.4

3.4

Arm control

1.5 ± 0.3

25+ 0 .5 · -0.8

1.8

2.7

1.5 ± 0.3

25+0 .5 · -0.8

1.8

2.7

2.3 ± 0.5

30+ 0 .5 · -0.8

2.4

3.4

Buc ket control Swing control

CJ)

c ro

Travel control

Q; 0-

• At engine full speed • Hydraulic oil temperatu re: 45-55°C • Hook push· pull scale on center of lever knob to measure

0

-

Permissible value

Li n kaged type V'Jith PPC valve Li n kaged type With PPC valve

Boom control

;:

Condition

Ui

> - -

2

Forward

2.5 ± 1.0

3.8

Reverse

2.5 ± 1.0

3.8

Forward

5.5 ± 1.1

8.3

Reverse

6.0 ± 1.2

9

Lever

Pedal

c

0

u Low idling

H

Stop

12.0

Fuel control lever Low idling

H

Full speed

~~:g

15

10.0~~:~

www. k omat s upar t s book . c om Boom circuit Arm circuit

Bucket circuit Travel circuit

320 +10 -6

• Hydraulic oil temperature: 45 - 55°C • Relief pressure at engine full speed (Be relieved oil in only measuring circuit)

Swing circuit

297 +15 -10

275 +25 0

30 +5 0

30 ± 3

Charging circuit

-

-

E -':' CJ)

-""'-

TVC valve outlet pressure


~

~ ~

0-

.S! OJ

~

"0

>

I

NC valve outlet pressure

Difference pressu re of jet sensor

Lowered hydraulic pressu re

• Hydraulic oil temperatu re: 45 - 55°C • At engine full speed • Hydraulic oil temperatu re: 45 - 55°C • At engine full speed

320 +25 0

PC200·3

PC220·3

PC200-3

PC220-3

Lever at neu tral

23 ± 1

24 ± 1

Min.18

Min.18

At one pump relief (320 kg/cm 2 ) Average pressu re of two pump (160 - 170 kg/cm 2

16 ± 1

17 ± 1

15.5 ± 1.5

16.5 ± 1.5

)

Lever at neutral

Max. 7

Lever at stroke end Raise track on one side then rotate sprocket

Min.18

Lever at neutral

15 ± 1.0

15 ± 1.0

Lever at full stroke

Max.2

Max.2

Max. 5

Max. 5

• Hydraulic oil temperature: 45 - 55°C • Difference oil relief pressure between at engine full speed and at engine a half speed (Measure pressure in one circuit only)

Max.7

18

pe200, 220-3

62-17



Classification

Item

Condition

• Hydraulic oil temperature: 45 - 55°C • Open filler cap and run engine for 5 minutes. Fix filler cap and operate work equipment. And position work equipment to measure air pressure in tank.

In hydraulic tank

«

(kg/cm 2

Standard value

Permissible value

Max. 0.39

± 0.15

)

Bucket cylinder fully extended

Arm cylinder fully retracted

PC200-3

PC220-3

PC200-3

PC220-3

/

tt~-~~I ./-//

(Fig. 1) Swing brake angle

-

)

(

.. '

/-/h

"/

203F419 85 ± 10

• Engine speed: Full speed

85 ± 10

95

120

• Work equipment in posture in Fig. 1 • Hydraulic oil temperature: 45 - 55°C • Bucket unloaded

www. k omat s upar t s book . c om (degree)

• Braking angle after swing work equipment 180° with boom horizontal, arm cylinder fully retracted and bucket empty. (angle)

• • • •

Time taken to start swing (sec.)

Time taken to swing

• • • •

(sec.)

Engine speed: Full speed Hydraulic oil temperature: 45 - 55°C Bucket unloaded Measure time taken for 90° and 180° swing from starting point with work equipment in posture in Fig. 1

(mm)

Leakage from swing motor (Q/minJ

3.0 ± 0.3

3.2 ± 0.3

3.6

3.8

180°

4.3 ± 0.4

4.6 ± 0.5

5.2

5.5

Engine speed: Full speed Hydraulic oil temperature: 45 - 55° C Work equipment in posture in Fig. 1 Measure time taken to swing for 5 turns, after swinging one turn as an approach swing

• • • • •

Hydraulic drift of swing

90°

Engine speed: Stopped Hydraulic oil temperature: 45 - 55°C Work equipment in posture in Fig. 1 Bucket unloaded Stop the machine on 15° slope and set boom at 90° angle across the slope • Write the mach marks on the swing circle outer race and track frame. After 5 minutes, measure the lag of match marks. • • • •

Engine speed: Full speed Hydraulic oil temperature: 45 - 55°C Relieve oil in swing circuit Measure leakage from swing motor with measuring cylinder

24 ± 2

30

o

o

Max. 2.5

4

-

62-18 ®

PC200, 220-3



Classification

Item

Condition

T ravel speed (1)

(sec.)

• Engine speed: Full speed • Hydraulic oil temperature: 45 - 55°C • Raise track on one side, then measure time taken to rotate for 5 turns after rotating one turn as an approach travel • Repeat same way with track on other side • • • •

Travel speed (2) (sec.)

-

Standard value

Engine speed: Full speed Hydraulic oil wmperature: 45 - 55°C Machine is On level ground Measure time taken to travel for 20 m after traveling '10 m as an approach travel

~ ?Om

a; >

~

PC200-3 STD

Permissible value

PC220-3 STD

LC

LC

PC200-3 STD

PC220-3 STD

LC

LC

4 39±2 43±2 46±2 50±3 39 +4 43 +4 46+ 50 +5 -2 -2 -2 -3

4 19±2 21±2 21±2 21±2 19+ 21 +4 21 +4 21 +4 -2 -2 -2 -2

l

www. k omat s upar t s book . c om f-

205F2402

Travel deviation

Imm)

Hydraulic drift of travel

-

(mm)

Leakage from travel motor (Q/min.)

Max. 200

220

• Engine speed: Full speed • Hydraulic oil temperature: 45 - 55°C • Run the machine for about 30 m on firm and level ground. Layout a 20 m string from a point 5 - 6 m from the start, and measure the deviation (a) of the machine at the midway point (10 m mark)

• Engine speed: Stopped • Hydraulic oil temperature: 45 - 55°C • Stop the machine on 12° slope with setting sprocket on uphill • Measure distance moved by machine in 5 min. • Engine speed: Full speed • Hydraulic oil temperature: 45 - 55°C • Relieve oil in travel circuit with lock track shoe

0

0

Max.3

4

PC200, 220-3

62-19 @



Classification

Item

Condition

Standard value

(sec.)

Engine speed: Full speed Hydraulic oil temperature: 45 -55°C Bucket unloaded Arm and bucket cylinder fully retracted Measure time taken from bucket tooth touching the ground to cylinder fully extended (RAISE) • Measure time taken from cylinder fully extended to bucket tooth touching the ground (LOWER)

(sec.)

• Top of boom is in horizontal, and bucket cylinder fully extended • Measure time taken from cylinder fully retracted position to cyl inder fully extended position (IN) • Measure time taken cylinder fully extended position to cylinder fully retracted position (OUT)

PC200-3 PC220-3

• • • • •

Boom

Permissible value PC200-3

PC220-3

w

Ul

3.1±0.3 3.4 ± 0.3

3.9

a: a:

w

~

0

2.7 ± 0.3 3.3 ± 0.3

3.3

3.9

4.2 ± 0.2 5.0 ± 0.5

5.1

5.4

3.1 ± 0.3 3.5 ± 0.4

3.7

3.8

..J

-0

ll> ll>

c.

...<: ~

ll>

E

c. :> 0-

Arm

ll>

..><

(;

~

• Top of boom is in horizontal, and arm cylinder fully retracted • Measure time taken from cylinder fully retracted position to cylinder fully extended position (CURL) • Measure time taken from cylinder fully extended position to cylinder fully retracted position (DUMP)

z

-

l:::l

0

-

..J

www. k omat s upar t s book . c om Bucket

...<:

(sec.)

ll>

a: :::l u

3.5 ± 0.4 4.2 ± 0.4

4.2

4.9

2.2 ± 0.2 2.6 ± 0.3

2.7

3.5

Cl.

~ :::l Cl

E

c.

:> 0ll>

Bucket cylinder fully extended \

..><

(;

~

Top of boom horizontal ! Arm cylinder / fully retracted

~~ -~. ---~ ~

-.

Total work equipment

.

(Fig. 2)

...

c=-:)

. .'.'

.

,-

~

.GL

205F575

1440 (960)

Max. 960 (600)

-

.....;: -0 .~

-:>

~ -0

>-

I

(mm) Boom cylinder Arm cylinder

• Engine speed: Stopped • Hydraulic oil temperature: 45 - 55°C PC200: 1260 kg • Buc ket loaded PC220: 1620 kg • Work equipment in posture in Fig. 2 • Measure amount bucket tooth moved down (distance "a") in 15 min. • Measure immediately after setting Max. 50 (30)

(mm) (mm)

Bucket cylinder (mm)

60 (45) "_._-

• Measure amount each cylinder retracted in 15 min. (

): Unloaded

Max. 248 (110) Max. 30 (20)

300 (165) 45 (30)

62-20

PC200. 220-3

-



Classification

Item

Condition

Standard value

Permissible value

0

1.2 (Time lag is 0 sec, run the engine at min 1500 rpm)

0


0


• Engine speed: Low idling • Hydraulic oil temperature: 45 - 55°C Boom

~

c

(sec.)

OJ

E

• Bucket unloaded • Arm and bucket cylinder fully retracted • Measu re time taken from bucket tooth touching the ground to the machine raised

en

~

0::J

OJ

0-

E

OJ

f=

"'0"

• Top of boom is in horizontal, arm cylinder fully retracted

Arm

S

-

(sec.)

• Measure time taken from arm stopped when arm came into vertical to arm moved again

(sec.)

• Arm is in vertical • Measure time taken from bucket stopped when bucket tooth came in bottom to bucket moved again

Bucket

OJ

u

en

c


c

ro

PC200-3

PC220-3

PC200-3

PC220-3

www. k omat s upar t s book . c om .~

E

(;

-0

c

ro

OJ

0-

c

c

0

0

~

~

~

OJ

00

OJ

00

c

§

0

ro

roc

(; E

:n

Arm and Swing 90°

• Bucket unload • Arm is in vertical and boom cylinder is extended fully

3.5±0.4


• Operate at "Boom raise" and in "Swing" at the same time, and measure the time taken and the amount arm top pin moved up when swing for 90°

Time

3.5 ± 0.4

3700 ± 370

4400 ± 440

Min. 2700

Min. 3400

(sec.)


co

0

Time

(sec.)

0 0

E

U

-

Boom and Swing 90°

• Engine speed: 2100 rpm • Hydraulic oil temperature: 45 - 55°C

Charging pump discharge

Min. 50

43

Max. 100

Max. 100

Max. 100

Max. 100

Max. 120

Max. 120

Max. 120

Max. 120

Max. 120

Max. 120

• Relief pressure is 30 kg/em' (Q/min.) Hydraulic oil temperature

• Oil levels and coolant level within specifications • Convert the atmospheric temperature reading in ° F to ° C, using the formula

Engine coolant temperatu re •

OJ

u

c

ro ro

.0 ~

Engine oil temperature

ro

• •

OJ

I

Swing gear case oil temperature

Final drive case oil temperature

•

•

~ (F

- 32) = C.

Estimate the temperature inside the cab on the basis of the known temperature difference between the atmospheric temperature Drain the antifreeze and use a forcibly open type thermostat. Wind velocity, maximum 5 m/sec.: Do not conduct the test in extremely bad weather Surface conditions: Flat and sandy soils with Nd Value 10 - 20 Nd: niobium With engine running at full speed, dig a ditch whose width is about the same as the machine and whose depth is about 2/3 the max. digging depth, swing 90°, and dump. Continue until the heat balance is achieved. As far as possible, keep the oil pressure below the set pressure of the relief valve and use simultaneous operations while digging.

PC200, 220-3

62-21 (~



-

TABLE OF S, L POSITION VALUE

*

The following table indicates the reference values for various actions when the mode selector switch is changed over from H position to S or L position. Classification

Item

Conditions

S position


Boom

L position

PC200-3

PC220-3

PC200-3

PC220-3

3.6 ± 0.4

3.7 ± 0.4

3.8 ± 0.4

3.9 ± 0.4

3.1 ± 0.3

3.4 ± 0.3

3.2 ± 0.3

3.5 ± 0.4

w (/)

~

Bucket teeth on the ground

a:

Cylinder fully extended

a:

205F2421

(sec.)

w

~

0

• Engine speed: High idling • Oil temp.: 45 - 55°C

-l

_.


z

"0

....c

:E

Arm

E

o:

Cylinder fully retracted

:::l

.~

g-

Cl>

=

4.6 ± 0.5

5.4 ± 0.5

4.8 ± 0.5

5.7 ± 0.6

www. k omat s upar t s book . c om c.

Cl>

0Cl>

5-

~

t


Cl>

o

.><

~

o

(

~

(sec.)


)

I6

3.3 ± 0.3

3.8 ± 0.4

3.5 ± 0.4

3.9 ± 0.4

3.6 ± 0.4

4.3 ± 0.4

3.7 ± 0.4

4.3 ± 0.4

205F2422

Posture of work equipment -l

g;

u

Bucket Cylinder fully retracted

t

-


a..

205F2423 (sec.)

~

2.5 ± 0.3

2.7 ± 0.3

2.5 ± 0.3

2.7 ± 0.3

10.6 ± 0.6

9.8 ± 0.5

11.2±0.610.1±0.5

Cl

• Engine speed: High idling • Oil temp.: 45 - 55°C Posture of work equipment Max. reach

Cl

C .~

Normal swing speed

(/)

(sec.)

62-22 @

• Engine speed: High idling .Oil temp.: 45 - 55°C • Measure time taken to swing for :! turns, after swinging one turn as an approach swing.

PC200, 220-3

-



Classification

Conditions

Item

S position PC200-3

Travel posture

L position

PC220-3

PC200-3

4'6° <~~

I

PC220-3

- (c l_~ ~1S<

·~~~:tt.:~tw . . . .... ~......ti.",.:l

.'

205F2409


-

Travel deviation

• On a flat surface, make an approach run of at least 10m, then travel another 20 m. Measure the travel deviation.

~

Max. 200

Max. 200

l

20~

www. k oma~ t s upar t s book . c om 205F2402

Qj

>

.='"

(mm)

* Measure dimension Q. Machine posture with track spinning

"l.

-

~

\\

Travel speed

STD

LC

STD

LC

STD

LC

STD

LC

t~=~~----1 El tiiii1

~

~

··~l'f$:'i~1J)1-~c;,iJ·'£1lliJ~:~·~~~Wrl-,~r~;s;·~jf'~ ~':! .~...')<}.¥.:&~~:~~£t,;r;,~.~~~~ ..~t."~'l:\.'JC:;,~".; ~}~;;:~~l;~'Jf ..~

19±2 23±2 19±2 21±2 20±2 25±2 21±2 23±2

205F2427

(sec.)

• Engine speed: High idling • Oil temp.: 45 - 55°C • Raise one track off the ground, let it spin one revolution, then measure the time required for it to spin 2 revolutions. Repeat this procedure for the other track.

-.-

PC200, 220-3

62-23 @



-

FLOW CONTROL FEATURE TVC VALVE

*

The following table shows the reference values for use when troubleshooting.

Classification

Item

Condition

H position


S position

L position

PC200-3

PC220-3

PC200-3

PC220-3

PC200-3

PC220-3

3.5 ± 0.4

3.5 ± 0.4

3.8 ± 0.4

3.8 ± 0.4

4.0 ± 0.4

4.0 ± 0.4

Q)

"c '" E

£' Q;

Q.

c .Q ~

~

Boom and swing 90°

Q)

Q.

~~ ~

205F2407


0

c 0

~

'"c .0

E 0

U

(sec.)

• Bucket loaded • Operate at "Boom raise" and in "Swing" at the same time, and. measure the time taken when swing for 90°

-

Posture of work equipment "

www. k omat s upar t s book . c om )J

!'sd'/'

Minimum engine speed (rpm) at boom raise, and boom raise speed

"

205F242I

~

;: '" ~

-

(sec.)

e

• Engine speed: Full speed • Hydraul ic oi I temperature: 45 - 55°C • Measure time taken from bucket tooth touching the ground to cylinder fully extended (RAISE)

3.1 ± 0.3 (2020±50)

3.4 ± 0.3 3.6 ± 0.4 3.7 ± 0.4 3.8 ± 0.4 3.9 ± 0.4 (2130± 50) (2160± 50) (2180±50) (2190±50) (2200±50)

~

c 0


"i: 0

u::

~=~'~'L"'~". .

Note. Bucket dump speed when relieving oil in swing circuit

,

! '

l

~

~JI.~.
3.1 ± 0.5

3.1 ± 0.5

3.5 ± 0.5

3.7 ± 0.5

3.8 ± 0.5

4.0 ± 0.5

205F2426

(sec.)

Note:

• Engi ne speed: Full speed • Hydraulic oil temperature: 45 - 55°C

With the control performance check of the TVC valve, it becomes the control position (approximately position A on the curve) when (swing relief pressure 297 ~~5 + bucket operation pressure) -;- 2 = average pressure.

S, L position

d i: o

d i: o

..... '0 ;:

;;:::

'0

o'" E

~

c

'o" E

«

« Pump discharge pressure P

62-24 (5)

Pump discharge pressure P

PC200, 220·3

-

-

JUDGEMENT TABLE

TROUBLESHOOTING

2) JUDGEMENT TABLE (2-STAGE MODE SELECTOR OLSS) (From measuring voltage of solenoid valves, go to electrical system Troubleshooting Charts No. E) Troubleshooting tool

""ro

Tester· T -adapter

SO/eno' Id Valve 1J6/esh °Ot·Ing

tJro c

TVC solenoid valve

e(jlJre 1.

Stop engine, turn starting switch OFF.

2.

Connect T-adapter (socket adapter) to

3.

Turn starting switch ON.

4.

Is voltage between CN13 (TVC solenoid valve)

CN13 (female) (TVC solenoid).

(1) and (2) as shown in following table?

~

$. "'"?

"'' ' '~

'?",

(Normal) Position of mode selector switch

Measuring voltage

S mode

OV

L mode

20-30V

Go to Troubleshooting Chart

www. k omat s upar t s book . c om Electrical system

Hydraulic, mechanical system

E -1

H - 1

Troubleshooting mode

1

-

-

Machine deviates excessively (when traveling normally)

0

Hydraulic, mechanical system defective Electrical system defective

As above table: Not as above table:

2

Mach ine deviates excessively (during compound operations)

-

-

H-2

3

Machine deviates excessively (when starting)

-

-

H-3

4

Control levers are heavy

-

-

H-4

5

Work equipment, travel, and swing start suddenly

-

-

H-5

6

Speeds for work equipment, swing, and travel are all extremeIy slow, or there is no power

7

Engine stalls or engine speed drops during operations

B

No change in output when mode selector switch is operated

0

As above table:


Not as above table: -

0

As above table:

1

-

HYdraulic, mechanical system defective Electrical system defective

Not as above table:

E-

E-4

H-6

H-7

H-B

10

Abnormal noise comes from around pump

-

-

H -

11

Swing speed is slow

-

-

H -11

12

Upper structure does not swing

-

14

Excessive hydraulic drift of work equipement

-

-

H-6 d) section

15

Parking brake does not work (no slopes)

-

-

-

16

Excessive time lag for work equipment

-

-

H -16

PC200.220-3

E-6

H -

10

12

62-23-2 (4;

JUDGEMENT TABLE

TROUBLESHOOTI NG

2) JUDGEMENT TABLE (2-STAGE MODE SELECTOR OLSS) WITH AUTO-DECELERATION AND SWING MECHANICAL BRAKE

-

(From measuring voltage of solenoid valves, go to electrical system Troubleshooting Charts No. E-xx, or hydraulic Troubleshooting tool

Tester' T-adapter

SOlenoid ita/lie

TVC solenoid valve

Auto-deceleration solenoid valve

7-,., °V61. "sf,

00,. 11)9

~ro

<'''01

vr "

1.


1.

2.

Connect T-adapter (sOcket adapter) to

2.


Stop engine, turn starting switch OFF. Connect T-adapter (socket aadpter) to CN40, CN41 (auto-deceleration solenoid valve) (female).

3.


4.

Is voltage between CN27 ITVC solenoid

3.

valvel 11) and (2) as shown in following

4.

Turn starting switch ON. Is voltage between CN40, CN41 lautodeceleration solenoid valve) 111 and (2) as

table?

shown in following table?

't

~ "'-?;. "'?..

'<.

(Normal)

'Go", Position of mode selector switch

Measuring voltage

S mode

OV

L mode

20 - 30 V

Measuring voltage

When operating each control lever

Operated

Solenoid B (2-pin side)

-

20 - 30 V

www. k omat s upar t s book . c om Neutral

Solenoid A (3-pin sidel

OV after approx. 5 sec. delay


1

2

3

Machine deviates excessively (when travel ing normally)

0

As above table:


Not as above table:

Machine deviates excessively (during compound operations)


-

-

-

-

-

4


-

-

5


-

-

6

Speeds for work equipment, swing, and travel are all extremely slow, or there is no power

7


8


0

As above table:

Hydraulic, mechanical system defect'lve Electrical system defective

Not as above table:

-

0

As above table:


Not as above table:

Auto-deceleration does not work properly

-

10


-

11

Swing speed is slow

-

9

12


-

-

0

As above table:


Not as above table:

defective Electri cal system defect ive -

0

As above table:


Not as aobve table:

13

Excessive hydraulic drift of swing

-

-

14


-

-

15

Parking brake does not work Ino slopes)

-

-

16


-

-

62-23-3 @

-

-

PC200, 220-3

-

TROUBLESHOOTING

JUDGEMENT TABLE

and mechanical system Troubleshooting Charts No. H-xx.)

Tester

Swing brake solenoid valve

1.

Disconnect swing brake solenoid and connector.

2.

After running engine for at least 10 seconds,

stop engine and turn starting switch ON. 3.

~

Swing lever Neutral

-

Operated.

(Normal) When operating swing lever

Measuring voltage

Operated

20 - 30 V

Go to Troubleshootihg Chart

Electrical system


-

E- 1

H-1

-

-

H-2

-

-

H-3

-

-

H-4

-

-

H-5

-

E - 1

H-6

-

-

H-7

-

E-4

H-8

-

E-5

H-9

www. k omat s upar t s book . c om OV

after approx. 5 sec. delay

Neutral

-

PC200.220-3

-

-

H - 10

-

-

H - 11

-

E-6

H - 12

-

E-6

H -13

-

-

H-6 d) section

-

-

-

-

-

H - 16

62-23-4 ®

METHOD OF USING THE TROUBLESHOOTING CHART

TROUBLESHOOTING

3) METHOD OF USING THE TROUBLESHOOTING CHART (2-STAGE MODE SELECTOR OLSS) (See "Example 1")

CD

Problem number and symptoms The problem number and symptoms are written at the top left of the toubleshooting chart. Problem No.

Location of failure

E-M

Electrical system of electric OLSS, auto-deceleration (if equipped), swing mechanical brake (if equipped)

H-XX

Hydraulic or mechanical system of electric OLSS, auto-deceleration (if equipped), swing mechanical brake (if equipped)

M-OO

Machine monitor (use symptom to go immediately to troubleshooting; Judgement Table not used)

®

Troubleshooting tools Prepare the tools listed under "Troubleshooting tools" at the bottom left or right before starting troubleshooting.

®

Categories for same symptom Even though the symptom is the same, if the machine model or component is different, the method of using the troubleshooting chart may be different. In such cases, the symptom is divided into sections a), b). etc. Select the appropriate section and start toubleshooting from that point. If there are no sections, start troubleshooting from the beginning.

-

www. k omat s upar t s book . c om @ Following the troubleshooting chart • Carry out the check or measurement inside the box. If the result is "YES", follow the YES arrow; if the result is "NO", follow the NO arrow. • If the YES or NO arrow leads direcly to the Cause column, take the action given in the Remedy column; if the arrow leads to another box, carry out the check listed in the box. (Note: The number at the top right corner of each box is only a list number; it does not necessarily indicate the order for troubleshooting.) • Any instructions given below the box are work to be carried out before making the check listed in the box. These instructions include preparatory work, operations to be carried out, and judgement values. If the preparatory work is not carried out, or the operations are carried out wrongly, mistakes will be made in judgement, or the machine may be damaged. Therefore, before making the check or measurement in the box, read these instructions carefully and carry them out in the order listed. Then go on to the check or measurement.

®

General precautions In the troubleshooting chart some precautions apply to the whole troUbleshooting procedure for that symptom. Such symptoms are marked and are listed below the symptom. The precautions marked are not usually repeated in the instructions under each box, but they apply in each case and must not be forgotten.

*

®

-

*,

The page following the Troubleshooting Chart (See Example 2) gives the places to be checked or measured, and the connector pin numbers. • Photograph showing location of connector, fuse or plug for measuring • Diagram showing location of connector pin number

62-23-5 @

PC200, 220-3


TROUBLESHOOTING

Example 1 Troubleshooting Chart No. E-4 (2-STAGE MODE SELECTOR OLSS) Failure mode: No change In output when mode switch is operated.

T -adapter or socket adapter

Tester

,~

IforMICI



Ifor EKONOJ

lforDLlJ

S-mode performance in L-mode

Cause 4 YE ::'

Remedy

For travel deviation, see H- 1

r-:-'s-r-es-'-is-'-'-an-c-e"'"b-e---::''':' r- For lack of power, see H-8 YES tween CN34

-

(female) (1) and (2) within standard

"'l,,:~;:;al.:;;~e"'o~-n-e-c'''''T,.._--1..,~ Resistance defective adapter

YES 2

2)

(female) (l) and (2)

3)

10-25fl>

Is eN 13 (female) OJ, (2) - chassis ground insulated?

YES

Is resistance between NC13

1)

NO

(socket) to CN34 (female) Leave male disconnected Turn starting

switch OFF

L....,..,.-=.;;...:.:::.:..::.-----_-l TVC solenoid defective

Connect

:-10

Replace

www. k omat s upar t s book . c om T -adapter

2)

1)

Is voltage between CN13 Imalel III and (2) within standard value?

'4)

2)

3)

Connect Tadapter (socket) to CN 13 (female) Leave male disconnected. Turn starting switch OFF

1) Turn mode selector switch

3)

Turn starting switch ON Connect T adapter (socket) to CN13 (male)

NL,.,:~:.:.I--:.T:::"r.:.:n.:s.::ta.:.:rt:::.in:;;g,:s:,:W:.:i'::Ch.:.:O::F.:F

NO

YES

Is resistance between CN34 within standard value?

2) 3)

Replace

-

Harness defective ~=-------I"'"1) Disconnection in wiring harness 2) Short circuit

Replace

NO L.:.:.:::..-

Replace

--I-I Mode selector switch defective

Connect T -adapter (socked to CNP4 (femalel. Leave male disconnected Turn starting switch OFF

- - - - - - 1 Resistance defective

Turn mode selector switch

,;-;:4.:.:1.:.:Tc:"",rn.:.:m=od::ec:s:.:e:.:le.:.c':.:o.:.:rs::w.:.:i.:.:tc",h.::IL::.'.:.:_

NO

III 2)

121' 1)

Ifemalel111 - 121

1)

-.I TVC valve defective

YES

Is there continuity between CNP4 (female) (1) and

5

ILl. 2)

(socket) to eN 13 (female) Leave male disconnected.

Replace

Turn starting switch OFF

!!

(~)

* *

PC200

55 ± 5%

PC220

40:::t: 5%

Turn the starting switch OFF before disconnecting the connectors or connecting the T-adapter (or socket). For T-adapters, connect to both the male and female ends; for the socket, connect to the connector marked in (

).

Example 2 POSITION OF CONNECTORS FOR TROUBLESHOOTING E-4 1 _ Measure voltage between CN13 Imalel (1) and 121_

2.

Check for short circuit between CN13 Ifemale) (1), (2) and chassis ground.

3.

Measure resistance between CN13 (female I 11 ) and (21.

fJ<: ~ frn1iTI[ 1

PC200, 220-3

P205021

2

62-23-6 ®

TROUBLESHOOTING

HOW TO USE THE JUJ)'.:iEMENT TABLE

TROUBLESHOOTING (except troubleshooting for machine monitor)

--

1) HOW TO USE THE JUDGEMENT TABLE (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED) This judgement table covers the electronic OLSS, auto-deceleration, and swing brake systems. It is used to decide if the problem is in the electrical, or in the hydraulic or mechanical system of the machine. The table then shows whether to go to the troubleshooting tables for the electric system (E-l'>X) or to the troubleshooting tables for the hydraulic and mechanical system (H-XO). This judgement table use two of the following checks to show which troubleshooting item to go to. Visual checks of the self-testing display (two LEDs on the control box), checks by switching over prolix circuit, and checks of the voltage at the inlet of the swing brake solenoid (shown as. in the chart on the next page). With the machine monitor, use the failure mode to go directly to troubleshooting of the machine monitor (M-M).

*

1.

Self testing display The self display uses two LEDs (red and green). The combination of these LEDs (OFF, ON, flashing) shows if the machine is normal, or indicates the system which is the cause of the abnormality.

LED (Light Emitting Diode)

LED (Light Emitting Diode) Machine condition

Red LED

Green LED

Red LED

Green LED

--

Location of abnormality in electrical system

www . k o ma t s u p a r t s b o o k . c o m • • * '* * *• * (') 'J

•

ON

S mode except when using deceleration

OFF

Fast flashing (five times per second)

H or L mode (except when using deceleration)

ON

OFF

Slow flashing (once every 2 seconds)

All modes during deceleration

Flashing (twice per second)

OFF

0

OFF

0

0

Flashing (twice per second) ON

• *

ON

0

*

OFF

Power supply

ON

Control box

OFF

TVC solenoid system


Rotation sensor system

OFF

Throttle sensor system


Auto-deceleration solenoid system

--

If the self-testing display shows no abnormality, or when the swing brake system (which does not pass through control bos) is marked by. in the judgement table, go to the following checks.

2.

Checking by switching over prolix circuit Switch over the prolix circuit switch (located at the side of the control box) and see if the problem is corrected. Depending on the result, proceed to diagnosing processes E-Xl'> or H-O by following the indication ..... in the Troubleshooting Table.

3.

Checking voltage of swing brake solenoid Run the engine for about 10 seconds to charge the accumulator pressure, then stop the engine, turn the starting switch to ON, and check if the voltage at the chassis wiring end of the connector for the swing brake solenoid is normal or not.

-62-24 @

PC200, 220-3

-



MAIN PISTON PUMP PERFORMANCE PC200-3 Main piston pump (H mode)

210+----,----,----,------,--------,,-----------,,-----------,

\

189

..

168

147

-

c

~

:2!. 0

126

~

C ::J

0

E

105

'" > 0;

>

www. k omat s upar t s book . c om Qj ""0 0-

84

E ::J

"-

63

42

21

T

u

2i)O

I,(]


Pi + P2 2

(kg/em 2 ) 205F2404A

Check point


Other pump del ivery pressure (kg/em 2 )




(1)

Pi

P2

Pi + P2 2

See graph

See graph

(2)

320

0-20

160 -170

27

±

20

0

(3)

305

0-20

152.5 - 162.5

77

±

20

57

(4)

180

320

250

95

±

20

75

(5)

300 - 280

0-20

150

153

±

20

133

(6)

50

0-20

25 - 35

195 + 5 -10

185

PC200, 220-3

62-25




200 1;;;;;;====±;;;;;;:------+-----__+----_+-----+-----+-------1

150 1 - - - - - - + - - -

a

-

~

C ::J

o E

100

ro

~----j---------+----___+'

~

'"> "0 '"

www. k omat s upar t s book . c om C.

E ::J

c..

5b

~----j---------+----__+----_+-----'


PI + P,

2

(kg/em' )

Check point

Test pump del ivery pressure (kg/em' )

Other pump del ivery pressure (kg/em' )




(1)

P,

P,

PI + P, 2

See graph

See graph

(2)

320

0-20

Note

15 +20 -10

0

(3)

280

320

300

30 ± 20

10

(4)

180

320

250

60 ± 20

40

(5)

300 - 280

0-20

150

125 ± 20

105

(6)

0-20

0-20

10 - 20

195 + 5 -10

185


62-26 (~

PC200, 220-3

-




200 ~----+-----j--------i------+----+-----+-----J

150

-

c

-€ C<

-

d

C

::J

0

E ell

100

~

Q)

.~

www. k omat s upar t s book . c om "iii

-c c.

E ::J

c..

50

o L..-..l...-J..-J..-J..-5.L..0.....L......l-....l--'-1-:0'""=0-'-....l........l........l....1.....l5-0...l-...l-...l-..l...-2.J..00.....J.......J..-L..-L-25.L..O-l...-I...-I...-I...3-01....0-l...-L-I.......l.......J

3 50

PI + P2 2


-

(kg/em 2

)



See graph

See graph

Check point


Other pump delivery pressure (kg/em 2 )

(1)

PI

P2

(2)

320

320

320

15 ± 10

0

(3)

200 - 180

0-20

100

140 ± 20

120

(4)

80

320

200

75 ± 20

55

(5)

0-20

0-20

10 - 20

190 +10 20

170


PI + P2 2

PC200, 220-3

62-27 ®



PC220-3 Main piston pump (H mode)

210

VU

189

\!

>/!\.

" :0;\f)....

168

ji

;

V >:

147

\jjP iff {If>,

c

'\ ifi;;

..§. DI

::ii

126

!f!:~

;'i

i'"

d

..., c

'\iJf!!

:;)

0

E co

105

"'-

> Q;

> tii

84

-

;;~~ !8

~~""" II~

rl www. k omat s upar t s b o o k . c o m ~I "tJ

c.

E :;)

c..

63

42

t00

21

50

()

:SCJ

10[)

;)00


):J(J

P, + P, 2

)O(J ) 0

(kg/em' )

205F2405A

Check point






(1)

P,

P,

P, + P, 2

See graph

See graph

(2)

320

0-20

160 - 170

27 ± 20

0

(3)

305

0-20

152.5 - 162.5

100 ± 20

80

(4)

180

320

250

119 ± 20

99

(5)

300 - 280

0-20

150

192 + 5 -20

172

0-20

25 - 35

195 + 5 -10

185

(6)

50

-

62-28 (5)

PC200, 220-3

JUDGEMENT TABLE

TROUBLESHOOTING

2. Does NORMAL display appear) 1)

21

During deceleration (H, Sand L modes)

0

H\'cj

0

Ila'[,'"9

Green

.}-

. Is voltage at inlet of

auto-deceleration solenoid correct?

OFF

r

flashing

1)

-

21

All control levers at neutral Engine at full throttle

I 1) Lever NEUTRAL solenoid A (3~pjn side) 20 - 30V 2) Lever operation solenoid B (2-pin

Auto-deceleration switch at OFF Engine at half throttle Operate mode switch H ---+ S ---+ L.

21 3)

Lever at

ncutra,l

["" When operating

times per second)

1)

chart

3. Does problem disappear 4. Is voltage at inlet when prolix circuit port of swing brake switch is operated? solenoid normal?

Other than decele· ration (H and L modes)

Rc(1

Of'F

Troubleshooting

Checking swing brake solenoid voltage

Checking by switching prolix circuit

Checking voltage of auto·deceleration solenoid

Check self·testing display

11

~wlng

1

23

I

30V

I

ov

Go to E -60 for abnormal ities in electrical system; go to H - OX for abnormalities in hydraulic or mechanical system.

1} Disconnect connector of swing brake solenoid 2) Run engine for about 10 sec. 3) Stop engine, and turn starting switch to ON. 4} Move swing lever between neutral and sWing.

Engine at half throttle or above

side) 20 - 30V 3) Engine at half

throttle or more 4) Measu re solenoid A after about 5 seconds

- - - - - - - - " E-l

YES

_

E .

- -'l

II

---------'l

H

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ -'l

H

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~2!;-~r

1---------

(Step 91

H - 1


-

-

-

-

-

-

-

-- -

-

-

4

- - - - - - - - - - - - - - - - - 1 - - - - - - - - - 0 ) II 1 - - - - - - - - - - " F:

-----

----------------

--

-

-- - - - - - -

AYES --

f-- _

~--~ NO

-- -

-

-

-

-- -

-

-

-

-

-

-

-

-

-

-

-

-

-

-

- -

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-"

H E

E

-

-

-

-

-

-

-

-

-

-

-

-

-

-

YES

-----------.--i~

--------

{Step 91

3 3

--------+-------- -------

2

6

-

-

-

-

-

-

-

I- -

-

-

-

-

---'

{Step 81

r:

--------1---------

II

----------------'

E

8 (Step 5)

(Step 41

1---------

II

10

+----------------1--------"

II

11

p.~--,

II

- - ~L'.'J~--,

13

r:

+ --------1- --------------------

--~---

I

!

---------1-------

------- -

I-- - - - - - - - -

1----------------- ------- ----

-

6 H - 6

------- ----------------' -------1--------

PC200. 220-3

- - - - - - - - - - - - - - - - - ; : II

16

62-27-2 Q)


TROUBLESHOOTING

3) METHOD OF USING THE TROUBLESHOOTING CHART (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED)(See "Example 1")

CD

Problem number and symptoms The problem number and symptoms are written at the top left of the toubleshooting chart.

Location of failure

Problem No.

E-M

Electrical system of electronic 0 LSS, auto-deceleration, swing brake

H-XX

Hydraulic or mechanical system of electronic OLSS, auto-deceleration, swing brake

M-OO


®


®

Categories for same symptom Even though the symptom is the same, if the machine model or component is different, the method of using the troubleshooting chart may be different. In such cases, the symptom is divided into sections a), b), etc. Select the appropriate section and start toubleshooting from that point. If there are no sections, start troubleshooting from the beginning.

®

Following the troubleshooting chart • Carry out the check or measurement inside the box. If the result is "YES", follow the YES arrow; if the result is "NO", follow the NO arrow. • If the YES or NO arrow leads direcly to the Cause column, take the action given in the Remedy column; if the arrow leads to another box, carry out the check listed in the box. (Note: The number at the top right corner of each box is only a list number; it does not necessarily indicate the order for troubleshooting.) • Any instructions given below the box are work to be carried out before making the check listed in the box. These instructions include preparatory work, operations to be carried out, and judgement values. If the preparatory work is not carried out, or the operations are carried out wrongly, mistakes will be made in judgement, or the machine may be damaged. Therefore, before making the check or measurement in the box, read these instructions carefully and carry them out in the order listed. Then go on to the check or measurement.

-


®

General precautions In the troubleshooting chart some precautions apply to the whole troubleshooting procedure for that symptom. Such symptoms are marked and are listed below the symptom. The precautions marked are not usually repeated in the instructions under each box, but they apply in each case and must not be forgotten.

*

®

*,


62-28

PC200, 220-3

-

-




150 c

-

.§. 0<

d

c: :l

0

100

E co

> Q;

>

Qj "0 C.

www. k omat s upar t s book . c om E :l a.

50


-

-

PI + P2

2

(kg/em 2 )


Check point

Test pump delivery pressure (kg/em 2 )

Other pump de, ivery pressu re (kg/em 2 )

(1)

P,

P2

(2)

320

0-20

Note

27 ± 20

0

(3)

280

320

300

55 ± 20

35

(4)

80

320

200

120 ± 20

100

Average pressure (kg/em 2 ) P, + P2

2

See graph

Judgement standard for del ivery Q (Q/min) (bottom level) See graph

(5)

80 - 100

0-20

100

185 +15 -20

165

(6)

0-20

0-20

0-20

195 + 5 -10

185


PC200. 220-3

62-29 (~




200 ~~~~mmtim~~~l~~~~1~~~~1~~~~T~~~~T~~~1

150

C

:§: ~

-

0

c " E 0

co

100

~ CIJ > Qi "0

www. k omat s upar t s book . c om a. E

"

0-

50


Pi + P, 2

(kg/em' )

Standard value for delivery Q (new machine) (12/min)

Judgement standard for delivery Q (12/min) (bottom level)

See graph

See graph

Check point



(1 )

PI

P,

(2)

320

0-20

Note

27 ± 20

0

(3)

280

320

300

40 ± 20

20

(4)

80

320

200

105

20

85

(5)

180 - 200

0-20

100

170 ± 20

150

0-20

0-20

0-20

195 + 5 -10

185

(6)

Average pressure (kg/em' ) P, + P,

2

±


62-30 @

PC200, 220-3

-


TROUBLESHOOTING

Example 1

CD

Troubleshooting Chart No. E-2 Failure mode: Work equipment, swing, travel speeds extremely slow, or lack of power.

Tester T-adapter or socket adapter (forEKONOJ

@

a)

T-adapter or socket adapter (forMICI T-adapter or socket adapter (forDLII

Self-testing display shows abnormality

-

YES

YES

Is voltage between eNl0 (female) (l) and {2120 ~ 30 V 7

';.:.(:....J

OFF

OOFF

O

Is voltage between fuse 4 and chassis ground 20 - 30 V?

1)

Connect T -adapter

2)

Turn starting switch ON. (Do not start engine)

'::.,'1

n:s

Is voltage between eN 10 (female} (2) and chassis ground

Abnormality in power supply

(socket) to eNl 0

QV?

www. k omat s upar t s book . c om Red

Green


,)

2)

Connect T -adapter (socket) to eN' 0 Turn starting switch ON (Do not start engine)

r! ! J - - - - - - Abnormality

®

* *

In

control box

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket), For T -adapters. connect to both the male and female ends; for the socket, connect to the connector marked in (

),

Example 2

®

2,

3,

Measure voltage between CN10 (female) (1) and (2). Measure voltage between CN10 (female) (2) and chassis ground,

PC200. 220-3

62-29 CD

TROUBLESHOOTING

E-'

-

Troubleshooting Chart No. E-1 (2-STAGE MODE SELECTOR OLSS) Failure mode: Machine deviates excessively (always deviates)

*

All work equipment. swing, and travel speeds extremely slow or lack power.

* Mode selector switch (5)

Cause

YES

Remedy

For travel deviation, See H-1 For lack of power, see H-6

3

YES

1) Turn starting switch ON. 21 Turn mode selector switch (S),

2

YES 1 Is resistance between CN13 (female) (1) and (2) 10 - 25 iP

Is voltage between CN13 (male) (1) (2) OV?

Is CN13 female (1), (2) - chassis ground insulated?

4Y~ NO

Is there continuity between CNP4 (female) (31 and (4)? 1)

1)

Connect Tadapter (socket) to CN13 (female). 2) Leave female disconnected. 31 Turn starting switch OFF.

Turn starting switch OFF. Leave female disconnected. Turn mode switch (S).

Mode selector switch defective

Replace

-

-

ToA

NO


2) 3)

ConnectTadapter (socket) to CN13 (female) Leave female disconnected. Turn starting switch OFF.

21

3)

NO

NO

YES 6

YES 5

From A

Is there continuity between CN20 (male) (6) and (12)? 1)

Connect Tadapter (socked to CN20 (male). 2) Leave female disconnected. 3) Turn starting switch OFF.

, Cl

~c:

Tester

fQ';:;

::>0'"

T -adapter or socket adapter (forEKONO)

o~£ ~.<:

~'",

62-29-1 @

Is there continuity between CN35 (male) (21 and (4)?

TVC solenoid defective

Replace

TVC valve defective

Replace

Short circuit in wiring harness between CN13 (male) (1), (21 and CN35 (malel (21, (4).

Replace

-

r-

1)

Connect Tadapter (socket) to CN35 (male). 2) Leave female disconnected. 3) Turn starting switch OFF.

NO

NO

Defective contact in wiring harness between CN20 (female) (6), (12) and CN35 (female) (2), (4).

Replace

Short circuit in wiring harness between CNP4 (male) (3), (4) and CN20 (female) (6), (12).

Replace

T -adapter or socket adapter (forMIC) T -adapter or socket adapter (for DLD

-pe200.220-3

E-1

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-1 1. 2.

Measure resistance between CN13 (female) (1) and (2). Check for short circuit between CN13 (female) (1), (2) and chassis ground.

3.

Measure electric current between CN13 (male) (1) and (2).

~ ~rn § [ 1 _

4.

2

Check for continuity between CNP4 (female) (3) and (4).


Check for continuity between CN20 (male) (6) and (12).

6.


-

PC200, 220-,)

62-29-2 ®

TROUBLESHOOTING

E-1

-

Troubleshooting Chart No. E-1 (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED) Failure mode: Machine deviates excessively.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in

(

a)

l. Self-testing display shows abnormality

Abnormality in control box ON

I

! !

ON

I

1-------------------------------------------------

YES

2 Is CN13 (male) (11. (2) - chassis ground insulated?

YES

4 Is resistance between CN36 (female) (1) and (2) 10 - 25 11? Is each pin to chassis ground insulated?

YES 1)

1 2)

Is resistance be-

3

Connect T -adapter (socket) to CN 13 (male). Turn starting switch OFF.

NO

tween CN13 (male) (1) and (2) 10 - 25 n?

YES

Is resistance between CN36 Ifemale) (3) and (5) 10 - 25 11? Is each pin to chassis ground insulated?

1)

~

Connect T -adapter Isocket) to CN36 (female). Turn prolix circuit switch OFF.

-

o


Green

1)

2)

2) Return CN 13 to original position. Connect T -adapter :'\0 Isocket) to CN36 (femalel. Turn starting switch OFF.

1)

Connect T -adapter (socket) to CN13 (malel. Turn starting switch OFF.

2)

;\;0

3)

• When using T -adapter 3

YES 2 Is voltage between CN9 (1) and (2) Vcc/2?

YES Abnormality in potentiometer

ONe Red

OOFF

Green

I

...-

-:>

-'1:, , Is voltage between CN9 (female) (1) and (3) 5 - 5.2 V?

1) 2)

1)

Connect T -adapter (socket) to CN9. Turn starting NO switch ON.

2) r

ConnectT -adapter to CNI o. 2 g L-_)_T_u_rn_s_t_a_rt_in_ _s_w_it_c_h_O_N_.

Measurement conditions same as in previous step. Take voltage between CN9 (1) and (3) as Vcc.

Is voltage between CN 10 (male) (7) and (8) 5 - 5.2 V? 1)

•

NO

1)

NO

I 2)

YES\

Is voltage between CN 10 (6) and (7) Vcc/2?

3

Is resistance between CN9 (male)

K n ? Is it insulated from chassis ground?

~c

Tester

..c'.;::;

:l0~

000

~~E

T-adapter or socket adapter (forEKONO)

62-30 @

1) Disconnect CN9. 2) Do not start engine. 3) Governor lever at FULL.

Is difference in resistance between CN9 (male) (1) and (21. and resistance between (2) and (3) less than 30 n? Measurement conditions same as in previous step.

YES

Is difference in resistance between eN 10 (fern aIel (6)

YES

(1) and (3) 5 ± 1

-

NO

When using socket adapter

2

T -adapter or socket adapter (forMIC) T-adapter or socket adapter (for DLI)

I

Connect T -adapter to CN10. Turn starting switch ON.

YES

_

YES

3

, O'l

I

and (7), and res istance between (7) and (81 less than ~.ll?

1) 2) 3)

Connect CN9. Disconnect CNI O. Do not start engine.

NO

NO

I I

I i

NO

pe200.220-3

-



TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE

-

TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE Component

System

Connector No.

Testing method

~

B (J

'"cc

Measurement conditions

Judgement table

1) When using the short connector,

1) Starti ng switch ON

the following results show that the sensor is defective

0

(J

t::

Short connector connected

Monitor goes out

CN2 disconnected

Monitor I ights up

0 .J::

en

--

Coolant level sensor

CN2 (Male) 1) When carrying out a continuity test,

.~

the following results show that the sensor is normal

c c

Coolant level normal

Continuity

Coolant level abnormal

No continuity

:J

~

1) Starting switch OFF

-

0

()

B (J

1) When using the short connector,

1) Starti ng switch ON

the following results show that the sensor is defective

www. k omat s upar t s book . c om '"cc

0

(J

~

0 .J:: en

.~c

Engine oil level sensor


Monitor goes out

CN4 disconnected

Mon itor Iights up

CN4 (Male) 1) Starting switch OFF

1) When carrying out a continuity test,

0

E

.~

0>

c

:J

the followi ng reSults show that the sensor is normal

c:

.J:: (J

~

'" ~

c: 0

Engine oil level normal

Continuity

Engine oil level abnormal

No continuity

()

1) Starting switch OFF

The following results show that the sensor is normal "'0>

Engine water temperature sensor (engine water temperature gauge)

C

(J

'= CN5 (Male)

c

:J '" V> ~

Normal temperature (25° C)

Approx. 37-50kr2

~~

100°C

Approx.3.5-4.0kr2

ro.~ 0> V>

B (J

0>

C

1) When using the short connector, the following results show that the sensor is defective

-

1) Engine started

c: 0

(J ~

0


Monitor goes out

CN6 disconnected

Monitor I ights up

.J::

en

Engine oil pressure sensor

CN6 (Male) 1) When carrying out a continuity test,

.~ :J

the following results show that the sensor is normal

1) Engine started

.~ ~

C

0 ()

62-32

Engine oil pressure over 1 kg/cm 2 Engine oil pressure under 0.3 kg/cm 2

Continuity No continuity

PC200, 220-3



System

Component

Connector No.

Testing method

B u


Judgement table

1) Starting switch ON

1) When using the short connector, the following results show that the sensor is

(l)

defective

c c

0 u ~

0


Monitor goes out

CN 14 disconnected

Monitor lights up

.r=

(/)

Hydraulic oil level sensor

CN14 (Male)

~

2) When carrying out a continuity test, the following resu Its show that the sensor is normal

:::J

-

c .;::;

CN14 (Male) 1 - 2

1) Starting switch OFF 2) Disconnect CN14

c 0

U

Hydraulic oil level normal

Continuity

Hydraulic oil level abnormal

No continuity

(l)

u

1) Starting

The following results show that the sensor is normal (Normal temperature 25° C)

c

.;

switch OFF 2) Disconnect CN15

www. k omat s upar t s book . c om Fuel level sensor (fuel gauge)

'" ~

CN15 (Male)

CN15 (Male) 1 - 2

Cl

c

'C:

~

co

Full

Approx.12n or less

Empty

Approx.85-110n

(l)

::2'

8c

(l)

Cl

0

(l)

c

.r: u co

Engine running (over half throttle)

-~ 0 >

E

Cl

Alternator

-

c

'C:

~ co

::2'

(l)

~

*

1) Engine started

27.5 - 29.5V

I n cold areas or when the battery is dete'riorated, the voltage may not rise for some time after the engine is started.

::2'

Monitor module The voltages for Hand L in the table are as follows, *1 Engine oil pressure signal H 3.5 - 30V L Approx.OV *2 Starting signal from starting motor H 3 - 30V L Approx.OV *3 Alternator signal H

27.5 - 29.5V

L Max.5V *4 Sensor signal H 3.5 - 30V L Approx.OV

PC200, 220-3

If the resu Its are as in Tables 1 and 2, the monitor module is normal.

>;: Monitor Items

Monitor auxiliary signal input Engine oil pressure signal *1

Starting signal of starting motor *2

Alternator signal *3

CNP13 (2)

CNP14 (1)

CNP13 (1)

-

H

Engine oil pressure CNP13 (2)

- ---

------

Goes out

L

Coolant level CNP14 (3)

Engine oil pressure signal L or starting signal of Goes out starting motor H

Engine water temperatu re CNP13 (3)

Engine oil pressure signal L ---or starting signal of Goes out starting motor H

Battery charge CNP13 (1)

Flashes

Table 1

H

Flashes

----

Engine oil pressure signal L Flashes or starting signal of Goes out starting motor H

-----

-

H H

-----

L H

Flashes

H

----L

L -

H

PPC oil pressure CNP14 (11)

----


H

Overload warn ing CNP13 (7)


H

Flashes

Flashes

----

Sensor signal input for monitor items

1) Engine started 2) Connect T-adapter

H 1-----L

--~--L

62-33 (~



S ystem

Component

Connector No.

Testing method


Judgement table

1) Engine started 2) Connect T-adapter (two T-adapters needed for B and D)

Table 2

A

B

CNP14 (2), (5), (6), (9), (12), (13), (14) CNP13 (4) (Open terminals) CNP14 (4), (7), (8), (10), CNP13 (5), (6), (1) Ground connection)

Open (no wiring connected) Each terminal - CNP14 (16) 20 - 30V Lamp switches I,ll 20 - 30V

C

Voltage between CNP14 (15) and chassis (night lighting input) Lamp switches 0 F F OV

-

Starting switch ON 20 - 30V

Mon itor module

0

CNP14 (16) - CNP14 (8) (+24V input) Starting switch OF F OV

www. k omat s upar t s book . c om .gc 0

E

E

OJ

c

.<:

CNP13 (8) (warning buzzer output) Disconnect CN2 (Coolant level sensor) Connect short connector to CN2 .

When connector is removed, buzzer sounds or changes repeatedly as follows: Over 1.2V 0.8 sec. OV 0.8 sec.

u

ell

When short connector is connected, buzzer stops, or voltage is OV

~

Gauge module The voltage for Hand L in the table are as follows. *1 Engine oil pressure signal H 3.5 - 30V Approx.OV L *2 Starting signal from starting motor H 3 - 30V Approx.OV L *3 Alternator signal H 27.5 - 29.5V L Max.5V *4 Sensor signal 3.5 - 30V H L Approx.OV

62-34 (~)

If the results are as in Tables 3 and 4, the gauge module is normal.

Table 3

Monitor auxiliary signal input Signal

Monitor items

Engine oil pressure signal *1

Starting signal of starting motor *2

Alternator signal *3

CNP12 (14)

CNP12 (6)

CNP12 (13)

L

Engine oil pressure signal H and starting signal of starting motor L

L


L


-

1-----

Hydraulic oil level CNP12 (11)

f-----

Preheat CNP12 (4)

f------

Flashes Goesout Flashes Goesout Flashes Goesout

-

H

Flashes Engine oil pressure signal H Coolant level f-----and starting signal of CNP12 (12) Goesout starting motor L Engine oil level CNP12 (5)

Sensor signal input for monitor items *4

1) Connect T-adapter 2) Starting switch ON

f-----L H 1------

L H -----

L H

f-----L

PC200, 220-3

-



System

Component

Connector No.

Testing method


Judgement table

Table 4

~

Display level resistance (k.l1) (module input resistance)

Position of gauge display

Start mg

SWI tch

0N

Starting switch OFF

Minimum - Maximum All out Top

-

t Engine cooling water gauge Measure resistance between CNP12 (female) (10) - (8).

Position of display

1) Measure

resistance with starting switch turned OFF. 2) Check display with starting switch turned ON. 3) Connect socket.

- 0.34

0

7

0.28 - 2.62

6

2.48 - 3.67

5

3.46-4.19

4

3.95 - 5.07

3

4.78 - 6.75

2

6.36 - 10.05

1

9.47 - Disconnected

www. k omat s upar t s book . c om t

Bottom

.~c::

Top

0

E

Gauge module

t

7

0-1

6

12.0 - 27.2

5

24.6

4

34.2 - 42.8

3

38.7 - 51.9

2

47.0 - 82.0

1

72.6 - 726

OJ

c::

.!::

u

to

Fuel level gauge Measure resistance of CNP12 (female) (3) - (16).

~

-

Position of display

t Bottom

All out

~

37.8

594 - Disconnected

OJ OJ

Between pins CNP12 (female) (7) - (16) (GND) (night lighting input)

:!l 0

>

Lamp switch OFF

OV

Lamp switch I

20 - 30V

OJ

c::

.;: :J ~

1) Starting

switch ON 2) Connect T-adapter

to

OJ

~

1) Starti ng OJ OJ

:!l CNP12 (9) - (16) (GND) (Emergency output)

(5

OV

Connect short connector to CN5.

3.5 - 6V

Disconnect short connector from CN5

Approx.OV

>

OJ

c

.;:

~

to OJ

~

PC200. 220-3

For 3 sec. after tu rning starting switch ON

switch ON 2) Connect short connector to CN5 (coolant temperature sensor) . 3) Connect T-adapter

62-35 (~



S ystem

Component

Connector No.

Testing method

Measu rement conditions

Judgement table

1) Turn starting

Q)

OJ

switch ON. 2) Connect T-adapter.

~

Between CNP12 (female) (15) - (16) (GND) (+24V)

0

>

Starting switch OFF

OV

Starting switch ON

20 - 30V

OJ

c

:::J ~

co

Q)

~

Gauge module 1 ) Connect socket. CNP12 (female) pin (16) (GND)

~ :::J

c

C 0

u

Between CNP12 (16) (female) - chassis, and between CNP3 (2) (female) [controller] - chassis

Continuity

1) Connect

Q)

OJ

~

Between CNP1 (female) (1) - (4) (GND) (+24 V output)

0

>

Starting switch ON

-

CNP3. 2) Connect socket.

-~-27V

OJ

www. k omat s upar t s book . c om c

~ co

Starting switch OFF

OV

~----

Q)

~

B c

11 Connect CNP3. 21 Connect socket.

Q)

OJ

0

~

E Between CNP2 (female) (1) ground connection (+24Voutput)

Q)

c .c u co ~

U

0

Starting switch ON

:;

Starting switch OFF

> OJ c

~

co

Q)

~

l

15 - 27V OV

1) Start engine. 2) Connect T -adapter.

Q)

OJ

~

Controller

Between CNP2 pins (1) - (2) (buzzer outputl

0

>

OJ

c

I

Engine oil pressure, coolant level, engine water temperature sensor connectors disconnected

15 - 27V (Buzzer soundsl

Above sensors connected

OV

~ co

-

Q)

~

Q)

OJ

Between CNP3 (female) pins (1) - (2) (+24V)

-~ 0 >

Starting switch ON

20 - 30V

Starting switch OFF

OV

OJ

c

:; ~

11 Disconnect CNP3 21 Connect socket

co

Q)

~

CNP1 (male) 4 pinCNP3 (female) 2 pin (GND)

~ :::J

c

~

c 0

U

Between CNP1 (4) (male) - chassis, and between CNP3 (2) (femalel - chassis

Continu ity

11 Disconnect CNP1, CNP3 2) Connect socket

62-36

PC200, 220-3

-



Component

System

Connector No.

Testing method


Judgement table

1) Turn

Q)

u

c

;;

'v;

~ OJ

c

.;:

Engine speed sensor (3-mode selector OLSSif equ ipped)

iilOJ Q)

Resistance between CNS (male) (1) - (2)

300 - 1000rl

Between CNS (male) (1) chassis, and between CNS (male) (2) chassis

No continu ity

starti ng switch OFF 2) Disconnect CNS

::2:

CNS pins (1),12)

1) Screw in the speed sensor until it contacts OJ

the ring gear, then tu rn back one tu rn. 2) Should work normally after this adjustment.

c

~

:;

-

ii'

«

OJ

Q)

c

u

c

iilOJ ~ Q)

"v;

::2:

~

Resistance between CN9 (male) (1) - (3)

4 - 6 krl

1) Engine started

1) Turn starti ng switch OFF

www. k omat s upar t s book . c om (j) (j)

-I

0

Potentiometer 13-mode selector OLSS if equipped)

CN9 (male) pins (1), (2), 13)

OJ

c

.S! c

'5;

2

ii'

VOltage Vcc between CN9 (male) 11) - (3)

4.S - 5.2V

Adjust voltage between CN9 (male) (1) - (2) to Vcc/2

-

:l

«

u

Q)

a;

""(J

1) Turn starting switch ON 2) Use T-adapter 3) Fuel lever FULL

c

OJ

u u Q)

W

1) Continuity must be as in following table.

-

CN36 pin numbers ~

Prolix switch (3-mode selector OLSS if equipped)

CN36 (male) pins (1), (2), (3), (5), (6), (S)

:l

c

";;

c 0

U

1) Turn

starting switch OFF

Prolix switch OFF

ON

Between pins (1) - (3)

Continuity

No continuity


Continuity

No continu ity


No continuity

Continuity

Between pins (5) - (S)

No continuity

Continuity

2) There must be no continuity between the chassis and any of the following: prolix switch CN36 (male) (1), (2), (3), (5), (6), (S)

.

--

TVC valve solenoid I t is impossible to check the operation of the TVC solenoid valve by itself, so see Troubleshooting.

PC200. 220-3

Q)

u

CN13 (male) pins (1) - (2)

c

.; V> Q)

a:

Resistance between CN 13 (male) (1) - (2)

10 - 25rl

Between each terminal and chassis

No continuity

1) Turn starting switch OFF

62-37 (~



S ystem

Component

Connector No.

Testing method

Cl

Resistor for prolix circuit (3-mode selector OLSS if equipped)

CN34 (male) pins (1), (2)


Judgement table

1) Turn

OJ

.~

u

c:

aco 'u;t1

OJ

Resistance between CN34 (male) pins (1) - (2)

Approx. 10- 30n

starting switch OFF

~

:2

Input signal normal if it satisfies Tables 1 - 3. Table 1 Between CNP4 (1) (male)CNP4 (2) (male) No continuity

(f) (f)

Between CNP4 (3) (male) CNP4 (4) (male)

...J

0

1) Turn

starting switch OFF 2) Turn mode selector switch to H mode

u

c:

g u

OJ OJ

CNP4 (male) (1), (2), (3), (4)

"D

c:

co

.~

Mode selector switch

~ ~

u

OJ

UJ

[eh"klm ] continuity between CNP4 (male) (1)- (2), (4); (3) - (2), (4)

Table 2

~

c: .'"" c: 0

u

Between CNP4 (1) (male)CNP4 (2) (male)

No continuity

Between CNP4 (3) (male) CNP4 (4) (male)

Continu ity

1 ) Turn starting switch OFF 2) Turn mode selector switch to S mode

www. k omat s upar t s book . c om Table 3

Between CNP4 (1) (male) CNP4 (2) (male) Continuity Between CNP4 (3) (male) CNP4 (4) (male)

1) Turn starti ng switch OFF 2) Turn mode selector switch to L mode

1) Turn

Limit switch for travel ing

CN31 (male) pins (1), (2) CN32 (male) pins (1), (2)

.~

When traveling in a straight line

No continuity

When not traveling in a straight line

No continuity in one of CN31 or CN32

"c:

~

c: 0

u

starti ng switch OFF

-

:0 OJ

0. 0.

"

C"

~

OJ

.....

2u

-c:

1) When using the short connector, the following results show that the sensor is defective.

1) Start engine 2) Fuel lever FULL

OJ

c: c:

.Q

0

~

u

~


Deceleration works normally

CN33 disconnected

Deceleration does not work

~

a

OJ

Qj

u

.J::;

OJ

(f)

V

2

Hydraulic sensor for arm, boom, bucket pick-up

«"

CN33 (male) pins (1), (2) 1) When carrying out a continuity test, the

following resu Its show that the sensor is normal. ~

"c:

~

c:

Each control lever at neutral

Continuity

Any lever in operating position

No continuity

1) Turn starting switch OFF

0

U

62-38 @

PC200, 220-3

-



System

~ Q)

n. n.

Component

Auto-deceleration cancel switch

Connector No.

Between both terminals of switch

::J

Testing method

.~

Auto-deceleration switch ON

::J

c::

C

Continuity

Q)

1) Turn starting switch OFF.

-

Auto-deceleration switch OFF -

0

U

0-


Judgement table

.

No continuity

.-

~

c:: 0

~

Q)

Q)

u

c::

Q)

u

Q)

u

-

8 ::J

Auto-deceleration solenoid

CN 12 (male) (AI pins (1) and (2) CN40 (male) (B) pins (1), (2)

.~

Resistance of solenoid

50 - SOrl.

CN12 (male) (1) - chassis (CN40 (malell CN 12 (male) (21 - chassis (CN40 (male))

No continuity

1) Turn start ing switch ON.

~

~ Cl

c::

.;:

::J ~

co

Q)

:;;

Cl

c::

11 Turn starting switch OF F.

www. k omat s upar t s book . c om CN10 (female) (1) pin (+24V)

Q)

Cl

~ ~ co

Voltage between CN1 0 (1 ) (female) - chassis

20 - 30V

Q)o

:;;

>

11 Turn

~

CN10 (female) (2) pin (GND)

::J

Between CN10 (2) (female) - chassis

c::

C

starting switch OFF.

Continuity

0

u

-u

Q)

n. n.

CN11 (7) (male)CN11 (S) (male)

::J

0Q)

No continuity

~

-

--

CN10 (3) (female)CN10 (1) (femalel --

I

c::

11 Turn start ing switch OFF. 2) Turn mode selector switch to H.

0

~

Q)

a;

CN10 (1) (female) CN11 (9) (malel (input for mode selector switch I

::J

co

crJcrJ ..J

0

.~

CN11 (7) (male) CN11 (S) (malel

c::

.- -_."--

::J

~

CN 10 (3) (female) CN10 (1) (female)

c::

0

u

~

.

_

.

.

2

_

Control box -

Q)

u

_

u

No continuity

Continuity

11 Turn starting switch OFF. 2) Turn mode selector switch to S.

'--

.S' c::

2 u

11

Q)

w CN11 (7) (male) CN11 (S) (male) Continuity CN10 (3) (female)CN10 (1) (femalel

CN10 (female) (6), (7), (S) (potentiometer input signal)

PC200, 220-3

--

C>Q)

c:: u .- c::

~ co .;;;

~

Q)

:;;

Resistance between CN1 0 (female) (6) - (S)

Turn starting switch OFF. 2) Turn mode selector switch to L.

4 - 6r1.

11 Turn starting switch OFF.

~

62-39 ®



System

Component

Connector No.

CN10 (female) (11), (12) (input circuit for auto·deceleration, sensor, switch)

Testing method

>-

~

::l

c

C 0

u

:0 OJ

u

a. a.

1 ) Engine started.

All control levers at neutral, and auto-deceleration cancel switch OF F

Continuity

Control levers operated, or auto-deceleration cancel switch ON

No continuity

Resistance between CN11 (male) (1)

OJ


Judgement table

~

1) Turn

(2)

starting switch OF F.

c

::l

c-

OJ

--

I c ,2

~

CN 11 (male) (1), (2)

'Vi

(TVC solenoid output)

''::

~

'"c ::l

Prolix switch OFF

15 - 25n

Prolix switch ON

No continuity

-

~

ttl

OJ

~

~

ttl

di

-&

Carry out test of prolix switch.

a;

u OJ -0

Control box


CN11 (malel (3), (4)

::l ttl

(auto-decelerati on solenoid (A) output)

vi

(/)

....J

0

"'OJ C U ,- C

~

.~

~

ttl

Resistance between CN11 (male) (3) - (4)

::

CN10 (female) (9), (10)

U OJ

w

(a uto-decelerati on solenoid (6) output)

50 - son

~

OJ

~ ~

U C

~

"'OJ C u ,- C ::l

~

~

ttl

OJ 'Vi

.

~stance b'etween CN10 (female) (9) -

(10)

~ ~

~O- son

Continuity between CN11 (male) (7) CN11 (male) (7), (S)

~

(mode selector S, L signal input)

C

::l C

0

U

(S)

Mode selector switch S

No continuity

Mode selector switch L

Continuity

1) When using the short connector (swing lever at neutral)

2u 0 u

OJ a. a.

~

0

.r::

::l

c-

-

(/)

OJ

-

OJ

""-

Disconnect CN24.

OJ C C

--0

Swing brake hydrau Iic sensor

1) Turn starting switch OFF,

Connect short connector.

I

11 Turn starting switch OFF.


11 Engine started.

Five seconds after short connector is connected Swing brake operates (electricity flows to swing brake solenoid) Swing brake released

CN24 (male) (1), (21

ttl

.0

';:'"

1) When carrying out a continuity test

C

(/)

1) Engine started.

.~ ::l

"

Swing lever at neutral

No continuity

Swi ng lever operated

Continuity

~

C

0

U

62-40

PC200, 220-3



Component

S ystem

Connector No.

Testing method

Measu rement conditions

Judgement table

C1l

u

c

Swing mechanical brake solenoid

l'l

CN18 (male) (1), (2)

Between CN18 (male) (1) - (2)

~

~

10

~

30n

C1l

]

1) Engine started.

a:

Continuity


20 - 30V

1) Turn stari tng switch ON.

~ :::J

CN19 (female) (1) (GNO)

Between CN19 (1) (female) - chassis

c

C 0

U

-

Ol

c

CN19 (female) (2) (+24V)

'0

C1l

:::J

Voltage between CN 19 (2) (female) - chassis

OJ)

C1l

~

C1l

~

:'ii~

C1l

a. a. :::J

0-

C1l

-

C1l OJ)

C1l

(2)

1) Engine started.

;3

""" C1l

..0

Voltage between CN19 (female) (3) -

0

www. k omat s upar t s book . c om OJ)

Timer

.":

;:

CN 19 (female) (3) - (2) (sensor input)

(f)

>

OJ)

c


OV

Swing lever operated

20 - 30V

~

C1l

C1l

~

Voltage between CN19 (2) -

(4), (2) - (5)

C1l OJ)

CN 19 (female) (2) - (4) (2) - (5)

;3 0

(Solenoid, lamp output)

.C:

• OV

Swing lever operated

20 - 30V

>

OJ)

c

~

C1l

C1l

~

-


1) Engine started. 2) Connect T-adapter.

.

Approx. 5 sec. after swing lever is placed in neutral, voltage becomes OV. (I t is also possible to use the short connector instead of placing the swing lever in neutral)

PC200, 220-3

62-41 (~


TROUBLESHOOTING TOOLS

-

TROUBLESHOOTING TOOLS Troubleshooting chart No. H No.

Troubleshooting tools -1

-2

-3

-4

-5

-6

-7

0

0

0

0

0

0

-8

-9

-10 -11 -12 -13 -14 -15 -16

Diagnostic tools 1

Hydraulic tester

0

2

Stop watch

0

3

Thermistor kit

0

4

Measuring cylinder

0

5

Push pull scale

6

Scale

7

Multi-purpose tachometer

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0 0

0

0

0

0

0

0

0 0

-

0

0

Replacement parts


Servo valve

9

Jet sensor rei ief valve

0

0

0

0

0

0

0

0

0

0

10


11

Swing safety valve

0

12

Swing check valve

0

13

Main relief valve

14

Control valve, suction valve

0

0

0

0

0

-

KES parts

0

15

Cap plug (07376-50315) 3 pieces

16

Sleeve nut (07221-20210,20315,20422) 0

0

0

0

0

0

0

0

0

17

Plug (07222-00210,00312,00414)

0

0

0

0

0

0

0

0

0

18

Flange (07379-00500,00600)

0

62-42 (~

pe200.220-3


TESTING TRAVEL AND OPERATING FORCE

TESTING TRAVEL AND OPERATING FORCE 1. TESTING TRAVEL OF CONTROL LEVERS Measuring Travel Set the scale on the bottom of knob (1) of the control lever, and measure the travel need to move the lever to each position.

* _

If the result of the measurement shows that the travel is not within the standard value, check as follows. 1) In linkage type (travel control lever), lever travel is the same as valve spool travel. If there is no abnormal ity in the rod, check the travel of control valve spool. 2) In PPC valve type, if the linkage between control lever and PPC valve is normal, disassemble the PPC valve and check.


_

Adjusting Travel Levers at Neutral Position • When the each lever position is not in line and lever contacts to cab in operating, check according to the following procedure. 1) See if the rod is bent, twisted, worn, or has other abnormalities. 2) Adjust the lever stopper as follows. i) Loosen locknut (4) of the stopper bolt. ii) With the lever moved to the end of its stroke, adjust stopper bolt (5) so that it lightly touches the lever. iii) Then turn back the stopper bolt by 1/3 to 1/2 turns and secure it with the locknut.

PC200. 220-3

62-43 ®


TESTING TRAVEL AND OPERATING FORCE

2. TESTING OPERATING FORCE OF CONTROL LEVERS

*

When measuring, engine is full speed and hydraulic oil temperature is 45 - 55°C.

Measuring Operating Force Hook push-pull scale CD on the bottom of knob (1) of the control lever, and measure the force needed to move the lever to each po~ition.

*

If the result of the test shows that the operating force is not within the standard value, check as follows. 1) The operating force of valves which are pulled directly is decided by the return spring of the valve spool. If there is no abnormality in the rod, yoke or any other part, disassemble the control valve and check. 2) In PPC valve, if the linkage between control lever and PPC valve is normal, disassemble the PPC valve and check.

-

www. k omat s upar t s book . c om 3. TESTING TRAVEL OF CONTROL VALVE SPOOLS Measuring Travel Set the scale to the spool (1) measured, and measure the travel when operating the control lever. When measuring by one person, pull the control lever by a cord or disconnect the linkage (rod) from spool and pull the spool directly. Except linkage type, it is impossible to measure the travel of spool.

*

-

*

*

If the result of the measurement shows that the travel is not within the standard value, check as follows. 1) Remove cover (1). Check the bolts (2) loosened. If there is no abnormality, disassemble control valve and check. 2) In PPC valve type, first check the PPC valve.

2

i

205F2419

62-44

PC200, 220-3

-

MEASURING HYDRAULIC OIL TEMPERATURE


MEASURING HYDRAULIC OIL TEMPERATURE Special tool

A

-

Part No.

Part Name

Q'ty

790-500-1300

Thermistor temperature aauae

1

Lower the work equipment completely to the ground and stop the engine. Operate the control lever several times to release the remaining hydraulic pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the remaining oil pressure in the hydraulic tank. • •

Remove cover (1), then measure the oil temperature using thermistor A. When hydraulic oil temperature is lower than 45°C, raise the oil temperature as follows. Start the engine and warm up running. Operate the arm or bucket control lever fully to relieve oil from main relief valve so that oil temperature is raised. Continued operation in above is within 30 seconds.


*

Note: When relieving oil in boom, arm, bucket or travel circuit, CO valve acts and main pump delivery is minimum. In result, as oil flows only for hydraulic tank - main pump - main relief valve - hydraulic tank, operate boom, arm and bucket cylinders to raise the temperature of components sometimes.

-

PC200, 220-3

62-45 ®


AIR BLEEDING

--

AIR BLEEDING 1. AIR BLEEDING IN HYDRAULIC CYLINDER

*

When removing hydraulic cylinder or disconnecting piping, bleed air in hydraulic cylinder as follows. 1) Start the engine and run at low idling for 5 minutes. 2) Raise and lower the boom at 5 times repeatly in engine slow speed. When operating, stop the piston rod before 100 mm of stroke end, and never rei ieve oi I. 3) Operate 2) in engine full speed. 4) Operate boom control lever fully to relieve oil. 5) For arm and bucket cylinders, operate as the same procedure as above 2), 3) and 4).

*

2.

*

AIR BLEEDING IN MAIN PUMP

--

When replacing or dismounting the main pump, bleed air in main pump to prevent pump inner parts seizing as follows. 1) Remove plug (1). 2) Disconnect drain hose (2). 3) Supply oil from drain plug hole fully. 4) Connect hose (2). 5) Attach O-ring and tighten plug (1).


* *

REMAIN-PRESSURE RELIEVING IN PPC CIRCUIT When disconnecting piping between hydraulic cylinder and control valve because of open circuit, relieve remainpressure in circuit as follows. As travel circuit are not remain-pressure, remove cap only to relieve remain-pressure. 1) Loosen the filler cap gradually to relieve pressure. 2) Operate control lever several times to relieve pressure of accumulator. 3) Start engine and run for "5 sec." and stop engine. Then operate control lever. Continue 2 and 3 times repeatedly above opetion to relieve remain-pressure completely.

--

*

4.

*

AIR BLEEDING IN TRAVEL MOTOR When removing travel motor or disconnecting piping, bleed air as follows. 1) Start engine and run for about 5 min. at low idling speed. 2) At low idling, loosen plug (1) until oil without air issues. Never work at the front of plug because oil is spurted out often. 3) When completing the air bleeding, tighten plug (1).

*

-62-46 (5)

PC200. 220-3

TESTING AND ADJUSTING HYDRAULIC PRESSURE (WORK EQUIPMENT, SWING, TRAVEL CIRCUITS)


TESTING AND ADJUSTING HYDRAULIC PRESSURE (WORK EQUIPMENT, SWING, TRAVEL CIRCUITS) Special tool

A

Part No.

Part Name

Q'ty

799-101-5000

Hydraulic tester

1

1. MEASURING MAIN RELIEF PRESSURE

*

Oil temperature when measuring: 45 - 55°C Lower the work equipment to the ground anEl stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

1.

Remove pressure pick-up plug (1) or (2) (PT1/8) from the circuit to be measured, and install hydraulic tester A (600 kg/cm 2 ). Start the engine, operate the circuit to be measured, and measure the main relief pressure with the engine at full throttle. Condition of actuator when measuring i) When measuring the cylinders, operate each cylinder to the end of its stroke. ii) When measuring the swing, lock with the swing lock pin. iii) When measuring the travel, fit block under the grouser at the front of the track, or fit block (2) between the sprocket and frame to lock the track, then measure one side at a time.


3.

-

Pump Front pump

(Rear pump)

205P2500

1

(F ront pump)

Actuator controlled Arm cylinder Boom cylinder Swing motor Right travel motor

Rear pump

Arm cylinder Boom cylinder Bucket cylinder Left travel motor

Note 1: The set pressure of the safety valve at the swing motor and boom cylinder head end is lower than the main relief pressure, so theset pressure of the safety valvei is measured. 2: The set pressure of the safety valves in the other equipment is higher than the main relief pressure, so it is impossible to measure the pressure directly. However, it ispossible to judge if the pressure is correct as follows.

PC200, 220-3

62-47 ~)



*

Example for rear pump When measuring the relief pressure for the four items of equipment, if the relief pressure for all of the equipment is low, the main relief pressure has dropped; if the pressure of only certain equipment is low, the set pressure ofthe safety valve for that equipment has dropped. Table of set pressure for safety valve for each actuator Set pressure (kg/cm 2

Actuator Boom cylinder

Arm cylinder

Head end

250

Bottom end

340

Head end Bottom end

Bucket cylinder

Travel motor

340

-

Head end Bottom end

Swing motor

)

340 297 +15 -10 360

www. k omat s upar t s book . c om 2. ADJUSTING AMIN RELIEF PRESSURE

2

Adjuste the main relief valve as follows. • Loosen locknut (1) and turn adjustment screw (2) to adjust. Adjust with the adjustment screw as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. After adjusting, repeat Section 1 above to check the pressure again.

*

-

*

205F2420

62-48 (9)

PC200, 220-3


3.


ADJUSTING RELIEF PRESSURE OF SWING MOTOR

Adjust the relief pressure of the swing motor safety valve as follows. • Loosen locknut (1) and turn adjustment screw (2) to adjust. * Adjust withthe adjustment screw as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. * After adjusting, repeat Section 1 above to check the pressure again.

2

205F2474

* -

Safety valve (3) is for left swing, and safety valve (4) is for right swing.


PC200, 220-3

62-49 ®

TESTING AND ADJUSTING PRESSURE OF CHARGING CIRCUIT


~..

TESTING AND ADJUSTING PRESSURE OF CHARGING CIRCUIT Special tool

A

Part No.

Part Name

Q'ty

799-101-5000

Hydraulic tester

1

1. TESTING AND ADJUSTING RELIEF PRESSURE OF CHARGING PUMP

*

1.

*

Oil temperature when measuring: 45 - 55°C Measuring relief pressure i) Remove pressure pick-up plug (1) (PT 1/8). and install hydraulic tester A(60 kg/cm 2 ). ii) Start the engine, run at full throttle, and measure the pressure. When testing for internal leakage in any of the equipment in the charging circuit, use the parts given below to block the following parts of the circuit, and measure the relief pressure.

-


Portion of hydraulic circuit shut off

Equipment that can be tested

1

Charging pump outlet port

. Charging pump . Relief valve

2

Main pump inlet port

Main pump

3

Auto-deceleration solenoid valve inlet port


4

Right PPC valve inlet port

Right PPC valve

5

Left PPC valve inlet port

Left PPCvalve

6

Swing brake solenoid valve inlet port


-

Use the following parts to shut off the circuit. Sleeve nut: 07221-20210,07221-20422 Plug: 07222-00210,07222-00414 Auto-deceleration solenoid valve


Left PPC valve ~ L

6

Main pump Charging pump

62-50 ®

205F2475

PC200, 220-3

-

-

E-4

TROUBLESHOOTI NG

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-4 1. Measure voltage between CN13 (male) (1) and (2). 2.

Check for short circuit between CN13 (female) (1), (2) and chassis ground.

3.

Measure resistance between CN13 (female) (1) and (2).

~ 11 m {Jill ~ 1

-

2

4,5. Measure resistance between CN34 (female) (1) and (2).

~n:Jrro] m~ www. k omat s upar t s book . c om 2

6.

1

1

2


-

PC200, 220-3

62-49-2 @

TROUBLESHOOTING

E-4

-

Troubleshooting Chart No. E-4 (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED) Failure mode: No change in output when mode switch is operated.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters. connect to both the male and female ends; for the socket. connect to the connector marked in (

a)

).

YES

2

Self-testing display shows abno rmality

YES Abnormality in power supply OFF

OOFF

O Red

Green

Is voltage between CN10 (female) (1) and (2) 20 - 30 V? 1)

->

Is voltage between fuse 4 and chassis ground 20 - 30 V? • Turn starting switch ON. IDo not start engine)

YES

Is voltage between CN10 (female) (2) and chassis ground V?

Connect T-adapter (socket) to CNl O. Turn starting switch ON. (Do not start engine)

2)

3

NO

1

o 1)

2)

:\0

NO

Connect T-adapter (socket) to CNl O. Turn starting switch ON.

Abnormality in control box

YES


YES

Is CN13 Imale) 111, (2) - chassis ground insulated?

1)

Abnormality in TVC solenoid

1 2)

Is resistance between CN 13 (male) (1) and 12110 - 25 Red

4 Is resistance be-

Connect T-adapter (socket) to CN13 (malel. Turn starting switch OFF.

3 Is resistance be-

tween CN36 Ifemale) 131 and (5) 10 - 25 117 Is

l\JO

each pin to chassis

1)

2)

ground insulated? 1)

Connect T -adapter (socket) to CN13 (male!. 2)

;\iO

b)

tween CN36 (female) 11) and 12) 10 - 25 ll? Is each pin to chassis ground insulated?

YES

1P

Green

...YES

Connect T-adapter (socket) to CN36 (female!. Turn starting switch OFF.

Turn starting switch OFF. Turn prolix circuit switch OFF

~(

;,\0

-

If cause is removed when switching to prolix circuit (when self-testing display shows normal!

• In H-mode, display is not 0

~

3 YES Is there continuity between CN20 (femalel (19) and (20)7

YES YES

1 Is mode selector switch normal?

1)

2)

Remove CNP4. Turn starting switch OFF.

Is there continuity between CN 10 (female) (11 and (3)? 1) 2)

Remove CNP4. Connect T-adapter (socket) to CN 10 (female).

::lOV>

000

~~~

Tester T -adapter or socket adapter (for EKONO)

62-50 @

1)

2) 3)

NO

Remove CN 10 (female) Connect T -adapter (socket) to CN20 Ifemale!. Turn starting switch OFF.

NO

NO

, 0>

~c

..c";:;

2

T -adapter or socket adapter (forMIC)

-

T -adapter or socket adapter (for DLD

PC200, 220-3


2.

TESTING AND ADJUSTING PRESSURE OF CHARGING CIRCUIT

Adjusting main relief pressure Loosen locknut (2) and turn adjustment screw (3) to adjust. Adjust with the adjustment screw as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. After adjusting, repeat Section 1 above to check the pressure again.

3

2

* *

205F2476

-


* 1.

MEASURING OUTPUT PRESSURE OF PPC VALVE Oil temperature when measuring: 45 - 55°C Remove pressure pick-up plugs (1). (2). and (3) (PT 1/8). and install hydraulic tester A (60 kg/cm 2 ). For hydraulic pressure of boom, bucket (1) For hydraulic pressure of arm (2) For hydraulic pressure of swing (3) Start the engine, run the engine at full throttle, then operate the control lever, and measure the pressure. When measuring the swing equipment, lock the swing with the lock pin. When measuring the work equipment, operate each cylinder to the end of its stroke.

* 2

*

PC200, 220-3

62-51 (9)


TESTING AND ADJUSTING CONTROL PRESSURE OF MAIN PUMP


Serial No. 20001

~

.

Special tool Part No. A

799-101-5000

Q'ty

Part Name Hydraulic tester

1

1. TESTING AND ADJUSTING OUTPUT PRESSURE OF TVC VALVE Note:

The output pressure of the TVC valve changes according to the average pressure (

P + P I

2

2) =

av-

erage pressure) for the discharge pressure of the piston pump, so before measuring, always adjust the main relief pressure to the specified pressure. See Fig. 1. Measuring output pressure of TVC valve Oil temperature when measuring: 45 - 55°C Measure the relief pressure of the charging pump first to check that it is normal. i) Remove pressure measurement plug (1) (Thread dia. = 10 mm, Pitch = 1.25 mm). and install hydraulic tester A (60 kg/cm 2 ). ii) Run the engine at full throttle, and measure the pressure with the control levers at neutral and with the pump relieved. See the STANDARD VALUE TABLE. Reference 1. The average pressure with one pump' relieved is approx. 170 kg/cm 2 . This is the average pressure of the discharge pressure of the relieved pump (320 kg/cm 2 ) and the discharge pressure of the pump not relieved (approx. 20 kg/cm 2 ). 2. For details of the relationship between the change in the output pressure of the TVC valve and the discharge volume of the pump, see Fig. 1 and 2.

-

*

1)

* *


up port for valve pressure

205P2503A

Fig. 1 (When i = O.18A)

18

100

-

300

200

PI + P 2 Pump discharge pressure (--2-) = average pressure (kg/cm 2

)

205F2477

Fig. 2

(Engine at full throttle)

90 1 - - - - - " " \ >

CD

-':o::.

Control area of TVC valve

o

c "o E co

Ql

~ co

45 Control area of NC valve

..

.t::

~ -0 C.

E

"

"-

100

200

300

PI + P2 Pump discharge pressure (--2-) = average pressure (kg/cm 2

)

205F2478

62-51-1 ®

PC200, 220-3

-

TESTING AND ADJUSITNG

2)


Adjusting output pressure of TVC valve If the results of the measurement show that the hydraulic pressure is not within the standard value, adjust as follows. i) Loosen locknut (2). ii) Turn adjustment screw (3) to adjust. If the adjustment screw is stiff and excessive force is used to turn it, the tip may break. * If the adjustment screw is stiff, remove the TVC valve assembly, then remove the cover assembly and add lubricant to the screw before trying to turn it. iii) Adjust with the adjustment screw as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. One turn of the adjustment screw adjusts the hydraulic pressure by approx. 3.5 kg/cm 2 • iv) After adjusting with the adjustment screw, repeat Section 1)-i), ii) to measure the output pressure again.

*

-

*


205F2479

PC200, 220-3

62-51-2 ®

TESTING AND ADJUSITNG


2. TESTING AND ADJUSTING OUTPUT PRE· SURE OF NC VALVE The output pressure of the NC valve controls the discharge amount from the piston pump flowing to the servo valve. The oil flows from TVC valve -+ CO valve -+ NC valve -+ servo valve. The output pressure changes as follows according to the operation of the control levers or work equipment. Control levers at neutral Because of the differential pressure of the jet sensor, the NC valve is actuated and the output pressure drops to below 7 kg/cm 2 . (The pump discharge amount becomes the minimum.) When hydraulic cylinders and travel circuit are relieved. The CO valve is actuated, and reduces the pressure to below 7 kg/cm 2 until it enters the NC valve. The NC valve continues to supply this pressure to the servo valve. (The pump discharge amount at this point is also the minimum.) When work equipment, swing, travel circuit are actuated. The output pressure of the TVC valve is not influenced by the CO valve or NC valve, and continues to supply pressure to the servo valve. (The pump discharge amount varies between the maximum and the point where the CO valve is actuated.) Oil temperature when measuring: 45 - 55°C

Solenoid

*

From charging pump

*

205F2480

Front end

4

4

Rear end

-

*


1)

As seen from bottom of pump

205F2481

Measuring output pressure i) Remove pressure pick-up plug (4) (Thread dia. = 10 mm, Pitch = 1.25 mm). This is on the body side of the servo valve. ii) Install hydraulic tester A (25 kg/cm 2 ).

*

•

Measuring pressure when NC valve is actuated Set all the work equipment levers at neutral, and measure the hydraulic pressure with the engine at full throttle. Set the auto-deceleration switch to OF F. 2 If the output pressure is more than 7 kg/cm , measure the differential pressure of the jet sensor.

-

* *

62-51-3 ®

PC200, 220-3



•

Measuring pressure when CO valve is actuated Relieve anyone of the boom (except LOWER), arm, bucket, or travel circuits, and measure the hydraulic pressure with the engine at full throttle.

•

Measuring pressure when work equipment, swing, and travel are actuated Measure the pressure when the swing circuit (front pump) is relieved, and the track is rotating under no load (front and rear pumps) at the same time as measuring the output pressure of the TVC valve. If there is an excessive difference from the output pressure of the TVC valve, the op~ration of the CO valve or NC valve is probably defective. When measuring the pressure with the work equipment operated, be extremely careful that the surrounding area is safe.

*

-

A


Adjusting CO valve and NC valve • Adjusting CO valve If the set pressure of the CO valve is too high, the discharge amount is not reduced when the circuit is relieved. As a result, the relief pressure becomes higher, so always adjust it to the standard pressure. i) Loosen locknut (5) and turn adjustment screw (6) to adjust. Adjust with the adjustment screw as follows. To INCREASE pressure, turn CLOCK• WISE. To DECREASE pressure, turn COUN• TERCLOCKWISE. One turn of the adjustment screw adjusts the hydraulic pressure by 41.25 kg/cm 2 . If the pressure is not reduced even when the adjustment screw is turned, there is probably some internal defect in the CO valve. ii) After adjusting with the adjustment screw, repeat Section 2.-i) to check the set pressure again.

*

-

*

*

*

Front end

Rear end 205F2482

5

6

205F2483

PC200, 220-3

62-51-4 ®



•

Adjusting NC valve The NC valve is actuated by the differential pressure of the jet sensor, so when adjusting, always check that the differential pressure of the jet sensor is normal. • Loosen locknut (7) and turn adjustment screw (8) to adjust. Adjust with the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNT• ERCLOCKWISE. One turn of the adjustment screw adjusts the hydraulic pressure by approx. 4.3 kg/cm 2 •

*

*

*

-


-

62-51-5 ®

PC200. 220-3

TESTINT AND ADJUSTING


3. TESTING AND ADJUSTING DI FFERENTIAL PRESSURE OF JET SENSOR.

Relationship between control lever stroke and differential pressure of jet sensor

The jet sensor produces high pressure and low pressure (high pressure - low pressure = differential pressure) at the outlet port of the control valve. The NC valve is controlled by this differential pressure. The differential pressure is highest when the control levers are at neutral, and is lowest when the control levers are operated to the end of their stroke. 1.

Measuring differential pressure Travel of control lever (mm)

Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

-

Remove pressure pick-up plugs (9) (high pressure side) and (10) (low pressure side) (PT 1/8). In both front and rear, the engine side is the high pressure side. ii) Install hydraulic tester A (high pressure side: 2 60 kg/cm 2 ; low pressure side: 25 kg/cm ) iii) Run the engine at fulll throttle, and measure the differential pressure with the control levers at neutral. High pressure (Pt) - Low pressure (Pd) = Differential pressure iv) Using the work equipment, raise the track assembly from the ground, and measure the differential pressure with the track rotating under no load (operate the control lever to the end of its stroke).

205F2486

i)

*


*

-

*

2.

.-i;ff

~

Front control valve (for rear pump)

Any lever can be operated, but it is better to operate the travel circuit under no load, because the measurement time can be selected freely. The differential pressure is the minimum.

Adjusting If the result of the measurement shows that the differential pressure is not within the standard range, adjust as follows. i) Loosen locknut (11) and turn adjustment screw (12) to adjust. Adjust the high pressure side with the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE. • To DECREASE pressure, turn COUNTERCLOCKWISE. After adjusting with the adjustment screw, repeat Section 3-i) to check the differential pressu re agai n.

*

*

PC200, 220-3

12

11

205F2487

62-51-6 ®

MEASURING DELIVERY OF MAIN PUMP


-

MEASURING DELIVERY OF MAIN PUMP Special tools Part No.

Part Name

a'ty

A

790-303-1001

Flowmeter kit

1

Al

790-303-1010

Flowmeter

1

A2

790-303-1030

Flange

2

A3

790-303-1440

Nipple

4

A4

790-303-1050

Hose

2

As

790-303-1410

Nipple

2

A6

790-303-1091

Adapter (flange)

1

A7

790-303-1081

Adapter (flange)

1

B

790-502-1001

.

Tachometer

207F238A

1

-

www. k omat s upar t s book . c om METHOD OF MEASURING DELIVERY 1.

Preparation 1) Set flowmeter kit A and tachometer in position. 2) When measuring with the flowmeter, do as follows to prevent the jet sensor from working. i) When measuring the L.H. pump, jack up the left track frame and lock the right track. ii) When measuring the R.H. pump, jack up the right track frame and lock the left track. iii) Or remove the hose from jet sensor and block the jet sensor at the hose side and the CO, NC valve side. Part number of blind plug: Jet sensor hose side (07376-50210) NC' CO valve side (07221-20210) (07222-00210) Procedure for measuring 1) Rotate the track on the side being measured (the side where the flowmeter is attached). Move the control lever to the end of its travel. (If this is done, the jet sensor will not function.) Or remove the hose from jet sensor and block the jet sensor at the hose side. 2) Set the engine speed to the rated speed, and measure the delivery at the pressures in the main pump performance of judgement standard value.

Flowmeter

P20503202

*

2.

*

62-52 (j)

Jet sensor hose

PC200,220-3

-


METHOD OF LOCATING DEFECTIVE EaUPMENT WHEN THERE IS TRAVEL DEVIATION

METHOD OF LOCATING DEFECTIVE EQUIPMENT WHEN THERE IS TRAVEL DEVIATION The ports of the piston pump, control valve, and swivel joint are connected to the travel motors as shown in Figs. 1 and 2. Therefore, if there is any deviation in travel, the cause is one of the following: 1. If the deviation is as shown in Fig. 3, the packing at the swivel joint is defective. 2. If the deviation is in the same direction when traveling in both forward and reverse, the problem is not in the swivel joint but in one of the following.

Control valve

Front pump

Drain Right A rear

Rear

Left B front Right C front

Front

Left Drear

Rear pump

205F2488

Fig. 1 Piping for travel system To judge which of these three the problem is in, do as follows. 1) Reverse the front and rear hoses between the piston pump and the control valve as shown in

Up

I

F

I

Right

Fig. 1. If the problem is reversed, the hydraulic pump is defective; if it is not reversed, the control valve or travel motor are defective. Reverse the left and right hoses at the swivel joint end between the control valve and swivel joint.

* 2)

R

Up

R

I

www k omat s upar t s book . c om * . (See Fig. 4) (Turn the top of the swivel joint 180°.) If the problem is reversed, the control valve is defectIve; if it is not reversed, the travel motor is defective.

Left

I

F

205F2303

Fig. 2 (Condition when connected normally) Forward

Forward Right reverse only

Drain

Left B front

Right reve and left forward

Right C front

Right for

Right A rear

R'' * f

Does not deviate

Forward

-

Left reverse only

Reverse

Left 0 rear

Bottom

'''\

and left reverse

Re verse

205F2489

Fig. 3 Location of defective swivel joint packing and direction of deviation in travel

Disconnect

-

Fig.4

PC200, 220-3

205F2432B

62-53 ®


MEASURING OIL LEAKAGE OF SWING, TRAVEL MOTOR

MEASURING OIL LEAKAGE OF SWING, TRAVEL MOTOR

* *

+ +

-

Oi I temperature when measuring: 45 - 55° C Lower the work equipment completely to the ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

Measuring oil leaking 1)

Disconnect the drain hose of the motor, and fit a blind plug at the tilnk end. i) For the travel motor, disconnect drain hose (1) of the travel motor, and fit a blind plug CO at the hose end. ii) For the swing motor, disconnect hose (2) and fit a blind plug (1) at the tank end. For the travel motor, disconnect drain hose and fit a bling plug (3) at the travel motor end.

-


Start the engine, and operate the actuator to be measured. i) For the travel motor, put a block under the track on the side to be measured to lock the track in position. ~ When measuring oil leakage from the travel motor, mistaken operation of the levers can lead to accidents, so always follow agreed signals when measuring. ii) For the swing motor, lock the upper structure with the swing lock pin. iii) Run the engine at full throttle, put a measuring cylinder under the disconnected hose, relieve the circuit for one minute and measure the leakage.

-

Note: When measuring, move the motor slightly (move the position of the valve plate and cylinder, and piston and cylinder). and measure several times. Turn the swing motor 180° when measuring.

62-54 (5)

PC200, 220-3


CHECKING AND ADJUSTING TRAVEL MOTOR PERFORMANCE

CHECKING AND ADJUSTING TRAVEL MOTOR PERFORMANCE CHECKING AND ADJUSTING DEVIATION IN TRAVEL CHECKING Carry out the test on a firm level road surface. Hydraulic oil temperature when measuring: 45 - 55°C

* * 1.

-

Adjust the track shoe tension as follows. 1) Using the boom and arm, raise the track frame and measure the clearance between the track link rotating surface and the tread of the 4th (PC200, 220-3) or 5th (PC200LC, PC220LC-3) track roller from the sprocket. Standard dimension: 60 - 100 mm 2) To increase the track tension, pump in grease through lubricator (1); to loosen the tension, loosen lubricator (1) to let some grease out.

20SF2427

*

~

Never loosen lubricator (1) more than one turn. If the grease does not come out properly, move the machine backwards and forwards sIi ghtl y.


Check that the stroke of the travel spool is within the standard value. For details, see "Checking stroke of control valve "spool".

3.

Measuring five rotations unloaded 1) Using the boom and arm, raise the track frame on the side to be measured. 2) Run the engine at full throttle, rotate the track one turn unloaded, then measure the time taken for the track to turn five more times unloaded. Measure in forward and reverse. Carry out the measurement several times and take the average.

-

*

4.

Measuring by driving 1) Set the machine in the travel position. For the travel position, extend the bucket and arm cylinder rod fully, and hold the boom at a 45° angle. 2) Drive the machine for 10 m, then measure the deviation over the next 20 m. When measuring, run the engine at full throttle, and measure for each mode.

*

*

_.

20SF2428

PC200, 220-3

62-55 @



ADJUSTMENT If the measurements are not within the standard value, adjust as follows.

*

For machines equipped with 2-stage mode selector switch.

~ Travel deviation Deviation to right

Deviation to left

*S

a: Adjust front pump with shims

b: Adjust rear pump with shims

L

c: Adj ust front pump by turning back screw

d: Adjust rear pump by turning back screw

Measurement mode"

*

If the travel deviation is not within the specified value even after adjusting according to the adjustment procedure, go to Troubleshooting "Excessive travel deviation". For the PC200-3, if the deviation cannot be corrected by shims, adjust by turning back the screw.

-


For machines equipped with 3-stage mode selector switch.

~Travel deviation Measurement

H

S,L

mod~

Deviation to right

Deviation to left

Adjust front pump with shims

b: Adjust rear pump with shims

c: Adj ust front pump by turning back screw

d: Adjust rear pump by turning back screw

a:

-

If the travel deviation is not within the specified value even after adjusting according to the adjustment procedure, go to Troubleshooting "Excessive travel deviation".

62-56 (5)

PC200. 220-3



Procedure for adjusting with shims 1) Loosen 4 bolts (1). The shims are a semi-split type, so it is unnecessary to remove them. 2) Insert shim (2) of a thickness to match the contact, then tighten bolt (1 ).

*

*

Additional shims and amount of travel deviation. (mm)

(Q/min)

-f-

;: .;: 10c OJ

'-'

g

5

c

-

+-----",1----1200 c

~

100

~

o o

"""--_~----=-_'_::_-___::_'_:=-------=,-l--::--......J

0.1

02

OA

O~

Additional shim thickness (mm)

*

www. k omat s upar t s book . c om The maximum additional shim thickness should be 0.4 mm. ~

Mounting bolt: 5.5 ± 2 kgm

Adjusting by turning back screw 1) Loosen locknut (4) of servo valve (3). 2) Turn back adjustment screw (5) an amount to match the deviation, then tighten locknut (4).

-

Screw return angle and amount of travel deviation.

*

(mm)

(Q/min)

"0

;:

20

400

15

300

c

10

200

OJ

'-' c ~

~

'"OJ C

0 ~

co

':;

~ 0

eco E

0

;;::

OJ

5

100

o "'-_.L-_.L-_.L-_.L-_.L-_.L------.J 20

40

60

80

100

Adjustment screw return angle (

*

120 0

"0 Q)

> co

~

)

Turn back the screw a maximum of 100°. ~


PC200, 220-3

62-57 (~


TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK

TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK

-

1. CHECK OF TVC VALVE SOLENOID 1)

2)

Remove TVC valve solenoid. (Leave the connector still connected) Turn the starting switch ON, and see if solenoid spool (1) moves when the mode selector switchis operated. (Be careful because oil will fly out when the spool moves.)

2. CHECK OF CONTROL VALVE SPOOL

-

Remove left and right cases of the control valve, then remove the left and right springs and see if spool (2) moves easi Iy.


CHECK OF ACTUATING PRESSURE OF SWING MECHANICAL BRAKE (IF EQUIPPED) Run the engine at low idling, and hold inlet hose (3) of the swing mechanical brake by hand. Check that there is vibration from the hose when the selector switch of the swing mechanical brake is operated.

4.

-

CHECK OF INLET PRESSURE OF DECELERATION CYLINDER (IF EQUIPPED) Run the engine at mid-range speed (1500 rpm or above), and hold inlet hose (4) of the deceleration cylinder by hand. Check that there is vibration from the hose when the auto decelerat ion se lecto r sw itch is operated.

62-58

PC200, 220-3

TROUBLESHOOTING Circuit diagram Connection table for connector pins Connector position for troubleshooting Troubleshooting procedure Checks before troubleshooting Abnormality judgement conditions for self-testing display " Troubleshooting Troubleshooting (except troubleshooting for machine monitor) Troubleshooting for electric system (El - E6) Troubleshooting for hydraulic and mechanical system (Hl - H16)

-

6262626262-

60 64 67 68 69

62- 71 62- 72 62- 78 62- 86 -62-140

www. k omat s upar t s book . c om Failure mode and components

62-169

-

PC200, 220-3

62-59 @

CIRCUIT DIAGRAM

TROUBLESHOOTING

CIRCUIT DIAGRAM E. OLSS AND AUTO-DECELERATION SYSTEM (IF EQUIPPED) PC200-3 (Serial No. 20001 21463) PC220-3 (Serial No. 20001 20364) CNJ3 Engine speed sensor

Swing oil pressure sensor

CN]?

Potentiometer

Limit switch (neutral)

CN]1

r---L.L-L.L..l---L.L---l.~=±==fCN

CN2CJ

1

~ON'=.W

1 011- 0LY oH- 02R

Control box

Auto-decelerator

02B

---._----'

O'lVV 0713

solenoid

-

www. k omat s upar t s book . c om Battery relay

:Mode selec-:

~S_~i~

Auto-decelerator switch

05W

Fuse box CN4D


-------, 02'(8

02 02LG

Tirner

02LG

CN33 I::nqllle

spf'ed

\1'[1501

POlen ('orn('lf'r

CN38

Resistor 02P 02V

Control box

Resistor

Battery relay

-

MW Fuse box

62-60 @

-

F20503064

PC200.220-3

TROUBLESHOOTI NG

CIRCUIT DIAGRAM

SWING BRAKE SYSTEM (IF EQUIPPED)

Timer

'--1-_ _--'

02Y1::l ()2GY

Swing mechanical brake solenoid

Oil pressure sensor

~~~~~~~ To battery relay terminal

Swing brake caution lamp


PC200. 220-3

62-61 @

TROUBLESHOOTING

CIRCUIT DIAGRAM

-

MONITOR SYSTEM Coolant

Water temp. Engine oil pres- Hydraulic oil sensor level sensor sure sensor


level sensor

,

fWi:\

I

<==~' '~'l----

~

I

1==

1==

~

~

CN·5

~

HH

CN:l

rrr

:iri'

"

'

~~9

~

00 11 12

21

1 2 3

5 6

0

11 12

21

\

,'----V

cI

i'---"

F

F

~ 1 2

CN·6

~

H

F=

??~

7

~

~

~5A

01 RB

(~P H ~P ~

F=

f.E

01BW 01 RL

03 2 1

~l

E

03 2 1

~l

Lamp output Buzzer output (+24VI output

4 03 2 1

4C 3C 2c 1C

Buzzer

01RL

p 005BW

P

005YG 005WG

Fuse box

rrrr-

Controller

R

GND

Lamp signal Buzzer signal (+24V) output

0

eN>'1

I

028

1

1

rt+t-+t--t-----fto;

111 02B

21 21 20 20 19 19

02G

17 17

-

I1-+1H-+-++-_t--"0"'20::.-(_:tt~~0<~ (r~:r:~ijtCh;

---1

G{ U

02YG 02LR 02W

Lamp switch:

D05YG

01 RL 011/11

II

005G

01 RL

r--

www. k omat s upar t s book . c om y_l.._-_-l;_+-f--+/~_-_-++"""'-t--_-_--t--_-_-7.",,0~1"IA;:-/~=-~~ ~ Mode selector I 005YR 01 B 2 switch I 14,o+l-+""'''-'----f-+--+-J_+_, 005L rl+-++_-,0-,-1-"W-,B-+1O I 13 018

02YR 02L 028 02GY 02GW

14 13 12 12 11 11 10 10

'~f-'h~","""--+-+-H--H+H+--' 005GY

02BY 7 02BW To control box----------"-"-"--ttC 6

~

~--

-.J

( IJI'

005GW

005BY

7 6

Q1WB

02R 01 R To head lamp 2 2 02BW OlBW 1 1 To battery relay-Hf---------------=:..:.:..~~~~

eN)) 028 02GB 02BW 02Y

Fuel level sensor

eN 1')

(~

2

2

1

1

02BW 02Y

4

3 2 1

005B 005GB 005BW 005Y

4 3 2 1

-

I HEATER SWITCH CONNECTION Opposite connector terminal No.

~I

Position

OFF La Hi

4

3

2

1

E

L

M

H

0 '" 0 f-O oE" 0- f--- !-O z~

WIPER SWITCH CONNECTION LAMP SWITCH CONNECTION 0 pposite onnector

Opposite connector terminal No.

4

3

2

1

~al E

~minal Positio~

L

M

H

W'

erminal No.

oSition

OFF I II

62-62 ®

0

'" 10to o§" 0-to- 1-0 Z~

4

3

2

0. ::J

o

ELM

H

5>

Of--f-Q

ON

of-o

W

o-f-O-I-O

PC200, 220-3

CIRCUIT DIAGRAM

TROUBLESHOOTING

MONITOR SYSTEM PC200-3 (Serial No. 20001 - 30309), PC220-3 (Serial No. 20001 - 22627) Water temp. Engine oil pres- Hydraulic oil level sensor sensor sure sensor


Coolant level sensor

rAAi"A\

1==

1==

~

~

~ ~ 1 2

Hi

==

,~\

"

'

\

~~)i

oJ

F=

F=

~ 1 2

~

It

F===

1

2

01BW

-<~5A

01 RB

(~ 0 J

~E

-{5 6

01 RL

II: ~

~t

03 2 1

~t

4 03 2 1

40 f - GND 30 I-- Lamp signal 20 I-- Buzzer signal 10 I-- (+24Vloutput

11 03

Buzzer

0 GIRL

0 005BW

0

G05YG

Fuse box

005WG

Controller

f

d Lamp output Buzzer output (+24Vloutput

llFf~~ 00 11 12

21

12356701112

21

o

crJ

1

028

1

To control box

I

1

02b

1

I

err'!

02YG 02LH 02W

005YG

21 21 20 20 19 19

U2G

01 RL 01\1\'

[I

OUSt-;

www. k omat s upar t s book . c om 02YH

02L 026 02GY 02GW

1/

17

14 13 12 11 10

14 13 12 11 10

7 6

6

2

2

1

1

02l3Y

02BW To control box--------==-!+O

02R 028W

005YR 005L 018 005GY 005GW

J05BY

/

OlWB

01 R 01BW

U;

-

uel level sensor

028 02GB 028W 02Y

eN: 2 1

4 3

2 1

I

I)

0058

4

005GB 0058W 005Y

3 2 1

2 02BW 1 _II 02Y

HEATER SWITCH CONNECTION Opposite connector terminal No.

~I Position OFF Lo Hi

4

3

2

1

E

L

M

H

0 0 -0 0- -

-

'"

.~

oE

k>

zJ!l

WIPER SWITCH CONNECTION LAMP SWITCH CONNECTION 0 PPoslte onnector

OFF

I II

4

3

2

1

~I Position

E

L

M

H

4

3

2

1

E

L

M

H

W'

-

OFF

erminal No.

~I OSition

Opposite connector terminal No.

0 0- k> 0- k)- k>

PC200, 230-3

'" o§"

zJ!l

ON W

0 -

-0

0 - -0 0 -0 0-.0- -0

62-61-2

CIRCUIT DIAGRAM

TROUBLESHOOTING

--

PC200-3 (Serial No. 30310 and up) PC220-3 (Serial No. 22628 and up) C Galant Ie vel sensor

~

~

>---

f) >--1

~

I-CN~2

I

nglne 01 level sensor

2

I

i

w ater temp sensor

2

~

I

'"-


"

([I::)

~

2

I

2

Hydraulic oil level sensor

Fuel level sensor

~""

1-

~

I 2 3 4 0

eN I

~14

eN -15

2

I

-=-

2

-

-

I--

-

Starting

{ 8

t

----'

I

Fuse box ISA

I

SWitch

Ace

~

I

[ ~~p

b

To starting motor C termmal To alternator R terminal 10 0 0 00 I 2 3 4 5 6 7 8 9 10 I I 12 10

0

0

0

-

21J

I

C N-I

www. k omat s u p a r t s b o o k . c o m 1 """p ~ "''1 Electflcallntake air heater

Heater relay

J~l

crr;~~~ o

Wiper,

; -~

'---, CNP6f--------- -

Lamp

,

C~r---~ I

Mode

2 3

selector

~ 21 020 19 018 17 016 015 14 13 12

To control b ox

To control bo x

"

10 09 08 7 6 05 04 03 02

To control bo x

IL

-

I 2

3 0 0 0

CNP1

~:lj~r\~r(~;

3 4

5 6 7 08 9 010

0 0 0 0

(UUldl

~

2

III vpl

H'y'cl(c1UIH oil

III

I

-

g-

Willer temp

0

f-ul'llevel

o~(

Spdf('

6

Sparp

07 \

8

0

SlldlP iGNDI

3

--'--

,

':GNi)"

~

02

~c

;5> SP~HP

12

I

(J)

f- 'HJII"~ oil pr(!S'"Ht'

CNP2

0

I

t levpl

frll) III ()

~

3

1

--

,4V

I 2

I

0 0

0 0 0 0

I:

Service meter

"

08 07 06 05 -04

~

4 05

~

02 I

~/ T1 '77

CNP9

0

I

SW~C~

q

BUllP!

Do

,

--~

Battery relay

Buzzer

205F2457

62-62 (B)

PC200, 220-3

--

-

CIRCUIT DIAGRAM

TROUBLESHOOTING

ELECTRICAL SYSTEM Heater relay

Starting motor

lUI

""

Electrical intake

~~~~g~~~~;;±trr===~_a_ir_he_a-fter I

CN/'O

"l"

~ 1I[l;;;=u:~r""""'-~./

OOB

)

/

Antenna ~

~~

I

I

R~adio

~ID~

02V;

~

01 R

___Washer ::::-JI

cml

-

,

L L::

Room lamp

,...2.!Ol~RSiN~30fF~~ --~

IV

I~====~I 11 12

2

B L LB

(If equipped)

A, ..

(If equipped)

02W

LW

1 2 3 4

v

To cooler compressor

6

01LW alB alL 01LB

1 2 3 4

01R

05W

CN7

Wiper

CN29

CN28 01LW 02B 01 R 01 LB

nl

Alternator

1 ~ Speaker

;:cHI 001 o

To control_ box

20'0+1-"-°1c.R :-"L=-------HI+-Hr---1h

Ie

Cigarette lighte AlA.

17otf-°;;..O;;..5:..;C,--,- - - ,

eN2'J

130

I"

-

r-_~O~1l:,L!:,R--I~~, fF~~_1U-:.1122~5L:..!R~I---l

01WY 01YL 005BY

9 8 7

www. k omat s upar t s book . c om V,

608

~~i~d~ pressu re - - - - - - I l o

~ b

R

E

r

-HI+-H--HI+-HI----':0C!.1=.L~W-1to ,,01LB

01 YB 01BR 01WR 01 R

5 4 3 2

LW l I

125 1.25LB

Heater

C~(

~-.....:Oo.;l~Lc:.R:"---k>°;

Cooler or air conditioner

4+H+-"':~'-~C:~':'~:"--I<0)3 (If equipped)

.....:.

g;~R

BA

~

2 "3

CN17

Batterv relav Head lamp

8

CNlh II.

HEATER SWITCH CONNECTION

a pposite

onnector

erminal No.

_.

~I

2

1

E

L

M

H

Contact capacity

-

--

0 0- f-o 0- "-- k)

La Hi

7

3

oSition

OFF

o

4

'"c

3A

o§

zl"

Fuse box

t erminal No.

~l' oSitIon

OFF I

3

2

1

/

E

L

M

H

Contact capacity

-

--

0=

II

e--

'"

.~

-0-

Boom lamp

~rminal

f'-oSiti~ W'

-

OFF ON

4

3

2

E

L

M

o~

0--0

H

PC200, 220-3

15A ~ 3

01 RB

15A

I

4

01W

2

05W

1

I

20

I

CN23 01BR

lOA

L+H+H+H+

To monitor p a n e l -

4

..:0~0~5'!G~~3

Q1BR

~

01G

rr~~Ju,I~~7~~~~~~!j:fjj:rjlt::::::::::::::::::~~~G~IB=v::tl~~~J1=~ ~~y~ ~, ~

Contact

capacity

r

"'3: 2A

O-LQ IPea~~OA) 0+0 pea~~OA

W

15A

01 R

3A

E zl"

WIPER SWITCH CONNECTION connector

01YQ

02R

1

.110

Opposite ~terminal No.

CNll

O~W

1:(]~

01 RL

4

0 0- -0

1~6

01BrW

LAMP SWITCH CONNECTION

a pposite c onnector

15A

01 LR

lOA

5A (Peak lOA)

CNP5

gg i'J

Starting switch

CNP6 ~"' "'
0; 0; 0; 0;

000

CNP7

I II? 11, ~ I II? ! switch Heater' ! Lamp -! Wiper '! switch switch 2 3 4

I

L

23 4

I

02B

2 3

I

I

__ ----L- __ . . J - __ --.J

01GR

Horn switch

62-63 (~

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PINS

-

CONNECTION TABLE FOR CONNECTOR PINS ECONOSEALCONNECTORS

No. of pins 1 - - - -

Male connector (pin)

Female connector (socket)

(]rn §ill ~

~

2

2

2 142F401

2

3

2

142F400

-

3

Urn ~ ~ www. k omat s upar t s book . c om 3

142F403

142F402

3

4

3

4

[]rn §~

4

2

142F405

142F404

B

6

6

B

o

8

142F407

5

2

10

12

3

11

2

3

7

7

11

12

5

[]]

142F409

(5)

142F406

10

12

62-64

-

3

3

2

6

142F408

PC200. 220-3

-

CONNECTION TABLE FOR CONNECTOR PINS

TROUBLESHOOTING

No. of pins

MIC CONNECTORS

f-----------------.----------------Male connector (pin)

Female connector (socket)

1~3

3~1

4~5

5~4

5

rnmn

6

l8J 142F410

142F411

l~J

www. k omat s upar t s book . c om c c

8

c

CJ

13

13

142F412

142F413

9

9

17

17

10

10

17

r

l 142F415

142F414

11

11

21

21

12

12

142F416

PC200, 220-3

21

142F417

62-65 ®

E-5

TROUBLESHOOTING

b) Failure mode: Deceleration stays on (engine does not return to full throttle)

*

Auto-deceleration switch ON (at AUTO position)

YES

Solenoid A defective

1

YES

Does engine return to full throttle when auto-deceleration switch is turned to OFF? 1)

2)

Turn autodeceleration switch OFF. Pull fuel control lever full position.

Auto-deceleration switch defective

2 Is there continuity between autodeceleration switch (2) and (3)?

NO

1)

2)

Disconnect wiring of autodeceleration switch (1), (2). Turn autodeceleration switch OFF.

3

YES

Is there voltage between CN41 Imale) (1) and (21 20 - 30V'

NO 11

Connect Tadapter (socket) to CN12 (male). Turn starting switch ON. Turn aotdeceleration switch ON.

Solenoid valve defective Poppet operation defective Seizure


3)

,

Cl

Tester

~·S

0 '" 00 0 ~.J:: 0 ::l

f-U>_

62-67-3 ®


NO

Timer defective

T -adapter or socket adapter (forMIC) T -adapter or socket adapter (forDLU

PC200. 220-3

E-5

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-5 a-1. Measure resistance between CN41 (male) (1) and (2).

P20503053

(j-2. Measure voltage between CN39 (male) (1) and (2).

www. k omat s upar t s book . c om a-3. Check for continuity between CN33 (male) (1) and (2).

m~ 2

1

a-4. Check for continuity between CN31 (male) (1) --- (2), CN32 (male) (1) - (2).

pe200. 220-3

62-67-4 ®

TROUBLESHOOTING PROCEDURE

TROUBLESHOOTING

TROUBLESHOOTING PROCEDURE 1. When a request comes in for repairs, first ask the following points.

Good morning.

~

This is Komatsu. "

May I helP]. '.. ' you?

~

Name of customer Type and Seriel No. of machine Jobsite

.

C

- - - - -

-

-

-

- - - - - - -

-

I Lack

-

-

-

- - - - -

.

of digging power?

-

-

- -

~ ---_.

- - -

deviat~' -

Does machine when traveling?

- - - - -

.

Is swing defective?

-

!

2. Get an outline of the problem Ask the following points. Symptoms of failure What was machine doing when

" . ' " . ' " fI$ "

"

'.

.

,

it broke down? Operating environment Details of past repairs maintenance

Tool set

Tester

Hydraulic kit

and

3. Look at the table of special

wnw_w. k omat s upar t s book . c om -~

-

tools and decide what tools

are needed. Do not forget circuit tester and socket for troubleshooting.

.

*

f.

(O'illti'.············ 9'

G=-.JJ

~/17

4. Re-enact

failure and self-testing display

check

Operate the travel and work equipment, and check the symptoms. Check the display of the self testing system.

5.

Chec ks before starting Other checks items

.'..~.""., 9 i' i '.

'"

(j

Look at the Checks before troubleshooting, locate and repair simple problems first.

"

,

Self testing display 1)

Electronic OLSS, auto-deceleration, swing mechanical brake Self testing display

+ _rT!fp ~

Judgement table

Solenoid checker

(If equipped)

Electric [GO to electric s stem system Troubley f t' e shooting Charts d e ec IV No. E-1 - E-6.

Jl!4'1 (Connection of

-~ sWing brake valve)

+

~

Prolix circuit switch

~~. Hydraulic

Go to hydraulic "'-..,,)and and mechanical mechanical system Trou bl esystem shooting Charts defective No, H-1 - H-16. Go to machine

2) Monitor on machine -...

.----~

------->, monitor Trouble-

shooting Charts No. M-l - M-14.

62-68 ®

6. Troubleshooting (Main troubleshooting) 1) Electronic OLSS, auto-decele-

ration, swing brake 1) Using the Judgement Table, decide if the problem is in the electric system, or in the hydraulic or mechanical system. 2) Go to the troubleshooting chart indicated in the Judgement Table. 2) Monitor on machine 1) Choose the troubleshooti ng chart wh ich matches the problem.

PC200.220-3

-


-

E-G

TROUBLESHOOTING

Troubleshooting Chart No. E-6 Failure mode: Upper structure does not swing, or hydraulic drift of swing is excessive.

-

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( ). a) Hydraulic drift of swing is excessive Carry out all checks with the swing control lever at neutral.

*

3 YFS

Is there continuity between CN18 (female) (2) and chassis ground?

YES 2

YES

Is resistance between CN18 (malel 11) and (2) 10 - 30

!P 2)

11 Connect

2)

NO

11 Connect

T-adapter (socket) to CN 18 Imale!. T urn starting switch OFF.

T -adapter Isocket) to CN 18 (femalel. Turn starting switch OFF.

NO

• When using T6-adapter. -

I Does swing brake lamp light up normally 7

11

5 1)

Tum starting switch ON. Lights up about 5 seconds after stopping swing.

-

I

YES

Is voltage between CN 19 (femalel (3) and 11) 20 - 30V7

NO

Measurement conditions same as in previous

step. Turn starting switch ON.


YES

Is voltage between CN19 (21 and (1) 20 - 30V7

21

S

Is voltage between CN24 121 and chassis ground 20 - 30 V7

YES

11

4

NO

Is there continuity between CN 19 Ifemale) (1) and chassis ground?

Connect T -adapter (socket) to CN19. 2) Turn starting switch ON. 3) Place swing lever

7

Is voltage between CN24 (1) and chassis ground 20 - 30 V7

in neutral.

Measurement conditions same

as in previous step. Turn starting switch ON.

2)

11 Connect T- adapter

I

1) Connect T-adapter (socket) to CN1 9 (female). 2) T urn starting switch OFF.

1)

2) 31

to CN24. Turn starting switch ON. Place swing

NO

I

lever at neutral.

NO

• When using socket adapter.

6

6 11

Connect socket to CN 18 Ifemale) and CN19 (female!. Turn starting switch OFF.

21

2)

-

Connect socket adapter to CN19 (male!. Turn starting switch OFF.

NO S

,

YES Is voltage between CN24 111 and chassis ground 20 - 30 V7

11 Connect socket ~.c

~ocn

O~B II=~


62-68 CD


2)

adapter to CN24 (female!. Turn starting switch ON.

I :\0

11 Connect socket 2)

Tester

YES

Is there continuity between CN24 Imale) (11 and (2)7

7

, Cl

-

NO

Is resistance be-

tween CN19 (male) (1) and 121 200 300 !l7

,

YES

Is there continuity between CN 18 Ifemalel (1) and CN 19 Ifemale) (31?

YES

1)

,

I

adapter to CN24 (male!. Turn starting switch OFF.

I I, I

NO

I PC200, 220-3

-

-

CHECKS BEFORE TROUBLESHOOTING

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING (,. Checks before starting, 2. Other check items)

~

Judgement standard

Remedy

1. Check fuel level

-

Add fuel

2. Check for dirt or water in fuel

-

Clean, drain

3. Check hydraulic oil level

-

Add oil

u

4. Check hydraulic oil strainer

-

Clean, drain

0

5. Check swing machinery oil level

-

Add oil

6. Check engine oil level (Level of oil in oil pan)

-

Add oil

7. Check cooling water level

-

Add water

8. Check condition of dust indicator

-

Clean or replace

9. Check for loose or corroded battery terminals

-

Tighten or replace

10. Check for loose or corroded alternator terminals

-

Tighten or replace

11. Check for loose or corroded starting motor terminals

-

Tighten or replace

"-

Item

Q)

+-'

'"3::

OJ

e .-

OJ

t

e .-

'"

0

-

-.-

+-'
0

Q)

0 Q)

.0

OJ

e

.:>L

u

'';:::;

.J::

.;::

'"

Q)

U

U

.0

-

:J

-l

+-'

cti e U

Q)

.;:: E

E Q)

+-' Cl. U ._

.::

~

:J

w cr Q)
www. k omat s upar t s book . c om .-+-'

U

"'e

:"=.~Q) :J ee

'" "'0 "-.J::Cl.

~~E

I

E8

12. Check for abnormal noise or smell

-

Repair

13. Check for oil. leakage

-

Repair

14. Bleed air from system

-

Bleed air

15. Check battery voltage (engi ne stopped)
E Q)

.-

+-'

.:>L U Q)

.J::

u

"-

Q)

Q)

e 0

Replace

16. Check level of battery electrolyte

-

Add or replace

17. Check for discolored, burnt, or bare wiring

-

Replace

18. Check for missing wiring clamps, hanging wires

-

Repair

Cl.

.J::

E u

19. Checks for water leaking onto wiring (check carefully water leakage at connectors and terminals)

-

0

Disconnect connector and dry connection

u '" .;::

20 . Check for broken or corroded fuses

-

Replace

21. Check alternator voltage (engine running at over half throttle)

27.5 - 29.5 V

Replace

-

Replace

+-'

-

'" e

+-'

20 - 30 V

0

-

+-'

u

Q)

w

22. Noise when battery relay is operated (switch starting switch from on to off)

PC200, 220-3

62-69 ~

-


-

-

-

TROUBLESHOOTING

ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY

ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY 1.

Abnormality in power source If the battery input voltage goes below 15V or above 36V due to any cause such as filure of the alternator, the protection circuit of the power source circuit acts to cut the power for the circuits inside the control box, and both the LED displays go out.

2.

Abnormality in control box If any abnormality occurs in the computer system inside the control box, both the LED displays stay on.

3.

Abnormality in TVC valve solenoid system If there is any short circuit or disconnection in the TVC valve solenoid system, the current in the TVC valve solenoid becomes O. The red LED flashes (approx. 2 times/sec) and the green LED goes OFF.

4.

Abnormality in speed sensor If there is no output signal (that is, pulse) from the sensor for more than a certain time, this is detected, and both LEDs flash: red LED (approx. 2 times/sec.), green LED (approx. 2 times/sec.). If this error message is given, the TVC valve solenoid current is increased and the display is continued for 3 minutes. When the engine is started, or when there is a temporary abnormality, the abnormality display is also given for 3 minutes, but then the display returns to normal.


Abnormality in potentiometer When the input signal from the potentiometer is below 2V or above 4V, the red LED comes ON and the green LED goes OFF. (Input voltage when normal: 2.5 - 3.3V). When an abnormality is detected, the control box acts in the same way as for the setting when the engine is at full throttle.

6.

Abnormality in auto-deceleration solenoid system Applicable for PC200 (20001 - 21463) PC220 (20001 - 20364) If the signal to the auto-deceleration solenoid is the solenoid OF F signal, even if the auto-deceleration solenoid system is short-circuited, there is no adverse effect on the control box, so only a disconnection is detected and the abnormality is displayed. If the signal to the auto-deceleration solenoid is the solenoid ON signal, even if there is a disconnection in the autodeceleration solenoid system, the auto-deceleration function will not work, so there is no adverse effect on the control box. Only a short circuit is detected and the abnormality is displayed. When this abnormality is displayed, only the auto-deceleration function does not work. The other control functions are carried out normally.

Note: The above abnormality displays (except engine speed sensor abnormality) light up to show any momentary abnormality. Even when the normal situation is restored, the display stay on, so turn the power on and off several times to check whether the abnormality remains. There is the possibility an abnormality condition lasting only for short time, so do not use the troubleshooting flow check once only. Repeat it several times and take the necessary action.

PC200. 220-3

62-71

JUDGEMENT TABLE

TROUBLESHOOTING

-

TROUBLESHOOTING 1) HOW TO USE THE JUDGEMENT TABLE (2-STAGE MODE SELECTOR OLSS) Troubleshooting for Travel, Work Equipment, and Swing System. (OLSS, auto-deceleration, swing mechanical brake) 2) JUDGEMENT TABLE (S mode) (2·STAGE MODE SELECTOR OLSS) (From measuring voltage of solenoid valves, go to electrical system Troubleshooting Charts No. E)

~

roubleShootjngtool

Tester·T·adapter

+-----TV-C-,-o"-'O-id-'-."-,-----J

SOle n oid;. -. ,,-,

"'ro

(;Ole51)

OOtifl9/J,-0c

----f-------------.j

fJrIvre

1.

Stopeng;ne, turn stertingswitch OFF

2

Connect T -adapter (socket adapter) to eN13 (female) (TVC solenoid I

3.

4

Turn starting switch ON

Is voltage between eN13 nyC solenoid valvlll (1) lind (21 as shown in following teble?

-

(Normllil Position of mode saleetorswitch

Measuring

S mode

OV

Lmode

20- 30 V

voltage

Goto Troubleshooting Chart Eleetrical s stem y

I



MachinedeviatesexCE!ssively (when traveling normally)

o

As above table Not as above table

Hydraulic, mechanical synem defective Electrical system defective

E _1

www. k omat s upar t s book . c om Machine deviBtes excessively (during compound operations) MachinedeviatesexCElssivelY {when starting)

4

ContrOl levers are heavy

H-4

WorkeqUipment,travel,and swing start suddenly

6

Speeds for work equipment. swing, and trOVe I are ali extreme Iy slow, or there is no powt!r

H-5

0

As above table Not as above table

Hydra!-'Iic, mechanical system defectIve Electrical system defective

E-1

H-5

Engineuallsor engine speed drops during operations B

No change in output when mode selector switch IS operated

o

As above teble Not as above table

Hyd.aulic, mechanical system defective Eleetrical system defective

E-4

H-8 H -10

11

Swing speed is slow

12


14

Excessivehydraulicdrift of workequlpement

E-6

H -12

H-6 dlsaction

Parking brake does not work {no slopes) 16

EKCE!ssiva time lag for work eqUipment

H - 16

Step 1

Search for the troubleshooting mode After using indirect diagnosis and reproducing the failure (to confirm that a faulty symptom actually exists on the machine), find the applicable faulty symptom from among failure modes no. 1 through no. 16 in Judgement table.

Step 2

Decide whether the failure is in the electrical or the hydraulic-mechanical system 1) Connect a T-adapter or a socket adapter between the connector for a solenoid valve marked 0 and the wiring harness, and measure the voltages when operated according to the diagnostic procedure. Then, see if the measured voltage values are in the normal range. 2) See if the measured voltage is equal to the normal value in the table. If the measured voltage is same as the normal value given in the table -+ Failure in the hydraulic-mechanical system Proceed to the applicable regular diagnosis (H-M)

-

If the measured voltage is different from the normal value given in the table-+ Failure in the electrical system Proceed to the applicable regular diagnosis (E·M, Step 3

62-72 @

-

Proceed to the applicable regular diagnosis (Yes or No diagnosis).

PC200, 220-3

TROUBLESHOOTING

JUDGEMENT TABLE

-. 2) JUDGEMENT TABLE (2-STAGE MODE SELECTOR OLSS) (From measuring voltage of solenoid valves, go to electrical system Troubleshooting Charts No. E) Troubleshooting tool

Tester' T-adapter

SO/eno' Id valve

?'ro

TVC solenoid valve

IJblesl) °Ot· Ing IJro CeCilJre

1. 2.

Stop engine, turn starting switch OFF. Connect T-adapter (socket adapter) to CN13 (female) (TVC solenoid).

3. 4.

Turn starting switch ON. Is voltage between CN 13 (TVC solenoid valve) (1) and (2) as shown in following table?

~

~

<9,? <9"",

-.

t-

O'/.

"<9


Measuring voltage

S mode

OV

L mode

20 - 30 V

Go to Troubleshooting Chart Hydraulic, mechanical system

www. k omat s upar t s book . c om Electrical system


1

-

-.


0

As above table:


Not as above table:

E -1

H -

1

2

Mach ine deviates excessively (during compound operations)

-

-

H-2

3


-

-

H-3

4


-

-

H-4

5


-

-

H-5

6

Speeds for work equipment, swing, and travel are all extremeIy slow, or there is no power

7

Engi ne stall s or engi ne speed drops during operations

8


0

As above table:


Not as above table:

As above table:


Not as above table:

1

-

-

0

E-

E-4

H-6

H-7

H-8

10


-

-

H -

11

Swing speed is slow

-

-

H - 11

12


-

14


-

-

H-6 d) section

15


-

-

-

16

Excessive ti me lag for work equipment

-

-

PC200, 220-3

E- 6

H -

H -

10

12

16

62-73 ®

JUDGEMENT TABLE

TROUBLESHOOTING

2) JUDGEMENT TABLE (2-STAGE MODE SELECTOR OLSS) WITH AUTO-DECELERATION AND SWING MECHANICAL BRAKE

-

(From measuring voltage of solenoid valves, go to electrical system Troubleshooting Charts No. E-xx, or hydraulic Troubleshooting tool SOlenoid

Tester· T-adapter

Valve

TVC solenoid valve


/'~

°V6;. "'SI, oaf'

I,,!} 1)"0

(''''0:

v,.",

1.


1.


2.

Connect T-adapter (socket adapter) to

2.

Connect T-adapter (socket aadpter) to


CN40, CN41 (auto-deceleration solenoid

3.


valve) (female).

4.

Is voltage between CN 13 (TVC solenoid

3.

valve) (1) and (2) as shown in following

4.

table?

Turn starting switch ON. Is voltage between CN40, CN41 (autodeceleration solenoid valve) (1) and (2) as shown in following table?

'i-

~

"'-'?

"""t.~i:

.

(Normal)


Measuring voltage

S mode

OV

Lmode

20- 30 V

Measuring voltage

When operating each control lever

Operated

Solenoid B (2-pin side)

-

20 - 30 V

www. k omat s upar t s book . c om Neutral

Solenoid A (3-pin side)

OV after approx. 5 sec. delay


1


0

As above table:


Not as above table:

~

2

Machine deviates excessively (during compound operations)

-

-

3


-

-

4


-

5


-

6

Speeds for work equipment, swing, and travel are all extremely slow. or there is no power

7

Engine stalls or eng; ne speed drops during operations

B


0

As above table:

~


Not as above table:

-

0

-

As above table:

Hydraulic, mechanical system defective

Not as above table:

Electrical system defective

Hydraulic, mechanical system defective Electri cal s\lstem defect ive

As above table:

9


-

10


-

-

11

Swing speed is slow

-

-

12


-

0

0

Not as above table:

As above table:


Not as aobve table:

13


14


15


-

-

16


-

-

62-74 @

-

-

-

~

-

-

PC200, 220-3

-

TROUBLESHOOTI NG

JUDGEMENT TABLE

and mechanical system Troubleshooting Charts No. H-xx.)

Tester Swing brake solenoid valve

1.

Disconnect swing brake solenoid and connector.

2.

After running engine for at least 10 seconds,

stop engine and turn starting switch ON.

3.

Swing lever Neutral ----... Operated.

-

(Normal) When operating swing lever

Measuring voltage

Operated

20 - 30 V

Go to Troubleshooting Chart

Electrical system

Hydraulic, mechanical

system

www. k omat s upar t s book . c om OV

after approx. 5 sec. delay

Neutral

-

-

E- 1

H-1

-

-

H-2

-

-

H-3

-

-

H-4

-

-

H-5

-

-

PC200, 220-3

E- 1

-

H-6 H-7

-

E-4

H-8

-

E-5

H-9

-

-

H - 10

-

-

H - 11

-

E-6

H - 12

-

E-6

H - 13

-

-

H-6 d) section

-

-

-

-

-

H - 16

62-75 (2)


TROUBLESHOOTING

3) METHOD OF USING THE TROUBLESHOOTING CHART (2-STAGE MODE SELECTOR OLSS) (See "Example 1")

CD


Location of failure

E-M

Electrical system of electric OLSS, auto-deceleration (if equipped), swing mechanical brake (if equipped)

H-XX

Hydraulic or mechanical system of electric OLSS, auto-deceleration (if equipped), swing mechanical brake (if equipped)

M-OO


®


®

Categories for same symptom Even though the symptom is the same, if the machine model or component is different, the method of using the troubleshooting chart may be different. In such cases, the symptom is divided into sections a), b), etc. Select the appropriate section and start toubleshooting from that point. If there are no sections, start troubleshooting from the beginning.

@

Following the troubleshooting chart • Carry out the check or measurement inside the box. If the result is "YES", follow the YES arrow; if the result is "NO", follow the NO arrow. • If the YES or NO arrow leads direcly to the Cause column, take the action given in the Remedy column; if the arrow leads to another box, carry out the check listed in the box. (Note: The number at the top right corner of each box is only a list number; it does not necessarily indicate the order for troubleshooting.) • Any instructions given below the box are work to be carried out before making the check listed in the box. These instructions include preparatory work, operations to be carried out, and judgement values. If the preparatory work is not carried out, or the operations are carried out wrongly, mistakes will be made in judgement, or the machine may be damaged. Therefore, before making the check or measurement in the box, read these instructions carefully and carry them out in the order listed. Then go on to the check or measurement.

-


®


*

®

-

*,


62-76 ®

PC200, 220-3


TROUBLESHOOTING

Example 1

Troubleshooting Chart No. E-4 (2-STAGE MODE SELECTOR OLSSI Failure mode: No change in output when mode switch is operated.


Tester

IforMICI


T-adapter or socket adapter

(forEKONOI

Ifor DLiI

s -mode performance in L-mode

Cause

....

For travel deviation, see H-l For lack of power, see H-8

-

Resistance defective

4 YES YES

-

11 Connect Tadapter

3

YES 2

Is resistance between NC13

21

(female) (1) and (2)

31

10 - 25 IP

Is eN 13 (female) 0), (2) - chassis ground insulated"

YES

Is resistance between CN34 (female) (1) and (2) within standard value?

11 Connect T-adapter

(socket) to CN34 (female) leave male disconnected Turn starting switch OFF.

:-.10

Remedy

:-.10


Replace


Is voltage between

CN 13 Imalel 111

and (2) within standard value?

21 31

11 Connect T-

21

31

adapter (socket) to CN13 (female) Leave male disconnected Turn starting switch OFF

11 Turn mode

NO

31

Is there continuity between CNP4 (female) (1) and

YES 5

III Turn starting switch ON Connect Tadapter (socket) to CN,3 (male)

1\0

f-

121'

Is resistance between CN34

11

Ifemalel 111 - 121 within standard value?

21 31 41

11 Turn mode selector switch

NO

Connect T -adapter (socket) to CNP4 (female) Leave male disconnected Turn starting switch OFF. Turn mode selector switch (L)

NO

III 21

YES

6

selector switch

21

(socket) to eN 13 (female) Leave male disconnected Turn starting switch OFF

TVC valve defective

Replace

Harness defective 11 Disconnection in wiring harness 21 Short circuit

Replace


Replace


Replace

Turn starting switch OFF

II

-* *

PC200

55 ± 5%

PC220

40:::!: 5%

Turn the starting switch OFF before disconnecting the connectors or connecting the T-adapter (or socket). For T-adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( ).

Example 2 POSITION OF CONNECTORS FOR TROUBLESHOOTING E-4 1. Measure voltage between CN13 (male) (1) and (2). 2.


3.


2

1

~ I~lru (@;

PC200, 220-3

62-77 '5

TROUBLESHOOTING

JUDGEMENT TABLE

TROUBLESHOOTING (except troubleshooting for machine monitor)

-

1) HOW TO USE THE JUDGEMENT TABLE (H mode) This judgement table covers the electronic OLSS, auto-deceleration, and swing brake systems. It is used to decide if the problem is in the electrical, or in the hydraulic or mechanical system of the machine. The table then shows whether to go to the troubleshooting tables for the electric system (E-L'>X) or to the troubleshooting tables for the hydraulic and mechanical system (H-XO). This judgement table use two of the following checks to show which troubleshooting item to go to. Visual checks of the self-testing display (two LEOs on the control box), checks by switching over prolix circuit, and checks of the voltage at the inlet of the swing brake solenoid (shown as. in the chart on the next page). With the machine monitor, use the failure mode to go directly to troubleshooting of the machine monitor (M-M).

*

1.

Self testing display The self display uses two LEOs (red and green). The combination of these LEOs (OFF, ON, flashing) shows if the machine is normal, or indicates the system which is the cause of the abnormality. Normal display

Abnormal display

LED (Light Emitting Diode)

LED (Light Emitting Diode) Machine condition

No. Red LED

No.

Green LED

Green LED

Red LED

-

Location of abnormality in electrical system

www. k omat s upa t s b ok . c om • o •r 1

OFF

2

OFF

3

OFF

•

* *

ON

S mode except when using deceleration

1


H or L mode (except when using deceleration)

2

ON

Slow flashing (once every 2 seconds)

All modes during deceleration

3


4

5

6

7

*

* *

0

** • •

•

OFF

Flashing (twice per second) ON

ON

ON

0

0

* 0

* *

OFF

Power supply

ON

Control box

OFF

TVC solenoid system


Engine speed sensor system

OFF

Potentiometer system


Auto-deceleration solenoid system (A)

Slow flashing (twice per second)

Auto-deceleration solenoid system (8)

-

Normal display No.3 and abnormal display No.7 apply only to PC200-3 (20001 - 21463) and PC220-3 (20001 20364). If the self-testing display shows no abnormality, or when the swing brake system (which does not pass through control box) is marked by • in the judgement table, go to the following checks.

If the control box is defective and the system is switched to the prolix circuit, the LED will display "Control box defective". If the LED shows normal and the system is switched to the prolix circuit, and abnormality in the "TVC solenoid system" will be shown. If when turning the prolix circuit switch from ON to OFF, always turn the starting switch off first.

62-78 (5;

PC200, 220-3

JUDGEMENT TABLE

TROUBLESHOOTIN<3

-

2.

Checking by switching over prolix circuit Switch over the prolix circuit switch (located at the side of the control box) and see if the problem is corrected. Depending on the result, proceed to diagnosing processes E-Xl:. or H-O by following the indication ..... in the Troubleshooting Table.

3.

Checking voltage of swing brake solenoid Run the engine for about 10 seconds to charge the accumulator pressure, then stop the engine, turn the starting switch to ON, and check if the voltage at the chassis wiring end of the connector for the swing brake solenoid is normal or not.

Example

Failure mode (Engine stalls or engine speed drops during operations) Does the self-testing display indicate any abnormality? Check the red and green LEOs on the control box to see if the self-testing display indicates any abnormality.

Step 1

www. k omat s upar t s book . c om Troubleshooting

Check self-testing display

chart

( ..} . See 62·78 }

1. Is location of abnormality displayed]

Power supply

u

Go to E -6.0

Control

TVC solenoid

Engine speed

Potentiometer

Auto-deceleration

NORMAL

boo

system

sensor system

system

solenoid system

display

~

U

0

Red

GreenO

Green

Greene

0

OFF

Green __} FldSln"'j

(;re~n

0

Green

f;

Hashimj

Green.

for abnormali ties in electrical system; go to H - OX for abnormalities in hydraulic or mechanical

system. 1) Run engine at low idling.

*

*

If the - marks in the table below indicate some additional abnormality, this means that two or more abnormalities have occurred at the same time

YES

AhnormJI,tv In electrlCalsv,tem

Failure mode

(..·'"-----+-----"'·'"------+1-][ . 7


I

I

IJudgement I If the abnormalitv display corresponds to the -

mark in the above table --> abnormality in electrical system. Go to troubleshooting table E-3. If NORMAL display appears in other than S mode and during deceleration --> check next _ mark (checking by switching to prolix circuit).

Step 2

Checking by switching to prolix circuit Operate to prolix circuit switch, operate in the same way as when the failure symptom appears, and check that the same symptoms appears. Judgement If symptoms do not appear --> abnormality in electrical circuit. Go to E-3. If sumptoms appears --> abnormality in hydraulic or mechanical system. Go to H....7.

I


Troubleshooting chart

3. Does problem disappear

Go to E -!J.O for abnormali ties in electri· cal system: go to H - OX for abnormal ities in hydraulic or mechanical system.

when prolix circuit switch is operated?

I

1)


YES r

-.-

---~L!:J(!...._

PC200. 220-3

E

3 (Step 8)

H

7

62-79 ®

TROUBLESHOOTING

JUDGEMENT TABLE

2) JUDGEMENT TABLE (3-STAGE MODE SELECTOR OLSS - I F EQUIPPED) PC200-3 (Serial No. 20001 - 21463) PC220-3 (Serial No. 20001 - 20364)

Check self-testing display 1. Is location of abnormality displayed? Power supply

Control

TVC solenoid system

box

Red

a

OFF

Red.

ON

Red

-U

Green

0

OFF

Green.

ON

Green

a

Flashing

OFF

(-U

See 62-78 )

Engine speed

Potentiometer

Auto-deceleration

NORMAL

sensor system

system

solenoid system

display

Red

Green

-(} Flashing

Red.

ON

~ Flashing Green 0

Red.

OFF

ON

* I[~;:,,,,;1=}iY~Ei-S~-a~~~~~~~~~;~;~I l~a~l~r~~~I)eShOotiIl9

Does NORMAL

1~~I~ry~~\eshooting

display appear]

1~~i~r6~~~~s~3)ting

Failure mode Machine. deviates excessively

- ---

2

Machine deviates excessively (compound operations)

-- --

3


4


5


6


-

2) Other than

deceleration The situation durmg norm
electrical system

Check boom

AboD,m,l,ty m

II Check s.olenoid I ! voltage I

speed

1-----------------

ON

11 S mode

*

Is there any display

OFF

Green"':: Flashing Green.

1) Run engine at low idling. If the. marks in the table below indicate some additional abnormality, this means that two or more abnormalities have occurred at the same time.

of abnormality?

0

Red

f-----

•

www. k omat s upar t s book . c om ----f---------

------ --- -- --1-----

-----------------

- - -

-------'----

----+

('-.------f----7

----

----

YES

--e--

r-;O

Applies only to H mode (does not apply to S or L model

,I------

',-() YES

-'--~I__---___t_--.-.-J/

I- -


IL

NO

-

-

-

-

-._ )

YES

8

9


Auto-deceleration does not work properly No deceleration Deceleration stays on Time taken for deceleration to work

('-.-----___t_--------+--'--..J>-y - - - - - - - - - IL NO

_

('-.----+-_..----~--+----~_.-+--- +----

(about 6 seconds) is strange

---

1----- - - - - - - - - - - - -

10


r- - - -

11

Swing speed is slow

f-----

12


I---------f---- ---- -----

f-----

----------------1--------_.(

)

13


1----------------------

14

Excessive hydraulic drift or work equipment

15 Parking brake does not work (on slopes)

1--------- - - - - - - - - - - - - - - - 1---- - - - - - - - - - - - - - - - - - - - - - - - -

16 Excessive time lag for work equipment

1------------------------- ----

62-80 ®

PC200, 220-3

JUDGEMENT TABLE

TROUBLESHOOTING

Checking swing brake solenoid voltage

Checking by switching


prolix circuit

Troubleshooting chart

2. Does NORMAL display appear? 3. Does problem disappear 4. Is voltage at inlet -,:-)-=-Du-ri:-n-g-d:-e-ce-l-e-ra-t-io-nr-r--'-t-h-e-r-th-a-n-d-e-c-e-Ie--~ when prolix circuit port of swing brake (H, Sand L modes) ration (H and L switch is operated? solenoid normal?

Go to E -(\,0

2I O

for abnormali-

ties in electrical system; go to H - OX for

modes 1

0

Red Green

-

OFF Slow flashing (once every

~

0

Red

! I ~~~~

OFF

Lever at neutral

Fast flashing

Green -()

(Stimes per second)

2 secondsl

switch at OFF

3)

23 - 30V

OV

I I

abnormalities in hydraulic or mechanical

1) Disconnect connector of

,) Engine at half throttle or above

swing brake solenoid 2) Run engine for about

21 Engine at half

throttle

I I

system.

11 Auto-deceleration

All control levers at neutral 2) Engine at full 1)

operating

10 sec.

throttle Operate mode switch H-S-L.

3) Stop engine, and turn

starting switch to ON. 4) Move swing lever

between neutral and swmg.


- -

---------'l

H-1

~

H-2

- - - - - -

-- -

- - -

- - - - - - - - 7 H-3

--------~ H-4

--------

--------I---------~H--5 i - - - - - - - - - - ' ! £-2

-- - - - - - -

---- ----

YES

H

~---.-{==

6

(Step 91

E

NO

---------------- ----------------"£ YES r - -

--------i---------

------ ----- -

-

-

-

-

- -

-

--------- 1----- -

YES

---- ----- ---e--i~

-

£ - 3 (Step 8) H 7

--'

£

-.-0-+1'0 t..:.:

--------1---------

--------

4

H-3 E - 4

--------"

(Step 5)

----------------1----------> E

(Step 4) II

- - - - - - - - I-- - - - - - - -

--------

~

-

-

-

-

-

-

~

-

-

-

-

-

-

-"

10

H - 11

---------------- ------YES-" H -13

- - - - - - - - - - - - - - - -----------~-;;, ~

- -

-

-

- - - - -

- -- -

- - - - -

-

-., £ - 6

-- --

H

6

---------------------------~

-

-

-

-

-

-

-

PC200, 220-3

f- -

-

-

-

-

-

-

-

-

-

-

-

-

-

- -

-

-

-

-

-

-

-?

H -16

62-81 ®

TROUBLESHOOTING

JUDGEMENT TABLE

2) JUDGEMENT TABLE (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED) PC200-3 (Serial No. 21464 and up) PC220-3 (Serial No. 20365 and up)


1. Is location of abnormality displayed?

c:

Power

Control

supply

box

TVC solenoid system

Red

0

OFF

Red.

ON

Red

-(l-

Green

0

OFF

Green.

ON

Green

0

Potentiometer system

sensor system

FlashlmJ

OFF

( -(;- , See 62-78 )

Engine speed

Red

-(} Flashing

Red.

Green"') Flash'nq

Green

0

NORMAL display

Auto..::!eceleratlon solenoid system

ON

Hell.

ON

OFF

Green.;

Flash,nq

Red

0

OFF

Grt'p".

ON

1) Run engine at low idling.

_'2

*

11

If the - marks in the table below indicate some additional abnormality. this means that two or more abnormalities have occurred at the same time

21

than deceleraTion

The s,tuJliOn dunnq normal decplpratlon I';

-

on th"

tprn "'1 ht

dec"l"r,l!lon

Failure mode Machine deviates excessively

r---------------

2


1--

3


4


5


6


www. k omat s upar t s book . c om f---- 1----

--I-----I---~-----

-----~

r

---

~-

--j-~---

---- ----

-

----1-----

----

-------j----

.::tL.:..-:-~-=-=+__-__ Applies H mode to

>-« 'J:::~_ ~ ~:\()

or L

-~.--

_--r-:-=-~~":"-7


8


9

Auto-deceleration does not work properly No deceleration Deceleration stays on Time taken for deceleration to work (about 6 seconds) is strange

--

~ ~)-- -------.--,_/', IF S _~__ - __ +.~ yf-'.:.:c_

-.-

-~-

~ ~)---~~-+--~------+----

~--1-~

- - - ---t---

_-t---- >-« J

-

j-' ES

I L~(2...

... _

(

10


r----

11

Swing speed is slow

I-----------------!----I----

12


1---------1----- 1---- 1-----

)

I----I----------------- r ---- - --

-----_.(

13


14 Excessive hydraulic drift or work equipment 15

Parking brake does not work (on slopes)

16 Excessive time lag for work equipment

62-82 ®

-

--

)

f---------i-------------

--------r----- ----

---- - - - - - - - - - - - - - - - - - -

- -

-

-

- - - - - - - -

--

- - -

PC200, 220-3

-

JUDGEMENT TABLE

TROUBLESHOOTING

-

Check self-testing

Checking voltage of auto.-deceleration solenoid

display 2. Does NORMAL display appear?

0

Troubleshooting

solenoid voltage

chart

switch is operated?

• Is voltage at inlet of auto-deceleration

Go to E -/',0 for abnormali-

ties in electri-

solenoid normal?

cal system; go to H - OX for

solenoid correct?

OFF

I

Fast flashmg

Green -(}

Checking swing brake

3. Does problem disappear 4. Is voltage at inlet when prolix circuit port of swing brake

Other than decele· ration ( Sand L modes) Red


Lever at neutral

I ~~~~ operating

(5 tImes

per secondl

I

[20 - 30V

ov

[

1

abnormalities in hydraulic or mechanical

system.

1)

Auto-deceleration switch at OFF 2) Engine at half throttle 3) Operate mode switch

H ...... S-L.

1) Lever NEUTRAL solenoid A (3-pin side) 20 - 30V 21 Lever operation solenoid B (2-pin sidel 20 - 30V 3) Engine at half throttle or more 41 Measure solenoid A after about 5 seconds

1)

1) Disconnect connector of swing brake solenoid 2) Run engine for about 10 sec. 3} Stop engine, and turn starting switch to ON. 41 Move swing lever between neutral and swing.


www. k omat s upar t s book . c om --------.>

-

-

-

-

-

-

- -

-

-- -

-

-

- -'i

H-]

H

H-3

---------'l

-----------------~-------

H

H

5

f--------~ E-2 YES

----------------

r----.-{==~ NO

---------------- ----------------' YES

r - -

---------------

-

-

-

-

-

-

-

-...o---tLi:!<2..

---.--{~ - - - - - - - -

- -

-

-

-

-

-

-

_

-

~-

-

-

-

-

-

-

-

-

-

-

-

I- -

1--------------- -

------ -

-

-

-

-

(Step g)

£-3

H

7

E-4

-,

H- 8

--'l

E - 4

YES

• - -{;~ ------= ~-------- - -=----=- -= -=- -

6

E - 2

- , £ - 3 (Step 8)

-------1---------;; YES

H

(Step 5)

H-9

=:

-

~------

E - 5

(Step 4)

- , H -]0

-'

H

11

-------'yE.§..::, H -]3

- - - - - - - - >- - - - - - - - - - -

-

--

-

-

-----

-

-

-

-.....<>-..il!'~

,

~

- ---------

---31

- -------

-------------~

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -31

PC200. 220-3

E - 6

H

6

H -]6

62-83 ®


TROUBLESHOOTING

3) METHOD OF USING THE TROUBLESHOOTING CHART (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED)(See "Example 1")

CD


Location of failure

E-M

Electrical system of electronic 0 LSS, auto-deceleration, swing brake

H-XX

Hydraulic or mechanical system of electronic OLSS, auto-deceleration, swing brake

M-OO


®


®

Categories for same symptom Even though the symptom is the same, if the machine model or component is different, the method of using the troubleshooting chart may be different. In such cases, the symptom is divided into sections al, b), etc. Select the appropriate section and start toubleshooting from that point. If there are no sections, start troubleshooting from the beginning.

-

www. k omat s upar t s book . c om @ Following the troubleshooting chart • Carry out the check or measurement inside the box. If the result is "YES", follow the YES arrow; if the result is "NO", follow the NO arrow. • If the YES or NO arrow leads direcly to the Cause column, take the action given in the Remedy column; if the arrow leads to another box, carry out the check listed in the box. (Note: The number at the top right corner of each box is only a list number; it does not necessarily indicate the order for troubleshooting.) • Any instructions given below the box are work to be carried out before making the check listed in the box. These instructions include preparatory work, operations to be carried out, and judgement values. If the preparatory work is not carried out, or the operations are carried out wrongly, mistakes will be made in judgement, or the machine may be damaged. Therefore, before making the check or measurement in the box, read these instructions carefully and carry them out in the order listed. Then go on to the check or measurement.

®


*

®

-

*,


62-84 ~)

PC200, 220-3


TROUBLESHOOTING

Example 1

CD

Troubleshooting Chart No. E-2 Failure mode: Work equipment. swing. travel speeds extremely slow. or lack of power.

Tester T-adapter or socket adapter IforEKONOI

®

a)

T ~adapter or socket adapter (forMIC) T-adapter or socket adapter (for DUI

Self-testing display shows abnormality

YES

2

YES

Is voltage

between eN 10 (female) (ll and (2)

20 Abnormality in power supply

OFF

o

~

11

OOFF

Is voltage between fuse 4 and chassis ground 20 - 30 V 7

3 YES

\0

30V? Is resistance between CN10 (female) (2l and chassis ground 0

1 Connect T -adapter

(socket) to eNl 0 21 Turn starting switch ON. (00

n)

;'\()


Green

Turn starting switch ON (Do not start enginel

not start enginel

11 Connect T-adapter

21

(socketltoCN10 Turn starting switch OFF

:\()


®

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( )

Example 2

®

2. 3.

Measure voltage between CN10 (female) (1) and (2), Measure resistance between eN 10 (femalel (2) and chassis ground

1

2

~~PC200, 220-3

62-85 ®

-

-


-

-

E-1

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-1 1.


2.


3.

Measure electric current between CN13 (male) (1) and (2).

4.



5.


6

-

12

1 J 6.

Check for continuity between CN35 (male) (2) and(4).

2

4

PC200, 220-3

62-87 (5;

TROUBLESHOOTING

E-l

-

Troubleshooting Chart No. E-1 (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED) Failure mode: Machine deviates excessively.

* Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socked. * For T -adapters, connect to both the male and female ends; for the socket. connect to the connector marked in (

a)

l.

Self-testing display shows abnormality Abnormality in control box ON

I

~

! I----------------------------------------------ON

YES

2 Is CN13 (male) (1), (2) - chassis ground insulated>

YES

YES 1)

j -(t

OOFF

2)

Is resistance between CN 13 (male) (1) and (2)10 - 25 ll?

3

Connect T -adapter (socket) to CN 13 Imale). Turn starting switch OFF.

1

y ES

4

Is resistance between CN36 (female) (3) and (5) 10 - 25 117 Is each pin to chassis ground insulated>

Is resistance between CN36 (female) (1) and (2) 10 - 25 ll? Is each pin to chassis ground insulated? 1)

-

NO

L;.

Connect T -adapter (socket) to CN36 (female). Turn prolix circuit switch OFF.


Green

1)

2)

NO

2) Return CN13 to original position. Connect T -adapter (socket) to CN36 (female). Turn starting switch OFF.

1)

Connect T -adapter (socketl to CN13 (male). T urn starting switch OFF.

NO

2)

NO

3)

• When using T -adapter 3

YES

Is voltage between CN 1a (6) and (7) Vcc/27

2

I

YE1S

Is voltage between CNS 111 and (2) Vcc/2?

1)

.--------..:;, ONe

Red

OOFF

1) 2)

I --:..-

2)

Connect T -adapter (socket) to CNS. Turn starting switch ON.

1) 2)

r

same as in previous step. Take voltage between CNS (1) and (31 as Vee.

Is voltage between CN 1a (male) 171 and (8) 5 - 5.2 V>

NO

•

3


eN 10 Ifemalel 161 and (7), and res is-

3

tance between (7)

Is difference in

2

, C1

~c:

Tester

..0'';::; ::JOV>

000

~~P

T-adapter or socket adapter (for EKONO)

62-88 (5)

T-adapter or socket adapter Ifor MIC) T-adapter or socket adapter (for DLD

11 Disconnect eNg. 21 Do not start engine. 3) Governor lever at FULL.

resistance between

CNS (male) (11 and (21. and resistance between 12) and (3) less than 30 II > Measurement conditions same as In previous step.

y ES

Is difference in resistance between

YES

Is resistance between CNS (male) (1) and (3) 5 ± 1 K II > Is it insulated from chassis ground?

-

YES

Connect T -adapter to CN10. Turn starting switch ON

YES

_

I

,N O 1111 Measurement conditions

Is voltage between CNS (female) (1) and (3) 5 - 5.2 v>

Green

L

Connect T -adapter to CNl O. Turn starting switch ON .

2)

and (8lless than

--..2!!.n 7 1) 21 3)

Connect CNS. Disconnect CNl O. Do not start engine.

NO

I~~ o I

I i

"\0

PC200.220-3

E-1

TROUBLESHOOTING

Cause

5

-

YES

Is resistance be-

-

tween CN 11 (male) (1) and 12) 10 - 25 II 7 Is each pin to

Fn~~~:~~d?ound 1)

2)

Remedy

Control box defective.

Replace

TVC solenoid defective.

Replace


Replace

Disconnection in wiring harness,

defective contact or contact between chassis ground and CN36 (female) (1) and CN 1 1 (male) (1), or CN36 (female) (2) and CN1 1 (male) (2)

NO

Connect T -adapter Isocket) to CN1 1 Imale). Turn starting switch OFF.

Prolix circuit switch defective.

Clean (defective contact) or replace.

Replace

www. k omat s upar t s book . c om Disconnection in wiring harness,

defective contact or contact between chassis ground and CN1 3 Ifemale) (1) and CN36 (female) (3), or CN1 3 (female) (2) and CN36 (female) (5) TVC solenoid defective.

Replace

Control box defective. (circuit between CN1 0 (6), (7) and inside of box)

Replace

Disconnection in wiring harness, defective contact or contact 00-

tween chassis ground and CN9 (1),(2)- CN1 (151, (16)CN10 161, (81.

-

Potentiometer defective or mounting defective. Disconnection in wiring harness, defective contact or contact 00-

tween chassis ground and CN 10 (6), (8) - CN1 (15), (1 7) - CN9 (1), (31.

.-


Adjust or replace.


Control box defective. (circuit between CN1 0 (61, 181 and inside of box)

Replace

Control box defective. (circuit between CN1 0 (6), (7) and inside of boxl

Replace

Disconnection in wiring harness, defective contact or contact 00-

..

Clean Idefective contact) or replace.

tween chassis ground and CN9 (2) - CN1 (161 - CN10 (7)


Potentiometer defective or mounting defective.

Adjust or replace.

Potentiometer defective.

Replace

PC200.220-3

62-89 ®

E-1

TROUBLESHOOTING

b)

If cause is removed when switching to prolix circuit (when self-testing display shows normal)

Cause

2

YES 1 Is resistance between CN9 (male) (1 ) and (2) equal to 1/2 resistance between (1 ) and (3) ± 0.1 kill 1) Connect T -adapter (socket> to CN9. 2) Turn starting switch OFF.

Is mounting of engine speed sensor normal]

. NO

See TESTING AND ADJUSTING.

YES NO

Remedy


Replace

Engine speed sensor mounting defective.

Adjust

Potentiometer mounting defective.

Adjust

-


-

62-90 @

PC200.220-3

-

E-1

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-1 (Troubleshooting of TVC valve) 1. Measure resistance between CN13 (male) (1) and (2). 2. Check for short circuit between CN13 (male) (1), (2) and chassis ground.

2

1

~ IT5 "1m ~ 3.

4.

Measure resistance between CN36 (female) (3) and (5). Check for short circuit between CN36 (female) (3), (5) and chassis ground. Measure resistance between CN36 (female) (1) and (2). Check for short circuit between CN36 (female) (1), (2) and chassis ground.


Measure resistance between CN11 (male) (1) and (2). Check for short circuit between CN11 (male) (1), (2) and chassis ground.

2

1

B31G

PC200, 230-3

62-91 ®

TROUBLESHOOTING

E-1

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-1 (Troubleshooting of throttle sensor) 1. Measure voltage between CN9 (female) (1) and (3). 2. (T-adapter) Measure voltage between CN9 (1) and (2).

3. 4.

(T-adapter) Measure voltage between CN10 (6) and (7). Measure voltage between CN10 (male) (7) and (8).

-

(33)<1


2.

3.

7

(Socket) Measure resistance between CN9 (male) (3). Check for continuity between CN9 (male) and chassis ground. (Socket) Measure resistance between CN9 (male) (2). Check for continuity between CN9 (male) and chassis ground.

(1) and (1), (3) (1) and (1), (2)

3'.

(Socket) Measure resistance between CN10 (female) (6) and (7). Check for continuity between CN10 (female) (6), (7) and chassis ground.

62-92 (~

PC200, 220-3

TROUBLESHOOTING

E-1

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-1 (If problem is removed when switching to prolix circuit)

-

1.

Measure resistance between CN9 (male) (1) and (2).

2.

Check mounting of speed sensor.


PC200. 220-3

62-93 @

TROUBLESHOOTING

E-2

-

Troubleshooting Chart No. E-2 (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED) Failure mode: Work equipment. swing, travel speeds extremely slow. or lack of power.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters, connect to both the male and female ends; for the socket connect to the connector marked in

(

a)


YES

2

YES Abnormality in power supply

Is voltage between CN 10 (female) (11 and 12120 - 30 V7

O

OOFF

Red

Green

Is voltage between fuse 4 and chassis ground 20 - 30 V7

Connect T -adapter (socket) to CN 10. Turn starting switch ON. (Do not start engine)

2)

3

1)

NO

Connect T -adapter Isocket) to CN1 O. Turn starting switch ON. 100 not start enginel

21


YES

Is voltage between CN10 (female) (21 and chassis ground OV7

1 1)

OFF

NO

NO

-


www. k omat s upar t s book . c om YES

2

y lOS

Is CN13 (malel11l. 121 - chassis

YES

4

ground insulated?

1)

Abnormalith in TVC solenoid

1

Connect T -adapter (socket) to CN13 Imalel. Turn starting switch OFF.

21

Is resistance be-

Red

Is there

tween CN13 Imale) (1) and 1211025117

Green 1) 2)

YES

continuity

between CN36 Imale) (1) and (3), (2) and (5)7

3 Is resistance be-

\!O

tween CN36 (femalel (3) and 151 10-2511715 each pin to chassis

1) 2)

ground insulated 7 Connect T -adapter (socket) to CN36 (femalel.

Con nect T -adapter Isocketl to CN13 (male). Turn starting switch OFF.

Turn starting switch OFF. Turn prolix circuit switch OFF

NO

)J

o

-

NO

2 YES

'{ES

Is cause removed if engine speed sensor

is adjusted again 7 Abnormality in engine speed sensor

Red

Green

'---:>

tween CN1 0 Ifemale) 14) and 151 500 - 600 117

2)

• OJ

~c

:JO~

Tester

000

~~B

T-adapter or socket adapter (for EKONO)

62-94 @

• See TESTING AND ADJUSTING.

Is resistance be-

11

..c..;:::;

NO

1

3

Turn starting

switch OFF. Connect Tadapter (socketl toCN10.

YES

Is resistance be-

:'\0

T-adapter or socket adapter (forMIC) T-adapter or socket adapter (for DLIl

tween CNS (male) 11) and (2) 500 600 117

NO

Connect T -adapter (socket) to CNS.

PC200, 220-3

-


TROUBLESHOOTING

E-2

-

Troubleshooting Chart No. E-2 (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED) Failure mode: Work equipment, swing, travel speeds extremely slow, or lack of power.

* Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket).

*

For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in

(

a)


YES

2

YES

Is voltage between CN10 (female) (1) and (2) 20 - 30 V?

Is resistance between CNl 0 (female) (2) and chassis ground 00]

1 OFF

O

OOFF

Red

Green

1) Connect T -adapter (socket) toCN10. 2) Turn starting switch ON. (Do not start engine)


.


3 YES

NO

NO

1)

Connect T -adapter (socketl to CN-l O. 2) Turn starting switch OFF.

NO

-



4

Is there continuity between CN36 Imale) (1) - 13) and 12) - 15P

YES 3 Is resistance be-

tween CN36 (female) (3) and 15) 10 - 25 IPls each pin to chassis ground insulated]

YES 2

Abnormalith in TVC solenoid

f -(lRed

OOFF Green

1)

Is CN13 (male) (1), (2) - chassis ground insulated?

YES

I2)

1

-->

l) Connect T -adapter Isocket) to CN13 (malel. 2) Turn starting switch OFF.

Is resistance be-

tween CN13 (male) (1)and(2)1025lP

Connect T -adapter (socketl to CN13 (malel. 2) Turn starting switch OFF.

Connect T -adapter Isocket) to CN36 Ifemalel. Tum starting switch OFF.

~

o

N Turn starting L;. switch OFF. 2) Turn prolix circuit switch OFF. 31 Connect T -adapter Isocket) to CN36 Imal el. 1)

NO

-

NO

NO 2 YES

YES

Is cause removed if engine speed sensor is adjusted again?

NO

1

Red

Is resistance between CN10 (female) (4) and (5) 300 - 1000 O?

Green

1) T urn starting switch OFF. 2) ConnectTadapter (socket) toCN10. • 0>

~.~ ::10

~~E 1-'",

Tester T -adapter or socket adapter (forEKONOl

62-94 ®


3

NO


Is resistance between CNS (male) (1) and (2) 300 10000?

YES

NO

Connect T -adapter (socketl to CNS.

--

T -adapter or socket adapter (for DLI)

PC200,220-3

E-2

TROUBLESHOOTING

Cause

Control box defective. (circuit between CN10 (male) (11, (2) and inside of box)

Disconnection in wiring harness, defective contact or contact between chassis ground and CN 10 (1) - CN20 (20) - fuse 4. Disconnection in wiring harness. defective contact between CN 10 (2) - battery relay - terminal E, or battery relay defective.

-

-

Disconnection in wiring harness or defective contact between CN20 (20) - fuse 4 - CN21 '" (2) - battery.

*

PC200-3 Serial No 25924 and up

Remedy

Replace



Clean (defective contact) or. replace.

CN21 (2) and (4) PC220-3 Serial No. 21 556 and up CN21 (2) and (4)


Replace


YES


Replace

Disconnection in wiring harness. defective contact or contact between chassis ground and CN36 (female) (1) and CNll (male) (1), or CN36 (female) (2) and CNll (male) (21.

Clean (defective contactl or replace.


Replace

Disconnection in wiring harness, defective contact or contact between chassis ground and CN 13 (female) (1) and CN36 (female) (3), or CN13 (female) (2) and CN36 (female) (5).



Replace


Replace

Engine speed sensor adjustment defective.

Adjust

Control box defective. (circuit between CNl 0 (male) (4), (5) and inside of box)

Replace

Disconnection in wiring hamess, defective contact or contact between chassis ground and CN8 (1), (2) - CNl (13), (14) CN10 (4), (51.


Engine speed sensor defective. (Disconnection in wiring harness or contact with chassis ground)

Replace

Is resistance be-

-

tween CNll (malel 111 and (2) 10 - 25 II ? Is each pin to chassis ground insulated?

1)

:'lO

Connect T -adapter (socket) to CN 11 (malel. 2) Turn starting switch OFF. 3) Turn prolix circuit switch OFF.

PC200.220-3

62-95 ®

E-2

TROUBLESHOOTI NG

• When using T -adapter

I-Y;5

3 YES

IIt

Is voltage between CN10 (6) and (7) Vcc/2?

I

YES Abnormality in potentiometer

ONe Red

I

1

2)

Measurement condi-

1)

tions same as in

OOFF

NO I

I

NO

previous step 2) Take voltage between CN9 (1) and (3) as Vcc. 3) Place governor lever in FULL.

Is voltage between CN9 (female) (1) and (3) 5 - 5.2 V?

Green

Connect T - adapter toCN10. Turn starting switch OFF. 3) Place governor lever in FULL.

1)

Is voltage between CN9 (1) and (2) Vcc/2?

-

4

I)

Connect T -adapter (socketl to CN9. 21 Turn starting NO switch OFF.

-

YES

Is voltage between CN 10 (male) (7) and (8) 5 - 5.2 V?

NO

Connect Tadapter to CN10. Turn starting switch ON

1)

www. k omat s u ar t s book . c om •p 21

3


YES 3

YES 2

I

bl

If condition changes when switching to prolix circuit (when self-testing display shows normal) 2

YES 1

Is resistance between CN9 (male) (1) and (3) 5 ± I K n ? Is it insulated from chassis ground? 1)

2) 3)

Disconnect CN9. Do not start engine. Governor lever at FULL.

Is difference in resistance between CN9 (male) (1) and (21. and resistance between (2) and (3) less than 30 n? Measurement conditions same as in previous step.

Is difference in res istance between CN 10 (female) (6) and (81. and resistance between (7) and (8) less than 30 Q? 1) Connect socket adapter to CN9. 2) Disconnect CN10. 31 Tum starting switch OFF.

YES r-

INo I

I

NO

NO

I

YES

-

Is mounting of engine speed sensor normal?

NO

Is difference of resista nee between CN9 (male) (1) -

See TESTING AND ADJUSTING.

(2) and (2) - (3) below 30 n? 1)

Connect T -adapter (socketltoCN9. Turn starting switch OFF. Place governor lever in FULL.

2) 3)

NO

, Cl

~c:

Tester

..c".;::;

::>0'" 000

~-S£>


62-96 ®

T -adapter or socket adapter (forMIC) T-adapter or socket adapter (for DU)

PC200, 220-3

E-2

TROUBLESHOOTING

Cause

-

Remedy

Control box defective. (circuit between CNl 0 (61, (7) and inside of box)

Replace

Disconnection in wiring harness, defective contact or short circuit between chassis ground and CNS (1), (21 - CNl (15), (16) CN10 (6), (81.



Adjust or replace.

Disconnection in wiring harness, defective contact or contact between chassis ground and CNl 0 (6), (8) - CNl (15), (17) - CNS (1), (31.

Clean (defective contactJ or replace.

Control box defective. (circuit between CN 10 (6), (81 and inside of box)

Replace

Control box defective. (circuit between CNl 0 (6), (71 and inside of box)

Replace

Disconnection in wiring harness, defective contact or contact between chassis ground and CNS (2) - CNl (16) - CN10 (7).


www. k omat s upar t s book . c om Potentiometer defective or mounting defective.

-


Replace


Replace

Engine speed sensor mounting

Adjust

defective.

Potentiometer mounting defective.

pe200.220-3

Adjust or replace.

Adjust

62-97 ®

E-2

TROUBLESHOOTING

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-2 Troubleshooting of power source 1. Measure voltage between fuse 4 and chassis ground.

2. 3.

Measure voltage between CN10 (female) (1) and (2). Measure resistance between CN 10 (female) (2) and chassis ground.

-

2

www. k omat s upar t s book . c om E-2 (Troubleshooting of TVC valve) 1. Measure resistance between CN13 (male) (1) and (2). 2. Check for short circuit between CN13 (male) (1), (2) and chassis ground.

·1

3.

4.

Measure resistance between CN36 (female) (3) and (5). Check for short circuit between CN36 (female) (3), (5) and chassis ground. Check for continuity between CN36 (male) (1) and (3), (2) and (5).

2

[53). 5 2

1 3

3

62-98 ®

-

5

PC200.220-3

E-2

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-2 5. Measure resistance between CN11 (male) (1) and (2). Check for short circuit between CN11 (male) (1), (2) and chassis ground.

2

1

[5lJ]G -

E-2 (Troubleshooting of speed sensor) 1. Measure resistance between CN10 (female) (4) and (5).

4

5

(I)[[] www. k omat s upar t s book . c om 2.

Adjust speed sensor (CN8) again.

3.


2

j0S

PC200, 220-3

1

m[~~

62-99 ®

E-2

TROUBLESHOOTING

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-2 (Troubleshooting of throttle sensor) 1. Measure voltage between CN9 (female) (1) and (3). 2. (T-adapter) Measure voltage between CN9 (1) and (2).

3. 4.

(T-adapter) Measure voltage between CN10 (6) and (7). Measure voltage between CN10 (male) (7) and (8).

-

8l~


7

2.

(Socket) Measure resistance between CN9 (male) (3). Check for continuity between CN9 (male) \ and chassis ground. 3. (Socket) Measure resistance between CN9 (male) (2). Check for continuity between CN9 (male) and chassis ground.

3

(1) and (1), (3) (1) and (1), (2)

-

1

~~ 3'.

(Socket) Measure resistance between CN10 (female) (6) and (7). Check for continuity between CN10 (female) (6), (7) and chassis ground.

7

6

62-100 @

PC200, 220-3

E-2

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-2 (If problem is removed when switching to prolix circuit)

1.


1

2

~¥ 2.



PC200, 220-3

62-101 @

TROUBLESHOOTING

E-3

Troubleshooting Chart No. E-3 (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED)

-

Failure mode: Engine stalls during operations, or engine speed drops.

*

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket!.

* For T -adapters. connect to both the male and female ends; for the socket, connect to the connector marked in ( a)

). Self-testing display shows abnor mality

2

YES

21

Is voltage between CN 10 (female) (1) -and (2) 20 - 30 V?

3 YES

NO

1

Abnonnality in power supply

I~

YES

Is resistance

between CN10 (female) (2) and chassis ground On?

1) Connect T-adapter (socket! to CN1 O. 2) Turn starting switch ON. (Do not start engine)

Is voltage between fuse 4 and chassis ground 20 - 30 V? • Turn starting switch ON. (Do not start engine)

NO

Connect T -adapter (socket) to CN 1O. 2) Turn starting switch OFF.

1)

NO

Abnonnality in control box

ONe eONI l

Red

Green

_

-

.

...YES


Is there continuity between CN36 (male) (1) - (3) and (2) - (5)7

YES 3

Is resistance be-

tweenCN36 (female) (3) and (5) 10 - 25 II? Is' each pin to chassis ground insulated?

YES 2

YES Abnormality in TVC solenoid

j -(t Red

OOFF Green

1 l)

Is resistance between CN 13 (male) (1) and (2) 10 - 25 n? 1)

2)

Connect T-adapter (socket) to CN 13 (malel. Tum starting switch OFF.

2)

Connect T-adapter (socket! to CN13 (malel. Turn starting switch OFF.

1)

Connect T-adapter (socket) to CN36 (female). 2) Turn starting switch OFF.


CN9 (male) (1) and (2) Vcc/2?

Red

1 Is voltage between CN9 (female) (1) and (3) 5 - 5.2 V?

Green 1)

Connect T-adapter (socket) to CN9. 2) Turn starting switch ON.

tV g> ..e'-

Tester

gg~

T -adapter or socket adapter (for EKONO)

t=~

62-102 ®

T -adapter or socket adapter (forMIC) T -adapter or socket adapter (for DUl

NO

• When using T-adapter (for socket adapter see page 62-46.1 3 YES,

YES' n,...."',._:

OOFF

No

NO

YES

ONe

Turn starting switch OFF. 2) Turn prolix circuit switch OFF. 3) Connect T -adapter (socket) to CN36 (mal el.

NO

~Abnonnality in potentiometer

1)

1)

Measurement

NO

-

Is voltage between CN 10 (6) and (7) Vcc/]

NO 1)

2) 3)

Connect T- adapter toCN10. Tum starting switch ON. Place governor lever in FULL.

I I

conditions same as in previous step

l NO

2) Take voltage between CN9 (1) and (3) as Vcc. 3) Place governor lever in FULL.

A

YES Is voltage between CN 10 (male) (7) and (8) 5 - 5.2 V?

NO 1)

Connect T-adapter (socket! to CNI O. 2) Turn starting switch ON.

PC200,220-3

E-3

TROUBLESHOOTING

-

Cause

Remedy

Control box defective. Icircuit between CNl 0 (male) (1), (2) and inside of box)

Replace

Disconnection in wiring harness. defective contact or contact between chassis ground and CNl 0 (1) - CN20 (20) - fuse 4.


Disconnection in wiring hamess, defective contact between CN 10 (2) - battery relay - terminal E, or battery relay defective.


Disconnection in wiring hamess or defective contact between CN20 (20) - fuse 4 - CN21 "-' (2) - battery.


*

PC200-3 Serial No. 25924 and up· CN2' (2) and (4)

-

PC220-3 Serial No, 21556 and up CN21 12l and (4)

5 YES

-

Is resistance between CNll (male) 11) and 12)10 - 2511> Is each pin to chassis ground insulated 7


Replace


Replace

www. k omat s upar t s book . c om NO

1) Connect T-adapter (socket) to CNll (male). 2) Turn starting switch OFF. 3) Turn prolix switch OFF.

PC200, 220-3

Disconnection in wiring harness. defective contact or contact between chassis ground and CN36 (female) (1) and CNll (male) (1), or CN36 (female) (2) and CNll (male) (2).



Replace

Disconnection in wiring hamess, defective contact or contact between chassis ground and CN 13 (female) (1) and CN36 (female) (3), or CN13 (female) (2) and CN36 (female) (5).



Replace


Replace

Control box defective. (circuit between CNl 0 (6), (7) and inside of box)

Replace

Disconnection in wiring harness, defective contact or contact between chassis ground and CN9 (1), (2) - CNll 116), (17) - CN10 (6), (7).



Adjust or replace.

Disconnection in wiring harness. defective contact or contact between chassis ground and CN10 (6), (8) - CNll (15), (17) - CN9 (1), (3).


Control box defective. (circuit between CNl 0 (6), (8) and inside of box)

Replace

62-103 ®

E-3

TROUBLESHOOTING

Cause

adapter • When using socket -

I

-

-

3 YES

YES 3

I

YES 2

J

I

Is resistance between CN9 (male) (1)and(3)5±1 K n ? Is it insulated from chassis ground?

Remedy

Is difference in resistance between CN9 (male) (1) and (2), and resistance between (2) and (3) less than 30 n? Measurement conditions same as in previous step.

Is difference in res istance between CN 10 (female) (6) and (7), and resistance between (7) and (8) less than 30 n? 'l-. 1) Connect CN9. NO 2) Disconnect CN10. 3) Do not start engine.

NO

Control box defective. (circuit between CN 10 (6), (7) and inside of box)

Replace

Disconnection in wiring harness. defective contact or contact between chassis ground and CN9 (2) - CN1 (16) - CN10 (7)



Adjust or replace.


Replace

I

1) Disconnect CN9. 2) Do not start engine. 3) Governor lever at FULL.

NO

I

If condition changes when switching to prolix circuit (when self-testing display shows normal)

-

--

www. k omat s upar t s book . c om b)

2

YES 1

Is difference of resistance between CN9 (male) (1) (2) and (1) - (3) below 30 n? 1) Connect T-adapter (socket) to CN9 (male). 2) T ~rn starting switch OFF. 3) Governor lever at FULL.

Is mounting of engine speed sensor normal?


NO

YES

NO


Replace

Engine speed sensor mounting defective.

Adjust

Potentiometer sensor mounting

Adjust

defective.

-

62-104 ®

PC200. 230-3

E-3

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-3 (Troubleshooting of power source) 1. Measure voltage between fuse 4 and chassis ground.

-

2. 3.

Measure voltage between CN10 (female) (1) and (2). Measure resistance between CN 10 (female) chassis ground.

(2) and

www. k omat s upar t s book . c om E-3 (Troubleshooting of TVC valve) 1. Measure resistance between CN13 (male) (1) and (2). 2. Check for short circuit between CN13 (male) (1). (2) and chassis ground.

3.

4.

Measure resistance between CN36 (female) (3) and (5). Check for short circuit between CN36 (female) (3), (5) and chassis ground. Measure resistance between CN36 (female) (1) and (2). Check for short circuit between CN36 (female) (1), (2) and chassis ground.

1

2

-.

PC200, 230-3

62-105 ®

TROUBLESHOOTING

E-3

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-3 (Troubleshooting of TVC valve) 5. Measure resistance between CN 11 (male) (1) and (2). Check for short circuit between CN11 (male) (1), (2) and chassis ground.

2

1

B31G E-3 (Troubleshooting of throttle sensor) 1. Measure voltage between CN9 (female) (1) and (3), 2. (T-adapter) Measure voltage between CN9 (1) and (2).

1

-

3

~tQJ www . k omat s upar t s book . c om 3. 4.

(T-adapter) Measure voltage between CNlO (6) and (7). Measure voltage between CN10 (male) (7) and (8).

2.

3.

(Socket) Measure resistance between CN9 (male) (3). Check for continuity between CN9 (male) and chassis ground. (Socket) Measure resistance between CN9 (male) (2). Check for continuity between CN9 (male) and chassis ground.

(1) and (1), (3) (1) and (1), (2)

1

[05im~ 3

62-106 @

-

2 PC200. 220-3

E-3

T ROUB LESHOOTI NG

E-3 (Troubleshooting of throttle sensor) 3'. (Socket) Measure resistance between CN10 (female) (6) and (7). Check for continuity between CN10 (female) (6), (7) and chassis ground.

_

E-3 (If problem is removed when switching to prolix circuit) 1. Measure resistance between CN9 (male) (1) and (2).

1

2

~m¥ www. k omat s upar t s book . c om 2.


-

PC200, 220-3

62-107 (5)

TROUBLESHOOTI NG

E-4

-

Troubleshooting Chart No. E-4 (2-STAGE MODE SELECTOR OLSS) Failure mode: No change in output when mode switch is operated.

* *

S-mode performance in L-mode L-mode performance in S-mode Remedy

Cause

4Y~

YES

Is resistance between CN34 (female) (11 and (2) within standard value? 1) Connect T-

adapter (socket) to CN34 (female!. 2) Leave male disconnected. 3) Turn starting switch OFF.

3 Is resistance between NC13 (female) (1) and (2) 10-25!l?

YES 2

YES

Is CN13 (female) (1), (2) - chassis ground insulated? 11 Connect Tadapter (socked to CN13 (female!. 2) Leave male disconnected. 3) Turn starting switch OFF.

1 Is voltage between CN13 (male) (1) and (2) within standard value?

1) Connect NO T-adapter (socket) to CN 13 (female!. 2) Leave male disconnected. 3) Turn starting switch OFF.

NO 6

YES

~

NO

For travel deviation, see H-l For lack of power, see H-B



Replace

TVC valve defective

Replace

Harness defective 1) Disconnection in wiring harness 21 Short circuit

Replace


Replace


Replace

-


Turn mode selector switch (Ll. 2) Turn starting switch ON. 3) Connect Tadapter (socked to CN13 (malel.

Is there continuity between CNP4 (female) (1) and (2P

YES 5

NO

Is resistance betweenCN34 (female) (1) - (2) within stanC:ard value?

1)

2)

1)

2) 3) 41

Turn mode selector switch (Ll Turn starting switch OFF.

~

NO

Connect T -adapter (socked to CNP4 (femalel. Leave male disconnected. Turn starting switch OFF. Turn mode selector switch (Ll.

NO !l

PC200

55 ± 5%

PC220

40 ± 5%

-

d>Cl

~.§

Tester

::JO'"

o~f f-", ~..c

T -adapter or socket adapter (for EKONO)


62-108 ®

PC200, 220-3

E-4

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-4 1. Measure voltage between CN13 (male) (1) and (2).

-

2.


3.


4, 5. Measure resistance between CN34 (female) (1) and (2).



3

PC200, 220-3

62-109

TROUBLESHOOTING

E-4

-

Troubleshooting Chart No. E-4 (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED) Failure mode: No change in output when mode switch is operated.

* Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). * For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( l.

a)

YES

2

Self-testing display shows abn ormality

YES 1

Abnormality in power supply OFF

l)

OOFF

->

O Red


Green


Connect T-adapter (socket) to CNl O. Turn starting switch ON. (Do not start engine)

2)

• Turn starting switch ON. (Do not start engine)

NO

3 YES

NO

Is resistance between CN 10 (female) (21 and chassis ground OO}

NO

1)

Connect T-adapter (socket) to CNl O. 2) Turn starting switch OFF.


ION! !ONII---

_

-


~

Is there continuity between CN36 (male) (1) and (31. (2) and (5)?

YES

resistance betweenCN36 (female) (31 and (51 10 - 25 ll} Is each pin to chassis ground insulated} IS

YES Is CNl 3 (male) (1). (2)chassis ground insulated?

YES Abnormality in TVC solenoid

f l}

cJFF

LI-

Red

Green

Is resistance between CNl 3 (male) (1) and (2) 10 - 250}

~->

• Connect T-adapter (socket) to CN13 (malel.

b)

1)

Connect T-adapter (socket) to CN 13 (male!. 2) Turn starting switch OFF.

1) Connect T-adapter (socket) to CN36 (female). 2) Turn starting switch OFF.

1)

Turn starting switch OFF. 2) Turn prolix circuit switch OFF.

~

NO

NO

-

NO

If cause is removed when switching to prolix circuit (when self-testing display shows normal)

• In H-mode. display is not 0

:(r

3 YES Is there continuity between CN20 (female) (19) and (20)7

YES YES

1 Is mode selector switch normal}

1)

2)


Is there continuity between CN 10 (female) (1) and (3)7 1)

2)

Remove CNP4. Connect T-adapter (socket) to CNl 0 (female).

Tester

..c.~

::lo~

000

~-SP


62-110 ®

1)

2) 3) 4)

NO

Remove CNl 0 (female) Connect T -adapter (socket) to CN20 (female). Turn starting switch OFF. Remove CNP4.

NO

NO

, C'l

~c

2

T -adapter or socket adapter (forMIC) T -adapter or socket adapter (for DU)

PC200.220-3

E-4

TROUBLESHOOTING

-

Cause

.. YES

Remedy

Control box defective. !circuit between CNl 0 (male) (11. (2) and inside of box)

Replace

Disconnection in wiring harness. defective contact or contact between chassis ground and CN 10 (1) - CN20 (20) - fuse 4.


Disconnection in wiring harness, defective contact between CN 10 (2) - battery relay tenminal E. or battery relay defective.


Disconnection in wiring harness Or defective contact between CN20 (20) - fuse 4 - CN21 (2) - battery.



Replace


Replace

www. k omat s upar t s book . c om Is resistance be-

-

tween CN 11 (male) (1) and (2) 10 - 25 !l 7 Is each pin to

~~~~~~~9?ound

1)

2) 3)


defective contact or contact between chassis ground and CN36 (female) (1) - CNll (male) (1). Or CN36 (female) (2) - CNll (male) (21.

NO

Connect T -adapter (socket) to CNll (malel. Turn starting switch OFF. Turn prolix circuit switch OFF.

Prolix circuit defective.


Replace

Disconnection in wiring harness.

defective contact or contact between chassis ground and CN 13 (female) (1) - CN36 (female) (3). or CN13 (female) (2) CNll (female) (51.

..

PC200. 220-3



Replace


Replace

Contact between + 24V terminal and wiring harness from CN20 (female) (19) to CNP4 (31.

Repair or replace.

Short circuit between +24V terminal and wiring harness from CN 10 (female) (3) and CN20 (male) (191.

Adjust or replace.


Replace

Mode selector switch defective.

Replace

62-111 (5)

TROUBLESHOOTING

E-4

• In S-mode. display is not

6 YES

•

OFF

ON

0

5

YES 4 Is there continuity between CN 11 (male) (7) and chassis ground?

YES 3 Is voltage between CN 10 (female) (2) and (3) 20 V to 30 V?

1) Turn starting switch OFF. 2) Connect T-adapter (socket) to CNll (male).

Connect T-adapter (socket) to CN 10 (female). 2) Turn starting switch ON.

Is there continuity between CN20 (female) (19) and CNP4 (female) (3)7

YES

2

YES


YES

Green

Red

Is there continuity between CN35 (female) (3) and chassis ground] 1) Connect T-adapter (socket) to CN35 (male). 2) Turn starting switch OFF.

[

o

1)

Connect T-adapter (socket) to CN20 (female). 2) Turn starting switch 0 FF.

NO

-

NO 7

1)

YES


Is voltage between CNP4 (female) (4) and chassis ground 20V to 30V?

1)

2)

Connect T-adapter (socket) to CNP4 (female). Turn starting switch ON. (Do not start engine,)

Is mode switch selector normal?

NO

1)

1) 2)


2)

NO

NO

Turn starting switch OFF. Connect T-adapter (socket) to CN20 (female) and CNP4 (female).

NO

OFF

• In L-mode. display is not

Flash

O-()Red

Green

-

YES 2

YES

Is there continuity between CNll (male) (7) and (8)?

YES NO Is there continuity between CN35 (female) (3) and (4)7

1)

1 Is there continuity between CNP4 (male) (1) and (2)7 1)

2)

Connect T-adapter (socked to CNP4 (female). Turn starting switch ON. (Do not start engine,)

Connect T-adapter (socket) to CNll (male). 2) Turn starting switch OFF.

NO

3

NO Is there continuity between CN20 (female) (6) and (12)7

1)

Turn starting switch OFF. 2) Connect T-adapter (socket) to CN35 (female). 3) Remove CNll.

4

1)

2) 3)

YES

NO

Remove CNll and CN35. Connect T-adapter (socked to CN20 (female). Turn starting switch OFF.

62-112 ®

PC200. 220-3

-

E-4

TROUBLESHOOTING

Cause

.. -

Remedy

Contact between chassis ground and wiring hamess between CN20 (female) (6) and CNP4 (1).

Repair or replace

Contact between chassis ground and wiring hamess between CN35 (female) (3) and CN20 (male) (6).

Repair or replace

Contact between chassis ground and wiring hamess between CN 11 (male) (7) and CN35 (male) (3).

Repair or replace


Replace

Disconnection in wiring harness or defective contact between CN20 (male) (1 9) and CN 10 (female) (3l.


www. k omat s upar t s book . c om Disconnection in wiring harness or defective contact between CN20 (female) (19) and CNP4 (female) (3).


Mode selector switch defective.

Replace

Disconnection in wiring harness or defective contact between fuse 4 and CNP4 (female) (4).

Clean (defective contact! or replace.


Replace

Disconnection in wiring harness

or defective contact between CN11 (male) (7) and CN35 (male) (3) or CN11 (male) (8) and CN35 (male) (4). Disconnection in wiring harness or defective contact between CN35 (female) (3) and CN20 (male) (6) or CN35 (female) (4) and CN20 (male) (12). Disconnection in wiring harness or defective contact between CN20 (female) (6) and CNP4 (female) (1) or CN20 (female) (12) and CNP4 (female) (2l. Mode selector switch defective.




Replace

PC200. 220-3

62-113 ®

TROUBLESHOOTING

E·4

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E·4 (Troubleshooting of power source) 1. Measure voltage between fuse 4 and chassis ground.

2. 3.

Measure voltage between CN10 (female) (1) and (2). Measure resistance between CN 10 (female) (2) and chassis ground.

-

www. k omat s upar t s book . c om E-4 (Troubleshooting of TVC valve) 1. Measure resistance between CN13 (male) (1) and (2). 2. Check for short circuit between CN13 (male) (1), (2) and chassis ground.

3.

4.

Measure resistance between CN36 (female) (3) and (5). Check for short circuit between CN36 (female) (3), (5) and chassis ground. Check for continuity between CN36 (male) (1) and (3), (2) and (5).

2

811. 5 2

1 3

3

62-114 (9)

-

5

PC200, 220-3

E-4

TROUBLESHOOTI NG

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-4 (Troubleshooting of TVC valve) Measure resistance between CN11 (male) (1) and (2). Check for short circuit between CN11 (male) (1), (2) and chassis ground.

5.

2

1

K~i -

E-4 (Green LED does not flash in H mode) 1. Check mode switch.


2.

Check for continuity between CN10 (female) (1) and (3).

3

1

~l[]

3.


20

19

PC200, 220-3

62-115

TROUBLESHOOTING

E-4

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-4 (Green LED does not flash in S mode) 1. Measure voltage between CNP4 (female) (4) and chassis ground. 2. Check mode switch.

3.

Measure voltage between CN10 (female) (2) and (3).

-


Check for continuity between CN11 chassis ground.

(male) (7) and

5.

Check for continuity between CN35 (male) (3) and chassis ground.

62-116

PC200. 220-3

E-4

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-4 (Green LED does not flash in S mode) 6. Check for continuity between CN20 (female) (6) and chassis ground. 7. Check for continuity between CN20 (female) (19) and CNP4 (female) (3).

19

6

-


pe200, 220-3

62-117

E-4

T ROUBLESHOOTI NG

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E·4 (Green LED does not flash in L mode) 1.

Check for continuity between CNP4 (male) (1) and (2).

3

2.


[5l[]]'


3.

7


81J]w 4

4.

-

3


6

12

62-118 @

PC200. 220-3

-

-


TROUBLESHOOTING

E-5

--

Troubleshooting Chart No. E-5 (3-STAGE MODE SELECTOR OLSS EQUIPPED)

WITH AUTO-DECELERATION - IF PC200-3 (Serial No. 20001 - 21463) PC220-3 (Serial No. 20001 - 20364)

Failure mode: Auto-deceleration does not work.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T-adapter (or socket), For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( ). a) Self-testing display shows abnormality

YFS " 2

YES 1

Abnormality in power supply OFF

l)

OOFF

O Red


Green


• Turn starting switch ON. (Do not start engine)

Connect T-adapter (socket) to CNl O. 2) Turn starting switch ON. (Do not start engine.)

NO

Is resistance between CN 10 (femalel (2) and chassis ground 0 n? 1)

2)

NO

3

YES

NO

Connect T-adapter Isocket) to CNl O. Turn starting switch OFF.

-


-

, Ol

~c

Tester

~.gU)

e~E

~'"

T -adapter or socket adapter (forEKONOl

62-120 ®

T -adapter or socket adapter (forMIC) T-adapte·r or socket adapter (for DLI)

-PC200.220-3

E-5

TROUBLESHOOTING

Cause

...

Remedy

Control box defective. !circuit between CN1 0 (male) (11, (2) and inside of box!

Replace

Disconnection in wiring harness. defective contact or contact between chassis ground and CN 10 (1) - CN20 (20) - fuse 4.



defective contact between CN 10 (2) - battery relay terminal E, or battery relay defective.

Disconnection in wiring harness or defective contact between CN20 (20) - fuse 4 - CN21 (2) - battery.




PC200.220-3

62-121 (9)

TROUBLESHOOTING

E-5

b) Self-testing display shows normality

YES Table

------

1

Resistance

Swing. travel levers at neutral AUTO deceleration switch

Continuity

Swing, travel levers at operation position

No continuity

6 auto-deceleration

switch (1 ) and (2) as shown in table?

5 AreCN31 (male) (1), (2) - chassis ground, and CN32 (1). (2) - chassis ground insulated?

--

Is condition between

YES

Is condition between CN10 (female) (11) and (12) as shown in table?

'!-ES

.

www. k omat s upar t s book . c om YES 4

1)

Connect T-adapter (socked to CN 10. 2) Turn starting switch ON. 3) Start engine

3

YES


2

NO

Is condition between CN33 (male) (1) and (2) as shown in table?

1)

2)

ConnectTadapter (socket) to CN33 (male!. Turn starting switch OFF.

Is condition between CN31 (male) (1) and (2). and CN32 (male) (1) and (2) as shown in table?

1) Connect T-adapter (socket) to CN31 and CN32. 2) Turn starting switch OFF.

1)

2)

Connect T-adapter (socket) to CN31 and CN32. Turn starting switch OFF.

Turn starting switch OFF.

N(

NO

NO

1)

Connect T-adapter (socket) to CN33. 2) Turn starting switch ON. 3) Start engine

L-

-

NO

-62-122 (S)

pe200.220-3

E-5

TROUBLESHOOTING

Cause

-

7 YES

-

Is auto-deceleration switch terminals (1), (2) - chassis ground insulated? • Turn starting switch OFF.

NO

Remedy


Replace

Auto-deceleration switch defective.

Replace

Disconnection in wiring harness. defective contact between CN 10 (female) (11) - CN33 - CN32 - CN31 - CN20 - Autodeceleration switch - CN20 CN10 (female) (12), or abnormal contact with chassis ground.



PC200, 220-3

Auto-deceleration switch defective.

Replace

Limit switch defective.

Replace

Limit switch defective.

Replace

Oil pressure switch defective.

Replace


Replace

62-123 @

TROUBLESHOOTING

E-5

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-5 (Troubleshooting of power source) 1. Measure voltage between fuse 4 and chassis ground.

2.

Measure voltage between CN10 (female) (1) and (2).

3.

Measure resistance between CN 10 (female) chassis ground.

-

(2) and

2

www. k omat s upar t s book . c om E-5 (Troubleshooting of auto-deceleration solenoid valve) 1. Measure resistance between CN12 (male) (1) and (2). 2. Check for short circuit between CN12 (male) (1), (2) and chassis ground.

3.

Measure resistance between CN11 (male) (3) and (4). Check for short circuit between CN11 (male) (3), (4) and chassis ground.

4

3

1M. 62-124 @

PC200, 220-3

E-5

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-5 (Operation of auto-decelerator defective) 1. Measure resistance between CN10 (female) (11) and (12).

11

_

2. 3.

12

Measure resistance between CN33 (male) (1) and (2). Is circuit between CN33 (male) (1), (2) and chassis ground insulated?

2

1

rmDrn ~ www. k omat s upar t s book . c om 4. 5.

-

Measure resistance between CN31 (male) (1) and (2), and between CN32 (male) (1) and (2). Check insulation between CN31 (male) (1), (2) and chassis ground, and between CN32 (male) (1), (2) and chassis ground.

1

2

IL[IIIC~m ~ 6. 7.

Measure resistance between auto-deceleration switch (1) and (2). Check insulation between auto-deceleration switch (1), (2) and chassis ground.

PC200. 220-3

62-125

TROUBLESHOOTING

E-5

Troubleshooting Chart No. E-5


(WITH AUTO-DECELERATION - IF EQUIPPED) a)

-

Failure mode: Auto-deceleration does not work. (engine at full throttle)

YES

1 Is resistance between CN41 (male) (1) and (2) 55 70 n and is there continuity between CN41 and chassis?

-

YES

1)

Travel. work equipment lever at neutral. 2) Turn autodeceleration switch ON.


NO

6

Is voltage between CN39 (male) (1) and (2) 20 - 30 V?

YES 5

YES 4 Is there continuity

between CN31 Imale) (1) - (2). CN32 (male) (11 (2) as shown in table]

YES 3

NO

Is there continuity between CN33 (male) (1) and (2) as shown in table]

IsCN31 Imale) 111. (2) to chassis ground. CN32 (male) (11. (2) to

Is there continuity between autodeceleration switch I-(1) and 12) as shown in table]

. Turn starting switch OFF.

chassis ground

insulated? . Turn starting switch OFF.

. Turn starting switch OFF.

-

• Turn starting switch OFF.

NO NO NO Continuity Swing. travel levers at neutral. Turn auto-deceleration switch ON.

Yes

Swing. travel levers at operation position. Turn auto-deceleration switch ON.

,

Ol

., c ::0 "';:::

Tester

::> 0

on

~..c:

0

000

f-on_

62-126 (~


No

T -adapter or socket adapter (forMIC) T-adapter or socket adapter (for DU)

PC200, 220-3

E-5

TROUBLESHOOTING

-

Cause

8

YES

YES

Remedy

Auto-deceleration solenoid defective

Replace


Replace

Timer defective

Replace

Is there voltage between CN39 (1) and (2) 20 - 30 V 7


Y ES

-

-

Is auto-deceleration switch (1), (2) to chassis ground insulated?

' Turn starting switch OFF.

NO

NO

Power source defective

Disconnection in wiring

NO

harness, defective contact or short circuit between (male) (3) - CN33 - CN32 - CN31 - CN20 - auto-deceleration switch - CN20 - CN39 (malel (4)

Replace

Replace


Replace

Limit switch defective

Replace

Limit switch defective

Replace

Oil pressure switch defective

Replace

PC200. 220-3

62-127

TROUBLESHOOTING

E-5

b) Failure mode: Deceleration stays on (engine does not return to full throttle)

*

Auto-deceleration switch ON (at AUTO position)

Cause

YES

Remedy

Solenoid A defective

1

YES

Does engine return to full throttle when auto-deceleration switch is turned to OFF? 1)

2)

Turn autodeceleration switch OFF. Pull fuel control lever full position.


2 Is there continuity between autodeceleration switch (2) and (3)7

NO 1)

2)

Disconnect wiring of autodeceleration switch (1), (21. Turn autodeceleration switch OFF.

3

YES

Is there voltage between CN41 (male) (11 and (2) 20 - 30V 7

NO 11

Connect Tadapter (socket) to CN12 (malel. Turn starting switch ON. Turn aotdeceleration switch ON.

NO


-

Timer defective


3)

-

,

C>

'" c:

::c.~

0 '" 000 ~.c: 0 1-",::l

Tester

T -adapter or socket adapter (for MIC)


T -adapter or socket adapter (for DU)

62-128 (5)

PC200, 220-3

-

E-5

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-5 a-1. Measure resistance between CN41 (male) (1) and (2).

P20503053

-

a-2. Measure voltage between CN39 (male) (1) and (2).

www. k omat s upar t s book . c om a-3. Check for continuity between CN33 (male) (1) and (2).

a-4. Check for continuity between CN31 (male) (1) -- (2), CN32 (male) (1) - (2).

1

~fQ] 2

PC200, 220-3

62-129

TROUBLESHOOTING

E-5

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-5 a-5. Check for short circuit between CN31 (male) (1), (2) chassis ground, CN32 (male) (1), (2) - chassis ground.

1

t;j) [[JIU 2

b-3. Measure voltage between CN41 (male) (1) and (2).


-

62-130

PC200, 220-3

-

--


--

E-G

TROUBLESHOOTING

Troubleshooting Chart No. E-6 Failure mode: Upper structure does not swing, or hydraulic drift of swing is excessive.

-

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( ). a) Hydraulic drift of swing is excessive Carry out all checks with the swing control lever at neutral.

*

3 YES,


YES 2

YES

Is resistance between CN18 (male) (1) and (2) 10 - 30 Il?

11

2)

NO

1)

Connect T-adapter (socket) to CN18 (female!. 2) Turn starting switch OFF.

Connect T-adapter (socket) to CN18 (male!. Turn starting switch OFF.

NO

• When using T-adapter . 6

i

1 Does swing brake lamp light up normally?

1)

5 1)

Turn starting switch ON. Lights up about 5 seconds after stopping swing.

-

YES

Is voltage between CN 19 (female) (3) and (1) 20 - 30V?

NO

Measurement conditions same as in previous

step. Turn starting switch ON.


YES

Is voltage between CN19 (2) and (1) 20 - 30V?

2)

8

Is voltage between CN24 (2) and chassis ground 20 - 30 V?

YES

11

4


NO 11

2)

Connect T-adapter (socket) to CN1 9 (female). Turn starting switch OFF.

Connect T-adapter (socket) to CN19. 2) Turn starting switch ON. 3) Place swing lever in neutral.

7

Is voltage between CN24 (1) and chassis ground 20 - 30 V?

.,

1) 2)

Connect T - adapter to CN24. Turn starting

1)

Measurement conditions same as in previous step.

2)

T urn starting switch ON.

NO

switch ON. 3)

NO

I

Place swing lever at neutral.

• When using socket adapter.

6

between CN 18 (female) (1) and CN 19 (female) (3)7

6 11

Connect socket to CN 18 (female) and CN19 (female). Turn starting switch OFF

2) 1)

Connect socket adapterto CN19 (male).

2)

Turn starting

NO

switch OFF.

-

8

,

YES Is voltage between CN24 (1) and chassis ground 20 - 30 V? 1)

~.~ =>0

e~E 11-"",

Tester T -adapter or socket adapter (forEKONO)

62-132


2)

Connect socket adapter to CN24 (female). Turn starting switch ON.

YES

I

Is there continuity between CN24 (male) (1) and (2)?

7


-

:\0

Is resistance be-

tween CN19 (male) (1) and (2) 200 300 ll?

,

YES

Is there continuity

YES

• Ol

,

I

:\0 11 2)

Connect socket adapter to CN24 (male). Turn starting switch OFF.

I I,

I

NO

I PC200, 220-3

-

E-6

TROUBLESHOOTING

Cause

..

Remedy

Disconnection in wiring harness. defective contact between CN 1 8 (female) (1) and CN19 (female! (3) or CN18 (female) (1) and CN20 (male) (181.


Disconnection in wiring harness or defective contact between CN 18 (female) (2) and chassis ground.


Swing solenoid defective.

Replace

Disconnection in wiring harness or defective contact between CN 1 9 (female! (3) and CN 18 (female) (11.


Swing brake relay defective.

Replace

www. k omat s upar t s book . c om Disconnection in wiring harness or defective contact between CN24 (female) (2) and CN19 (female) (21.


Oil pressure sensor defective.

Replace

Disconnection in wiring harness or defective contact between fuse 3 - CN20 (5) - CN24 (female) (1).


Disconnection in wiring harness or defective contact between

-

PC200. 220-3

CN19 (female) (1) - CN18 (female) (2) and chassis ground, or between swing brake lamp CN21 (1) and chassis ground.



Replace

Disconnection in wiring harness or defective contact between CN18 (female) (1) and CN19 (female) (31.



Replace

Disconnection in wiring harness or defective contact between CN24 (female) (2) and CN19 (female) (21.


Oil pressure sensor defective.

Replace

Disconnection in wiring harness or defective contact between fuse 3 - CN20 (5! and CN24 (female! (11.

contact) or replace.

Clean (defective

62-133 (5)

TROUBLESHOOTI NG

E-6

b)

*

Upper structure does not swing. Check items marked * after running engine for at least 10 seconds.


4 YES

-

* YES 3

* 2

* 1 When CN18 is disconnected. does ma-

21

chine swing?

Do not start engine. Tum starting switch ON. Operate swing lever.

1)

Connect Tadapter to CN19. Turn starting switch ON. (Do not start engine.! Operate swing lever.

2)

Connect Tadapter to CN24. Turn starting switch ON. (Do not start engine.1 Operate swing lever.

I

I

-

NO

31 11

1) 2)

3)

Is voltage between CN24 (2) and chassis ground as in Table 17

YES'

:\0

Is voltage between CN 19 (2) and chassis ground as in Table 1 7

YES

I

Is voltage between CN19 13) and (2) as in Table 2?

NO


,

NO

• When using socket adapter

,

YFS

YES

Is there continuity between CN24 (male) (1 ) and 1217

YES

adapter to CN24lmalel. Turn starting switch OFF.

,:!i

3

Is voltage between CN 1 9 Ifemale) 12)

I

as in Table 27 11

21 31

~

Voltage

Neutral

Swing

NO

Is resistance be-

tween CN19 Imale) (2) and (1) 200 300 117

1)

21 11

and chassis ground

NO

Table 1

Is there continuity between CN 1 9 (malel (3) and (217

4

II Connect socket 21

YES

5

2

21

Connect socket adapter to CN19 (male). Turn starting switch OFF.

Connect socket adapter to CN19 Imalel. Turn starting switch OFF.

I

-

NO

Connect socket :\0 adapter to CN19 (female) Turn starting switch ON. (Do not start engine) Operate swing lever.

~

Voltage

20 - 30V

Neutral

Approx OV

Approx.OV

Swing

20 - 30V

Table 2

62-134

PC200, 220-3

-

TROUBLESHOOTING

E-6

Cause

-

Remedy

Mistaken connection of wiring harness between CN 19 (female) (3) - CN8 (female) (1) - CN20 and swing brake lamp, or fuse 3 and CN20 (5), or abnormal contact with + 24 V caused by contact with water or dirt.

Repair or replace (wrongly connected wiring) Dry, clean or replace (abnormal contact with +24V)


Replace

Mistaken connection of wiring harness between CN19 (female) (2) and CN24 (female) (2), (1), or abnormal contact with + 24 V caused by contact with water or dirt.

Repair or replace (wrongly connected wiring) Dry, clean or replace (abnormal contact with + 24 V)


Replace

www. k omat s upar t s book . c om ..

Swing brake solenoid defective.

Replace


Replace


Replace

Mistaken connection of wiring harness between CN 19 (female) (3) - CN18 (female) (1) - CN20 and swing brake lamp, or fuse 3 and CN20 (5),or abnormal contact with + 24 V caused by contact with water or dirt.



Replace

Mistaken connection of wiring harness between CN24 (female) (1), (2) and CN19 (female) (2), or abnormal contact with + 24 V caused by contact with water or dirt.


PC200, 220-3

62-135 @

E-G

TROU BlESHOOTI NG

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-G (Hydraulic drift of swing excessive) a-1 Check lighting of swing brake pilot lamp.

a-2 Measure resistance between CN18 (male) (1) and (2). a-3 Check for continuity between CN 18 (female) (2) and chassis ground.

2

1

[a{!] m~

-

2

@ tQE www. k omat s upar t s book . c om a-4 Check for continuity between CN 19 (female) (1) and chassis ground. a-5 Measure voltage between CN19 (female) (1) and (2). a-6 (T-adapter) Measure voltage between CN19 (3) and (1).

a-7 (T-adapter) Measure voltage between CN24 (1 ) and chassis ground. a-8 (T-adapter) Measure voltage between CN24 (2) and chassis ground.

62-136 ($)

pe200. 220-3

E-6

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-6 (Hydraulic drift of swing excessive) a-6 (Socket) Measure resistance between CN19 (male) (1) and (2l. a-6' (Socket) Check for continuity between CN18 (female) (1) and CN19 (female) (3).

-

www. k omat s upar t s book . c om a-7 (Socket) Check voltage between CN24 (male) (1) and chassis ground. a-8 (Socket) Check for continuity between CN24 (male) (1) and (2).

-

pe200, 220-3

62-137 @

E-G

TROUBLESHOOTING

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-G (Upper structure does not swing) b-1 Can upper structure be swung if CN18 is disconnected?

b-2 (T-adapter) Measure voltage between CN24 (3) and chassis ground.

-

www. k omat s upar t s book . c om b-3 (T-adapter) Measure voltage between CN19 (2) and chassis ground. b-4 (T-adapter) Measure voltage between CN19 (3) and (2).

b-2 (Socket) Check for continuity between CN24 (male) (1) and (2).

1

~~

"[ill

2

~ -

62-138

pe200. 220-3

E-6

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING b-7 Measure voltage between CN 19 (female) (3) and (1).

3

b-8 Measure voltage between CNP16 (male) (2) and chassis ground.

www. k omat s upar t s book . c om b-9 Measure voltage between CN19 (female) (5) and (1).

PC200,220-3

62-139-6 (j)

TROUBLESHOOTING

H-1

-

Troubleshooting Chart No. H-1 Failure mode: Machine deviates excessively (during travel, travel lever at full stroke)

* * * *

For details of measuring deviation, see TESTING AND ADJUSTING. The judgment values given in the troubleshooting chart are the values for H mode. If there is any abnormality in the speed of the work equipment, go to H-6. Check the stroke of the travel control valve and the tension of the track before starting troubleshooting.

-

YES


2

YES r-

Deviates in same direction in both forward and reverse

Does condition 'become normal after adjusting according to procedure for adjusting travel deviation?

4

YES

Is output pressure of NC valve on side to which machine deviates normal? • It must be the same

3

NO 1

Is problem reversed if front and rear outlet hoses of pump are interchanged?

pressure as the TVC output pressure when the track is rotated freely or when carrying out normal travel operations.

NO

-

Table 1 How does machine deviate?

.a. See Fig. 1.

Front pump (rear control valve)

YES

Actuator controlled

Pump • • • •

8

Arm cylinder Boom cylinder Swing motor Right travel motor

NO Rear pump (front control valve)

• • • •

Arm cylinder Boom cylinder Bucket cylinder Left travel motor

Is main relief pressure normal for more than two systems in Table 1 ?

.320 +2g kg/em'

NO

'" Except BOOM (RAISE) and SWING

NO ~::~~~ ;;:~~~~~~~ ~~~:;:e ----------------------------------

62-140 ®

PC200,220-3

H-1

TROUBLESHOOTING

-

,,± f

\

Forward

Forward Right reverse only

Drain

Right A rear Does not deviate

Forward

Left B front Right C front

Left reverse only

'.""'~~."'

left forward

Reverse

Right forward and left reverse

Forward

f

Left Drear

Reverse

Reverse

Bottom

Swivel joint Fig 1

Location of defective swivel joint packing and direction of deviation in travel

-

Cause

Remedy

Defective adjustment of pump

See TESTING AND ADJUSTING

Internal leakage in pump

Replace

Pump servo valve defective

Replace

Relief valve of jet sensor defective

Adjust or replace

Orifice defective

Replace

Operation of NC.CO valve defective

Adjust or replace

Final drive defective

Replace

Travel motor defective

Replace

-All are low

Main relief valve defective

Adjust or replace

-

Drop in set pressure of travel motor safety valve

Replace

Swivel joint seal defective

Replace seal

5 YES


Does servo piston

move smoothly?

NO

*' If both left and right caps of the servo piston are removed, it can be moved by hand. *' Judgement can also be made by replacing the servo valve. 7

YES 6

-

Is problem reversed if left and right jet sensor hoses are interchanged?

*' It is also possible to judge by interchanging the relief valves.

*' It is also possible to measure the differential pressure. (However, YES and NO are reversed.!

9 YES

-

YES

Does condition become normal if relief valves of jet sensor are adjusted?

Are metal particles found in oil drained from final drive on side to which machine deviates?

NO

NO

Only travel is low

PC200.220-3

62-141 @

TROUBLESHOOTING

H-2

-

Troubleshooting Chart No. H-2 Failure mode: Machine deviates excessively during compound operations

*

The judgement values given in the troubleshooting chart are the values for H mode.

a)

There is deviation in travel when any of the arm, swing, bucket, or boom circuits are used when the machine is traveling.

1 YES

r------~

Cause

Remedy

Straight-travel valve defective

Replace or repair

Travel shuttle valve defective

Replace or repair

Is outlet pressure of travel shuttle valve normal? .30±3kg/cm' • Engine at full throttle

NO

b)

There is deviation in travel when one of the arm, swing, bucket, or boom circuits is used when the machine is traveling.

www. k omat s upar t s book . c om 2 YES

r---------,

YES 1 Operate PPC valve lever on side to which machine

Spool of travel shuttle valve stuck

Replace or repair

Shuttle valve between PPC valve and travel shuttle valve stuck

Replace or repair

T ravel shuttle valve defective

Replace or repair

PPC valve defective

Replace

Is inlet pressure of travel shuttle valve normal?

NO

.30 ± 3 kg/em"

deviates. Is control

pressure at inlet port of travel shuttle valve normal?

.30 ± 3 kg/em' • Engine at full throttle

3

NO

Operate PPC valve lever on side to which machine deviates. Is control pressure at inlet port of travel shuttle valve normal for both directions in which PPC lever is operated?

YES

NO .30 ± 3 kg/em'

-

62-142 (9)

PC200, 220-3

H-l

TROUBLESHOOTING

Cause

18

YES

Remedy

Chargmg pump defective

Replace

Control relief valve defective

Replace

Leakage inside PPC valve

Replace

Leakage inside servo valve

Replace

Block circuit between charging pump and PPC valve. Is pressure in control circuit 30

-

± 3 kg/em"

--

17

NO

-

YES

-

Oil leakage from auto-deceleration solenoid valve

-

Block circuit between control pump and autodeceleration. Is pressure in control circuit 30 ± 3 kg/em"

18

YES

Leakage Inside PPC valve

Replace

Replace

www. k omat s upar t s book . c om Block circuit between charging pump and PPC valve. Is

NO

pressure in control circuit

19

YES

30 ± 3 kg/em"

NO

-

Replace

valve- Is pressure in control circuit

30 ± 3 kg/em'>

NO

---

Leakage inside swing solenoid valve

Block circuit between charging pump and swing solenoid


Replace

-


Replace

Jet sensor orifice defective

Replace

Excessive leakage from control

valve spool

valve ass'y on side to which machine deviates

Lever link defective

Adjust or replace

Replace control

Operation of spool of travel con-

trol valve on side to which machine deviates defective or component inside spring case

Replace control valve

damaged Replace Link twisted

Adjust or replace

PC200, 220-3

62-143 @

I

H-2

TROUBLESHOOTING

-

Troubleshooting Chart No. H-2 Failure mode: Machine deviates excessively during compound operations.

Cause

YES

2

YES

Is cause removed


Straight-travel valve defective

Replace control valve ass'y

Machine deviates with certain combinations.

Does machine devi-

4

ate which combina-

YES

tion of arm, swing,

bucket, boom and travel is used?

YES 3

Replace travel shuttie valve

Shuttle valve between PPC and travel shuttle valve stuck

Replace shuttle valve

when travel shuttle valve is replaced?

NO

lever on side to

which machine deviates. Is control pressure at inlet port of travel shuttle valve 30 ± 3 kg/em'.

Shuttle spool of travel shuttle valve stuck

Is cause removed

Operate PPC valve

NO

Replace

-

when travel shuttle valve is replaced?

NO 1

Remedy

-

5

www. k omat s upar t s book . c om Machine deviates with every combination

:"i0

Operate PPC valve

lever on side to which machine devi-

ates. Is control pressure at inlet port of travel shuttle valve 30 ± 3 kg/em' for both directions in

which PPC lever is operated?

YES

:\0


Replace

PPC valve defective

Replace

-

'0>

~c

.c".;:;

Oil pressure gauge (60 kg/em')


~o~

000

~..co

f- "'..,

62-144

Thermistor kit

-

-

PC200, 220-3

-


TROUBLESHOOTING

H-3

-

Troubleshooting Chart No. H-3 Failure mode: Machine deviates excessively when starting

*

*

* * a)

If the machine also deviates during normal travel. go to H-1 "Machine deviates excessively." If the machine deviates when the work equipment is operated, go to H-2 "Machine deviates excessively during compound operations". Air must be bled from the circuits. The judgment values given in the troubleshooting chart are the values for H mode.

3 YES

There is deviation only when operating from N to the full stroke.

YES

Does servo piston move smoothly?

2 r---------,

YES

Is problem reversed if front and rear outlet hoses of pump are interchanged?

~ ~

NO

See TESTING AND ADJUSTING. Judgment can also be made by replacing the servo valve.

1

NO Is relief pressure in control circuit normal?

YES 4

.30 ± 3 kg/em' • Engine at full throttle

NO

Is any foreign material found in filter at outlet port of charging pump?

YES 5


NO


Is problem removed if relief valve in charging pump is adjusted (replaced)?


NO

b)

-

Machine starts to deviate immediately, regardless of whether the control lever is moved from N with fine control or to the end of its stroke.

*

3 YES

If the pump discharge amo unt is not the minimum when the control levers are at neutral.

YES


2

YES

Is output pressure of NC valve on fast side normal?

~

1 Control lever at neutral: Max.5 kg/em' With track raised from ground and rotated: Min. 18 kg/em'

Is differential pressure of jet sensor on fast side

(outside) normal?

4 Control lever at neutral: 15 ± 1 kg/em' When control lever is operated to end of travel: Max.2 kg/em'

NO

NO

If both left and right caps of the servo piston are removed. it can be moved by hand. ~ Judgement can also be made by replacing the servo valve.

NO YES

Is problem reversed if relief valves of jet sensor are

interchanged (adjusted) ?

-

NO

62-144 @

PC200, 220-3

-

H-3

TROUBLESHOOTING

Cause

Remedy

Operation of servo valve defective

Replace

Servo piston stuck

Replace pump

T ravel motor shaft brake defective

Replace motor

Charging pump defective

Replace charging pump

Charging pump relief valve defective

Replace


-

Block each circuit between (11 and (6) in Fig. 1. Is pressure in control circuit normal?

.•

30 ± 3 kg/em' Engine at full throttle

PC200. 220-3

NO

Excessive internal

leakage in equipment at location concerned.

Replace

Internal leakage in swing solenoid valve

Replace

Operation of servo valve defective

Replace

Servo piston stuck

Replace pump assembly

Operation of CO + NC valve defective

Replace


Replace


Replace

62-145 ®

TROUBLESHOOTING

H-4

-

Troubleshooting Chart No. H-4 Failure mode: Control levers are extremely heavy

*

The judgment values given in the troubleshooting chart are the values for H mode.

Cause

a)

Remedy

If travel lever is heavy

4 YES ,-------.,..YES

2

Servo piston stuck

Replace pump assembly

Operation of NC valve defective

Adjust or replace

-


Replace

-

Jet sensor orifice

L.-

~

Is output pressure of NC valve normal?

If both left and right caps of the servo piston are removed. it can be moved by hand.

Control lever at neutral: Max. 5 kg/em' With track raised from ground and rotated: Min. 18 kg/em' ~ The pressure is the same as the TVC pressure except when the levers are at neutral and during relief.

NO

NO

Is differential pressure of jet sensor for heavy lever normal?

YES

Replace


3

YES

Opertion of servo valve defective

Control lever at neutral: 15 ± 1 kg/em' When control lever is operated to end of travel: Max. 2 kg/em' ~ Judgment can also be made by interchanging the jet sensor hoses for the front and rear pump.

5 YES

-


NO

Is lever light when engine is stopped?

6 YES

,--------.,

NO

Is problem reversed if relief valves of jet sensor are interchanged?

NO

defective

Replace

Operation of control valve spool defective

Replace

Linkage and cable twisted

Adjust or replace

Is cable or link twisted?

NO

b)

If work equipment or swing control lever is heavy

1 YES

...-----.....:..,

Interference with boot

Replace boot

Internal part of PPC valve defective

Replace

Does lever become lighter if boot is removed?

NO

62-146 @

PC200.220-3

H-5

TROUBLESHOOTING

Troubleshooting Chart No. H-5 Failure mode: Work equipment, travel, and swing start suddenly during fine control operations

*

The judgment values give in the troubleshooting chart are the values for H mode.

a)

Work equipment and travel both start suddenly Cause

2 YES

YES 1

Travel lever at neutral: 15 ± 1 kg/em' When control lever is operated to end of travel: Max. 2 kg/em'

NO

3 YES

NO

Replace


Control lever at neutral: Max.5 kg/em' With track raised from ground and rotated: 18 kg/em'

Is differential pressure of jet sensor normal?

Servo valve defective

Remedy

CO

+ NC valves defective


Replace

Replace

Is problem reversed if relief valves of jet sensor are interchanged?


b)


Replace

PPC valve defective

Replace

PPC shuttle valve defective

Replace

Control valve defective

Replace

If only work equipment starts suddenly

YES 1 Is problem removed when hoses between PPC valve and PPC shuttle block are interchanged? Left side Swing -Arm Right side Boom - Bucket

NO

2 YES Is problem removed when hoses between PPC shuttle valve and control valve are interchanged? Left side Swing -Arm Right side Boom - Bucket

PC200.220-3

NO

62-147 @

TROUBLESHOOTING

H-6

-

Troubleshooting Chart No. H-6 Failure mode: Speeds for work equipment, swing, and travel are all slow, or there is no power (no abnormality in auto-deceleration)

* * * a)

Check that there is no abnormality in the auto-deceleration system. If there is any abnormality, go to H-9 "Autodeceleration does not work". If there is any symptom (black exhaust smoke, etc.! that indicates that there is lack of engine output, go to troubleshootYES ing for engine. The judgment values given in the troubleshooting chart are 4 the values for H mode. ...------; YES Is NC output pressure normal on side that Machine hardly moves does not move?

YES .-5 Is there any pin of servo sub assembly on side that does not move?

NO ..:,7 YES

Is there any abnormality in spool or piston of NC valve?

NO

3

YES

NO

abnormality in cotter

.....-

NO

. .;,6 !.ES

Is foretgn material found inoil drained from pump?

Is it the system on one side that does not work?

...--

YES 9

1.,0 ~S

Is foreign material found in oil drained from pump?

Is there any abnormality in cotter pin of servo sub assembly on both sides?

www. k omat s upar t s book . c om YES 8

2

YES

NO

Is NC output pressure normal NOon both sides?

Is output pressure of TVC valve normal?

NO

11 ...-------,

NO

YES

Is there any abnormality in spool or piston of NC valve 7

NO 12 Note 1

Remove solenoid valve of TVC valve. but leavE

YES

connector connected.

Is pressure in control circuit 30 ± 3 kg/cm 27

NO

When mode selector switch is moved. does spool of solenoid valve move?

[Engine at full throttle]

-

NO

1) Starting switch ON

YES

YES

13 Is any foreign material found in filter at outlet

N0 ~~~~ charging

17 YES r------...,-

14 Is problem removed if relief valve in control NO circuit is replaced 7

YES 16

YES 15

Note 1: If there is any abnormal noise heard from the pump, first check for any metal particles in the return element or oil drained from the pump to check if there is any damage to internal parts of the pump.

62-148 ®

NO

Is there any abnormality in drive system of charging pump?

Block circuit between charging pump and PPC valve. Is pressure in control circuit 30 ± 3 kg/cm 2 ?

Block circuit between charging pump and auto·deceleration.ls pressure in control circuit 30 ± 3 kg/cm 2 ?

-NO NO

-

NO

PC200, 220-3

TROUBLESHOOTING

H-6

Cause

Remedy

Cotter pin missing

Assemble

Pump sub-assembly defective

Replace

Servo valve stuck

Replace

NC valve spool, piston stuck

Repair or replace

NC + CO valve defective on side that does not move

AssembJe

Cotter pin missing

Replace

Front rear pump defective

Replace

Servo valves of front and rear pumps stuck

Replace


Repair or replace

CO + NC valves on both sides defective

Replace

TVC valve stuck

Replace

TVC valve srnenoid valve seized

Replace


Replace

Relief valve of charging pump defective

Replace

Shaft broken

Replace

www. k omat s upar t s book . c om 18 Block circuit between charging pump and swing s~enoid valve. Is pressure in control circuit

30 ± 3 kg/cmt?

PC200. 220-3

YES

Oil leakage from

NO

8uto-deceleratton

Replace

solenoid valve


Reptace


Replace


Replace

62-149 ®

TROUBLESHOOTING

H-6

b)

Abnormality in some part (abnormality on one side) Swing, travel, and bucket are slow; boom, arm move at half speed

5 YES Is problem removed if servo sub-assembly is replaced]

YES 4

YES

I

Is there any abnormality in the co valve seat (top, bottom)?

NO

3

YES

NO

Is output pressure of NC valve on problem side normal?

-

6 YES

2

YES

NO

Is differential pressure of jet sensor on problem side normal7

Is there any abnormality in the spool or piston of the NC valve]

NO


NO

1

YES

Is problem removed if relief valve of jet sensor is replaced?

NO

Is pressure of main relief valve on problem side normal?

YES

YES 8

NO

10

Is problem reversed if left and right relief valves are interchanged]

YES

Is problem reversed if hoses between pump and control valve are interchanged?

12 YES

-

YES 11

9 Is output pressure of PPC valve

NO

30

NO

-

Is problem removed when travel shuttle valve is replaced]

-

Does spool of control valve move smoothly?

No

~~ kg/em'?

NO

NO

Troubleshootingtools

62-150 ®

Oil pressure gauge (450 kg/em 2 ). (60 kg/em 2 ) Travel shuttle valve

Sleeve nut, plug

-

Servo valve

PC200, 220-3

H-6

TROUBLESHOOTING

Cause

Remedy

Deterioration of CO valve seat

Replace

Servo sub-assembly defective

Replace

Pump sub-assembly defective

Replace


Repair or replace

NC

+ CO valve defective

Replace


PC200.220-3


Replace

Jet sensor defective

Replace

Relief valve defective

Replace

Pump defective

Replace


Replace

Travel-straight valve defective

Replace

Spool of control valve stuck

Replace

PPC valve defective

Replace

62-151 ®

TROUBLESHOOTING

H-6

c)

Individual symptoms • If only swing speed is slow, go to H-11 "Swing speed is slow." • If only travel speed is slow, check if machine deviates. If machine does not deviate, check swivel joint. • If any work equipment speed is slow, go to next item.

d)

If any work equipment speed is slow

Cause

Remedy

-


YES

~~ kg/em'?

NO

Except for long lever

Is hydraulic drift of slow cylinder inside standard range?

YES 3

NO


Replace

Operation of right PPC valve defective

Replace

Cylinder piston packing defective

Replace

Safety valve defective

Replace


Replace

Is output pressure of PPC valve 30

1

YES

Is internal leakage of slow cylinder more than 20 cc/min?

4

NO

YES

Is problem removed if safety valve on HOLD side of slow cylinder is replaced?

NO

Troubleshooting tools

62-152 ®

Scale

Measuring cylinder

Stop watch

Oil pressure gauge (60 kg/em')

Sleeve nut. plug

-

-

PC200, 220-3

H-6

TROUBLESHOOTING

-

Remedy

Cause

-

Engine defective

Adjust

Servo valves on both sides stuck

Replace F, R pump aSs'y


Replace

Control relief valve defective

Replace



1 NO

:


-

-

-

•

-

YES

N0

Replace

7 YES Block circuit between charging pump and swing solenoid valve. Is pressure in control circuit 30 ± 3 kg/em'?

Replace

-

Oil leakage from autodeceleration solenoid valve

Replace


Replace


Replace

I


NO

----

-

-

Replace

-

TVC valve stuck

Replace

Solenoid valve burned

Replace

pe200, 220-3

62-153 (6)

H-6

TROUBLESHOOTING

-

b) Abnormality in some part (abnormality on one side) • Swing speed and right travel are slow, boom, arm move at half speed.

YES,

4

YES 3

YES

Is output pressure of NC valve normal 7

Is cause relieved if servo valve is replaced 7

t-

Also possible to replace servo + pump ass'y

NO

2 Control lever at neutral

PC200

YES

Max, 55 kg/em" (H model Max, 4,2 kg/em· (5 model pe22Q Max, 5,5 kg/em· (H model

Is differential pressure of jet sensor on cause side normal?

Max. 6.5 kg/em· (5 model With track raised from ground

Control lever at neutral: 14 - 15 kg/cm' Control lever at stroke Max. 2 kg/cm' end:

5 YES

and rotated Min. 18 kg/em· (All models)

Is cause reversed if relief valves of jet sensor are interchanged 7

NO

1

NO Is pressure of main relip.f valve normal?

-

YES Relief pressure: 320 +25 kg/cm' 0

YES

6 Is cause reversed if left and right relief valves are interchanged 7

8


YES

Is cause reversed if hoses between pump and control valve are interchanged 7

y ES

9

7

:\0

Is output pressure of PPC valve 30 ± 3 kg/cm'.

:\0

r-

Does spool of control valve move smoothly7

:.i(

Oil pressure gauge

'Cl

~<::

..0';;

:::JO~

(450 kg/em') (60 kg/em')

000

~.c:o

I- "' ...


-

Sleeve nut, plug Servo valve

c) Individual symptoms • If only swing speed is slow, go to H-ll "Swing speed is slow". • If only travel speed is slow, check if machine deviates. If machine does not deviate, check swivel joint. • If any work equipment speed is slow, check as next page.

62-154

pe200. 220-3

-


H-6

TROUB'LESHOOTING

e)

For failures except for those in (a), (b), (c) and (d). (Auto-deceleration is normal.)

* If auto-deceleration is fitted, check if auto-deceleration is normal. * If auto-deceleration does not work, go to H-9.

-

YES

YES

-

6

YES Sprocket speed nonnal when track is raised from ground. but are work equipment


Check both F and R pump


Conlrol lever at neutral

pe2Da

Max 5 5 kg. em' (H model Max 4.2 kg.'em.' ($ model

pe22a

speed and swing

Max 5 5 kg'em' (H model

speed extremety

5

slow'

Sprocket speed for 5 turns

YES

sec. PC200

39 +4 -2

PC200LC

43 +4 -2 46 +4 -2

PC220 PC220LC

Max 65 kg,'em" ($ mode)

~~~~;:~;;alsedfrom

2)

Is output pessure of TVC valve normal!

ground

'="N:":O: :".- - - - - - - -

Min 18 kg em' (All model!>1 One pump rehef

pe2Da Max 5 5 kg/em' (H model Max 42 kg/em' (S model

penD Control lever at neutral Min. 18 kg./em' (All models) One pump rehef

Max 5 5 kg/em' (H model Max 65 kg,em' ($ model 3~

PC20a 155 -.- 1.5 kg/em' (H model 150 ± 1 5 kg/em' IS model

4

(H mode only)

pe22a 165

50 +5 -3

YES

16

Is pressure in control circuit 30 ± 3

:!:

a ,.,

Interchange Jet sensor hoses IPt. Pd) at pump end (Both F and R) Min 85kg/cm'

1 5 kg/em' IH model 1 5 kg/em' (S model

kg/cm~?

NO 3

YES

14

Remove solenoid valve of TVC valve. but leave connector connected When mode selector switch is moved. does spool of solenoid valve move;>

YES

NO

Starting switch ON

Is pressure of main relief valve of F, R pump normal?

NO

320 +'5 kg/cm' -10

-

YES 15

2

NO

NO

Is engine speed normal when both one pump and two pumps are relieved?

Is cause reversed if main relief valves are interchanged;>

16 YES

,--------,

NO

PC200: Min. 2150 rpm PC220 MIn. 21 50 rpm Hydraulic oil temp.: 45 - 55°C 1) Relieve bucket circuit for one-pump relief 2) Relieve arm circuit for two-pump relief

NO

Are metal particles found in oil drained from defective pump?

NO 17 YES

.--------, Are metal particles found in oil drained from defective pump?

NO 'en

~c

..c".;:::;

Stop watch

Multi-tachometer

Oil pressure gauge (450 kg/cm')

Servo valve


-

:::JO~

000

~.<:o

I- "' ...

62-154 ®

PC200, 220-3

H-6

TROUBLESHOOTING

Cause

9 YES

~

YES i

8

YES

lL:

~~

Servo valve defective

Replace

Pump defective

Replace

PPC valve defective

Replace


Replace

PPC shuttle valve defective

Replace

NO YES

10 Is cause removed when PPC valv~ outlet hoses art'

NO

Replace

:

I

kg/em:.!

7


~

Also ~ssible 10 replace servo valve and pump as one unit.

Is outlet pressure of PPC valve 30

-:1

Is cause reli~ved it selVo valve IS laCed ?

Remedy

11 YES

interchanged?

Is CO valve seat

(upper, lowed

LH side Swing ....... Arm RH side Boom""'" Bucket

normal?

NO

Is cause removed when travel shuttle valve is replaced 7

NO

NO


12

Is differential pressure of jet sensor' kg/em:.! or less? (Control lever at end of travel)

Also possible to judge by interchanging jet sensor hoses.

13 YES

NO

co + NC valve defective

Replace


Replace


Replace

TVC valve stuck

Replace

Solenoid valve burned

Replace

Main relief valve defective

Replace

Pump defective

Replace

Pump defective

Replace

Pump defective

Replace

Is cause reversed if relief valves of jet sensor are interchanged'?

NO

Go back to troubleshooting item (a), step 3

Go back to troubleshooting item (e), step 2. (Check for problem in hydraulic system)

Go to troubleshooting of engine "Lack of power".

pe200, 220-3

62-155 ®

TROUBLESHOOTING

H-7

-

Troubleshooting Chart No. H-7 Failure mode: Engine stalls or engine speed drops during operations

* * *

If there is any symptom (black exhaust smoke, etc.) that indicates that there is lack of engine output, go to troubleshooting for engine. If the work equipment speed is slow, or it does not move, go to H-6 al. The judgment values given in the troubleshooting chart are the values for H mode.

Cause

YES 2

YES

1

Is NC output normal at front and rear pumps during relief?

3 YES

NO

Remedy

Pump defective

Replace

a-ring of CO valve defective

Replace

CO + NC valves defective

Replace

TVC valve stuck

Replace

Solenoid valve seized

Replace

Is a-ring on CO valve sleeve of front or rear pump damaged?

Is output pressure of TVC valve normal?

-


4

NO

Remove solenoid valve of TVC valve, but leave connector connected. ~hen mode selector switch is moved, does spool of solenoid valve move?

YES

NO

Troubleshooting tools

Oil pressure gauge (60 kg/em 2 )

Servo valve

Jet sensor relief valve

Thermistor temperature gauge

Sleeve nut, plug

-

62-156 ®

PC200, 220-3

TROUBLESHOOTING

H-8

Troubleshooting Chart No. H-8 Failure mode: No change in output when mode selector swtich is operated.

Cause

1 Remove solenoid valve of TVC valve, but leave connector connected. When mode selector switch is moved, does spool of solenoid valve move?

• Starting switch ON

YES

NO

TVC valve stuck

Solenoid valve

Remedy

Replace

Replace

burned


PC200.220-3

62-157 ®

H-9

TROUBLESHOOTING

-

Troubleshooting Chart No. H-9 (With auto-deceleration only) Failure mode: Auto-deceleration does not come on, or does not go off.

* This troubleshooting chart is for cases when the auto-deceleration system does not work automatically or when the auto-deceleration selector switch is operated. * If the work equipment speed is slow, or it does not move, go to H-6 (al.

a)

Auto-deceleration does not come on.

Cause

YES

Replace

1 When autodeceleration selector switch is operated. does deceleration cylincer move?

Remedy

2

• Engine at low idling

NO

Hold inlet hose of deceleration cylinder in the hand. When auto-deceleration selector switch is operated. can vibration be felt from hose)

YES

,....--------------------i

Auto-deceleration cylinder defective

Replace

'="N7"O:::------------------t

Auto-deceleration solenoid valve defective

Replace

-


Auto-deceleration remains in opeation

Hold inlet hose of deceleration cylinder in the hand. When engine is started. can vibration be felt from hose)

YES

NO

Auto-deceleration cylinder defective

Replace

Auto-deceleration solenoid valve spool defective

Replace

• Auto-decele ration switch OFF • Engine at low idling

-

62-158 @

PC200, 220-3

TROUBLESHOOTING

H-10

Troubleshooting Chart No. H-10 Failure mode: Abnormal noise comes from around pump.

Cause

YES

Remedy

Strainer clogged

Clean

Piping clamp loose

Tighten

~

Pump defective

Replace

•NO

Move for a short time and watch change in symptom

Check again (depends on change in symptom)

~

2

YES

YES

Is strainer clogged?

3 Is cause removed if

1

NO

Is oil level in hydraulic tank normal?

piping between tank and pump is tightened?

4

NO

YES

Are metal wear particles formed in drained hydraulic oil?

www. k omat s upar t s book . c om Oil level too low

Add hydraulic oil

NO

PC200, 220-3

62-159 ®

H-11

TROUBLESHOOTING

-

Troubleshooting Chart No. H-11 Failure mode: Swing speed is slow, or overrun when stopping swing is excessive

* * a)

If swing speed is slow when arm and swing are operated together, swing priority valve is defective. If other work equipment speed apart from arm is slow, go to H-6 "Speeds for work equipment, swing, and travel are all excessively slow." Swing speed is slow when swinging to both left and right. Remedy

Cause

YES

Swing motor defective

Replace

Swing motor brake defective

Replace

Solenoid valve of swing motor brake defective

Replace

3

1 Is foreign material found in drain piping of swing motor?

YES 2

NO

Is drain amount of swing motor within standard range? Less then 4 QImin

Put swing lock pin in LOCK position and operate swing. Hold brake hose of swing motor in the hand. Can vibration be felt from hose 7

YES

NO

-


b)


Replace

Check valve defective

Replace


Replace


Replace

PPC valve defective

Replace

Operation of spool of control valve defective

Replace

Swing speed is slow only in one direction (left or right)

YES 1 Is problem reversed if left and right check valves of swing motor are interchanged?

NO

YES

-

2 Is problem reversed if left and right safety valves of swing motor are interc ha nged?

NO

YES 3 Is pressure at outlet port of swing PPC valve normal?

4

NO

YES ,.....

Is problem reversed if output hoses of PPC valve are interchanged 7 "-

NO

62-160 ®

PC200, 220-3

TROUBLESHOOTING

H-12

Troubleshooting Chart No. H-12 Failure mode: Upper structure does not swing

* * a)

Set the swing release switch to AUTO. Run the engine at half throttle and put the left and right travel levers in FORWARD. If either of the sprockets does not move, go to H-1 "Machine deviates excessively." Upper structure does not swing in any direction (left swing or right swing)

Cause

Remedy

3

YES YES 2

YES 1

Is output pressure of swing PPC valve normal?

Put swing lock pin in LOCK position and operate swing. Hold brake hose of swing motor in the hand. Can vibration be felt from hose?

Does spool of swing control valve move smoothly if springs at both ends are removed?


Replace


Replace

NO '" It is also possible to judge by measuring the pressure at the inlet port of the spool.


NO

b)

-

PPC valve defective

Replace

Left PPC valve defective

Replace


Replace


Replace


Replace

Upper structure does not swing in one direction (left swing or right swing)

YES 1 Is problem reversed if left and right check valves of swing motor are interchanged?

2

NO

YES

Is problem reversed if left and rig ht safety valves of swing motor are interchanged?

NO

PC200, 220-3

62-161 ®

TROUBLESHOOTING

H-13, H-14

-

Troubleshooting Chart No. H-13 Failure mode: Excessive hydraulic drift of swmg Remedy

Cause

2

1 YES Solenoid valve make clicking noise when starting switch is switched ON and OFF? L-

---J


,.:Y:..;E=S

---t

Replace swing

Swing motor shaft brake defective

motor

Replace

NO

-:----------------------------t NO

L.

Solenoid defectivevalve of swing brake

Replace

-

Troubleshooting Chart No. H-14 Failure mode: Hydraulic drift of work equipment is excessive.

YES

,.:..:......:..-------------------------1

Defective cylinder packing

Replace

Defective sealing of safety valve or suction valve

Clean or replace

Defective sealing of control valve spool

Replace

Defective cylinder packing

Replace


3 YES

Does hydraulic drift increase when engine is stopped and lever is operated?

r-------,

YES 2

See table 1.

NO

Is internal leakage at end of cylinder stroke within standard value?

Hydraulic drift mm/Max. 15 min Boom

60 (45)

Arm

300 (165)

Bucket

45 (30)

Is hydraulic drift reduced when safety valves or suction valves are interchanged?

NO

NO

-

): Unloaded

Table 1

Position of work equipment when checking

Cylinder name

Position of work equipment

Direction of lever operation

Boom cylinder

• Maximum reach

• RAISE

Arm cylinder

• Arm cylinder fully extended • Bucket cylinder fully retracted

• ARM IN

Bucket cylinder

• Boom, arm horizontal • Bucket cylinder fully extended

·CURL

Remarks Bucket should be loaded if hydraulic drift is small.

* A PPC valve is installed, so operate the lever quickly. * Always check with the engine stopped. 62-162 @

PC200, 220-3

TROUBLESHOOTING

H-16

Troubleshooting Chart No. H-16 Failure mode: Excessive time lag for work equipment Cause

2

YES

YES

Suction circuit (filter) clogged

Replace

Go to H-6 "Speed of all work equipment is slow", step.

Replace

Suction .valve defective (suction amount too sma III

Replace

Control valve defective (spool throttle insufficient)

Replace

Is all work equipment speed normal?

1 Is there excessive time lag for either boom, armor bucket?

Remedy

NO ~

NO

YES

Is cause remved if suction valve on

problem side is replaced?

NO Time lag

sec.

Max. 1.2 Max. 1500 rpm

800m

www. k omat s upar t s book . c om Arm

Max.2.8

Max. 1500 rpm

8ucket

Max.3.5

Max. 1000 rpm

'0>

~c

..c";::; "0'" 000

~.<:o f-", ...

Stop watch Thermistor kit

PC200, 220-3

62-163 ®

-

-


-

-

TROUBLESHOOTING

H-11

Cause

-

-

-

-

..

Remedy


Replace


Replace

I

.. -

-

..

Solenoid valve of swing motor brake defective

Replace

Go to H-6 .

-


.-


Replace

...


Replace


Replace


Replace

Left PPC valve defective

Replace


Replace

Is cause removed

-

when PPC outlet hoses are interchanged?

:\0

PC200, 220-3

62-163 (5)

TROUBLESHOOTING

H-12

-

Troubleshooting Chart No. H-12 Failure mode: Upper structure does not swing

* Run the engine at half throttle and put the left and right travel levers in FORWARD. If either of the sprockets does not move, go to H-1 "Machine deviates excessively".

a)

Cannot swing in either direction

2 YES Does spool of swing control valve move smoothly if springs at both ends are removed?

YES 1

NO

Is output pressure of swing PPC valve 30 ± 3 kg/em'.

YES 3

Engine at low idling

Is cause removed when PPC valve outlet hoses are interchanged?

NO

-

4

NO

Is cause removed when travel shuttle valve is replaced?

www. k omat s upar t s book . c om • With swing brake

lif equipped)

3 YFS -,

YES 2

YES

Does spool of swing control valve move smoothly if springs at both ends are removed?

:\0

Is output pressure of swing PPC valve 30 ± 3 kg/em'.

YES 5

Engine at low Idling

1 Put swing lock pin in LOCK position and operate swing. Hold brake hose of swing motor in the hand. Can vibration be felt from hose?

NO

Is cause removed when PPC valve outlet hoses are interchanged?

6

:'\0

Is cause removed when travel shuttle valve is replaced?

-

NO b)

Can swing in one direction only.

YFS -, 1 Is cause reversed if left and right swing motor check valves are interchanged?

:W

2 YES Is cause reversed if left and right safety valves of swing

motor are interchanged?

NO 'Cl

~c:

..c.;:;

Pressure gauge

Measuring cylinder

Stop watch

Sleeve nut, plug

Thermistor kit


:::JO~

-

000

...

~..c:o

~"'

62-164

PC200, 220-3

H-12

TROUBLESHOOTING

Cause

Remedy


Replace


Replace

PPC valve defective

Replace


Replace

PPC valve defective

Replace

www. k omat s upar t s book . c om Swing motor defective

Replace


Replace

PPC valve defective

Replace


Replace

PPC valve defective

Replace

Solenoid valve of swing brake defective

Replace


Replace


Replace


Replace

PC200, 220-3

62-165

TROUBLESHOOTING

H-13

-

Troubleshooting Chart No. H-13 Failure mode: Excessive hydraulic drift of swing Remedy

Cause

YES


Replace


Replace

Suction valve defective

Replace

2 Is hydraulic drift excessive even when levers are moved to

YES

SWING and RAISE immediately after stopping engine?

1

NO Is hydraulic drift excessive on both left and right?

YES 3 Is problem reversed when left and right motor suction valves are interchanged?

YES

•s www. k omat s upar t book . c om NO

4

NO

Is problem reversed when left and right motor safety valves are interchanged?

YES 5

Is hydraulic drift ex-

cessive even when levers are moved to

NO

Motor safety valve defective

Replace

Swing motor defective 1) Housing damaged 2) Leakage from valve plate (slit)

Replace


Replace

SWING and RAISE immediately after stopping engine?

'-'

NO

• With swing brake (if equipped) Cause

Remedy

-

2

1

YES

Solenoid valve make clicking noise when starting switch is switched ON and OFF?


NO

YES

;'-;0

Swing motor shaft brake defective

Replace swing motor


Replace


Replace

62-166 ($)

PC200. 220-3

-

H-16

TROUBLESHOOTING

Troubleshooting Chart No. H-16 Failure mode: Excessive time lag for work equipment Cause

2 YES

YES 1

NO NO

-

Suction circuit (filter) clogged

Replace

Go to H-G "Speed of all work equipment is slow", step.

Replace

Suction valve defective (suction amount too small)

Replace

Control valve defective (spool throttle insufficient)

Replace

Is all work equipment speed normal 7

Is there excessive

time lag for either boom,armor bucket7

Remedy

YES

Is cause remved if

suction valve on problem side is replaced?

NO Time lag Boom

sec. Max. 1.2

Max. 1500 rpm

www. k omat s upar t s book . c om Arm

Max.2.8

Max. 1500 rpm

Bucket

Max. 3.5

Max. 1000 rpm

, Cl

~c

....

Stop watch

~..co

Thermistor kit

..0'-

::>0'" 000

I- "' ....

-

PC200, 220-3

62-167

-


-

-

0

0

0

0

0

0

0

0

0

0

0

0 0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0 0

0

0

0

0

0

0

0

0 0

0

0

0

0 0

0

0

0

0

0

0

0

0

0

0

0

0

0

0 0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0


0

0

0

0

0

0 0 0

0

0 0 0

0

0

0

0

0

0

0 0

0

0

0

0

0

0 0

0 0

0 0

0

FAILURE MODE AND COMPONENTS

TROUBLESHOOTING

)

FAILURE MODE AND COMPONENTS (3-STAGE MODE SELECTOR OLSS)

/

Charg~

~/

~ c

Electronic /

8 §• ~

"-

,£ 1

2

Machine deviates excessively (normal travel)

0

c .g E•

'"

c

~ 8 0

0

0:

0

e

~

0

f "

§ 'i

,

l l ~ ~

.8

.r

0

,

g

~

"

;

" e , E :.§

•

§

Failure mode

!

~

s,'"

§"

.l? 0

c

-"

i

J; I-

ill

i

0

"-

~

,

:l:

:r:

f

I

oJ

-"

~ 0

~

# g iii-" -" -" •

f!

-"

ff

.l?

0 0

"-

,~

f!

~

U QII• 0•~ '5 0

" " l :r: ~

0

0

1 1

'"

0

0

0

" '"

0

0

0

0

1

I .r


•


5


6


0

0

0

0

0

0

7


0

0

0

0

0

0

B


0

0

0

9


0

0

10


11

Swing speed is slow

12


0

0

13


0

0

"

Excessive hydraulic drift of work equipment

15

Parking brake does not work on slopes

16


0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0 0

0

0

0

0

0

0

0

0

0

0

0

0

0 0

0

0

0

0

0

0

0

0 0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

i

0

0

0

.l?

0

0

0

i 0

'"

8 "J

0

0

~

~

0

0

0

0

0

~

c

t'

2

'"

i

:r: :r:

0;

$

~

oJ

0

0

0

;;;

~

if 0

0 0

0 0

0

0

*

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0 0

;§

~

0 0

~

"

~ 0

0 0

~

.g"

0


3

t

I 'i ,~" ~ ~ " • g , cIE i?: IE," f! e ·S•" .S• !<' , .r E .e g :l: >." f! ·S !!'

c0

~

0

0

" 1 i'• ~

1

~

.Q

'"

0 0

J • 0

/

c

,I

l

iii 0

'"

0

0


I

" .'" f

"

0

~

l

~

"

~

~

l

~

i

-"

Mechanical

system

motorl 0

.g l I!' .- { l l '0 ~ .J: f! E 'If ~ g , l E , g l 1: , l l ,f J J l J ciii J cJ J :.§ f "-·8 -£e ~ fi" ~ S' ~S- , J § "- J J 1 • i?: .g i?: ~ ~ ~ ~ " f 0:0;•• -,• 0:f ," "J.e ~0 0;f! f to• ,E oS:f { ,g0 f iE "J.e 6•" :> 0 I-" !:! ~ ~ " .~ 0 c

Travel

0 0

I!'

Iii

Swing motor

.l?

IJ "

PPC' / valve

.:;;

~

I

~ ~

ff c"{ c .g

~

~

f!

f!

.l? c

~

Control system

lng pump

/

Auto-deceleration

OLSS

Pump control

Swing brake/

Electronic OLSS. auto-deceleration

Component causing failure

/

Hydraulic system

Electrical system

0

0

0

0

0

0 0

0

0

0

0 *: Auto-deceleration

)

62-170 ®

PC200, 220-3

HYDRAULIC SYSTEM 63 DISASSEMBLY AND ASSEMBLY CHARGING PUMP ASSEMBLY Removal Installation MAIN PUMP ASSEMBLY

.

63- 2 63- 3

.

Removal . . Installation . Disassembly . Assembly . Installation . CONTROL VALVE ASSEMBLY Removal . Installation . Disassembly . Assembly . TVC VALVE ASSEMBLY Removal and installation . CO, NC VALVE ASSEMBLY Removal and installation . SERVO VALVE ASSEMBLY Removal and installation . BOOM CYLINDER ASSEMBLY Removal and installation . ARM CYLINDER ASSEMBLY Removal and installation . BUCKET CYLINDER ASSEMBLY Removal and installation . HYDRAULIC CYLINDER ASSEMBLY Disassembly . Assembly . WORK EQUIPMENT ASSEMBLY Removal . Installation . Disassembly . Assembly . . . . . . . . . • . . . . . . . . . . . . .

63- 4 63- 7 63-9-1 63-9-5 63- 7 63-10 63-13 63-16 63-18


*

-

63-20 63-21 63-22 63-23 63-24 63-25 63-26 63-29 63-34 63-35 63-36 63-40

When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and piping, always bleed the air as follows: 1. Start engine and run at low idling. 2. 3. 4.

Operate hydraulic cylinder 4 to 5 times, stopping 100 mm from stroke end. Next, operate cylinder 3 to 4 times to stroke end. After doing this, run engine at normal speed.

*

After repair or long storage, follow the same procedure.

PC200, 220-3

63-1 Q;)


MAIN PUMP

REMOVAL OF MAIN PUMP ASSEMBLY Special tool

A

Part No.

Part Name

Q'ty

796-750-1410

Oil stopper

1

Lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulit tank. 1.

Oil stopper 1) Remove strainer cover (1), then take out strainer

(2). 2) 3)

Remove strainer and install tool A on rod (3). Assemble rod and tool A inside tank, then fit spring and install strainer cover. When not using tool A, remove drain plug (4) and drain the oil from the hydraulic tank .

ww• w. k omat s upar t s book . c om *

...:..


2.

Hood, cover 1) Open hood. 2) Remove top cover of main pump. 3) Open side cover.

3.


4.

Main pump outlet hoses Disconnect hoses (6) and (7) between pump and control valve, and branch hoses (8) and (9) together with block.

5.

Main pump drain hose Disconnect hose (10) between main pump and hydraulic tank.

6.

Charging pump hose Disconnect hose (11) accumulator.

63-4 CD

between charging pump and

PC200, 220-3


7.

8. _

MAIN PUMP

Jet sensor hose Mark the pilot hoses with tags to show their mounting position. Disconnect hoses (12) and (13) at rear, and hoses (14) and (15) at front between CO, NC valve and control valve.

*

Suction tubes Disconnect charging pump inlet tube (16), and main pump inlet tube (17).


Main pump assembly Sling main pump assembly, remove 12 mounting bolts, then lift off main pump assembly (18).

~

Main pump assembly: 200 kg

PC200, 220-3

63-5 CD


MAIN PUMP

REMOVAL OF MAIN PUMP ASSEMBLY (OPTION) Special tool

A

Part No.

Part Name

a'ty

796-750-1410

Oil stopper

1

Lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1.

Oil stopper 1) Remove strainer cover (1), then take out strainer (2).

2) 3)

Remove strainer and install tool A on rod (3) . Assemble rod and tool A inside tank, then fit spring and install strainer cover. When not using tool A, remove drain plug (4) and drain the oil from the hydraulic tank.

ww•w. k omat s upar t s book . c om *

...:..

2.


Hood, cover 1) Open hood. 2) Remove top cover of main pump. 3) Open side cover.

3.


4.

Main pump outlet hoses Disconnect hoses (6) and (7) between pump and control valve, and branch hoses (8) and (9) together with block.

5.

Main pump drain hose 'Disconnect hose (10) between main pump and hydraulic tank.

6.

Charging pump hose Disconnect hose (11) accumulator.

63-8 CD

r

between charging pump and

PC200, 220-3

-


MAIN PUMP

8. Wiring connector Connect wiring connector (8) of TVC solenoid valve. Fix the connector securely with the clip.

*

9. Air cleaner assembly -

Raise air cleaner assembly (7) and set in position on bracket. Tighten removed air cleaner band and hose clamp.

www. k omat s upar t s book . c om 10. Covers, hood 1) 2)

3)

Install bottom cover (6) and top cover (5). Close hood and lock with catch. Close side cover.

11. Oil stopper 1) 2) 3)

4)

*

-

Remove cover (1), then take out tool A. Remove tool A and install strainer (2) on rod (3). Assemble strainer inside tank, then install spring and cover again. Bleed air from main pump. For details, see section 62, TESTING AND ADJUSTING, BLEEDING AIR FROM MAIN PUMP. If tool A was not used and the oil was drained from the hydraulic tank, tighten the drain plug and add engine oil through oil filler (23) to the specified level.

W pe200, 220-3


63-9 CD


MAIN PUMP

-

DISASSEMBLY OF MAIN PUMP ASSEMBLY (HPV090 + 090) Special tools No.

Part No.

Part Name

Q'ty

A

790-501-5000

Unit repair stand

1

Al

790-901-2110

Bracket

1

A2

790-901-2150

1

A3

796-720-3530

Plate (For front pump) Plate (For rear pump)

1

Preparatory work Set pump assembly (1) in tool A.

-


2.

TVC and CO, NC valve assembly 1) Remove hose (2). 2) Remove tube (3). 3) Disconnect wiring (4), then remove TVC and CO, NC valve assembly (5). (Rear pump) 4) Remove CO, NC valve assembly (6). (Front pump)

-

Rear pump assembly 1) 51 ing rear pump assembly (7). 2) Remove 4 nuts at front pump assembly end, then remove rear pump assembly (7). Disconnect at the middle of the end caps.

*

'P20503079

63-9-1

PC200, 220-3

-

MAIN PUMP


*

The front pump can be further disassembled from this point, but for rear pump assembly (7), remove plate A3 before disassembling.

7 P20503080

3. _

Impeller Remove impeller (8) and spacer (9) from front pump. Check the number and thickness of the spacers, and keep in a safe place.

*


4.

5.

Servo valve assembly Remove servo valve assembly (12). End cap

1)

Remove bolts (13), then remove plate (14).

P20503083

2)

3) 4)

Remove shim (15), boss (16), and spacer (18). Check the number and thickness of the shims, and keep in a safe place. Remove outer race (20) and bearing (21). Remove end cap (23). Be careful not to drop the valve plate.

*

*

-

P20503084

PC200, 220-3

P20503085

63-9-2 ($)


MAIN PUMP

6.

Valve plate Remove valve plate (45).

7.

Pump shaft assembly Support cylinder block and shaft, then remove pump sub-assembly.

8.

Servo piston 1) Using forcing screws (Dia. = 10 mm, Pitch = 1.5 mm) and nut , remove cap (27) and shim (28). 2) Remove spring (31).

-

www. k omat s upar t s book . c om 3) 4)

Repeat Step 1) and remove cap (29) and shim (30). Remove servo piston (32). The servo pistons used for the front and rear are not the same part, so mark them to distinguish them.

*

9. Cylinder, shaft 1) Set pump sub-assembly (49) in a vice. Be carefu I not to damage the flange surface of the cradle. 2) Remove slider (38) and cylinder block (35).

*

63-9-3

PC200. 220-3

-


3)

Screw in forcing screws, and remove housing (40) and shim.

* *

MAIN PUMP

Check the number and thickness of the shims, and keep in a safe place.

40

10

The charging pump is installed to the rear pump, so collar (10) assembled in the pilot pump must be removed.

P20503095

-

4)

Remove shaft (14).


Remove inner race from pump drive shaft. i)

Remove snap ring (55), then remove washer (54).

ii)

Using puller (3), remove inner race (53).

*

-

For the rear pump shaft, using gear puller, remove inner race.

/55

s9===a;..::.--- 54 53

F20503065

10. Piston

F20503066

Remove 4 screws (56), then remove retainer bearing (57), shoe retainer (58), spacer (56), and piston (60).

58

56 1~--59

-

P20503097

F20703017A

PC200. 220-3

63-9-4

OISASSEMBl Y AND ASSEMBl Y

MAIN PUMP

-

ASSEMBLV OF MAIN PUMP ASSEMBLV (HPV090 + 090) Special tools No.

Part No.

Part Name

Q'ty

A

790·501·5000

Unit repair stand

1

Al

790·901·2110

Bracket

1

A2

790·901·1330

Plate

1

A3

796·720·3530

Plate

1

B

796·720·3810

Gau~e

1

B

796· 720·3840

(for min. swas plate anllle) Gau~e (for max. swas plate angle)

Cl

795·630·1803

Torque wrench set

1

C2

796·720·2220

Socket

1

C3

796·730·2120

Screwdriver

1

01

795·630·1803

Torque wrench set

1

02

796·720·2220

Socket

1

1

-

www. k omat s upar t s book . c om Precautions when assembling. Always use all parts supplied in the kit. In addition, always use the following parts as an assembly. 1) Cradle and rocker arm. 2) Cylinder block and valve plate.

-

Preparatory work Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil (E010·CO, new oil) before installing.

1.

Cradle and piston assem bly 1) Press fit bearing (68) (outside diameter: 85 mm) to cradle (65).

68

63-9-5

PC200, 220·3

MAIN PUMP


2)

Select shims to hold bearing as follows. i) Measure distance ® between bearing (68) and end face of cradle. ii) Measure distance (5) of housing (40). iii) Select shim thickness as follows. Shim thickness = ® - (5) - (0 to 0.1 mm)

@

P20503099

*

-

Forthe rear pump, install collar (66) to charging pump (67), and measure distance (5) of the

67

collar.


3)

Fit dowel pin, and install rocker cam stopper (64) to cradle (65). ~". ,

Stopper bolt:

Thread tightener (LT-2)

~

Stopper bolt:

1.35 ± 0.15 kgm

65

4)

Fit dowel pin to cradle, set rocker cam (62) in position, then install plate (63). The side of the rocker cam with the groove faces the oil hole side of the cradle.

*

*

~,

Plate bolt: Thread tightener (LT-2)

~

Plate bolt: 3.15 ± 0.35 kgm

63

After tightening the bolts, check that the rocker cam moves smoothly.

-

F20503052

PC200,220-3

63-9-6 (5)

..


MAIN PUMP

5)

Select the spacer thickness as follows. i) Assemble shoe retainer (58) to piston (60), put on the level block, then measure distance ® to top surface of shoe retainer. ii) Select spacer thickness as follows. Spacer thickness = distance ® + (0.03 to 0.07 mm) There are three types of spacer.

*

F20503053

6)

Install spacer (59) selected in Step 5)-i) and ii). then install piston (60), shoe retainer (58) and retainer bearing (57). ~c,

Bearing retainer bolt: Thread tightener

~

Bearing retainer bolt: 1.35 ± 0.15 kgm

-


Hold rocker cam in position, pull piston (60) with a force of 2 - 3 kg, and measure clearance ® between piston shoe and rocker cam. Measure the clearance with the rocker cam at position a or b, and measure for all nine piston.

*

* *

60

-

Clearance: 0.03 - 0.07 mm If clearance ® is not within the standard range, adjust the spacer again.

P20503105

Rocker cam

Pull

Piston

t

Retainer bearing Screw

I

Spacer

F20703021 Rocker cam

F20703022

63-9-7

PC200, 220-3

-

MAIN PUMP


-2.

Cylinder Align piston and install cylinder (35). Always install the valve plate (which forms a set with the cylinder) together with the cylinder, or make a mark and be careful not to make any mistake. Install the spring and washer inside the cylinder after adjusting the preload of the bearing.

*

*

-

3.

Shaft 1) Press fit inner race (53) (inside diameter: 45 mm) to shaft (41). 2) Fit washer (54), then install snap ring (55). 3) Select washer as follows. i) Install inner race (53) to shaft. ii) Install snap ring. Check that the snap ring is not deformed or damaged, and correct any burrs before installing. Install with the cut inside part facing the opposite direction from the inner race. iii) Using a feeler gauge, measure clearance @ between snap ring (52) and inner race. Push the snap ring securely into the groove on the opposite side from the inner race. iv) Install selected washer. Washer thickness = c1earance@+(Oto 0.1 mm) Check that there is no play between the snap ring and the washer. There are four types of washer.


*

@

----l~----l-ooI.-I---

......

*

-

r-ll...--_ _

Shaft

F20503054

PC200, 220-3

63-9-8 (5)

....

MAIN PUMP


4)

Set cradle and piston assembly (51) in vice 0). Put a block under the cylinder. Align shaft (41) with cylinder, and install.

*

5)

6)

Install housing as follows. i) Install oil seal (50) (outside diameter: 68 mm) to housing. ~.

ii)

*

Lip of oil seal: Grease (G2-L1)

Fit shim selected in Step 1-2), and install housing (40) to pump.

40

For the rear pump, do not install the charging pump at this point. If the charging pump is installed, it is impossible to stop the shaft from turning when adjusting the end play of the bearing. Be careful not to damage the lip of oil seal.

-


4.

Servo piston 1) Install pump case (33) in tool A. 2) Install servo piston (32). The servo pistons used for the front and rear are not the same part, so be careful not to make any mistake when assembling them.

*

P20503110

.-

End pump

Rear pump

L2

*

< Ll

The length (L2 < Ll ) from the center is different on the side with the spring and on the side with no spring.

F20503055

3)

Adjust stroke of servo piston as follows. i) Align tool B with dowel pin and groove 9 for servo valve arm of servo piston, and set tool B in position. As seen from the rear of the pump, the right side (the top when mounted on the machine; the side with the spring) is the maximum swash plate angle side. (maximum flow side) Note: For the rear pump, use the same tool turned over.

*

63-9-9 u))

PC200, 220-3

MAIN PUMP


Measure distance ® between servo piston and case. iii) Measure distance CW of cap (29). iv) Select shim thickness as follows. CW - ® = © ± 0.05 mm After adjusting the shim, put it in a set with the cap.

ii)

*

P20503116

-

Dowel pin

Dowel pin

Gauge

Gauge Servo valve mounting surface

Servo valve mounting surface CapB

Pump case

www+ . k omat s upar t s book . c om Cap A

Clearance

©

Servo piston -+Clearance

©

Clearance

a)---.+-~~

Servo piston

F20703026 F20703027

*

-

To adjust the minimum swash plate angle, replace tool B with the tool for the minimum angle, and repeat the same procedure as in Steps i) - iv). Note that the case faces in the opposite direction from the maximum swash plate angle side.

F20503056

5.

Pump SUb-assembly

1)

2)

3)

-

Install slider (38) and D-ring. Fit the D-ring in the pilot portion and the joint portion. Install 2 joints on case. Install with the small hole facing the cradle side. Align the slider with the servo piston, and install pump sub-assembly (49). ,,, Be careful that the D-ring is not caught. Also, be careful not to drop the cylinder.

*

*

I~

PC200, 220-3

Mounting bolt:

11.5 ± 1 kgm

63-9-10 (5)


MAIN PUMP

6.

Adjusting axial play of bearing 1) Install the following parts in the end cap. i) Install bearing (48) (outside diameter: 42 mm). ~"J

ii)

Bearing mount surface: Grease (G2-L1)

Install outer race (46) to end cap (42). Be careful not to damage the rolling surface of the roller. iii) Coat with engine oil, align with pin and bearing, and install valve plate (45). iv) Install joint (44). Install with the small hole facing the case side. Insta II the part with only one joint to the

*

*

suction port side.

45

-

44


44

Install end cap (42) to case (43).

~

Mounting bolt:

7 ± 0.5 kgm (front)

~

3)

Mounting nut: 28.5 ± 3 kgm (rear) (Tighten the nut of the stud bolt.) Install bearing (21), inner race (20), spacer (18) and

P20503121

boss (16). The outer race is slightly stiff, so support the shaft from the other end and tap the boss

* 4) 5) 6)

lightly. Measure distance

®

between end face of boss (16)

and shaft (41). Select shim as follows. Shim thickness = ® + (0.2 ± 0.1 mm) Assemble selected shim (15), fit plate (14), and

-

tighten bolts (13). Hold the shaft down from the other end (to stop it from turning) when tightening.

*

~

Bolt:

7 ± 0.5 kgm

16

0.1 - 0.3 mm

@-++-F20503057

F20503058

63-9-11 (5)

P20503 I :;~,1

PC200.220-3

-

-


MAIN PUMP

10. Adjusting impeller shim 1) Install impeller (8) to coupling (26)

P20503137

-

2)

Adjust impeller lock spacer as follows. i) Measure distance ® between spacer (18) and stepped part (25) of end cap of rear pump.

8

www. k omat s upar t s book . c om P2050~138.

F20503059

Measure distance @ between end face of vane and end face of coupling of impeller (8). Measure for all the vanes, and use the largest value. iii) Selece spacer as follows. ® - @ = © + (0.5 ± 0.1 mm) ii)

*

-

P20503139

F20503060

iv)

Measure distance @ between spacer (18) and stepped part (24) of end cap of front pump.

18

-

F20503061

PC200. 220-3

63-9-14 ®

DISASSEMBl Y AND ASSEMBLY

MAIN PUMP

Measure distance ® between stepped pat and coupling end face of impeller (8). vi) Select spacer as follows.

v)

@ -

® = CD + (0.5 ± 0.1

mm)

P20503140

F20503062

vii) Install selected shims at both ends of impeller, them measure overall distance @.

-


ix) Measure distance (6) between spacer (18) and end face of end cap of rear pump. x) Measure distance CD between spacer (18) and end face of end cap of front pump. xi) If impeller distance @ is greater than ((6) +CDl. a gap will from between front and rear end caps, so select spacer at both ends of impeller again.

-

F20503064

63-9-15 @

PC200, 220-3

-

-


3) 4) 5)

-

MAIN PUMP

Install selected spacer (10) to rear pump. Fit selected spacer (9) to front pump, then install impeller (8). Measure rotating torque of pump. i) Rotate pump shaft at 1 revolution every 3 5 sec then measure rotating torque. ii) Rotating torque: Max. 1.4 kgm (at minimum rocker cam angle)

11. Rear pump assembly 1) Install a-rings to front and rear end caps. 2) Raise rear pump assembly (7), align spline, and install. ~

7

28.5 ± 3 kgm

Mounting nut:

www. k omat s upar t s book . c om 12. TVC and CO, NC valve assembly 1)

Fit O·ring and install CO, NC valve assembly (6). (Front pump) ~

2)

3)

3.2 ± 0.3 kgm

Fit a-ring, install TVC and CO, NC valve assembly (5), then clamp wiring (4). (Rear pump) ~

Mounting bolt:

~

Clamp mounting bolt: 7 ± 0.5 kgm

3.2 ± 0.3 kgm

Fit a-ring and install tube (3). ~

4)

Mounting bolt:

Joint bolt:

1.8 ± 0.2 kgm

Install hose (2). ~

*

Sleeve nut:

8 ± 2 kgm

After completion of quality of the parts.

assembly,

check

the

After completing the assembly of the pump assembly, use a test stand (A type or C type) to check the quality.

*

For details of the procedure for checking quality, see TESTING METHODS.

PC200, 220-3

63-9-16 ®


MAIN PUMP

CHECKING CONTACT BETWEEN CYLINDER BLOCK AND VALVE PLATE, AND ROCKER CAM AND CRADLE 1. Checking contact between cylinder block and valve plate 1) Make a centering tool for the cylinder block and valve plate. The tool can be made of a soft material such as plastic or bakelite. 2) Remove grease from the parts to be checked. Do not wipe with a cloth. 3) Set the tool in position, and coat the cylinder block side with inspection paint. Apply the paint thinly. 4) Put the valve plate on top, push with a force of 4 5 kg, and rotate 2 - 3 times. 5) Remove the valve plate, transfer the contact surface to tape, and check the contact surface.

Cylinder block

Centering tool

* *

*

*

,I / (--~

I

I I

I

r--~ I I I I

I

II

I

I I

I I

I I

\..

\

I I

I

I I I

I I I

I

-

The standards for the contact surface are as follows.

www. k omat s upar t s book . c om Valve plate

a. Seal

Min.80%

Cylinder block

a. Seal

Min. 80%

F20703037

Valve plate

Cylinder block F20703038

63-9-17 @

PC200, 220-3


MAIN PUMP

2.

Checking contact between rocker cam and cradle 1) Remove grease from the parts to be checked. Do not wipe with a cloth. 2) Set the tool in position, and coat the cradle side with inspection paint. Apply the paint thinly. 3) Put the rocker cam on top, push with a force of 4 - 5 kg, and move 2 - 3 time from the stopper contact position to the maximum angle. 4) Remove the rocker cam, transfer the contact surface to tape, and check the contact surface.

* *

*

*

The standards for the contact surface are as follows. Pump Model

Dimension a (mm)

Contact surface

Contact b from a to outside

HPV 090

72

Min. 80%

Min. 50%

If there is no contact at the center but only at the outside, the contact is no good.

www. k omat s upar t s book . c om Locker cam

-

F20703039

-

Reference: If the contact is not within the contact standard value, when carrying, always lap both parts together. Parts with scratches cannot be reused.

*

PC200. 220-3

63-9-18 (5)


CONTROL VALVE

-

REMOVAL OF CONTROL VALVE ASSEMBLY Special tool Part No. 796-750-1410

A

Part Name Oil stopper

Q'ty 1

Lower the work equipment completely to the ground and stop the engine. Release the hydraulic pressure in the hydraulic piping. For details, see section 62, TESTING AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

* 1.

-

Mark the pilot hoses with tags to show their mounting position. 1) 2) 3)

Remove strainer cover, then take out strainer (1). Remove strainer and install tool A on rod. Assemble rod and tool A inside tank, then fit spring and install strainer cover. When not using tool A, remove drain plug (2) and drain the oil from the hydraulic tank .

ww•w. k omat s upar t s book . c om *

~

2.


Remove cover above control valve, then· open side cover.

3.

Disconnect travel control cables (3) and (4).

4.

Disconnect hose (5) between PPC check valve and control valve (boom spool).

5.

Disconnect hose (6) between PPC check valve and control valve (bucket spool).

6.

Disconnect hose (7) between PPC check valve and control valve (swing spool).

7.

Disconnect hose (8) between PPC check valve and control valve (arm spooll.

63-10

PC200, 220-3

-


4.

Charging pump hose Connect hose (11) between charging pump and accumulator.

5.

Main pump drain hose Connect hose (10) between main pump and hydraulic tank.

6.

Main pump outlet hoses 1) Fit a-rings and set branch hoses (9) and (8) on main pump. 2) Fit a-rings and connect hoses (7) and (6) between main pump and control valve.

7.

Air cleaner assembly Raise air cleaner assembly (5) and set in position on bracket. Tighten removed air cleaner band and hose clamp.

-.

8.

MAIN PUMP

r

Cover, hood 1) Install top cover of main pump, then close hood and lock with catch. 2) Close side cover.


-.

Refilling with oil 1) Remove cover (1), then take out tool A. 2) Remove tool A and install strainer (2) on rod (3). 3) Assemble strainer inside tank, then install spring and cover again. 4) Bleed air from main pump. For details, see 62 BLEEDING AIR FROM MAIN PUMP. If tool A was not used and the oil was drained from the hydraulic tank, tighten the drain plug (4) and add engine oil through oil filler (19) to the specified level.

*

W


-.

PC200, 220-3

63-11 CD


CONTROL VALVE

-

REMOVAL OF CONTROL VALVE ASSEMBLY Special tool

A

Part No.

Part Name

Q'ty

796-750-1410

Oil stopper

1

Lower the work equipment completely to the ground and stop the engine. Release the hydraulic pressure in the hydraulic piping. For details, see 62 TESTING AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

* 1.

-

Mark the pilot hoses with tags to show their mounting position. 1) 2)

Remove strainer cover, then take out strainer (1). Remove strainer and install tool A on rod. Assemble rod and tool A inside tank, then fit spring and install strainer cover. When not using tool A, remove drain plug (2) and drain the oil from the hydraulic tank .


*

•

~


2.

Remove cover above control valve, then open side cover.

3.

Disconnect travel control cables (3) and (4).

4.

Disconnect hose (5) between PPC check valve and control valve (boom spool).

5.

Disconnect hose (6) between PPC check valve and control valve (bucket spool).

6.

Disconnect hose (7) between PPC check valve and control valve (swing spool).

7.

Disconnect hose (8) between PPC check valve and control valve (arm spool).

63-12 CD

PC200,220-3

-

-


8.

Disconnect hoses (9) and (10) between PPC check valve and control valve.

9.

Disconnect hoses (11), (12), (13) and (14) between control valve and CO, NC valve.

CONTROL VALVE

10. Disconnect hoses (15) and (16) between PPC check valve and travel shuttle valve. 11. Disconnect hoses (17) and (18) between pump and control valve.

www. k omat s upar t s book . c om 12. Disconnect hose (19) between PPC check valve and control valve (boom spool). 13. Disconnect hose (20) between PPC check valve and control valve (bucket spool).

-

14. Disconnect hose (21 ) between PPC check valve and control valve (swing spool). 15. Disconnect hose (22) between PPC check valve and control valve (arm spool). 16. Disconnect hose (23) between control valve and inlet tube of pump. 17. Loosen intermediate clamp, then disconnect tubes (24) and (25) between control valve and swing motor. 18. Loosen intermediate clamp, then disconnect tubes (26) and (27) between control valve and arm cylinder. 19. Loosen intermediate clamp, then disconnect tubes (28) and (29) between control valve and swivel joint (L.H. travel ).

-

20. Loosen intermediate clamp, then disconnect tube (30) between control valve and hydraulic tank.

PC200, 220-3

63-13 CD


CONTROL VALVE

21. Loosen intermediate clamp, then disconnect tubes (31) and (32) between control valve and swivel joint (R.H. travel ). 22. Loosen intermediate clamp, then disconnect tubes (33) and (34) between control valve and boom cylinder. 23. Loosen intermediate clamp, then disconnect tubes (35) and (36) between control valve and bucket cylinder.

24. Using eyebolts CD (Dia. = 10 mm, Pitch = 1.5 mm), sling control valve assembly (37), then remove 8 mounting bolts and lift off control valve assembly.

&J

-

Control valve assembly: 170 kg


-

63-14 CD

PC200, 220-3

-

CONTROL VALVE


INSTALLATION OF CONTROL VALVE ASSEMBLY

* *

Tighten the hose joints (at taper seal) to the following torques. Install hose without twisting or interference. ~

Sleeve nut of hose

Width across flats of nut

-

1.

19 mm

2.5 ± 0.5 kgm

24mm

5 ± 2 kgm

27 mm

8 ± 2 kgm

32mm

18 ± 3 kgm

Using eyebolts CD (Dia. = 10 mm, Pitch = 1.5 mm), raise control valve assembly (37), and set in mounting position. Tighten 8 mounting bolts.


Fit a-rings and connect tubes (36) and (35) between control valve and bucket cylinder, then tighten intermediate clamp.

3.

Fit a-rings and connect tubes (34) and (33) between control valve and boom cylinder, then tighten intermediate clamp.

4.

Fit a-rings and connect tubes (32) and (31) between control valve and swivel joint (R.H. travel), tben tighten intermediate clamp.

5.

Fit a-rings and connect tube (30) between control valve and hydraulic tank, then tighten intermediate clamp.

6.

Fit a-rings and connect tubes (29) and (28) between control valve and swivel joint (L.H. travel), then tighten intermediate clamp.

7.

Fit a-rings and connect tubes (27) and (26) between control valve and arm cylinder, then tighten intermediate clamp.

8.

Fit a-rings and connect tubes (25) and (24) between control valves and swing motor, then tighten intermediate

-

-

clamp.

PC200, 220-3

63-15 CD


CONTROL VALVE

9. Connect hose (23) between control valve and inlet tube of pump. 10. Connect hose (22) between PPC check valve and control valve (arm spool). 11. Connect hose (21) between PPC check valve and control valve (swing spool). 12. Connect hose (20) between PPC check valve and control valve (bucket spool). 13. Connect hose (19) between PPC check valve and control valve (boom spool).

-

14. Fit a-rings and connect hoses (18) and (17) between pump and control valve. 15. Connect hoses (16) and (15) between PPC check valve and travel shuttle valve.

www. k omat s upar t s book . c om 16. Connect hoses (14), (13). (12) and (11) between control valve and CO, NC valve. 17. Connect hoses (10) and (9) between PPC check valve and control valve.

18. Connect hose (8) between PPC check valve and control valve (arm spool). 19. Connect hose (7) between PPC check valve and control valve (swing spool). 20. Connect hose (6) between PPC check valve and control valve (bucket spool). 21. Connect hose (5) between PPC check valve and control valve (boom spool).

63-16 CD

PC200, 220-3

-


CONTROL VALVE

22. Connect travel control cables (4) and (3). 23. Install cover above control valve, then close L.H. side cover.

-

24. Remove cover and take out tool A. Remove tool A from rod and install strainer (1). Then assemble inside tank and install cover. If tool A was not used, tighten drain plug (2) and add engine oil through the oil filler to the specified level.

*

www. k omat s upar t s book . c om ttl

*


Run the engine to circulate the oil through the system. Then check the oil level again.

25. Bleed air from hydraulic cylinders and travel motor. For details, see section 62 AIR BLEEDING IN TRAVEL MOTOR.

*

*

After bleeding the air, check the oil level.

-

PC200. 220-3

63-17 CD

DISASSEMBLY AND ASSEMBl Y

CONTROL VALVE

-

DISASSEMBLY OF CONTROL VALVE ASSEMBLY


-

205F2334

63-18 CD

PC200, 220-3

-


* 1. 2. 3.

*

-

* 4.

CONTROL VALVE

The set pressure of the safety valve cannot be adjusted when it is installed on the machine, so do not disassemble. Remove main relief valve (1) and jet sensor relief valve (2). Remove safety valve (3). and safety and suction valves (4) and (5). Disassemble PPC valve spool as follows. 1) Remove case (6). then remove spring (7) and retainer (8). 2) Remove spool (9). For the control valve on machines with wrist control, this applies to the boom, arm, bucket, swing, and arm Hi spools. With this type, there are shims (10) fitted at the spring of the boom, arm and swing spools, so be careful when removing. For the control valve on machines with long lever control, this applies to the arm, bucket, and swing spools. Disassemble mechanically linked spool as follows. 1) Remove case (11) and bolt (12), then remove retainer (13). spring (14) and retainer (15). Remove bolt (12) with the spool inside the body. 2) Remove spool (16) from body, then remove oil seal


(17).

*

Be careful not to damage the oil seal when removing the spool. 3) Remove plate (18), then remove oil seal (19). For the control valve on machines with wrist control, this applies to the travel spool. For the control valve on machines with long lever control, this applies to the travel and boom spools. Remove plate (20), then remove spring (21) and straighttravel spool (22). Remove plug (23), then remove washer (24), spring (25), washer (26), and arm throttle spool (27). This also applies to the swing priority valve. Remove plug (28). then remove spring (29) and check valve (30).

* *

-

5. 6.

* 7.

PC200, 220-3

63-19 CD


CONTROL VALVE

-

ASSEMBLY OF CONTROL VALVE ASSEMBLY


-

205F2334

63-20 CD

PC200. 220-3

CONTROL VALVE


* 1.

Clean all parts, and check for dirt or damage. coat the sliding surfaces of all parts with engine oil before installing. Be careful not to damage packing, dust seals or a-rings when installing. Assemble spring (29) and check valve (30) to plug (28), then install plug (28). ~"C,

2.

Plug:

Thread tightener (LT-2) (one drop only)

~ Plug: 15.5 ± 2.5 kgm Assemble arm throttle spool (27). then fit washer (26), spring (25) and washer (24). Fit a-ring and tighten plug (23). ~

-

Plug: 14 ± 2 kgm This also applies to the swing priority valve. Assemble straight-travel spool (22), then fit spring (21). Fit a-ring and install plate (20). Assemble mechanically linked spool as follows. 1) Install oil seal (17) in body, then assemble spool (16). Coat oil seal lip with grease (G2-L1) 2) Assemble retainer (15), spring (14) and retainer (13), then tighten bolt (12).

* 3. 4.

*


Bolt: 2.5 ± 1 kgm Tighten bolt (12) with the spool inside the body. Install case (11). then fit oil seal (19) and install plate (18).

*

3)

*

* 5.

-

*

* 6.

For the control valve on machines with wrist control, this applies to the travel spool. For the control valve on machines with long lever control, this applies to the travel and boom spools. Assemble ppe valve spool as follows. Assemble spool (9) in body, then install retainer (8) and spring (7). Fit a-ring and install case (6). For the control valve on machines with wrist control, this applies to the boom, arm, bucket, swing, and arm Hi spools. With this type, there are shims (10) fitted at the spring of the boom, arm and swing spools, so be careful when installing. For the control valve on machines with long lever control, this applies to the arm, bucket, and swing spools. Fit a-rings and install safety and suction valves (4) and (5). and safety valve (3). ~

7.

Safety valve, safety and suction valve: 14±2kgm Fit a-rings and install jet sensor relief valve (2) and main relief valve (1). Main relief valve:

10 ± 1 kgm

Jet sensor relief valve: 5.5 ± 0.5 kgm

PC200, 220-3

63-21 CD

DISASSEMBl Y AND ASSEMBLY

TVCVAlVE

-

REMOVAL OF TVC VALVE ASSEMBLY Open l.H. side cover. 2.

Remove 4 mounting bolts with hexagonal wrench, then remove TVC valve assembly (1).

2

-

www. k omat s upar t s book . c om INSTALLATION OF TVC VALVE ASSEMBLY

1.

Fit O-ring on CO, NC valve assembly (2).

2.

Set TVC valve assembly (1) on CO, NC valve assembly (2), then tighten 4 mounting bolts.

3.

Close l.H. side cover.

F205C3071

-

63-22 CD

PC200, 220-3

-


CO, NCVALVE

REMOVAL OF CO, NC VALVE ASSEMBLY 1.

Open L.H. side cover.

2.

Disconnect hoses (1) and (2) between CO, NC valve and control valve. Mark the hoses with tags to show their mounting position.

* 3.

Remove tube (3) between left and right CO, NC valve.

4.

Remove 4 mounting bolts with a hexagonal wrench, then remove CO, NC valve assembly (4).

-

www. k omat s upar t s book . c om INSTALLATION OF CO, NC VALVE ASSEMBLY

1.

Install filter (6) and a-ring on servo valve assembly (5).

2.

Set CO, NC valve assembly (4) on servo valve assembly (5), then tighten 4 mountings bolts. ~

-


3.

Fit a-ring and install tube (3).

4.

Connect hoses (2) and (1) between CO, NC valve and control valve.

5.

Close L.H. side cover

*


PC200, 220-3

63-23 CD


SERVO VALVE

-

REMOVAL OF SERVO VALVE ASSEMBLY 1.

Remove CO and NC valve assembly. For details, see 63 REMOVAL OF CO, NC VALVE ASSEMBLY.

2.

Remove 4 mounting bolts with a hexagonal wrench, then remove servo valve assembly (1).

INSTALLATION OF SERVO VALVE ASSEMBLY 1,

-

Install orifice (2) and filter (3) to servo valve assembly (1).


Fit O-ring, align arm with notch in servo piston, then set servo valve assembly (1) in case and tighten 4 mounting bolts. Install the servo valve assembly smoothly, and do not apply force to the protruding part of the arm.

*

~

3.

*

205F2330


Install CO and NC valve assembly. For details, see 63 INSTALLATION OF CO, NC VALVE ASSEMBLY. Run the engine to circulate the oil through the system. Then add oil to the hydraulic tank to the specified level.

-

63-24 CD

PC200. 220-3

-

-


-


PPC VALVE

-

REMOVAL OF PPC VALVE ASSEMBLY Lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

*

Before disconnecting PPC valve hoses, mark with tags to show their mounting position.

1.

Disconnect PPC valve hoses (1), (2), (3), (4), (5) and (6).

2.

Remove cover (7) of control box.

3.

Disconnect control rod (8) and (9).

-


Remove 3 mounting bolts of control box, then remove control box (10).

5.

Remove PPC valve bracket assem bly (11).

6.

7.

Loosen nut of yoke assembly fastening bolt (12), remove bolt, then remove 4 mounting bolts of PPC valve, and remove bracket (13).

13

Pull out pins (14) of yoke at 4 place, then remove spring (15), spacer (16) and yoke assembly (17).

15 16

14

17

12

P205C3170

63-26 CD

PC200, 220-3

-

-

PPC VALVE


INSTALLATION OF PPC VALVE ASSEMBLY 13 1.

Set spacer (16) on top and bottom of spring (15), install yoke assembly (17) then install pins (14) of yoke at 4 place.

2.

Install bracket (13), tighten 4 mounting bolts, install yoke assembly fastening bolts (12), then tighten nut.

15 16

14

17

12

P205C3170

-

3.

Install PPC valve bracket assembly (11).

4.

Set control box (10) in position, then tighten 3 mounting bolts.


6.

Connect control rod (9) and (8). Bend the cotter pin securely.

*

Install cover (7) of control box.

7.

Install PPC valve hoses (6), (5), (4), (3), (2) and (1). When connect the hoses, check the tags marked before disconnected.

*

PC200.220-3

63-27 CD


PPC VALVE

-

DISASSEMBLY OF PPC VALVE ASSEMBLY 1.

Remove bolt (1).

2.

Remove plate (2).

3.

Remove seal (3), then remove collar (4).

4.

Remove spool (5).

5.

Remove valve assembly and center spring (7) from valve body (10).

6.

11 12

Remove collar (11), then remove retainer (6), shim (12) and spring (8) from valve (9).

9

10

-

F205C3072

1~ www. k omat s upar t s book . c om ASSEMBLY OF PPC VALVE ASSEMBLY 1.

Install shim (12), spring (8). and retainer (6) on valve (9), then install collar (11).

2.

Install center spring (7) and valve assembly on valve body (10).

3.

Install valve (5).

4.

Fit O-ring and install collar (4).

5.

Install seal (3).

6.

Set plate (2) in position, then tighten bolt (1). ~

-

Bolt: 4.5 ± 0.5 kgm

10

F205C3073

63-28 CD

PC200, 220-3

-

DISASSEBMLY AND ASSEMBLY

BOOM CYLINDER

REMOVAL OF BOOM CYLINDER ASSEMBLY

it 1. 2. 3.

4.

Extend the arm and bucket fully, lower the work

equipment completely to the ground and stop the engine. Disconnect greasing tu be (1).

Remove lock bolt (2), then remove plates (3). Sling boom cylinder assembly (4), push connecting pin (5) to opposite side, then remove piston rod from boom. Start engine and retract piston rod fUlly. Tie the rod with wire to prevent it from coming out.

-

Stop the engine and release the hydraulic pressure in the hydraulic piping. For details, see section 62, TESTING AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve.

\

www. k omat s upar t s book . c om CD.

5. 6.

Raise boom cylinder assembly (4), then set on stand Disconnect hoses (6) and (7).

7.

Sling boom cylinder assembly (4) and remove lock plate (8). Using forcing screw ® (Dia. = 12 mm, Pitch = 1.75 mm), remove pin (9), then lift off boom cylinder assembly (4).

205P2269

~-

6tJ

Boom cylinder assembly:

185 kg (PC200) 200 kg (PC220)

-

INSTALLATION OF BOOM CYLINDER ASSEMBLY 1.

Raise boom cylinder assembly (4), and position bottom connecting pin hole on frame. Assem ble spacer, knock in pin (9), and install lock plate (8).

*

Adjust with spacers so that the clearance between the revolving frame and the cylinder bottom is less than 1 mm.

2.

Fit O-rings and connect hoses (7) and (6).

3.

Raise boom cylinder assembly (4). Start engine, extend piston rod and align with pin hole, then knock in pin (5).

4. 5.

Fit plate (3), then secure with lock bolt (2). Connect greasing tube (1).

*


PC200, 220-3

63-29 CD


ARM CYLINDER

-

REMOVAL OF ARM CYLINDER ASSEMBLY ~ 1. 2.

Set stand CD under the arm, lower the work equipment completely to the ground and stop the engine.

Sling arm cylinder assembly, remove lock plate (1), then pull out pin (2). Start engine and retract piston rod fully.

~

Tie the rod with wire to prevent it from coming out. Stop the engine and release the hydraulic pressure in the hydraulic piping. For details, see section 62, TESTING AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve.

3. 4. 5.

-

Disconnect arm cylinder hoses (3) and (4) at cylinder end. Disconnect greasing tube (5). Remove lock plate (6), pull out pin (7), then lift off arm cylinder assembly (8).

www. k omat s upar t s book . c om L~

Arm cylinder assembly:

245 kg (PC200) 280 kg (PC220)

INSTALLATION OF ARM CYLINDER ASSEMBLY 1.

2. 3. 4.

* *

7

Raise arm cylinder assembly (8) and position bottom connecting pin hole. Knock in pin (7), then secure with lock plate (6). Connect greasing tube (5). Fit O-rings and connect arm cylinder hoses (4) and (3). Start engine, extend piston rod, knock in pin (2), then secure wth lock plate (1).

6

I

-

Adjust with spacers so that the clearance between the boom and arm cylinder bottom is less than 1 mm. Run the engine to circulate the oil through the system. Then add oil to the hydraulic tank to the specified level.

63-30 CD

PC200, 220-3


BUCKET CYLINDER

REMOVAL OF BUCKET CYLINDER ASSEMBLY Lower the work equipment completely to the ground and stop the engine. 1.

2.

Remove lock bolt (1), then pull out pin (2). Insert block between the cylinder and the arm. Pull out pin (2) until the piston rod comes out. Start engine and retract piston rod fully.

* *

CD

~

Tie the bucket cylinder rod with wire to prevent it from coming out. Stop the engine and release the hydraulic pressure in the hydraulic piping. For details, see section 62, TESTING AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve.

3.

Disconnect bucket cylinder hoses (3) and (4) at cylinder end. Sling bucket cylinder assembly (5), remove lock plate (6). then pull out pin (7). Lift off bucket cylinder assembly (5).

www. k omat s upar t s book . c om 4. 5.

/~--

Lk91

Bucket cylinder assembly: 140 kg (PC200) 185 kg (PCnO)

INSTALLATION OF BUCKET CYLINDER ASSEMBLY -

1.

Raise bucket cylinder assembly (5) and position bottom connecting pin hole. Knock in pin (7), then secure with lock plate (6).

2.

Fit O-rings and connect bucket cylinder hoses (4) and (3).

* 3.

* *

Install hose without twisting or interference. Start engine, extend piston rod and align link and hole. Knock in pin (2), then install lock bolt (1).

Adjust with spacers so that the clearance between the arm and bucket cylinder bottom is less than 1 mm. Run the engine to circulate the oil through the system. Then add oil to hydraulic tank to the specified level.

PC200, 220-3

63-31 CD

HYDRAULIC CYLINDER


-

DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY Special tool Part No.

Part Name

Q'ty

A

790-502-2000 or 790-502-1001

Cylinder repair stand

1

Al

790-302-1430

Socket (Width across flats: 85mm)

1

A2

790-302-1450


1

A3

790-101-1102

Pump

1

1.

-

Set cylinder assembly (1) on tool A.

www. k omat s upar t s book . c om A

2.

205P2279

Remove head bolts (2).

2

3.

Pu II out piston rod assembly (3) about 1 m, then lift off. Prepare a container to catch the oil which comes out when the piston rod assembly is removed. Remove the cylinder from tool A.

* *

i 205P228I

63-32 CD

PC200, 220-3

-

HYDRAULIC CYLINDER


4.

Disassemble piston rod assembly as follows. •

Bucket cylinder 1) Set piston rod assembly in tool A. 2) Using tool A, remove nut (4). Width across flats of nut: 85 mm (PC200) 95 mm (PC220)

*

3)

Remove piston assembly (5) and cylinder head assembly (6) from piston rod (7).

205P2282

-

•

Arm cylinder 1) Set piston rod assembly in tool A. 2)

3)

Using tool A, remove nut (8).

*

Width across flats of nut: 95 mm Remove piston assembly (9), plunger (10) and cylinder head assembly (11) from piston rod ( 12).


4)

Remove screw (13), take out 12 balls (14), then remove plunger (15).

15

/

205F2335

•

205P2284

Boom cylinder 1) Set piston rod assembly in tool A. 2) Using tool A, remove nut (16). Width across flats of nut: 85 mm (PC200) 95 mm (PC220)

*

3)

Remove

piston

assembly (17), plunger (18)

and cylinder head assembly from piston rod

(19).

PC200, 220-3

63-33 CD


HYDRAULIC CYLINDER

5.

Disassemble piston assembly as follows. Remove wear ring (20) and slipper seal (21) from piston.

6.

Disassemble cylinder head assembly as follows. 1) Remove snap ring (22), then remove dust seal (23) from cylinder head. 2) Remove packing (24), bushing (25), a-ring (26) and backup ring (27) from cylinder head.

20

205P2286

26 27

26

24

24 25

-

26

25

27

23


205F2336

205P2287

-

63-34 CD

PC200, 220-3

--

HYDRAULIC CYLINDER


ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY Special tool

*

Part No.

Part Name

Q'ty

A

790-502-2000 or 790-502-1001

Cylinder repair stand

1

Al

790-302-1430


1

A2

790-302-1450


1

A3

790-101-1102

Pump

1

B

790-702-1000

Expander

1

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Be carefu I not to damage packing, dust seals or O-ring when installing.


Assemble cylinder head assembly as follows. 1) Using push tool, install bushing (25) on cylinder head. Outside diameter of bushing: 80 mm (PC200 bucket) 90 mm (PC200 boom) 95 mm (pC220 boom, bucket) 100 mm (PC200, 220 arm) Be careful not to deform the bushing when press fitti ng. 2) Install packing (24). Be careful to install the packing facing in the correct direction. 3) Install backup rings (27) and O-rings (26) in turn on cylinder head. Do not try to force the slipper seal into position. Warm it in warm water (50 - 60°C) before fitting it. 4) Using push tool, install dust seal (23) and secure with snap ring (22).

*

*

-

*

26 27

24

26

25

27

1rn--.....-r-23

*

22 205F2336

24 25

26

27

--

205P2287

PC200, 220-3

63-35 CD

HYDRAULIC CYLINDER


2.

Assemble piston assembly as follows. 1) Using tool B, expand slipper seal (21). Set the slipper seal on the expander and turn the handle 8 - 10 times to expand the ring. 2) Remove slipper seal (21) from tool, and install on piston.

*

21 205P2289

3)

Set ring CD in positIOn, then using clamp ®, compress slipper seal (21). Part number of ring 796-720-1660 (PC200 bucket cylinder) 796-720-1670 (PC200 boom, arm cylinder) (PC220 bucket, boom cylinder) 796-720-1680 (PC220 arm cylinder)

-

*


Part number of clamp 07281-01279 (PC200 bucket cylinder) 07281-01589 (PC200 boom, arm cylinder) (PC220 bucket, boom cylinder) 07281-01919 (PC220 arm cylinder)

2

205F2338

205F2337

4)

Install wear ring (20) on piston.

20

63-36 CD

Z05P2292

PC200, 220-3

-


HYDRAULIC CYLINDER

3.

Assemble piston rod assembly as follows. • Boom cylinder 1) Set piston rod (19) in tool A. 2) Install cylinder head assembly, plunger (18) and piston assembly (17) on piston rod (19l. 3) Using tool A, tighten nut (16). ~

-

•

Nut:

720 ± 72 kgm (PC200) (Width across flats: 85 mm) 1040 ± 104 kgm (PCnO) (Width across flats: 95 mm)

Arm cylinder 1) Set piston rod (12) in tool A. 2) Position plunger (15) on piston rod, then assemble 12 balls (14). 3) Tighten screw (13) fully, then turn back about 1/2 turn. Check play at tip of plunger, then caulk. Play at tip of plunger: Approx. 6 mm

13

\

15 I

\


205P2284

Caulk

205F2339

4)

5)

Install cylinder head assembly (11), plunger (10) and piston assembly (9) on piston rod (12). Using tool A, tighten nut (8). ~

-

Nut:


205P2283

PC200. 220-3

63-37 CD


HYDRAULIC CYLINDER

•

Bucket cylinder 1) Set piston rod (7) in tool A. 2) Install cylinder head assembly (6) and piston assembly (5) on piston rod. 3) Using tool A, tighten nut (4). ~

Nut:

720 ± 72 kgm (PC200) (Width across flats: 85 mm) 1040 ± 104 kgm (PC220) (Width across flats: 95 mm)

205P2282

4.

Set cylinder in tool A.

5.

Raise cylinder head and piston rod assembly (3). and assemble in cylinder. Coat the inside face of the cylinder and the outside face of the piston with engine oil when installing.

-

3

*


Assemble cylinder head assembly in cylinder, then tighten head bolts (2). Align the punch marks and ports when assembling. (There is no punch mark on the bucket cylinder.)

*

2

7.

Remove cylinder assembly (1) from tool A.

A 205P2279

63-38 OJ

PC200. 220-3

-

-

-


-

WORK EQUIPMENT


-

REMOVAL OF WORK EQUIPMENT ASSEMBLY Special tool Part No.

Part Name

Q'ty

A

796-900-1200

Remover

1

Al

790-101·3800

Cylinder (50 ton)

1

A2

790-101-1102

Pump

1

~

1. 2. 3. 4.

Extend the arm and bucket fully, lower the work equipment completely to the ground and stop the engine.

Disconnect greasing tube (1). Remove lock bolt (2). then remove plates (3). Sling boom cylinder assembly (4), push connecting pin (5) to opposite side, then remove piston rod from boom. Start engine and retract piston rod fully.

\

5

-


Tie the rod with wire to prevent it from coming out.

'!'!'Y

Stop the engine and release the hydraulic pressure in the hydraulic piping. For details, see section 62, TESTING AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve. Raise boom cylinder assembly (4) and lower on to stand

Y

5.

205P2294

CD.

* 6. 7. 8. 9.

Remove the other boom cylinder assembly in the same way, and lower on to the stand. Disconnect head lamp wiring (6) at connector. Disconnect bucket cylinder hoses (7) and (8), and arm cylinder hoses (9) and (10). Sling work equipment assembly, and remove lock plate (11). Using tool A, remove pin (12). Lift off work equipment assembly (13).

~

-

Work equipment assembly: 3400 kg (PC200) 3700 kg (PC220)

63-40 CD

PC200, 220·3

-


WORK EQUIPMENT

INSTALLATION OF WORK EQUIPMENT ASSEMBLY 1.

Raise work equipment assembly (13), and positIOn boom foot connecting pin hole on revolving frame. Knock in pin (12), then secure with lock plate (11).

2.

Fit O-rings and connect arm cylinder hoses (9) and (10) and bucket cylinder hoses (7) and (8). Install hose without twisting or interference.

*

-

3.

Connect head lamp wiring (6) at connector.

4.

Raise boom cylinder assembly (4). Start engine, extend piston rod and align with pin hole, then push in pin (5).

5.

Fit plate (3), then secure with lock bolt (2).

6.

Connect greasing tube (1).

*

Install the other boom cylinder in the same way.


*

Adjust with spacers so that the clearance between the revolving frame and the boom foot is less than 1 mm.


*

After installing the work equipment assembly, grease all the pins with grease (G2-L1).

-.

PC200, 220-3

63-41 CD


WORK EQUIPMENT

-

DISASSEMBLY OF WORK EQUIPMENT ASSEMBLY Special tools Part No.

Part Name

Q'ty

A

796-900-1200

Remover

1

Ai

790-101-3800

Cylinder (50 ton)

1

A2

790-101-1102

Pump

1

1.

Bucket 1) Lower work equipment to ground so that bottom of bucket (1) is on ground. 2) Remove lock bolt (2). then remove cylinder connecting pin (3). 3) Start engi ne and retract bucket cy I inder rod fu Ily. 4) Remove lock bolt (4).

~

E:~ 4

-

www. k omat s upar t s book . c om 5) 6)

Loosen 4 mounting bolts of cover (5). and remove shims (6). Pullout arm connecting pin (7). then remove bucket (1). ~~

Ck~J

Bucket: 560 kg (PC200) 720 kg (PC220)

P205C3173

2.

Link 1) Lower tip of arm to ground. 2) Set link (8) on block then remove lock bolt (9). Pullout pin (10), and remove link (11). 3) Start engine and retract bucket cylinder rod fully. Tie the bucket cyl inder rod with wire" to prevent it from coming out.

CD.

8 P205C3174

63-42 Q)

PC200, 220-3

-

WORK EQUIPMENT


4)

Remove lock bolt (12). pullout link pin (13). and remove link (14).

P205C3175

-

3.

Bucket cylinder assembly

¢ 1)

Release the hydraulic pressure in the hydraulic piping. For detai Is, see section 62, TESTI NG AND ADJUSTING, Bleeding pressure from hydraulic circuit in machine with PPC valve. Disconnect 2 bucket cylinder hoses (15). After disconnecting the hoses, fit blind plug @ in the tube flange to prevent oil from coming


out.

2)

Sling bucket cylinder assembly (16). then remove lock plate (17). Pullout pin (18) and lift off bucket cylinder assembly (16).

L£

4.

Bucket cylinder assembly: 140 kg (PC200) 160 kg (PC220)

1\ j

17

Arm 1) Pull in arm fully, and lower on to block (height: approx. 500 mm). 2) Remove lock plate (20), then remove pin (21). 3) Start engine and retract arm cylinder rod fully.

~

4)

Tie the arm cylinder rod with wire to prevent it from coming out.

Remove lock plate (22). then remove pin (23).

PC200, 220-3

63-43 CD


WORK EQUIPMENT

5)

Start engine and operate work equipment control lever to raise boom (24). lift off arm (19).

~

Arm: 600 kg (PC200) 700 kg (PC220)

205P2308

5.

Boom cylinder assembly 1) 2) 3)

-

lower tip of boom completely to ground. Disconnect greasing tube (25). Remove lock bolt (26), then remove plates (27).


Sling boom cylinder assembly (28), push connecting pin (29) to opposite side, then remove piston rod from boom. Start engine and retract piston rod fully.

5)

Tie the boom cylinder rod with wire to prevent it from coming out.

6)

-

lower boom cylinder assembly (28) on to stand (3).

*

lower the other boom cylinder assembly on to the stand in the same way.

63-44 CD

PC200, 220-3

-


6.

WORK EQUIPMENT

Bucket hoses, arm hose Release the hydraulic pressure in the hydraulic piping. For details,see section 62, TESTI NG AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve. Disconnect bucket cylinder hoses (30) and (31), and arm cylinder hoses (32) and (33).

-

7.

Head lamp wiring Disconnect head lamp wiring (34) at connector.

8.

Arm cylinder, boom assembly 1) Remove lock plate (35).


Sling boom, then pullout pin (36) with tool A.

3)

Raise arm cylinder and boom assembly (37), and pullout to front to remove.

-

Arm cylinder, boom assembly: 1700 kg (PC200) 2000 kg (PC220)

-

zu,,pz;, 14

pe200, 220-3

63-45 CD


WORK EQUIPMENT

-

ASSEMBLY OF WORK EQUIPMENT ASSEMBLY 1.

Arm cylinder, boom assembly 1) Raise arm cylinder and boom assembly (37), and position boom foot connecting pin hole on revolving frame.

-

205P2314 ~.,;

2)

*

Knock in pin (36), then secure with lock plate (35). Adjust with spacers so that the clearance between the revolving frame and the boom foot is less than 1 mm.

-


Head lamp wiring Connect head lamp wiring (34) at connector.

3.

Bucket hoses, arm hoses Fit O-rings and connect arm cylinder hoses (33) and (32), and bucket cylinder hoses (31) and (30).

4.

Boom cylinder assembly 1) Sling boom cylinder assembly (28). Start engine, extend piston rod and align with pin hole, then push in pin (29).

63-46 CD

pe200, 220-3

-


2) 3)

*

5. -

WORK EQUIPMENT

Fit plate (27), then secure with lock bolt (26). Connect greasing tu be (25). Install the other boom cyli'nder in the same way.

Arm 1) Raise arm (19), and lower on to block approx. 500 mm).

®

(height:

•


2)

3)

*

6.

Operate control lever and align pin holes of boom and arm (19). Knock in connecting pin (23), then secure with lock plate (22). Start engine, extend piston rod. Knock in connecting pin (21), then secure with lock plate (20). Adjust with spacers so that the clearance at the joint of the arm and boom is less than 1 mm.

Bucket cylinder assembly 1) Raise bucket cylinder assembly (16), and align connecting hole at bottom. Knock in pin (18), then secure with lock plate (17).

17

1\ I

PC200. 220-3

63-47 CD


WORK EQUIPMENT

2)

Fit O-rings and connect 2 bucket cylinder hoses (15).

*

7.

Adjust with spacers so that the clearance between the arm and bucket cylinder bottom is less than 1 mm.

Link 1) Align pin hole of link (14), knock in pin (13), then secure with lock bolt (12). Adjust with spacers so that the clearance between link (14) and the arm is less than 1 mm.

-

*

www. k omat s upar t s book . c om Set link (8) on block CO, raise link (11) and align connecting pin hole of bucket cylinder rod. Knock in pin (10), then secure with lock bolt (9).

2)

8.

P205C3175

Bucket 1) 2)

3)

Set bottom of bucket (1) on ground. Fit O-ring on both side of bucket. Operate control levers, and align bucket (1) with arm pin hole. Knock in arm connecting pin (7). Install shims (6), then tighten 4 mounting molts of cover (5). Adjust with shims (6) so that the clearance between arm and bucket retainer is 0.25 to

-

* 4)

0.5mm. Tighten lock bolt (4).

B P205C3174

P205C3173

63-48 CD

PC200, 220-3

-

-


5)

WORK EQUIPMENT

Extend bucket cyl inder rod and al ign pin hole. Knock in link connecting pin (3), then secure with lock bolt (2).

-


-

PC200, 220-3

63-49 CD

-

-


-

HYDRAULIC SYSTEM 64 MAINTENANCE STANDARD

-

PPC valve

64- 2

PPC shuttle valve Control valve Hydraulic cylinder Charging pump Work equipment

64- 4 64- 6 64-14 64-16 64-18


PC200, 220-3

64-1


PPC VALVE

PPC VALVE

-


205F2223

Unit: mm

No.

Check Item

Criteria

Remedy

Standard size Free length 1

Center spring

2

Spring

3

Tightening torque for bolt

Repair limit

x 0.0.

Installed length

Installed load

44.8 x 12.2

36.0

0.9 kg

-

0.7 kg

31.4 x 7.4

29.4

1.7 kg

-

1.4 kg

Free length

Installed load

Replace spring if any damages or deformation are found

4.5 ± 0.5 kgm Tighten

4


64-2

-

1.8 ± 0.4 kgm

PC200, 220-3

WRIST CONTROL


-


Unit: mm No.

Check Item

Criteria

Remedy

Standard size

1

Centering spring (for swing and bucked

Repair limit

Free length x 0.0.

Installed length

Installed load

44.8 x 12.2

36.0

0.9 kg

-

0.7 kg

41.8 x 12.6

36.0

2.6 kg

-

2.1 kg

31.4x7.4

29.4

1.7 kg

-

1.4 kg

2

Center spring (for arm and boom)

3

Spring

4

Tightening torque for nut

3.5 ± 0.5 kgm

5

Tightening torque for joint

3.5 ± 0.5 kgm

6


1.8 ± 0.4 kgm

PC200, 220-3

Free length

Installed load Replace spri ng if any damages or deformations are found

Tighten

64-3 ®


LONG LEVER CONTROL

-

LONG LEVER CONTROL 1. PPC VALVE FOR ARM, SWING AND BUCKET LEVER

-


205F2223

Unit: mm No.

Check Item

Criteria

Remedy


Center spring

2

Spring

3

Tightening torque for bolt

Repair limit

x 0.0.

Installed length

Installed load

Free length

Installed load

44.8 x 12.2

36.0

0.9 kg

-

0.7 kg

31.4 x 7.4

29.4

1.7 kg

-

1.4 kg

Replace spring if any damages or deformation are found


4


64-4 ®

-

1.8 ± 0.4 kgm

PC200, 220-3

LONG LEVER CONTROL


2.


IN-LINE SERVO VALVE FOR BOOM LEVER

4

3

2

5

7

6

-


Unit: mm

-

No.

Standard size

1

-

Remedy

Criteria

Check Item

Spool return spring

2

Input spool and holder

3

Pi lot spool and spacer

Repair limit

Free length x 0.0.

Installed length

Installed load

88.4 x 26.0

37.0

8.0 kg

Free length

-

Installed load 6.4 kg

Confirm the following points. • No scratches on sliding surface • Smooth movement of spool when putting it into valve body

4

Pilot spool
5

Piston and valve body

6


Replace spring if any damages or deformations are fou nd

Repair or replace ass'y


7

Tightening torque for joint

PC200, 220-3

6.5±1.0kgm

64-5


PPC SHUTTLE VALVE

-

PPC SHUTTLE VALVE •

FOR L.H. PPC VALVE

il

0

0

0

0 0

0

0

0

0

0

0 0

-

TI

www. k omat s upar t s book . c om \1 t~ ® 0 0

0 0 Section A-A 205F2225

--

Unit: mm No.

1

Check Item


64-6

Criteria

Remedy

3.5 ± 0.5 kgm

Tighten

PC200, 220-3

--

CONTROL VALVE


-

/

B

5

Section A-A

7

2 Section B-B

www. k omat s upar t s book . c om F205C3056

Unit: mm

No.

Check Item

Criteria

Remedy

Standard size Free length x 0.0.

Installed length

Installed load

83.4 x 34.8

39.5

14.0 kg

-

11.2 kg

Spool return spring (for Arm-Hi, bucket)

51.0 x 29.6

50.0

8.36 kg

-

6.68 kg

3

Spool return spring (for swing, service, arm-Lo)

51.0 x 29.6

50.0

8.36 kg

-

6.68 kg

4

Spool return spring (for R.H. travel, boom Hi)

83.4 x 34.8

39.5

14.0 kg

-

11.2 kg

5

Jet sensor main valve spring

23.3 x 7.2

18.0

2.46 kg

-

2.0 kg

6

Jet sensor pilot valve spring

28.4 x 7.5

27.0

0.63 kg

-

0.5 kg

7

Tightening torque for union

2.2 ± 0.2 kgm

8

Tightening torque for jet sensor relief valve

5.5 ± 0.5 kgm

9

Tightening torque for jet sensor orifice

5.5 ± 0.5 kgm

1

-

-

Repair limit

2

Spool return spring (for L.H. travel, boom-Lo)

PC200, 220-3

Free length

Installed load

Replace spring if any damages or deformations are fou nd

Tighten

64-7


CONTROL VALVE

5

6

8 7

9 ,

I I I

I I I

10

{,(~~i

2

1~~!

00

"

I

I I I

I I I I

® 000 !g I

-

,

iff)

0

0

0

Section C-C Section 0-0


12

-

13 14

4 Section E-E

F205C3057

64-8

PC200. 220-3

-

CONTROL VALVE


3 4

7

8

Section A-A

9

\

2

6

Section B-B

5

www. k omat s upar t s book . c om 205F2218A

Unit: mm No.

Check Item

Criteria

Remedy

Standard size Installed length

Installed load

83.4 x 34.8

39.5

14.0 kg

-

11.2 kg


51.0 x 29.6

50.0

8.36 kg

-

6.68 kg

3


51.0 x 29.6

50.0

8.36 kg

-

6.68 kg

4


83.4 x 34.8

39.5

14.0 kg

-

11.2 kg

5


23.3 x 7.2

18.0

2.46 kg

-

2.0 kg

6


28.4 x 7.5

27.0

0.63 kg

-

0.5 kg

7


2.2 ± 0.2 kgm

8

Tightening torque for jet sensor relief valve

5.5 ± 0.5 kgm

9

Tightening torque for jet sensor orifice

5.5 ± 0.5 kgm

1

2

-

Repair limit

Free length x 0.0.


PC200, 220-3

Free length

Installed load

Replace spring if any damages or deformations are found

Tighten

64-9


CONTROL VALVE

7

9 8

6

10

11 3 2

Section C-C Section D-D


13

14

-

15

5 Section E-E 205F2219A

64-10

PC200, 220-3

-

CONTROL VALVE


-


No.

Check Item

Remedy

Criteria

-

Standard size

1

In-line check valve spring

Repair limit

Free length x 0.0.

Installed length

Installed load

468x26.2

25.0

0.76 kg

2


7.0 ± 1.0 kgm

3


14.5 ± 2.0 kgm

4

Tightening torque for suction valve (for swing)

14.5 ± 2.0 kgm

5

Tightening torque for safety valve (for boom cylinder bottom)

14.5 ± 2.0 kgm

6

Tightening torque for suction valve (for boom cylinder bottom)

14.5 ± 2.0 kgm

7

Tightening torque for safety-suction valve (for boom cylinder head)

14.5 ± 2.0 kgm

Free length

-



Tighten

-

PC200, 220-3

64-11


CONTROL VALVE

4

2

o

-


Section J - J

5

3 6

-

Section L - L

64-12

7

F205C3059

PC200, 220-3

-

CONTROL VALVE


-

-

www. k omat s upar t s book . c om Unit· mm

No.

Item

-

Criteria

Remedy

Standard size ~-_._--.-- - -

1

In-line check valve spring

Free length x 0.0. f---------24.4 x 12.8

..- - -

Repair limit - --

Installed length

Installed Free length load t------- - - -I-r-----.--- 16.0

0.3 kg

2

Tightening torque for safety-suction valve (for bucket cylinder head)

14.5 ± 2.0 kgm

3

Tightening torque for safety-suction valve (for bucket cylinder bottom)

14.5 ± 2.0 kgm

4


-


Replace spring if any damages or deformations 'Ire found


-

5


14.5 ± 2.0 kgm

6

Tightening torque for safety valve (for arm cylinder head)

14.5 ± 2.0 kgm

7

Tightening torque for safety-suction valve (for arm cylinder bottom)

14.5 t 2.0 kgm

PC200, 220-3

64-13


HYDRAULIC CYLINDER

-

HYDRAULIC CYLINDER

o 4

3

www. k omat s upar t s book . c om 5 F205C3060

-

64-14

PC200, 220-3

HYDRAULIC CYLINDER


Unit: mm

No.

Cylinder name

Appl ication

Standard size

Clearance between piston rod and bushing Arm cylinder

Tolerance Shaft

Hole

Standard clearance

Clearance limit

PC200-3

85

-0.120 -0.207

+0.235 +0.060

0.180 0.442

0.742

PC220-3

90

--0.120 -0.207

+0.270 +0.061

0.181 0.477

0.777

PC200-3 PC220-3

95

-0.120 -0.207

+0.235 +0.060

0.180 0.442

0.742

PC200-3

75

-0.100 -0.174

+0.291 +0.077

0.177 0.465

0.765

PC220-3

90

-0.120 -0.207

+0.270 +0.061

0.181 0.477

0.777

Boom cylinder 1

Remedy

Criteria

Check Item

Bucket cylinder

Replace bushing

www. k omat s upar t s book . c om PC200-3

80

-0.030 -0.076

+0.457 +0.370

0.400 0.533

PC220-3

80

-0.030 -0.076

+0.457 +0.370

0.400 0.533

PC200-3 PC220-3

80

-0.030 -0.076

+0.457 +0.370

0.400 0.533

1.0

PC200-3

70

-0.030 -0.076

+0.424 +0.350

0.380 0.500

1.0

80

-0.030 -0.076

+0.457 +0.370

0.400 0.533

1.0

1.0

Boom cylinder

2

Clearance between piston rod support and bushing

Arm cylinder

Bucket cylinder

PC200-3

70

-0.030 -0.076

+0.424 +0.350

0.380 0.500

PC220-3

80

-0.030 -0.076

+0.457 +0.370

0.400 0.533

PC200-3 PC220-3

80

-0.030 -0.076

+0.457 +0.370

0.400 0.533

1.0

PC200-3

70

-0.030 -0.076

+0.424 +0.350

0.380 0.500

1.0

PC220-3

80

-0.030 -0.076

+0.457 +0.370

0.400 0.533

1.0

Boom cylinder

3

Clearance between cylinder bottom support and bushing

Arm cylinder

Bucket cylinder

4

5

-

Tightening torque for piston nut

Tighten ing torque for cylinder head mounting bolt

PC200, 220-3

1.0

-----

PC220-3

-

1.0

Boom cylinder

PC200: 720 ± 72 kgm (width across flats: 85) PC220: 1,040 ± 104 kgm (width across flats: 95)

Arm cylinder

PC200:

Bucket cylinder

PC200: 720 ± 72 kgm (width across flats: 95) PC220: 1,040 ± 104 kgm (width across flats: 85)

Boom cylinder

PC200: 28.5 ± 3.0 kgm PC220:

Arm cylinder

PC200: 28.5 ± 3.0 kgm pcno: 39.5 ± 4.0 kgm

Bucket cylinder

PC200: 28.5 ± 3.0 kgm PC220:

pcno:

Replace pin and bushing

1.0

1,040 ± 104 kgm (width across flats: 95)

64-15


CHARGING PUMP

-

CHARGING PUMP BAR25

-

www. k omat s upar t s book . c om 205F221 I

Unit: mm No.

Check Item

Criteria

Remedy

Standard size -

1

-

Repair limit --

-----~

Top clearance of gear 0.090 - 0.130

0.145 Replace

2

Side clearance of gear

0.055 - 0.075

0.105

3

Cleilrance between gear shaft and bushing

0.045 - 0.076

0.13

Standard value Delivery 4

5

BAR25

Tightening torque for housing case mounting bolt

64-16

Repair limit --~_._.

Engine oil CLASS-CD SAE10W 50 ± 5°C 30 kg/em'

Revolution speed (rpm)

Delivery (Q/min)

-------

Revolution speed (rpm)

Delivery (Q/min)

3200

68

--

3200

72

11.25 ± 1.25 kgm

Replace

Tighten

PC200, 220-3

-

-

CONTROL VALVE


4

9

8

7

2


Section A-A

205F2213

Unit: mm

No.

Check Item

Criteria

Remedy


-

-


Repair limit

x 0.0.

Installed length

Installed load

83.4 x 34.8

39.5

14.0 kg

-

11.2 kg

Free length

Installed load

2


51.0 x 29.6

50.0

8.36 kg

-

6.68 kg

3


51.0 x 29.6

50.0

8.36 kg

-

6.68 kg

4


83.4 x 34.8

39.5

14.0 kg

-

11.2 kg

5


23.3 x 7.2

18.0

2.46 kg

-

2.0 kg

6


28.4 x 7.5

27.0

0.63 kg

-

0.5 kg

7


2.2 ± 0.2 kgm

8

Tighten ing torque for jet sensor relief valve

5.5 ± 0.5 kgm

9

Tighteni ng torque for jet sensor orifice

5.5 ± 0.5 kgm

PC200, 220-3


Tighten

64-17 (2)


CONTROL VALVE

7

9

6

10

11

2

Section C-C Section 0-0


13

-

14 15

5 Section E-E

64-18 ®

205F2214A

PC200. 220-3

-


-


WOR K EQUIPMENT

-

WORK EQUIPMENT o

F

G=~~I

-


H

16

17

6

7

Section H-H Section A-A

15

14

-

Section E-E

Section B-B Section I-I

B

Section F-F

4 Section C-C

9 Section G-G Section D-D

/

11

Section K-K

13 205F2229

64-18

PC200, 220-3

-

-


WOR K EQUIPMENT

PC200-3 No.

Unit: mm

Remedy

Criteria

Check Item

Tolerance

1

-

ClearancEt between boomrevolving frame mounting pin and bushing

Standard size

Standard clearance

Clearance limit

Shaft

Hole

80

-0.030 -0.076

+0.337 +0.273

0.303 0.413

1.0

-0.030 -0.076

+0.1 0

0.030 0.176

1.0

~0.030

+0.1 0

0.030 ~ 0.176

1.0

-0.076

+0.1 0

0.030 ~ 0.176

1.0

2

Clearance between boomrevolving frame mounting pin and boss hole

80

3

Clearance between boom cylinderrevolving frame mounting pin and boss hole

70

4

Clearance between boomboom cylinder rod mounting pin and boss hole

80

5

Clearance between boomarm cylinder mounting pin and boss hole

80

-0.030 -0.076

+0.1 0

0.030 0.176

1.0

6

Clearance between boom-arm mounting pin and boss hole

90

-0.036 -0.090

+0.1 0

0.036 0.190

1.0

7

Clearance between boom-arm mounting pin and bushing

90

-0.036 -0.090

+0.343 +0.271

0.307 0.433

1.0

8

Clearance between armarm cylinder mounting pin and boss hole

80

-0.030 -0.076

+0.1 0

0.030 0.176

1.0

9

Clearance between arm-bucket cylinder mounting pin and boss hole

70

~0.030

+0.1 0

0.030 0.176

1.0

10

Clearance between arm-link mounting pin and bushing

70

~0.076

+0.335 +0.275

0.305 0.411

1.0

11

Clearance between arm-bucket mounting pin and bushing

80

-0.030 -0.076

+0.337 +0.273

0.303 0.413

1.0

12

Clearance between arm-link mounting pin and link

70

-0.030 -0.076

+0.1 0

0.030 0.176

1.0

13

Clearance between arm-bucket mounting pin and boss hole

80

-0.030 -0.076

+0.2 0

0.030 0.276

1.0

14

Clearance between bucket cylinder-link mounting pin and bushing

70

-0.030 -0.076

+0.335 +0.275

0.305 0.411

1.0

15

Clearance between bucket cylinder-link mounting pin and link

70

-0.030 -0.076

+0.1 0

0.030 0.176

1.0

16

Clearance between link-bucket mounting pin and bushing

80

-0.030 -0.076

+0.331 +0.265

0.295 ~ 0.407

1.0

17

Clearance between link-bucket mounting pin and boss hole

80

-0.030 -0.076

+0.2 0

0.030 0.276

1.0

-0.076 ~0.030


-.

-.

PC200, 220-3

Replace

~0.076

-0.030

64-19


WORK EQUIPMENT

PC220-3 No.

1

Unit: mm Check Item

Clearance between boomrevolving frame mounting pin and bushing

Criteria

Standard size

90

Tolerance

Remedy

Standard clearance

Clearance limit

Shaft

Hole

-0.036 -0.090

+0.342 +0.269

0.305 0.432

1.0

-0.036 ~0.090

+0.1 0

0.036 0.190

1.0

-0.030 -0.076

+0.15 0

0.030 0.226

1.0

2

Clearance between boomrevolving frame mounting pin and boss hole

90

3

Clearance between boom cylinderrevolving frame mounting pin and boss hole

80

4

Clearance between boom-boom cylinder rod mounting rod and boss hole

80

-0.030 -0.076

+0.17 +0.07

0.030 0.246

1.0

5

Clearance between boom-arm cylinder mounting pin and boss hole

80

~0.030

-0.076

+0.1 0

0.030 0.176

1.0

6

Clearance between boom-arm mounting pin and boss hole

90

-0.036 -0.090

+0.1 0

0.036 0.190

1.0

7

Clearance between boom-arm mounting pin and bushing

90

-0.036 -0.090

+0.343 +0.271

0.307 0.433

1.0

8

Clearance between arm·arm cylinder mounting pin and boss hole

80

-0.030 -0.076

+0.1 0

0.030 0.176

1.0

9

Clearance between armbucket cylinder mounting pin and boss hole

80

-0.030 -0.076

+0.1 0

0.030 0.176

1.0

10

Clearance between arm-link mounting pin and bushing

80

-0.030 -0.076

+0.337 +0.273

0.303 0.413

1.0

11

Clearance between arm-bucket mounting pin and bushing

80

-0.030 -0.076

+0.337 +0.273

0.303 0.413

1.0

12

Clearance between arm-link mounting pin and link

80

-0.030 -0.076

+0.1 0

0.030 0.176

1.0

13

Clearance between arm-bucket mounting pin and boss hole

80

-0.030 -0.076

+0.1 0

0.030 0.176

1.0

14

Clearance between bucket cylinder-link mounting pin and bushing

80

-0.030 -0.076

+0.337 +0.273

0.303 0.413

1.0

15

Clearance between bucket cylinder-link mounting pin and link

80

-0.030 -0.076

+0.1 0

0.030 0.176

1.0

16

Clearance between Iin k-bucket mounting pin and bushing

80

-0.030 -0.076

+0.331 +0.265

0.295 0.408

1.0

17

Clearance between linkbucket mounting pin and boss hole

80

-0.030 -0.076

+0.2 0

0.030 0.276

1.0

-

www. k omat s upar t s book . c om Replace

64-20

-

PC200, 220-3


Autodecelel-ation solenoid

Wiper motor

lamp

Starting motor (with

Alter-nator

Ground

www. k omat s upar t s book . c om Connecting


Boom lamp

lamp (LH)


Auto-deceleration release switch

Horn switch

Monitor buzzer

Horn relay

Swing mechanical brake switch


Engine

switch

Engine speed sensor

www. k omat s upar t s book . c om Oil press sWitch for sWing

8.

ELECTRIC AND ELECTRONIC SYSTEM STRUCTURE AND FUNCTION

Electrical wiring diagram Electrical circuit diagram Electronic components of 3-stage mode selector OLSS (If equipped) EVMS (Electronic Vehicle Monitoring System) ..

-

81-2 81-5 81-6 81-9


PC200, 220-3

81-1 (8)

ELECTRIC AND ELECTRONIC SYSTEM

ELECTRICAL WIRING DIAGRAM

•

LONG LEVER CONTROL TYPE

11 13

9 8* \

6

www. k omat s upar t s book . c om /'~"'17 ~

///// ////~

14 *

15

16

18*

u///

205F2178A

Note

*:

1. 2. 3. 4. 5. 6. 7.

These parts are installed only on machines equipped with auto-deceleration system, swing mechanical brake, and 3-stage mode selector OLSS. Washer tank Electronic vehicle monitor ass'y Mode selector switch Heater switch Lamp switch Wiper switch Starting switch

8. Swing caution lamp (if equipped) 9. Cigarette lighter 10. Radio (if equipped) 11 . Controller 12. Horn relay 13. Buzzer

14. Solenoid relay (if equipped) 15. Fuse box 16. Speaker (if equipped) 17. Socket (if equipped) 18. Ratchet relay (if equipped)

81-4 @

PC200, 220-3


EVMS


3. CONTROLLER PC200·3 (Serial No. 20001 - 30309), PC220-3 (Serial No. 20001 - 22627) • The controller acts as the power source box and provides electric power to the monitor panel. The power source (battery, alternator) for the machine has a large difference in voltage, so the controller converts this to a stable voltage and supplies it to the panel. Even if excessive voltage is generated by failure in the alternator or regulator, it is cut by the controller. This protects the panel assembly. In addition, the controller acts to receive the signal from the panel assembly, and to operate the buzzer.

4. SENSORS •

F0202133

The signals from the sensors are input directly to the monitor panel. One of the contact points of the sensors with contacts is always connected to the chassis GND. When the contacts are closed and the signal is connected to the chassis, the panel reads the signal as a normal signal.

www. k omat s upar t s book . c om Classification of indication CHECK MONITOR GROUP CAUTION

Sensing type

Normal

Abnormal

Coolant level

Contact type

ON

OFF

Engine oil level

Contact type

ON

OFF

Hydraulic oil level

Contact type

ON

OFF

Engine oil pressure

Contact type

ON

OFF

Coolant temperature

Resistance type

-

-

Fuel level

Resistance type

-

-

Type of sensor

GAUGE GROUP

81-12 ®

PC200. 220-3


• 1)

EVMS

Structure of sensors Engine oil level sensor


5

4

3

/

2

/

Composition of circuit

To EVMS and body ground

ON-OFF

1. 2. 3.

F0202134

Switch Float Plug (Tightening torque: 25 - 31 kgm) Wiring Connector


5.


5

4

3

2


ON -.. _ _..- OFF 21TAF01047

1. 2. 3. 4. 5.

Switch Float Plug (Tightening torque: 25 - 31 kgml Wiring Connector

PC200, 220-3

81-13 ®

EVMS


5)

Coolant temperature sensor

5

1. 2.

2

~\

I

I

3. 4. 5.

Composition of circuit \

@)

~~~e=~=::JD~~~

·To EVMS and body ground

6)

Thermister (bead type) Plug (Tightening torque: 3 - 5 kgm) Tube Wire Connector

F0202138

Fuel level sensor


www. k omat s upar t s book . c om +-------102


ViewZ

1]0

3

4

5

1. 2. 3. 4. 5.

81-16 CfD

Float Gear Variable resistance Contact face Connector

F0202139

PC200, 220-3

EVMS



F

-

/1'''''- ... ' ' \

,

\,

,

.//


21TAF01051

1. 2. 3. 4.

Float Variable resistance Contact face Connector

PC200, 220-3

81-17 (8)


EVMS

5.

WIRING HARNESSES

PC200-3 (Serial No. 20001 - 30309) PC220-3 (Serial No. 20001 - 22627) •

Wiring harnesses are used to connect the controller,

The wiring harnesses consist of the following.

monitor panel and sensors.

• • •

CNPl4 (l6P)

I

Connector Electric lead Protective cover

,,,,,,,

0

CNPl3 (8P)

!

I

@

-

CNPl2 (l6P) CNP9 (SPI

www. k omat s upar t s book . c om ~ i 8 CN20 CN22

~2>sensor

Controller

CNPl (4PI

CN" (3PI

GNP3 (3P)

F0202140

o

Operation of monitor panel If the monitor panel is working normally, the lamps on the monitor panel will work as follows. 1) When the starting switch is turned to ON. a) All monitor lamps will light up for 3 seconds. b)

c)

CHECK MONITOR GROUP a)

b)

81-18

The CHECK item lamps will go out when the engine is started. (Judge whether the engine is running by the rise in the engine oil pressure, or see if there is a voltage of over 10V from the alternator.)

The panel light will light up for 4 seconds. 3)

2)

-

All monitor lamps will light up for 3 seconds, then if there is any abnormality in any check item, that item will flash. (About 0.8 seconds ON, then 0.8 seconds OFF repeated.) If the outside air temperature is low (below about _lOoC), the flashing interval will change sl ightly, but this is not an abnormality.

CAUTION MONITOR GROUPS a)

b)

All monitors are working from the time the engine starts to the time the engine stops. If there is any abnormality in the machine, the lamp for that item will start to flash (0.8 sec ON, 0.8 sec OFF). If there is any abnormality in the machine, the lamp in the CAUTION MONITOR GROUP (caution item) will flash. At the same time, the buzzer will sound.

PC200. 220-3

-

-

82 Note:

ELECTRIC AND ELECTRONIC SYSTEM TESTING AND ADJUSTING

The troubleshooting in this section is common for the following Serial Nos. For later Serial Nos. see page 82-35. PC200-3 (Serial No. 20001 - 30309) PC220-3 (Serial No. 20001 - 22627)

TROUBLESHOOTING FOR MACHINE MONITOR M-l When starting switch is turned ON, monitor panel display does not appear (a) No display at all appears on monitor panel (gauge and monitor) (b) Display does not appear on monitor panel (appears only on gauge or monitor) (c) Display does not appear on part of monitor panel assembly. M-2 M-3

82- 2

When starting switch is turned ON, monitor panel display does not go out When starting switch is turned ON (engine stopped), CHECKS BEFORE STARTING item flash, or PREHEATING item lights up (a) Cooling water level is correct, but lamp flashes. (b) Engine oil level is correct, but lamp flashes. (c) Hydraulic oil level is correct, but lamp flashes. (d) PREHEATING lamp lights up.

82- 3 82- 6

www. k omat s upar t s book . c om M-4

M-5

-

When starting switch is turned ON (engine started), CHECKS BEFORE STARTING items flash (CHECK item "Electrolyte level" is correct) . (a) Alternator system (after checking alternator system, check engine oil pressure circuit) (b) Engine oil pressure circuit When starting switch is turned ON (engine stopped), CAUTION items flash

. .. 82-12

82-14

M-6

When starting switch is ON (engine started), CAUT ION items flash (a) Engine oil pressure lamp flashes (b) The radiator water level lamp flashes (c) The engine water temperature lamp flashes (d) Battery charge lamp flashes

M-l

When starting switch is turned ON (engine stopped) for 2 seconds, warning buzzer does not sound

. 82·20

M-8

No ABNORMAL display on monitor but warning buzzer sounds

. 82-22

M-9

Monitor panel lamps do not light up (light crystal display normal) (a) No lamps on panel light up (b) Some lamps on panel do not light up

. 82-24

M-10

Service meter does not move when engine is started; or does not stop moving when engine is stopped (a) Service meter does not move. (b) Service meter does not stop moving.

M-11

82-16

............................. "

Engine water temperature gauge shows abnormally low temperature

82-26

. 82-30

M-12

Engine water temperature gauge gives no display

. 82-30

M-13

Fuel gauge always shows full tank

M-14

Fuel gauge gives no display

. 82-32 . 82-32

.PC200, 220-3

82-1 (8)

M-'

TROUBLESHOOTING

-

Troubleshooting Chart No. M-1 Failure mode: When starting switch is turned ON, monitor panel display does not appear.

* Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). * For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( ). Remedy Cause * After checking fuse (4) for broken wires, go to troubleshooting chart.

a) No display at all appears on monitor panel

3

(gauge assembly and monitor panel assembly).

YES

.--------, _ Is voltage between YES CNP1 (female) (1) and (4) 20 V - 30 2 V?

Is voltage of CNP3 (female) (1) and (2) over20V - 30V?

YES

1)

2)

Connect T -adapter or socket adapter to CNP3 (female) Turn starting switch ON.

1) 2)

Starting switch ON Connect T -adapter or socket adapter to CNP1 (female)

-

Disconnection in wiring harness, or defective contact between CNP1 (male) (1) and CNP9 (female) (1), CNP1 (male) (1) and CNP12 (female) (15), CNP1 (male) (1) and CNP14 (female) (16) or between CNP1 (male) (4) and CNP9 (female) (5), CNP1 (male) (4) and CNP12 (female) (16), CNP1 (male) (4) and CNP14 (female) (8)


Auxiliary controller defective

Replace

Disconnection in wiring harness, or defective contact between chassis ground and fuse (4) to CNP3 (x2) (1), or CNP3 (x2) (2) to CN9 (1)


:--10

'-:-J-O---------.-J ,

Is voltage at chassis ground and fuse (4) over 20 V - 30V7

www. k omat s upar t s book . c om • Turn starting switch ON.

Disconnection in wiring - . j harness, or defective contact

'-

NO

between fuse box - CN 1 2 (2) and battery ( +)


b)

Display of monitor assembly or gauge assembly does not appear on monitor panel. • When using T -adapter

........----......:;2 Is voltage between CNP14 (1 6! and (8! 20V - 30V?

YES

1

YES

Replace


NO

Is voltage between CNP12 (15) and (16)20V-30V?

1) 2)

L-----------------------------_r

Connect T -adapter to CNP12 NO Turn starting switch ON (Do not start engine)

• When using socket adapter. 2 YES

1 Is there continuity between CNP12 (female) (16) and CNP14 (female! (8)?

Is there continuity between CNP12 (female) (15) and CNP14 (female! (16)? L1)

2) 1!

2)

~

r-Y_E_S

NO

L---'-

Connect socket adapter to CNP12 (female) and CNP14 (female) Turn starting switch ON

Disconnection in wiring harness, or defective contact between CNP1 2 (female) (15) and CNP14 (female) (16) or between CNP12 (female) (16) and CNP 14 (female) (81.

~ Gauge assembly defective Monitor panel assembly defective

.....,. . .

Disconnection in wiring harness or defective contact between CNP12 (female) (15) and CNP14 (female) (16) Disconnection in wiring harness or defective contact

L..--:-----------------------------J between CNP12 (female)

Connect socket adapter to CNP12 NO (female) and CNP14 (female) T urn starting switch ON

(16) and CNP14 (female) (81.


-

Replace



'OJ

~c .0"';;

::lO'" 000

~'<:O

f-"",~

82-2 Q)

Tester

Short connector


T -adapter or socket adapter (for EKONO-SEAU

PC200, 220-3

-

M-4

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING M-4 (troubleshooting of alternator system (charge amount)) a-l Check voltage between alternator terminal R and chassis ground.

-

a-2 Check voltage between CNP12 (female) (13) and chassis ground.

13

www. k omat s upar t s book . c om M-4 (Troubleshooting of engine oil pressure system) b-1 Set short socket adapter to CN6.

-

b-3 Check for continuity between CNP12 (female) (14) and (16).

14 16

PC200, 220-3

82-13

TROUBLESHOOTING

M-5

-

Troubleshooting Chart No. M-5 Failure mode: When starting switch is turned ON, (do not start engine), CAUTION items flash.

* Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socked. * For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in (

*

If

l.

[~J (engine oil level) or [~ I !coolant level) flash, go to M-3 steps (a) and (bl. Remedy

Cause

YES I Does flashing of CAUTION lamp assembly stop removing CN6?

YES

NO

Engine oil pressure sensor defective.

Replace

Short circuit between CN6 (female) (1) - CNl (9) CN20 (14) - CNP 13 (female) (2) and chassis ground.

Repair or replace

Alternator defective.

Replace

Short circuit in wiring harness of 24 V line between alternator terminal R - CNl (11) - CN20 (13) - CNP13 (female) (1).

Repair or replace

Monitor panel assembly defective.

Replace

-


Is there continuity between CNP 13 (female) (2) and chassis ground?

1)

RemoveCN6 (engine oil pressure sensor). 2) T urn starting switch ON.

1)

2)

Connect Tadapter (socket) to CNP13 (female). Turn starting switch OFF.

YES

NO

3

Is voltage between alternator terminal R and chassis ground 27.5 V - 29.5 V?

1)

2)

Remove wifing of alternator terminal R. Engine start (half-throttle)

4 YES

)iO Is voltage between chassis ground and wiring harness of terminal R 20 V 30 V? 1)

2)

3)

Engine stop. Remove wiring of alternator terminal R. Turn starting switch ON

~

. NO

-

'OJ

~c

Tester

Short connector

T-adapter or socket adapter (for DU)


.0.-

:JoCl) 000 ~.c 0

1-"' ....

82-14

PC200, 220-3

M-7

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING M-7 (Troubleshooting of buzzer (does not sound)) 1. Short the circuit between CNP13 (female) (8) and CNP9 (female) (1). 2. Check for continuity between CNP13 (female) (8) and CNP1 (male) (2).

B

3. 4.

Check voltage between CNP2 (female) (1) and (2). Check for continuity between CNP2 (male) (1 l, (2) and buzzer terminal.


PC200, 220-3

82-21 Q)

TROUBLESHOOTING

M-8

-

Troubleshooting Chart No. M-8 Failure mode: No abnormal display on monitor but warning buzzer sounds.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in

(

l.

4

,YES

rJ?;tage between YES CNP2 (femalelll I 2 and 121 20V I 30V?

I

YES

I

Does buzzer sound?

1 Does buzzer sound?

1) 2)

1)

21

Remedy

Cause


Remove CNP1. Turn starting switch ON.

I

Connect Tadapter to CNP2. Turn starting switch ON.

NO

I

NO

Auxiliary controller defective.

Replace

Short circuit between chassis

ground and CNP2 (malel to buzzer (-I.

Adjust or replace

-

Disconnection in wiring harness

between CNP13 (femalel 181 and CNPl Imalel (21.

Adjust or replace



21

3

YES

Monitor lamp assemlby defective.

Is there continuity between chassis ground and CNP14 (femalel 141?

11

2)

Connect Tadapter to CNP14 (femalel Turn starting switch OFF .

Replace

Disconnection in wiring harness, or defective contact

between CNP 14 (malel (41 and CNPl (malel (41

NO

Adjust or replace

• When using socket adapter Remedy

Cause

YES

Auxiliary controller defective

Replace

4 Is voltage between CNP2 Ifemalel (11 and (21 20 - 30V? 1)

2)

'0>

~c

Tester

..c..;:::;

::JO~

000

~..co

I-

~+-'

T-adapter or socket adapter (for DU)

82-22

Short circuit between chassis

Connect

socket adapters to CNP2 (female) Turn starting switch ON.

-

"J()

ground and CNP2 Irnalel to buzzerl-L

Adjust or replace

Short connector

-


PC200, 220-3

M-10

TROUBLESHOOTING

-

Cause

bl

Remedy

Service meter does not stop moving. T -adapter • When using -

-

Y

E~

2

YES , 1

I

Is voltage between CNPS (3) and (4) OV - 1V?

Do..

3

"N;"~'"

I YES

Short circuit between CNPS (female) (4) - CN20 (14) CN 1 (female) (S) and chassis ground

Repair or replace

move?

1) RemoveCN1. 2) Turn starting switch ON.

I

NO

I

Short circuit between CN 1 (male) (S) - CN3 (female) (1) and chassis ground

Repair or replace

I a www. k omat s up r t s book . c om Does service meter move?

1)

2)

Remove CN6 (engine oil pressure) Turn starting switch ON (do not start engine)

1)

2)

NO

Connect Tadapter to CNS. Turn starting switch ON.

Service meter monitor lamp defective

NO

I,

-


defective

• When using socket

r[0"

-

I

2 ,YES

,

m_..,,,

I

Replace

Replace

Engine oil pressure sensor defective

Short circuit between CN6 (female) (1) - CN1 (male) (S) and chassis ground

Repair or replace

Short circuit between CN1 (female) (S) - CN20 (14) - CNPS (female) (4) and chassis ground

Repair or replace

moving?

I 1)

2)

Remove CNS. Turn starting switch ON.

NO

PC200, 220-3

82-27 (5)

TROUBLESHOOTING

M-10

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING M-10 a-1 Movement of service meter defective

a-2 Check for continuity between CNP9 (female) (3) and (4).

-

www. k omat s upar t s book . c om b-3 Check voltage between CNP9 (3) and (4).

-

82-28 Q)

PC200, 220-3

-


-

TROUBLESHOOTING

M-11, M-12

-

Troubleshooting Chart No. M-11 Failure mode: Engine coolant temperature is high, but lowest level displayed.

* Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). * For T -adapters, connect to both the male and female ends; for the socket. connect to the connector marked in (

).

Cause

1

YES

Has display of engine coolant tem-

Remedy

Engine coolant temperature sensor defective

Replace

Disconnection in wiring harness. or defective contact between CN5 Ifemalel (1) 121 - CNl (6) (71 - CN22 (3) (4) - CNP12 (female) (8) (10)

Clean Idefective contactlor replace

peratureJauge dis-

appeare when conneet short socket adapter to CN5'

11 Connect short

NO

connector to CN5 Ifemalel. Turn starting switch ON

21

-

, OJ

~c

Tester

Short connector

www. k omat s upar t s book . c om ..c.,;:::;

:>o~

000 ~.<: 0

I-

~+"'

Troubleshooting Chart No. M-12 Failure mode: Engine coolant temperature gauge gives no display.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters, connect to both the male and female ends; for the socket. connect to the connector marked in

(

l.

Cause

YES Has display of engine coolant temperature gauge appeared'

11 Remove engine

2)

coolant temperature sensor CN5. Turn starting switch ON.

NO

Remedy

Engine coolant temperature sensor defective.

Replace

Short circuit, or mistake cannection between CN5 (female) (1) (21 - CN1 161 171 - CN23 131 (4) -CNP12 (femalel (8) (10)

Repair or replace.

-

82-30 @

PC200, 220-3

PC200-3 (Serial No. 30310 and up), PC220-3 (Serial No. 22628 and up) M-l

When starting switch is turned ON, monitor panel display does not appear a) No display appears on monitor panel (gauges and monitor items) b) Display does not appear on part of monitor panel assembly

M-2 M-3

When starting switch is turned ON, monitor panel display does not go out· When starting switch is turned ON (do not start engine), CHECK BEFORE STARTING item flash or PREHEATING item lights up (Fluid level CHECKS BEFORE STARTING items are correct) a) (coolant level) flashes . b) (engine oil level) flashes . c) (hydraulic oil level) flashes Starting switch is not preheating, but preheat monitor lights up When starting switch is turned ON (engine started), CHECK BEFORE STARTING items flash a) Alternator system b) Engine oil pressure system

M-4

M-5

When starting switch is turned ON, (do not start engine), CAUTION items flash When starting switch is ON (engine started), caution items flash a) (engine oil pressure) flashes b) (coolant level) flashes c) (coolant temperature gauge) flashes d) (cha rge level) flashes

M-6

. 82-36 . 82-36 . 82-36 82-36 .

. . . .

82-37 82-37 82-37 82-38 82-40

. 82-41 . 82-41 . 82-41 . . . . . .

82-43 82-44 82-44 82-44 82-45 82-45


M-8 M-9 M-10 M-11

M-12 M-13 M-14 M-15

When starting switch is turned ON (engine stopped) for 1 second, or when CAUTION items are flashing, warning buzzer does not sound No abnormal display on monitor but warning buzzer sounds Monitor panel lamps do not light up (indication on monitor panel is correct) When engine is started, service meter does not move When engine is stopped, service meter moves a) Service meter does not move, when engine is started b) Service meter does not stop moving, when engine is stopped· Engine coolant temperature is high, but lowest level displayed Engine coolant temperature gauge gives no display Fuel tank is not full but display shows full tank No display is given for fuel level

PC200. 220-3

.

. 82-47 82-47 . 82-49 . . . . . . .

82-50 82-50 82-50 82-52 82-52 82-54 82-54

82-35 (8;

M-l,M-2

TROUBLESHOOTING

-

Troubleshooting Chart No. M-1 Failure mode: When starting switch is turned ON, monitor panel display does not appear.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socked. For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( l.

a)

No display appears on monitor panel (gauges and monitor items)

Remedy

Cause

2 YES

YES

Is voltage between CNP1 (femalel (1) and (2) 20 - 30V?

1 Is voltage between fuse 4 and chassis ground 20 - 30V?

1)

2) 1)


Connect T -adapter (socket) to CNP 1 (female). Turn starting switch ON.

NO

NO

Monitor module defective

Replace

Defective contact. or disconnection in wiring harness between fuse 4 - CNP1 (femalel (1) or CNPl (female) 121 - CN20 (1 I - chassis ground.

Clean Idefective contact) or replace

Defective contact. or disconnection in wiring harness between fuse box - starting switch - CN21 (21. (4) - battery (+ I.

-



Display does not appear on part of monitor panel assembly.

I , Cl


Replace

-

Tester

'>c: :i3+::

,,0'" 000

°

~.J:: 1-",-


Troubleshooting Chart No. M-2

Cause

Remedy

Failure mode: When starting switch is turned ON, monitor panel display does not go out.

IL.-

-t


Replace

82-36 @

PC200, 220-3

M-3

TROUBLESHOOTING

Troubleshooting Chart No. M-3 Failure mode: When starting switch is turned ON (do not start engineL CHECK BEFORE STARTING item flash or PREHEATING item lights up. (Fluid level of CHECKS BEFORE STARTING items are correct.)

* * *

If CHECKS BEFORE STARTING items continue to flash even after engine starts, check M-4 first. Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( ).

l~l

a)

Cause

Remedy

(coolant level) flashes. Table Short

Continuity

connector

-

Connect

Yes

Removed

No

YES

Coolant level sensor defective

Replace

1


Connect short connector to CNE 15 (femalel !coolant level sensorl. Tum starting switch ON.

21

~i--.J


Replace

Defective contact, or disconnection in wiring harness betweenCN2 (1) - CNl 131 - CN20 110) - CNl (5) CNP8 (female) (51.


Is continuity

YES

between CNP 1 (female) (5) and 121 as shown in the table]

2

Is there continuity

Connect T -adapter Isocketl to CNP 1 (female) 2) Connect - disconnect short connector to CN2 (female) 3) Tum starting switch OFF.

chassis ground?

Connect T -adapter (socket) to CN2 (female) Tum starting switch OFF.

11

NO

1)

between CN2 (femalel (2) and

NO

2)

b)

YES

3

When short connector is connected, does go out> E;'!

NO

Defective contact, or disconnection in wiring harness between CN2 (2) - CN 1 1211 - chassis ground, defective connection of chassis ground

Clean (defective contact) or replace, or inspect and adjust (defective contact of chassis groundl

Engine oil level sensor defective

Replace


Replace

(engine oillevell flashes.

-r-

YES I

Is continuity

YES

NO 1)

2)

Connect short connector to CNE4 (female) lengine oil level sensor). Tum starting switch ON.

between CNPl (female) (6) and 121 as shown in the table?

2

Is there continuity

between CN4 (female) (21 and chassis ground? 1)

2)

Connect T -adapter (socket) to CNE4 (female). Turn starting switch OFF.

Connect T -adapter (socket) to CNP 1 (female!. 2) Connect - disconnect short connector to CN4 (femalel. 31 Tum starting swtich OFF.

'CIl

Tester

e,gg

~"'-


PC200, 220-3

Defective contact, or disconnection in wiring harness

between CN4 (female) 111 CNl (1) - CN20 Ill) - CNPl (female) (6) Defective contact, or disconnection in wiring harness

between CN4 (21 - CN 1 (21) - chassis ground.

NO

Clean (defective contact) or replace


Table Short

,,0'"

NO

1)

connector

~.~

YES

:;

When short connector is connected, does Q. go out>

Continuity

Connect

Yes

Removed

No

Short connector T -adapter or socket adapter (for ECONO)

82-37 @

M-3

TROUBLESHOOTING

c)

[~

I (hydraulic oillevell flashes. Table Short connector

Continuity

Connect

Yes

Removed

No

YES

Remedy

Cause

Hydraulic oil level sensor defective

Replace


Replace

I When short connector is connected, does go out?

3

YES

Is continuity

between CNPl (femalel (71 and 121

YES

~

2

1)

Connect short connector to CN53 (female) (hydraulic oil level sensor!. 2) Turn starting switch ON.

NO

Is there continuity betweenCN14 (female) (2) and chassis ground? 1) Connect T -adapter (socket) to CN 14 (fernalel. 2) Turn starting swtich OFF.

as shown in the

table? 1)

NO

Connect T -adapter (socketl to CNP1 (femalel. 2) Connect - disconnect short connector to CN 14 (female). 3) Turn starting switch OFF.

NO

Defective contact, or disconnection in wiring harness


between CN 14 (female) (11 CN20 (21) - CNP1 (female) (7) Defective contact, or disconnection in wiring harness

between CN 14 (female) (2) -

-


chassis ground.


-

82-38 (8)

PC200. 220-3

TROUBLESHOOTING

M-3

M-3

a)

Related electrical circuit diagram

CNPI

CN20

Monitor module

205F2458

M-3

b)


www. k omat s upar t s book . c om Gauge module

205F2459

M-3

C)


CNPI

CN20

Gauge module

205F2460

PC200, 220-3

82-39 Cll)

TROUBLESHOOTING

M·4

-

Troubleshooting Chart No. M-4 Failure mode: Starting switch is not preheating, but preheat monitor lights up.

* * *

When disconnecting connectors to connect the T -adapter (or socket adapter), always turn the starting switch OFF. For the T -adapter, connect to both the male and female ends; for the socket, connect to the connector l. marked in ( After checking, connect disconnected connectors immediately.

Remedy

Cause Starting sWitch defective, or contact In preheating circuit 24 V Wiring harness defective between heater relay - CN 1 (21 - CN20 (7) - starting switch Rl - CNP 2 Ifemalel 151

YES 1 Is voltage between heater relay and chassIs ground 20 V - 30V7 1)

Turn starting

2)

sWltchON. Turn preheat switch OFF.

2

Disconnection in wiring harness, or defective contact

YES

between heater realy - CN 1 121 - CN20 (71 - CNP 2 151

Is resistance

between CNP 2 (femalel (51 and chassis ground over 30117

NO

Gauge assembly defective

Replace Clean Idefectlve contact) or replace.

Clean Idefectlve contact) or replace.

-

Replace


21

'C>

T -adapter Isocket) to CNP 2 (femalel Turn starting switch OFF

NO

Tester

~'E "OUl

000 ~.<: 0 I- UI_

M-4

Connect



CNP2

CN20

CNI Electrical intake air heater

205F2461

82-40

PC200, 220-3

M-5

TROUBLESHOOTING

Troubleshooting Chart No. M-5 Failure mode: When starting switch is turned ON, (engine started), CHECK BEFORE STARTING items flash.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socked. For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( ).

* *

After checking, connect disconnected connectors immediately. Check the alternator system and the engine oil pressure system.

a)

Alternator system

Cause

2 YES

YES


Is voltage between CNP1 Ifemale) (4) and chassis ground 27.5 - 29.5V?

Remedy

Replace


Is voltage between alternator terminal R and chassIs ground 27.5 29.5V?

11

1)

2)

Turn starting switch ON. Start engine. (Run at half throttle or higher!

b)

NO

Connect T -adapter Isocket! to CNP 1 Ifemale). Turn starting switch ON. S tart engine.

NO

YES Is there continuity between CN6 (femalel 121 and chassis ground?

YES 1 When short connector is connected to CN6, does lamp flash?

2)

1)

Connect short connector to CN6 (female) (engine oil pressure sensor). Turn starting swtich ON.

Connect T -adapter Isocket! to CN6 (female). Turn starting swtich OFF.

NO

1)

Connect T -adapter (socket) to CNP1 Ifemale) 2) Connect - disconnect shoft connector to CN6 (femalel 3) Turn starting switch OFF.

Alternator defective

Replace

Engine oil pressure sensor defective

Replace


Replace

Short connector

ContinUity

Connect

Yes

Removed

No

T -adapter or socket adapter (for DLiI

Short connector

T -adapter or socket adapter (for ECONOI

PC200, 220-3

Defective contact, or disconnection in wiring harness Clean (defective between CN6 Ifemale) (1) contact) or replace CNl (9) - CN20 (141 - CNPl (female) (91. Defective contact, or disconnection in wiring harness between CN6 Ifemale) (2) CN 1 (21) - chassis ground.


Table

Tester

'OJ

YES

NO

:0";'

",0'" 000 ~-'= 0 f- "'_

3 Is continuity between CNP 1 Ifemale) (g) and (2) as shown in the table?

NO

2)

-


Engine oil pressure system

2

11

Defective contact. or disconnection in wiring harness between alternator terminal R CN1 (11! - CN20 (13) CNP1 Ifemale! (41.

82-41 (8

M-5

TROUBLESHOOTING

M-5

a)

MoM",

M-5

b)


mOd~N~r--_o

Alternator R terminal

-


www. k omat s upar t s book . c om 411....-_.. . .

-

82-42 (8)

PC200. 220-3

M-6

TROUBLESHOOTING

-

Troubleshooting Chart No. M-6 Failure mode: When starting switch is turned ON, (do not start engine), CAUTION items flash.

*

*

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socked. For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( ).

*

If

I.@.!

(engine oil level) or

S? I

1

(coolant level) flash, go to M-3 steps (a) and (b).

Cause

-

YES 1 Does flashing of CAUTION lamp assembly stop removing CN6?

YES

Remedy

Engine ad pressure sensor defective

Replace

Short circuit between CN6 (femalel (1) - CNl (9) CN20 (14) - CNP1 (femalel (91 - chassis ground.

Repair or reptace


Replace

Short circuit in wiring harness of 24V line between alternator terminal R - CNl (11) CN20 (13) - CNPl (femalel (4)

Repair or replace

Monitor panel assembly defective

Replace


2)

Remove CN6 (engine oil pressure sensod Turn starting switch ON.

2

Is there continuity between CNPl (female) (9) and chassis ground?

NO

1) Connect T -adapter (socketl to CNPl (female). 2) Turn starting switch OFF.

YES

3

NO

Is voltage between alternator terminal R and chassIs ground 275 V - 29.5 V7

1)

2)

Remove wiring of alternator terminal R. Engine start (half-throttle)

4YES NO

Is vohage between chaSSIS ground and Wiring harness of termInal R 20 V 30V7 1) 2)

3)

"g> DO+:<

Tester

Short connector


T -adapter or socket adapter (for ECONO)

Engine stop. Remove wiring of alternator terminal R. Turn starting switch ON.

~

~

jO~

000 ~~ 0

1-<1>_

M-6


CNPI

CN20

CNI Alternator R terminal

Monitor module

-

205F2462

PC200,220-3

82-43 @

TROUBLESHOOTING

M-7

-

Troubleshooting Chart No. M-7 Failure mode: When starting switch is ON (engine started), caution items flash. (Fluid level of CHECKS BEFORE STARTING items and engine are correct.)

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket) For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in (

).

1.(0. I ~

a)

(engine oil pressure) flashes.

Cause

YES

Remedy

Engine oil pressure sensor defective.

Replace

Monitor panel assembly defective.

Replace

I Does engine oil

:)

pressure monitor lamp go out with connecting short socket adapter?

YES

Is there continuity between CNPl (female) (91 and chassis ground as shown in table)

-


Connect short socket adapter to CN6 (female, engine oil pressure

YES

:\0

2

Is there continuity

between CN6 (female) (2) and chassis ground?

11

21

sensor)

2)

Turn starting switch ON. Engine start.

, Cl

Connect T-adapter Isocket! to CN6 Ifemalel. 2) Turn starting switch OFF.

31

,,0'" 000

°

~.l: f--",_

T -adapter or socket adapter IforDU)

lID

Connect T-adapter Isocketl to CNPl (female!. Connect and remove short socket adapter to CN6 (female). Turn starting switch OFF.

NO

Disconnection in wiring harness, or defective contact between CN6 (femalel (1) CN1 191 - CN20 (141 - CNP1 (femalel 191

contact), or

Disconnection in wiring harness, or defective contact between CN6 (femalel 121 CN1 (211 - chassis ground

Clean (defective contact), or replace

Clean (defective

replace

Table Short connector

Continuity

Connect

Yes

Removed

No

-

5 hort connector

Tester

~ .§

b)

1)

:\0


(coolant level) flashes.

I----------I..~

See M-3 a)

82-44 @

PC200. 220-3

TROUBLESHOOTING

I

c}

i

M-7

I

E?

J

(coolant temperature gauge) flashes.

2 YES When short

YES 1 Is coolant temperature gauge

11

connected to CN5 Ifemale), does 0 go out?

3)

Start engine. (Run

Remedy

Coolant temperature sensor defective

Replace


Replace


Replace

connector is

11 21

in red range?

Cause

NO

Remove CN5. Connect short connector to CN 5 (female!. Start engine.

at half throttle)

NO

wwLQJ w. k omat s upar t s book . c om (charge leve\) flashes.

d}

2 YES CNP1 Ifemalel (41 and chassis ground 20 - 30V?

1 Is voltage between alternator terminal R and chassis ground 20 - 30V?

-

11 21

11

Monitor defective

Replace

Is voltage between

'{ES

Connect T -adapter Isocket) to CNPl (female!.

Defective contact, or

NO

disconnection in wiring harness between alternator terminal R

- CNl (111- CN20(131CNPl (femalel (41.

Clean (defective contactl or replace

Turn starting

switch ON. Start

Start engine. (Run at half throttlel

engine.


Replace

NO

, C>

Tester

Q)C

:0"';:;


:00'"

000 ~.c

0

.-"'-

T -adapter socket adapter Ifor DU)

pe200, 220-3

82-45

M·7

TROUBLESHOOTING

M-7

a)


41--~

Service meter

-


c)


Monitor module

CNP8

-

Monitor module

205F2463

M-7

d)


CNP I Moo;,,,

mOO02

CN20

CN I

~1--

_ _0AlternatorR terminal

82-46 ®

PC200, 220·3

-

M-8, M-9

TROUBLESHOOTING

Troubleshooting Chart No. M-8 Failure mode: When starting switch is turned ON (engine stopped) for 1 second, or when CAUTION items are flashing, warning buzzer does not sound.

* * *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socketl. For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( l. If only CHARGE is abnormal amont the CAUTION items, the buzzer does not sound.

Cause

-

1 YES When CNP2 Ifemale) (8) and chassis ground are connected. does buzzer sound?

11

Connect T -adapter to CNP2. Turn starting switch ON.

;,\0

Remedy


Replace

Disconnection in wiring harness between CNP2 (femalel (81 buzzer(-I, or +24V - buzzer ( +), or defective buzzer

Replace


Troubleshooting Chart No. M-9 Failure mode: No abnormal display on monitor but warning buzzer sounds.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socketl. For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( l.

Cause

1

YES

Remedy

Contact (short circuit! between chassis ground and wiring harness between CNP2 (female) (8) - buzzer( -)

Inspect, repair, or replace


Replace

Does buzzer

sound?

1'\0 1)

2)

-


, C>

Tester

CDC ]5.';: ::>0

en

~.c

0

000

f-en_

T -adapter socket adapter Ifor DU)

PC200, 220-3

82-47 (~)

M-8, M-9

TROUBLESHOOTING

M-8, M-9


Fuse

+24V Buzzer

-

Monitor module

205F2464


-

82-48

PC200, 220-3

-

M-10

TROUBLESHOOTING

Troubleshooting Chart No. M-10 Failure mode: Monitor panel lamps do not light up (Indication on monitor panel is correct)

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T-adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( l.

Cause

YES

Bulb broken, or defective contact

1

3 Is there any defective contact in

YES

bulb?

Is voltage between

Remove bulb. Check bulb visually for disconnection.

Defective contact, or disconnection in wiring

harness between CNP6 (fernalel (31 and CNP9 (femalel (21

Replace bulb, or clean (defective contact)


CNP6 (31 and chassis 20 - 30V?

2 11 2)

YES

Remedy

www. k omat s upar t s book . c om Is voltage between CNP6 (female) (4) - chassis ground 20 - 30V?

NO

1)

.or?


21

Turn starting switch ON. Turn lamp switch ON.

NO

NO

Head lamp switch defective

Replace

Defective contact, or disconnection in wiring harness Clean (defective between CNP6 (femalel (41 contact) or replace fuse 1


Tester

D"';::;

11

::JO.!?

000 ~J:: 0 1-",-

M-10

T -adapter or socket adapter (for ECOND)


CNPI

CN21

1 ......- - . . . ,

Monitor module

Head lamp switch

Service meter

LL LL

o

-

I 2 205F2465

PC200. 220-3

82-49

TROUBLESHOOTING

M-11

-

Troubleshooting Chart No. M-11 Failure mode: When engine is started. service meter does not move. When engine is stopped. service meter moves.

* Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socked. * For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in (

a)

l.

Service meter does not move. when engine is started

Remedy

Cause

YES

For details. see M-7 Item a).

1 Does engine oil pressure caution lamp light up? 1)

2 YES

Turn starting switch ON. Start engine.

Is voltage between CNP9 (female) (1) and (3) 20 - 30V?

Replace

-

Clean (defective contactl or replace

Service meter defective


1)

Connect T -adapter to CNP9. Turn starting switch ON. Start engine.

2)

NO

Defective contact, or disconnection in wiring harness between CNP11 (female) (1) CNP8 (male) (1), or CNP1 0 (female) (4) - CNP8 (male) (9)


b) Service meter does not stop moving. when engine is stopped

2 YES Are CNP9 (male) (3) and (4) connected?

YES 1 Does service meter move?

1) 2)

1) 2)

Remove CN20. Turn starting switch ON.

Connect T -adapter to CNP9 (male) T urn starting switch OFF.

NO

NO

Service meter defective

Replace

Contact between chassIs ground and wiring harness between CN20 (malel (14) CNP9 (male) (4)


Contact between chassis ground and CN20 (female) (14)


-

Tester

"2' :0".-

,,0"

°

000 I.. _ ~~

82-50 (8)


PC200.220-3

-

TROUBLESHOOTING

M-"

M·"


CNP9

4 Fuse

CN20 CNPI

www. k omat s upar t s book . c om Monitor module

205F2466

-

PC200, 220-3

82-51 ®

M-12, M-13

TROUBLESHOOTING

-

Troubleshooting Chart No. M-12 Failure mode: Engine coolant temperature is high, but lowest level displayed.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in (

).

Cause

Remedy

1

YES

Has display of coolant temperature gauge disappeared when connect short socket adapter to CN57

Coolant temperature sensor defective.

..

NO

l)

Connect short connector to CN 5 If e m aIe) 2) Turn starting switch ON

Replace

Disconnection in wiring harness, or defective contact between CN5 (female) (11, 121 - CNl (61, 17) ~ CN22 (31, 141 - CNP2 (femalelll I, CNP8 121, (81


-

www. k omat s upar t s book . c om , Ol

Tester

~.~

,,0<1>

~~~

Short connector


Troubleshooting Chart No. M-13 Failure mode: Engine coolant temperature gauge gives no display.

*

*

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket) For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in (

)

Cause

1 Has display of coolant temperature gauge appeared? l)

Remove coolant temperature sensor CN5. 2) Turn startIng SWItch ON

YES

NO

Remedy

Coolant temperature sensor defective.

Replace

Short circuit, or mistake connection between CN5 (female) 11 I, (2) ~ CNEl (61, (7) - CN22 (3), (41 - CNP2 (female) 11 I, CNP8 (21, (8)

Repair or replace.

82-52 @

pe200, 220-3

TROUBLESHOOTING

M-12, M-13

M-12, M-13


Monitor module

Monitor module


pe200, 220-3

82-53 (8)

M-14, M-15

TROUBLESHOOTING

-

Troubleshooting Chart No. M-14 Failure mode: Fuel tank is not full but display shows full tank.

* Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socked. * For T -adapters, connect to both the male and female end!?; for the socket, connect to the connector marked in (

l.

Remedy

Cause

YES

Replace

Fuel level sensor defective

1

YES

Does fuel gauge display go out whenCN47 is removed] 1)

2) 3)

Remove CN15 Ifuellevel sensor!. Turn starting switch ON. Waitforapprox. 1 minute.

Does fuel gauge display go out when CN22 is removed?

2 Does fuel gauge display go out when CNP9 is removed?

NO 1) 2)

1) 2)

Remove CNP2. Turn starting switch ON. Wait for approx. 1 minute.

3 YES

Remove CN22. Turn starting switch ON.

NO

Abnormality in wiring harness between CN22 (malel (1) CN 15 (female) (1)


Abnormality in wiring harness between CN22 Ifemale) (11 CNP2 (female) (31.

Inspect. repair. or replace

-


NO


Troubleshooting Chart No. M-15 Failure mode: No display is given for fuel level.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( l. Remedy

Cause

YES 1 Is FULL display given when CN 15 is removed'? 1)

2)

NO

2

YES

Is there continuity between CN2 (femalel (3) and (4)7

Remove CN15 (fuel level sensor!. Connect short

connector. 3) 4)

Turn starting switch ON. Wait for approx. 1 minute.

11 2)

Remove CN15 Connect short

3)

Connect T -adapter to CN2 Ifemale).

Tester

f-U>_

T -adapter or socket adapter (forDLO

82-54 (8)

Replace


Replace

Defective contact, or disconnection in wiring harness between CN 1 5 Ifemalel (1) CN22 (1) - CNP2 (3)


connector.

cOg>

]5"';:; "0u> 000 ~.c 0

NO

Fuellevel sensor defective

Short connector

-


PC200, 220-3

-

M-14, M-15

TROUBLESHOOTING

M-14, M-15


CNP2

CN22

Monitor module

205F2467


PC200, 220-3

82-55 (!~)

-~


-

-

OTHERS 93 DISASSEMBLY AND ASSEMBLY

OPERATOR'S CAB ASSEMBLY Removal Installation COUNTERWEIGHT Removal Installation

-

93-2 93-2 93-4 93-4


PC200, 220-3

93-1 CD


OPERATOR'S CAB

-

REMOVAL OF OPERATOR'S CAB ASSEMBLY 1.

Disconnect room lamp wiring (1) at connector.

2.

Disconnect wiper wiring (2) at connector, then remove from clamp.

3.

Remove 3 mounting bolts of control stand (3), then move to inside.

4.

Remove 9 mounting bolts (4) of operator's cab.

5.

Lift off operator's cab assembly (5).

~

*

-

Operator's cab assembly: 230 kg

Be careful not to hit the operator's cab assembly against any other parts when raising.

www. k omat s upar t s book . c om INSTALLATION OF OPERATOR'S CAB ASSEMBLY 1.

Raise operator's cab assembly (5) and set in mounting position.

2.

Tighten 9 mounting bolts (4) of operator's cab.

3.

Set control stand (3) in mounting position, then tighten 3 mounting bolts.

4.

Connect wiper wiring (2) at connector.

5.

Connect room lamp wiring (1) at connector.

-

,\

~ \

J-lliLZdAll. 93-2 CD

PC200, 220-3

-

OPERATOR'S CAB


REMOVAL OF OPERATOR'S CAB ASSEMBLY (OPTION) 1.

Disconnect wiper wiring (1) at connector, then remove from clamp. If equipped with washer tank, remove and move toward floor.

* 2. 3.

Disconnect antenna wiring (2) and room lamp wiring (3). Remove 3 mounting bolts of control stand, then move to inside.

4.

Remove 9 mounting bolts of operator's cab, then lift off operator's cab assembly (5).

~

*

Operator's cab assembly: 240 kg

Be careful not to hit the operator's cab assembly against any other parts when raising.

www. k omat s upar t s book . c om INSTALLATION OF OPERATOR'S CAB ASSEMBLY (OPTION) 1. -

Raise operator's cab assembly (5) and set in mounting position, then tighten 9 mounting bolts.

2.

Set control stand (4) in mounting position, then tighten 3 mounting bolts.

3.

Connect room lamp wiring (3) and antenna wiring (2).

4.

*

Install washer tank (if equipped).

Connect wipper wiring (1) at connector, then secure with clamp.

~\1"

PC200, 220-3

93-3 CD


COUTERWEIGHT

-

REMOVAL OF COUNTERWEIGHT

1.

Sling counterweight (1).

2.

Remove4 mounting bolts (2). then lift off counterweight (1).

~

Counterweight:

3000 kg (PC200) 4000 kg (PC220)

K:O:MATSU

INSTALLATION OF COUNTERWEIGHT 1.

-

Raise counterweight (1), set in mounting position, then tighten 4 mounting bolts (2).



-

93-4 CD

PC200, 220-3

manual PC200(210)(220)(240)-3 SM

Recommend Documents